SYSTEM AND METHOD FOR ULTRA-LOW FIRE GAS HEAT ALGORITHMS

Description

FIELD

The present disclosure relates to ultra-low fire gas heat algorithms, and, more particularly, to a system and method for supporting and controlling ultra-low fire gas heat.

BACKGROUND

Many existing gas heat algorithms have been in use, for decades, for the express purpose of improving overall system fuel efficiency. But these existing gas heat algorithms all rely on some type of signal feedback to the ignition control, to inform the timing of its operation. Examples include, signal feedback indicating indoor and/or outdoor temperature(s); signal feedback indicating a particular demand intensity percentage, relative to maximum system heat capacity; and/or signal feedback indicating a previous heat call duration, relative to a calculated and/or expected duration. And these various feedback signals to the ignition control often increase system complexity, and/or require the purchase and installation of additional system accessories. Either way, these feedback systems add to the overall system cost.

Also, existing gas heat algorithms may not fully appreciate the thermal properties and restrictions of the particular system within which they are operating. For example, existing gas heat algorithms may unintentionally waste fuel in the early minutes of a gas heat call, before the heat exchanger has reached thermal stability at operating temperature. Existing gas heat algorithms may also waste fuel even as the system approaches thermal stability, since they do not explicitly consider theoretical outdoor average temperatures and/or theoretical short cycle call duration. And finally, existing gas heat algorithms may unintentionally waste heat after the gas heat call has been terminated, by not taking proactive steps to recover as much residual heat as possible.

This background section is intended to introduce the reader to various aspects of art that may be related to various aspects of the disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, these statements are to be read in this light, and not as admissions of prior art.

BRIEF SUMMARY

In one aspect, a gas-powered heating system includes a modulating gas valve to variably control a flow of gas through the gas valve assembly and a controller configured to control operation of the modulating gas valve. The controller is programmed to i) receive a heat start call; ii) control the modulating gas valve to increase the flow of gas through the gas valve assembly to a first amount of gas to light a flame; iii) control the modulating gas valve to decrease the flow of gas through the gas valve assembly to an ultra-low flame amount; iv) delay a predetermined amount of time; and/or v) subsequent to the predetermined amount of time, control the modulating gas valve to increase the flow of gas through the gas valve assembly to a second amount of gas. The gas-powered heating system may have additional, less, or alternate functionalities, including those discussed elsewhere herein.

In another aspect, a computer device includes at least one processor in communication with at least one memory device and in communication with a remote computer device via a communication module. The at least one processor is programmed to i) receive a heat start call; ii) control a modulating gas valve to increase the flow of gas through the gas valve assembly to a first amount of gas to light a flame; iii) control the modulating gas valve to decrease the flow of gas through the gas valve assembly to an ultra-low flame amount; iv) delay a predetermined amount of time; and/or v) subsequent to the predetermined amount of time, control the modulating gas valve to increase the flow of gas through the gas valve assembly to a second amount of gas. The computer device may have additional, less, or alternate functionalities, including those discussed elsewhere herein.

Advantages will become more apparent to those skilled in the art from the following description of the embodiments which have been shown and described by way of illustration. As will be realized, the present embodiments may be capable of other and different embodiments, and their details are capable of modification in various respects. Accordingly, the drawings and description are to be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The Figures described below depict various aspects of the systems and methods disclosed. It should be understood that each Figure depicts an embodiment of a particular aspect of the disclosed systems and methods, and that each of the Figures is intended to accord with a possible embodiment thereof. Further, wherever possible, the following description refers to the reference numerals included in the following Figures, in which features depicted in multiple Figures are designated with consistent reference numerals. There are shown in the drawings arrangements presently discussed, it being understood, however, that the present embodiments are not limited to the precise arrangements.

FIG. 1 illustrates a perspective view and a schematic cut-away view of one embodiment of a gas valve assembly for use with ultra-low fire gas heat algorithms in accordance with at least one embodiment.

FIG. 2 illustrates an example fuel fired heating system that is supplied with fuel by the gas valve shown in FIG. 1.

FIG. 3 illustrates an example control circuit for use with the gas valve assembly shown in FIG. 1.

FIG. 4 illustrates a graph of a first ultra-low fire gas heat algorithm in accordance with at least one embodiment.

FIG. 5 illustrates a process for the first ultra-low fire gas heat algorithm using the control circuit shown in FIG. 3.

FIG. 6 illustrates a graph of a second ultra-low fire gas heat algorithm in accordance with at least one embodiment.

FIG. 7 illustrates a process for the second ultra-low fire gas heat algorithm using the control circuit shown in FIG. 3.

FIG. 8 illustrates a graph of a third ultra-low fire gas heat algorithm in accordance with at least one embodiment.

FIG. 9 illustrates a process for the third ultra-low fire gas heat algorithm using the control circuit shown in FIG. 3.

FIG. 10 illustrates a graph of a fourth ultra-low fire gas heat algorithm in accordance with at least one embodiment.

FIG. 11 illustrates a process for the fourth ultra-low fire gas heat algorithm using the control circuit shown in FIG. 3.

FIG. 12 illustrates an example configuration of a client computer device, in accordance with one embodiment of the present disclosure.

