U.S. patent number 3,829,276 [Application Number 05/362,387] was granted by the patent office on 1974-08-13 for burner control.
This patent grant is currently assigned to Sundstrand Corporation. Invention is credited to Robert J. Lenski, James H. Meyer.
United States Patent |
3,829,276 |
Lenski , et al. |
August 13, 1974 |
BURNER CONTROL
Abstract
A control system for an oil burner including a motor for pumping
fuel to the burner, an igniter for lighting the fuel, and an
electronic switch for controlling energization of the motor and the
igniter, all in a line voltage circuit, together with a low voltage
circuit for controlling operation of the motor and igniter switch
including a relay controlling the gate of the switch, a second
electronic switch and a thermostat in circuit with the relay for
energizing the relay, a third electronic switch for triggering the
second switch, a gate circuit for triggering the third switch
including a light-sensitive flame detector cell and a light for
indicating operability of the flame detection circuitry.
Inventors: |
Lenski; Robert J. (Rockford,
IL), Meyer; James H. (Rockford, IL) |
Assignee: |
Sundstrand Corporation
(Rockford, IL)
|
Family
ID: |
23425923 |
Appl.
No.: |
05/362,387 |
Filed: |
May 21, 1973 |
Current U.S.
Class: |
431/14;
431/79 |
Current CPC
Class: |
F23N
5/082 (20130101); F23N 5/203 (20130101); F23N
2231/10 (20200101); F23N 2239/06 (20200101); F23N
2227/28 (20200101); F23N 2229/00 (20200101); F23N
5/08 (20130101); F23N