Corresponding reference characters indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

The present embodiments may relate to, inter alia, systems and methods for supporting and controlling ultra-low fire gas heat. Note that in a typical furnace application, ultra-low fire gas heat is defined as a gas outlet pressure≤1″ WC (water column). In other applications, the gas outlet pressure for ultra-low first gas heat may include other values. In at least one embodiment, the gas outlet pressure for ultra-low first gas heat is below the value for ignition, but above the value where the flame is extinguished due to lack of fuel. This ultra-low fire gas heat is of substantially lower outlet pressure, than even the normal ‘low’ fire and/or ‘modulating’ outlet pressure of systems in use today.

In one example embodiment, the methods may be performed by a controller. The present embodiments relate to a controller for controlling the flame of a gas heating system. The present system describes a controller programmed to optimize the thermal properties of system heat exchangers during the gas heat operating loop. The controller is programmed to prevent the waste of fuel in the early minutes of a gas heat call. This includes before the heat exchanger has reached thermal stability at the desired operating temperature. The controller is further programmed to prevent the waste of fuel by considering the theoretical outdoor average temperatures and/or the theoretical short cycle call duration. The controller is also programmed to prevent the waste of heat and/or fuel after the gas heat call has been terminated, but before the heat exchanger has reached thermal stability at idle temperature.

An example controller is programmed to utilize ultra-low gas fire techniques, without the need for any signal feedback to inform the timing of its operation. To accomplish this goal, the controller is programmed to improve system fuel efficiency in the early minutes of a gas heat call. The controller is also programmed to improve system fuel efficiency in the case of short cycle gas heat call. In addition, the controller is programmed to improve system fuel efficiency at the end of a gas heat call. Another example controller is programmed to improve overall system fuel efficiency for gas heating systems. The controller executes an algorithm that employs intermittent periods of ultra-low fire gas heat.

Another example controller is programmed to employ the intermittent periods at specific times, during the gas heat operating loop. The controller is also programmed to employ the intermittent periods for specific duration, during the gas heat operating loop. Various embodiments of the disclosure may adjust these specific times, and durations. But the controller does not require any signal feedback to the ignition control from other system components, in order to make these adjustments. However, that this does not preclude the use signal feedback to affect the algorithm if desired. Accordingly, the present embodiments may work in systems that use signal feedback; however, that signal feedback may not be used to trigger the ultra-low fire gas heat as described herein.

For conciseness, examples will be described with respect to a gas powered furnace. However, the methods and systems described herein may be applied to any suitable system or appliance that uses a variable (modulated) gas valve including an agricultural heater, a gas fireplace, a gas oven, and the like. Also for conciseness, examples will be described with respect to a stepper motor regulated gas valve, but the methods and systems described herein may be applied to a system including any modulating gas valve, such as a solenoid coil (also referred to as a voice coil) controlled valve, a pulse width modulation controlled valve, a servo (rotary actuator) controlled valve, or the like. Furthermore, the methods and systems described herein may also be applied to a system include a ‘non variable’ modulating valve, such as a two stage or nth stage valve could simply be configured to have its lowest stage output equivalent to the ‘ultra-low fire’ rate. In other words, the algorithm does not necessarily require a variable valve output, with significant or incremental precision.

At least one of the technical solutions to the technical problems provided by this system may include: (i) reducing wasted fuel; (ii) reducing on cycle sensible heat losses; (iii) maximizing short cycle system efficiency while minimizing the impact on total heat output during longer run times; and/or (iv) maximizing supply air temperature throughout the post cool delay, while minimizing flue gas temperature at the end of the post-cool delay time.

The methods and systems described herein may be implemented using computer programming or engineering techniques including computer software, firmware, hardware, or any combination or subset thereof, wherein the technical effects may be achieved by performing at least one of the following steps: a) receive a heat start call; b) control the modulating gas valve to increase the flow of gas through the gas valve assembly to a first amount of gas to light a flame; c) control the modulating gas valve to decrease the flow of gas through the gas valve assembly to an ultra-low flame amount; d) delay a predetermined amount of time; e) subsequent to the predetermined amount of time, control the modulating gas valve to increase the flow of gas through the gas valve assembly to a second amount of gas; f) wherein the ultra-low flame amount is a gas outlet pressure≤1″ WC (water column); g) wherein the ultra-low flame amount is a minimum amount of gas outlet pressure to maintain the flame being lit; h) wherein the second amount is based upon the heat start call; i) wherein the first amount of gas and the second amount of gas are the same; j) wherein the first amount of gas and the second amount of gas are different; k) wherein the predetermined amount of time is a pre-heat delay; l) wherein the gas-powered heating system is non-condensing, and wherein the pre-heat delay is less than or equal to 150 seconds; m) wherein the gas-powered heating system is condensing, and wherein the pre-heat delay is less than or equal to 60 seconds, n) wherein the heat call start is received from an integrated furnace controller (IFC); o) delay a second predetermined amount of time while a flow of gas is flowing through the gas valve assembly at the second amount; p) subsequent to the second predetermined amount of time, control the modulating gas valve to decrease the flow of gas through the gas valve assembly to the ultra-low flame amount; q) delay a third predetermined amount of time; r) subsequent to the third predetermined amount of time, control the modulating gas valve to increase the flow of gas through the gas valve assembly to the second amount; s) subsequent to the third predetermined amount of time, delay the second predetermined amount of time while a flow of gas is flowing through the gas valve assembly at the second amount; t) subsequent to the second predetermined amount of time, control the modulating gas valve to decrease the flow of gas through the gas valve assembly to the ultra-low flame amount; u) repeat the delays for the second predetermined amount of time and the third predetermined amount of time; v) wherein the second predetermined amount of time and the third predetermined amount of time are based upon operation of a circulator; w) receive a heat stop signal; x) control the modulating gas valve to decrease the flow of gas through the gas valve assembly to an ultra-low flame amount; y) delay a fourth predetermined amount of time; z) subsequent to the fourth predetermined amount of time, control the modulating gas valve to cease the flow of gas through the gas valve assembly, aa) wherein the fourth predetermined amount of time is a post-cool delay; bb) wherein the gas-powered heating system is non-condensing, and wherein the post-cool delay is between five seconds and ten seconds; cc) wherein a post-purge delay occurs between an end of the post-cool delay and an inducer shutting down, wherein the post-purge delay is 30 seconds; dd) wherein the gas-powered heating system is condensing, and wherein the post-cool delay is between ten seconds and fifteen seconds; ee) wherein a post-purge delay occurs between an end of the post-cool delay and an inducer shutting down, wherein the post-purge delay is less than five seconds; and/or ff) wherein the predetermined amounts of time are independent of signal feedback.

FIG. 1 illustrates a perspective view and a schematic cut-away view of one embodiment of a gas valve assembly 100 for use with ultra-low fire gas heat algorithms in accordance with at least one embodiment. FIG. 1 shows an example stepper-motor regulated gas valve assembly 100. The stepper-motor regulated gas valve assembly 100 includes a gas valve 101 and a controller 130. The gas valve 101 includes a main diaphragm chamber 102, and a main diaphragm 104 disposed in the main diaphragm chamber 102. The main diaphragm 104 controllably displaces a valve 106 relative to a valve opening 108 in response to changes in pressure in the main diaphragm chamber 102, to thereby permit adjustment of the flow of fuel through the valve opening 108. The gas valve 101 further includes a servo-regulator diaphragm 110, which is configured to regulate fluid flow to the main diaphragm chamber 102. The servo-regulator diaphragm 110 therefore controls the fluid pressure applied to the main diaphragm 104, to control the rate of fuel flow through the valve opening 108. The gas valve 101 also includes a stepper motor 120 configured to move in a stepwise manner to displace the servo-regulator diaphragm 110, for regulating fluid flow to the diaphragm chamber 102 to thereby regulate the rate of fuel flow through the valve 106.

The example accordingly provides for stepper-motor control over the extent of opening of the valve opening 108, to provide modulated fuel flow operation. The example gas valve 101 is governed by a stepper motor 120, rather than a voice coil operator that is used in some embodiments for modulating the position of a valve 101 in some other modulating valves. For a valve 101 utilizing a stepper motor 120, such as the valve 101, the valve 101 is displaced and the flow rate set by controlling the motor 120 a required number of steps. Typical modulating valves 101 employing a voice coil operator are driven by a milliamp signal ranging from 0 to 180 milliamps, which causes the voice coil to move a distance that is proportional to the amount of milliamps conducted in the coil. For example, a typical modulating furnace controller using a voice coil based valve may generate a 180 milliamp signal where maximum heating capacity operation is desired, and may generate a 20 milliamp signal where minimum heating operation is desired.

The stepper-motor regulated gas valve assembly 100 includes a controller or control circuit 130 configured to receive an input control signal and to control the valve 101 based on the input control signal. The input control signal may be a particular number of steps to actuate the stepper motor 120, a particular flow rate desired, a relative flow rate or valve open percentage (e.g., 100% flow, 25% open, or the like), a milliamp signal as mentioned above, or any other signal to inform the valve assembly 100 how much to open or close the valve 101. Based at least in part on the input control signal, the control circuit 130 moves the stepper-motor 120 a number of steps, which displaces the servo-regulator diaphragm 110 and thereby controls the rate of fuel flow through the valve opening 108.

FIG. 2 illustrates an example fuel fired heating system 200 that is supplied with fuel by the gas valve 101 (shown in FIG. 1). The stepper-motor regulated gas valve assembly 100 may be included within a fuel-fired heating system 200 that includes a burner 210 that is supplied with fuel by the stepper-motor regulated gas valve assembly 100, as shown in FIG. 2. The fuel-fired heating system 200 further includes is an integrated furnace controller (IFC) 230 that that controls operation of the system 200, including communicating with the control circuit 130 for controlling the operation of the stepper-motor regulated gas valve assembly 100. The IFC 230 may also be referred to as a system controller. It should be understood that the stepper-motor regulated gas valve assembly 100 utilizes a set of motor step values that correspond to a plurality of positions of the stepper motor 120 for adjusting the regulator, which positions range between a closed no-flow position to a 100% full capacity position. The stepper-motor regulated gas valve assembly 100 may be employed in combination with a burner 210 that is supplied with fuel by the stepper-motor regulated gas valve assembly 100, and a IFC 230 in communication with the control circuit 130 for controlling the operation of the stepper-motor regulated gas valve assembly 100.

FIG. 3 illustrates an example control circuit 130 for use with the gas valve assembly 100 (shown in FIG. 1). The control circuit 130 includes a controller 136 in communication with the IFC 230 (also sometimes referred to as an integrated furnace controller). In the example, the controller is a microcontroller 136 including a valve processor 300 and a valve memory 302. The IFC 230 includes a processor 304, a memory 306, and at least one communication interface 308. In other embodiments, the controller 136 includes a central processing unit, microprocessor, reduced instruction set circuit (RISC), application specific integrated circuit (ASIC), logic circuit, or any other circuit or processor capable of executing the functions described herein, and random access memory (RAM) such as dynamic RAM (DRAM) or static RAM (SRAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), non-volatile RAM (NVRAM), or any other suitable memory.

The communication interface 308 is communicatively coupled to the controller 136 in the control circuit 130. Although only one communication interface 308 is shown coupled to the control circuit 130, the IFC 230 may include more than one communication interface 308 coupled to the control circuit 130. Moreover, the communication interfaces 308 may be different types of communication interfaces using different types of communication protocols. In some embodiments, for example, the communications interfaces 308 can include a milliamp signal interface, one or more heat signal interfaces, a data communication interface, and/or any other suitable communications interfaces for communication between the IFC 230 and the control circuit 130.

The communicative connection between the IFC 230 and the control circuit 130 using the communication interface 308 permits the IFC 230 to communicate with the control circuit 130 information, instructions, control signals, updates, data, or the like. The communication interface 308 may use any suitable wired or wireless communication protocol. Wireless communication may include a radio frequency (RF), Bluetooth®, Wi-Fi, a ZigBee®, near field communication (NFC), infrared (IR), and/or any other device and communication protocol for wireless communication. (Bluetooth is a registered trademark of Bluetooth Special Interest Group of Kirkland, Washington; ZigBee is a registered trademark of the ZigBee Alliance of San Ramon, California.) Wired communication may include any suitable wired communication protocol for direct communication including, without limitation, USB, RS232, I2C, SPI, analog, and proprietary I/O protocols. Moreover, in some embodiments, the wired communication may be performed using a wired network adapter allowing communication through a network, such as the Internet, a local area network (LAN), a wide area network (WAN), a mesh network, and/or any other network.

When a call for heat is determined or received by the IFC 230, the IFC 230 will send a command to the control circuit 130 to open the gas valve 101. The IFC 230 will also send a command corresponding to the desired amount of gas flow. The desired flow may be sent as part of the command to open the gas valve 101 or as a separate command. Moreover, in some embodiments, the desired flow may be sent first, so that the valve 101 may be preset to the desired flow rate before the valve 101 is opened. As will be explained in more detail herein, the desired flow rate may be sent as an actual rate (e.g., volume per minute), a pressure, a relative amount to open (e.g., 50% open), a relative flow rate (e.g., 50% of maximum flow rate), a specific number of steps to drive the stepper-motor 120, or the like. In embodiments, in which the control circuit 130 receives a specific number of steps for the stepper-motor 120, the control circuit 130 merely takes the action commanded by the IFC 230 and drives the stepper-motor the requested number of steps. In embodiments in which the desired flow rate is communicated without a specific number of steps, the control signal determines the number of steps the motor must turn or move to set the servo-regulator diaphragm 110 to the requested flow rate. The stepper motor gas valve 101 uses the select motor step value to drive the stepper-motor 120 in a stepwise manner, to the desired stepper motor position, which causes the stepper-motor 120 to displace the servo-regulator diaphragm 110 the desired distance and thereby regulate the output of the valve.

The example IFC 230 includes at least one sensor 310 and the example control circuit 130 includes at least one sensor 312. In other embodiments the IFC 230 or the control circuit 130 does not include any sensors. The sensors 310 and 312 may be any sensors suitable for measuring any variable value of interest. For example, the sensors 310, 312 may include temperature sensors, humidity sensors, air pressure sensors, accelerometers, or the like. In some embodiments in which the sensors 310 and/or 312 include accelerometers, the accelerometers are 1-axis accelerometers operable to detect an orientation of the IFC 230 and/or the control circuit 130 (and, accordingly, the orientation of the valve assembly 100) relative to gravity. In still other embodiments, at least one sensor 312 (such as an accelerometer) is mounted on a portion of the valve assembly 100 other than the control circuit 130.

The IFC 230 includes a remote device communication interface 314 for communication with a remote device 316, such as a mobile phone, a tablet computer, a laptop computer, or the like. The example communication interface 314 is a wireless communication interface for communicative coupling to the remote device. Other embodiments include a wired communication device. Wireless communication may include a radio frequency (RF), Bluetooth®, Wi-Fi, a ZigBee®, near field communication (NFC), infrared (IR), and/or any other device and communication protocol for wireless communication. (Bluetooth is a registered trademark of Bluetooth Special Interest Group of Kirkland, Washington; ZigBee is a registered trademark of the ZigBee Alliance of San Ramon, California.) Wired communication may include any suitable wired communication protocol for direct communication including, without limitation, USB, RS232, I2C, SPI, analog, and proprietary I/O protocols. Moreover, in some embodiments, the wired communication may be performed using a wired network adapter allowing communication through a network, such as the Internet, a local area network (LAN), a wide area network (WAN), a mesh network, and/or any other network.

The example IFC 230 includes an input device 318 and a display device 320. The example input device 318 includes one or more buttons. Alternatively, the input device 318 may include one or more dials, one or more switches, a keyboard, or the like. The display device 320 is one or more seven segment display devices. Alternatively, the display device 320 may be an LCD display, an LED display, a CRT display, a plurality of lights (such as LEDs), or the like. Some embodiments include a touchscreen display that functions as the input device 318 and the display device 320. The input device 318 and the display device 320 may be used together to input data, change settings, retrieve data or settings, and the like to/from the IFC 230.

The ambient temperature around the stepper-motor regulated gas valve assembly 100 can affect the flow through the stepper-motor regulated gas valve assembly 100. That is, the actual flow through the stepper-motor regulated gas valve assembly 100 (e.g., the outlet pressure) may not be the same as the expected flow through the stepper-motor regulated gas valve assembly 100. Without being limited to any particular theory or cause, this error may be caused for example by one or more parts of the gas valve 101 expanding and contracting with changing temperatures.

FIG. 4 illustrates a graph 400 of a first ultra-low fire gas heat algorithm in accordance with at least one embodiment. More specifically, graph 400 illustrates using process 500 (shown in FIG. 5) to reduce heat loses for the on cycle. Graph 400 illustrates a heat call start. Line 405 shows an inducer being turned on and set to a value in response to the heat call start. The inducer creates a draft or negative pressure within the combustion chamber. Line 410 shows the operation of a circulator, which forces air over a heat exchanger or heating elements. The hot air is then distributed to where it is needed. As shown in Line 410, the circulator begins operation a specific period of time after the flame at the gas valve has been lit. This period of time is the heat on delay. The circulator begins at a first, lower level of operation or speed. Then after a specific period of time, the circulator increases its level of operation or speed to a second higher level of operation or speed. The time between the lighting of the flame and the increase in circulator speed is considered the pre-heat delay. In a first embodiment, for a non-condensing system, the pre-heat delay is less than or equal to 150 seconds. In a second embodiment, for a condensing system, the pre-heat delay is less than or equal to 60 seconds.

Line 415 shows the operation of the gas valve 101 (shown in FIG. 1). The gas valve 101 activates to allow enough gas to flow through to light the flame. Once the flame is lit, the gas valve 101 lowers the flow of the fuel for the ultra-low fire. Note that in a typical furnace application, ultra-low fire gas heat is defined as a gas outlet pressure≤1″ WC (water column). In other applications, the gas outlet pressure for ultra-low first gas heat may include other values. In at least one embodiment, the gas outlet pressure for ultra-low first gas heat is below the value for ignition, but above the value where the flame is extinguished due to lack of fuel. This ultra-low fire gas heat is of substantially lower outlet pressure, than even the normal ‘low’ fire and/or ‘modulating’ outlet pressure of systems in use today. The gas valve 101 maintains the ultra-low fire until the completion of the pre-heat delay, when the circulator increases its operation and/or speed. Then the gas valve 101 increases the flow of fuel through the gas valve 101 to increase the heat from the flame. In some embodiments, the flow rate to ignite the flame and the regular flow rate of the fuel through the gas valve 101 are the same. In other embodiments, the two flow rates are different.

FIG. 5 illustrates a process 500 for the first ultra-low fire gas heat algorithm using the control circuit 130 (shown in FIG. 3). In the example embodiment, the steps of process 500 are performed by one or more of the IFC 230, the controller 130, and the gas valve 101. Process 500 is configured to reduce on cycle sensible heat losses. This includes slowing the rate of temperature increase at start-up. This reduces fuel waste, while the heat exchanger and surrounding air are warming up. Accordingly, algorithm 500 introduces a pre-heat delay, which overlaps with the traditional heat delay period. The heat delay period is the time from when the flame is initially lit to when the circulator turns on. The goal of process 500 is to maximize supply air temperature through-out the pre-heat delay, which minimizing the flue gas temperature at the end of the pre heat delay time. Accordingly, this reduces wasted fuel.

In step S505, the IFC 230 transmits instructions to the controller 130 for a heat start call. The heat start call could be to initiate a heating cycle such as in response to a change to a desired heating level. In some embodiments, the heat start call includes a desired heat level, including a desired value for the gas valve 101, such as a desired level for the stepper motor controlling the gas valve 101 or any other system for controlling the flow of fuel through the gas valve 101.

In step S505, the controller 130 receives the instructions from the IFC 230. In step S510, the controller 130 analyzes the instructions and determines a value for the gas valve 101. In step S515, the controller 130 transmits instructions for the gas valve 101 including an amount of fuel to allow through the gas valve 101 to light the flame. In some embodiments, in step S515, the controller 130 directly controls the gas valve 101 to allow an amount of fuel to ignite the flame.

After the flame is lit, in step S520, the controller 130 either transmits instructions to the gas valve 101 or directly controls the gas valve 101 to reduce the flow of fuel to the ultra-low fire level, which is a gas outlet pressure≤1″ WC (water column). In step S525, the controller 130 delays so that the gas valve 101 maintains the ultra-low fire until the completion of the pre-heat delay, when the circulator increases its operation and/or speed. Then in step S530, the controller 130 instructs or controls the gas valve 101 to increase the flow of fuel through the gas valve 101 to increase the heat from the flame to the level instructed by the IFC 230. In some embodiments, the flow rate to ignite the flame and the regular flow rate of the fuel through the gas valve 101 are the same. In other embodiments, the two flow rates are different.

FIG. 6 illustrates a graph 600 of a second ultra-low fire gas heat algorithm in accordance with at least one embodiment. More specifically, graph 600 illustrates using process 700 (shown in FIG. 7) to reduce heat loses for the short cycle. Short cycles occur during an active heat call. More specifically, for condensing furnaces, it is possible to increase condensate per cubic foot of natural gas. Process 700 is shown with a theoretical short cycle time of 10 minutes. However, other short cycle times may be used based on operating conditions. The goal of process 700 is to maximize short cycle system efficiency while minimizing the impact on total heat output during longer run times.

Graph 600 illustrates a short cycle. Line 605 shows an inducer running during the short cycle. Line 610 shows the operation of the circulator, which forces air over a heat exchanger or heating elements. During the short cycle, the circulator operates at a lower level for a period of time during the short cycle. The lower level of operations is for a period of time when the system is condensing. In some embodiments, this period of time is 90 seconds or less for a 10 minute cycle. In other embodiments, the period of time and/or the cycle time may be different. Line 615 shows the operation of the gas valve 101 during the short cycle. The gas valve 101 goes to ultra-low fire while the circulator is in the lower operation mode during the aforementioned period of time. The flow for ultra-low fire is a gas outlet pressure≤1″ WC (water column). The gas valve 101 maintains the ultra-low fire until the completion of the period of time, when the circulator increases its operation and/or speed. Then the gas valve 101 increases the flow of fuel through the gas valve 101 to increase the heat from the flame.

FIG. 7 illustrates a process 700 for the second ultra-low fire gas heat algorithm using the control circuit 130 (shown in FIG. 3). In the example embodiment, the steps of process 700 are performed by one or more of the IFC 230, the controller 130, and the gas valve 101. Process 700 is configured to maximize short cycle system efficiency while minimizing the impact on total heat output during longer run times. This reduces fuel waste, while condensing is occurring.

In step S705, the IFC 230 informs the controller 130 about the circulator going to the lower operation mode. In other embodiments, step 705 is the same as step S505 (shown in FIG. 5) initiating the heat call. In some of these embodiments, in step S710 the controller 130 tracks the time and initiates the ultra-low fire mode based on the time during the short cycle. For example, for a 10 minute short cycle, the controller 103 may initiate the ultra-low fire mode at 2.8 minutes into the short cycle and end the ultra-low fire mode at 9 minutes into the short cycle.

In step S715, the controller 130 either transmits instructions to the gas valve 101 or directly controls the gas valve 101 to reduce the flow of fuel to the ultra-low fire level, which is a gas outlet pressure≤1″ WC (water column). In step S720, the controller 130 delays so that the gas valve 101 maintains the ultra-low fire until the completion of the condensing or other reason for lowered circulator operation, when the circulator increases its operation and/or speed. Then in step S725, the controller 130 instructs or controls the gas valve 101 to increase the flow of fuel through the gas valve 101 to increase the heat from the flame, such as to the level previously instructed by the IFC 230.

FIG. 8 illustrates a graph 800 of a third ultra-low fire gas heat algorithm in accordance with at least one embodiment. More specifically, graph 800 illustrates using process 900 (shown in FIG. 9) to reduce heat loses for the off cycle. More specifically, process 900 is configured to redirect more of the residual heat to the supply air instead of the flue, while the heat exchanger and the surrounding air are cooling down. This reduces fuel waste. Process 900 introduces a new time delay period, known as a post-cool delay period, added to the end of a gas heat sequence. This post-cool delay period overlaps the traditional delay period.

Graph 800 illustrates a gas halt sequence for non-condensing devices, such as a gas furnace. Line 805 shows an inducer running from when an off signal is received, such as from the IFC 230, through a heat off delay. Line 810 shows the operation of the circulator, which runs for a period of time after the heat off delay. Line 815 shows the operation of the gas valve 101 during the gas halt sequence. The gas valve 101 goes to ultra-low fire mode when the off signal is received. The gas valve 101 operates at the ultra-low fire mode for the period of the post cool delay. In one embodiment, the post cool delay is between five and ten seconds. In other embodiments, the post cool delay may be shorter or longer. After the post cool delay, the gas valve 101 shuts off the gas. There is a post purge delay that lasts until the inducer shuts down. In some embodiments, the post purge delay is 30 seconds. Accordingly, the heat off delay includes both the post cool delay and the post purge delay.

FIG. 9 illustrates a process 900 for the third ultra-low fire gas heat algorithm using the control circuit 130 (shown in FIG. 3). In the example embodiment, the steps of process 900 are performed by one or more of the IFC 230, the controller 130, and the gas valve 101. Process 900 is configured to maximize supply air temperature throughout the post cool delay, while minimizing flue gas temperature at the end of the post-cool delay time. This reduces fuel waste.

In step S905, the IFC 230 transmits an off signal to the controller 130. In step S910, the controller 130 either transmits instructions to the gas valve 101 or directly controls the gas valve 101 to reduce the flow of fuel to the ultra-low fire level, which is a gas outlet pressure≤1″ WC (water column). In step S915, the controller 130 delays so that the gas valve 101 maintains the ultra-low fire until the completion of post cool delay. Then in step S920, the controller 130 instructs or controls the gas valve 101 to cease the flow of fuel through the gas valve 101 to stop the flame.

FIG. 10 illustrates a graph 1000 of a fourth ultra-low fire gas heat algorithm in accordance with at least one embodiment. More specifically, graph 1000 illustrates using process 1100 (shown in FIG. 11) to reduce heat loses for the off cycle for condensing devices, such as condensing furnaces. More specifically, process 1100 is configured to nearly eliminate the off cycle sensible heat losses by keeping the post purge time to below five seconds. This increases system efficiency while the heat exchanger and surrounding air are cooling down. This introduces a new post cool period with a maximum effect. It applies to condensing devices, e.g., condensing furnaces, since they operate at a much lower flue temperature. The goal of process 1100 is to maximize the supply air temperature throughout the post cool delay, while maximizing flue gas temperature at the end of the post-cool delay time.

Graph 1000 illustrates a gas halt sequence for condensing devices, such as a gas furnace. Line 1005 shows an inducer running from when an off signal is received, such as from the IFC 230, through a heat off delay. Line 1010 shows the operation of the circulator, which runs for a period of time after the heat off delay. Line 1015 shows the operation of the gas valve 101 during the gas halt sequence. The gas valve 101 goes to ultra-low fire mode when the off signal is received. The gas valve 101 operates at the ultra-low fire mode for the period of the post cool delay. In one embodiment, the post cool delay is between ten and fifteen seconds. In other embodiments, the post cool delay may be shorter or longer. After the post cool delay, the gas valve 101 shuts off the gas. There is a post purge delay that lasts until the inducer shuts down. In some embodiments, the post purge delay is less than five seconds. Accordingly, the heat off delay includes both the post cool delay and the post purge delay.

FIG. 11 illustrates a process 1100 for the fourth ultra-low fire gas heat algorithm using the control circuit 130 (shown in FIG. 3). In the example embodiment, the steps of process 900 are performed by one or more of the IFC 230, the controller 130, and the gas valve 101. The goal of process 1100 is to maximize the supply air temperature throughout the post cool delay, while maximizing flue gas temperature at the end of the post-cool delay time.

In step S1105, the IFC 230 transmits an off signal to the controller 130. In step S1110, the controller 130 either transmits instructions to the gas valve 101 or directly controls the gas valve 101 to reduce the flow of fuel to the ultra-low fire level, which is a gas outlet pressure≤1″ WC (water column). In step S1115, the controller 130 delays so that the gas valve 101 maintains the ultra-low fire until the completion of post cool delay. Then in step S1120, the controller 130 instructs or controls the gas valve 101 to cease the flow of fuel through the gas valve 101 to stop the flame.

FIG. 12 depicts an exemplary configuration of client computer devices, in accordance with one embodiment of the present disclosure. User computer device 1202 may be operated by a user 1201. User computer device 1202 may include, but is not limited to, controller 130 (shown in FIG. 1) and IFC 230 (shown in FIG. 2).

User computer device 1202 may include a processor 1205 for executing instructions. In some embodiments, executable instructions are stored in a memory area 1210. Processor 1205 may include one or more processing units (e.g., in a multi-core configuration). Memory area 1210 may be any device allowing information such as executable instructions and/or transaction data to be stored and retrieved. Memory area 1210 may include one or more computer readable media.

User computer device 1202 may also include at least one media output component 1215 for presenting information to user 1201. Media output component 1215 may be any component capable of conveying information to user 1201. In some embodiments, media output component 1215 may include an output adapter (not shown) such as a video adapter and/or an audio adapter. An output adapter may be operatively coupled to processor 1205 and operatively coupleable to an output device such as a display device (e.g., a cathode ray tube (CRT), liquid crystal display (LCD), light emitting diode (LED) display, or “electronic ink” display) or an audio output device (e.g., a speaker or headphones).

In some embodiments, media output component 1215 may be configured to present a graphical user interface (e.g., a web browser and/or a client application) to user 1201. A graphical user interface may include, for example, temperature information. In some embodiments, user computer device 1202 may include an input device 1220 for receiving input from user 1201. User 1201 may use input device 1220 to, without limitation, input temperature information.

Input device 1220 may include, for example, a keyboard, a pointing device, a mouse, a stylus, a touch sensitive panel (e.g., a touch pad or a touch screen), a gyroscope, an accelerometer, a position detector, a biometric input device, and/or an audio input device. A single component such as a touch screen may function as both an output device of media output component 1215 and input device 1220.

User computer device 1202 may also include a communication interface 1225, communicatively coupled to a remote device such as IFC 230 (shown in FIG. 2). Communication interface 1225 may include, for example, a wired or wireless network adapter and/or a wireless data transceiver for use with a wireless network.

Stored in memory area 1210 are, for example, computer readable instructions for providing a user interface to user 1201 via media output component 1215 and, optionally, receiving and processing input from input device 1220. A user interface may include, among other possibilities, a web browser and/or a client application. Web browsers enable users, such as user 1201, to display and interact with media and other information typically embedded on a web page or a website from IFC 230. A client application allows user 1201 to interact with. For example, instructions may be stored by a cloud service, and the output of the execution of the instructions sent to the media output component 1215.

Processor 1205 executes computer-executable instructions for implementing aspects of the disclosure. In some embodiments, the processor 1205 is transformed into a special purpose microprocessor by executing computer-executable instructions or by otherwise being programmed. For example, the processor 1205 may be programmed with the instructions such as processes 500, 700, 900, and 1100 (shown in FIGS. 5, 7, 9, and 11, respectively).

Additional Considerations

As will be appreciated based upon the foregoing specification, the above-described embodiments of the disclosure may be implemented using computer programming or engineering techniques including computer software, firmware, hardware or any combination or subset thereof. Any such resulting program, having computer-readable code means, may be embodied or provided within one or more computer-readable media, thereby making a computer program product, i.e., an article of manufacture, according to the discussed embodiments of the disclosure. The computer-readable media may be, for example, but is not limited to, a fixed (hard) drive, diskette, optical disk, magnetic tape, semiconductor memory such as read-only memory (ROM), and/or any transmitting/receiving medium, such as the Internet or other communication network or link. The article of manufacture containing the computer code may be made and/or used by executing the code directly from one medium, by copying the code from one medium to another medium, or by transmitting the code over a network.

These computer programs (also known as programs, software, software applications, “apps,” or code) include machine instructions for a programmable processor, and can be implemented in a high-level procedural and/or object-oriented programming language, and/or in assembly/machine language. As used herein, the terms “machine-readable medium” and “computer-readable medium” refer to any computer program product, apparatus and/or device (e.g., magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The “machine-readable medium” and “computer-readable medium,” however, do not include transitory signals. The term “machine-readable signal” refers to any signal used to provide machine instructions and/or data to a programmable processor.

As used herein, a processor may include any programmable system including systems using micro-controllers, reduced instruction set circuits (RISC), application specific integrated circuits (ASICs), logic circuits, and any other circuit or processor capable of executing the functions described herein. The above examples are example only, and are thus not intended to limit in any way the definition and/or meaning of the term “processor.”

As used herein, the terms “software” and “firmware” are interchangeable, and include any computer program stored in memory for execution by a processor, including RAM memory, ROM memory, EPROM memory, EEPROM memory, and non-volatile RAM (NVRAM) memory. The above memory types are example only, and are thus not limiting as to the types of memory usable for storage of a computer program.

As used herein, the term “database” can refer to either a body of data, a relational database management system (RDBMS), or to both. As used herein, a database can include any collection of data including hierarchical databases, relational databases, flat file databases, object-relational databases, object-oriented databases, and any other structured collection of records or data that is stored in a computer system. The above examples are example only, and thus are not intended to limit in any way the definition and/or meaning of the term database. Examples of RDBMS' include, but are not limited to including, Oracle® Database, MySQL, IBM® DB2, Microsoft® SQL Server, Sybase®, and PostgreSQL. However, any database can be used that enables the systems and methods described herein. (Oracle is a registered trademark of Oracle Corporation, Redwood Shores, California; IBM is a registered trademark of International Business Machines Corporation, Armonk, New York; Microsoft is a registered trademark of Microsoft Corporation, Redmond, Washington; and Sybase is a registered trademark of Sybase, Dublin, California.)

In another example, a computer program is embodied on a computer-readable medium. In an example, the system is executed on a single computer system, without requiring a connection to a server computer. In a further example, the system is being run in a Windows® environment (Windows is a registered trademark of Microsoft Corporation, Redmond, Washington). In yet another example, the system is run on a mainframe environment and a UNIX® server environment (UNIX is a registered trademark of X/Open Company Limited located in Reading, Berkshire, United Kingdom). In a further example, the system is run on an iOS® environment (iOS is a registered trademark of Cisco Systems, Inc. located in San Jose, CA). In yet a further example, the system is run on a Mac OS® environment (Mac OS is a registered trademark of Apple Inc. located in Cupertino, CA). In still yet a further example, the system is run on Android® OS (Android is a registered trademark of Google, Inc. of Mountain View, CA). In another example, the system is run on Linux® OS (Linux is a registered trademark of Linus Torvalds of Boston, MA). The application is flexible and designed to run in various different environments without compromising any major functionality.

As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited. Furthermore, references to “example” or “one example” of the present disclosure are not intended to be interpreted as excluding the existence of additional examples that also incorporate the recited features. Further, to the extent that terms “includes,” “including,” “has,” “contains,” and variants thereof are used herein, such terms are intended to be inclusive in a manner similar to the term “comprises” as an open transition word without precluding any additional or other elements.

As used herein, the terms “software” and “firmware” are interchangeable and include any computer program stored in memory for execution by a processor, including RAM memory, ROM memory, EPROM memory, EEPROM memory, and non-volatile RAM (NVRAM) memory. The above memory types are example only, and are thus not limiting as to the types of memory usable for storage of a computer program.

Furthermore, as used herein, the term “real-time” refers to at least one of the time of occurrence of the associated events, the time of measurement and collection of predetermined data, the time to process the data, and the time of a system response to the events and the environment. In the examples described herein, these activities and events occur substantially instantaneously.

In some embodiments, the system includes multiple components distributed among a plurality of computer devices. One or more components may be in the form of computer-executable instructions embodied in a computer-readable medium. The systems and processes are not limited to the specific embodiments described herein. In addition, components of each system and each process can be practiced independent and separate from other components and processes described herein. Each component and process can also be used in combination with other assembly packages and processes. The present embodiments may enhance the functionality and functioning of computers and/or computer systems.

The computer-implemented methods discussed herein can include additional, less, or alternate actions, including those discussed elsewhere herein. The methods can be implemented via one or more local or remote processors, transceivers, servers, and/or sensors (such as processors, transceivers, servers, and/or sensors mounted on vehicles or mobile devices, or associated with smart infrastructure or remote servers), and/or via computer-executable instructions stored on non-transitory computer-readable media or medium. Additionally, the computer systems discussed herein can include additional, less, or alternate functionality, including that discussed elsewhere herein. The computer systems discussed herein can include or be implemented via computer-executable instructions stored on non-transitory computer-readable media or medium.

As used herein, the term “non-transitory computer-readable media” is intended to be representative of any tangible computer-based device implemented in any method or technology for short-term and long-term storage of information, such as, computer-readable instructions, data structures, program modules and sub-modules, or other data in any device. Therefore, the methods described herein can be encoded as executable instructions embodied in a tangible, non-transitory, computer readable medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. Moreover, as used herein, the term “non-transitory computer-readable media” includes all tangible, computer-readable media, including, without limitation, non-transitory computer storage devices, including, without limitation, volatile and nonvolatile media, and removable and non-removable media such as a firmware, physical and virtual storage, CD-ROMs, DVDs, and any other digital source such as a network or the Internet, as well as yet to be developed digital means, with the sole exception being a transitory, propagating signal.

The patent claims at the end of this document are not intended to be construed under 35 U.S.C. § 112 (f) unless traditional means-plus-function language is expressly recited, such as “means for” or “step for” language being expressly recited in the claim(s).

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.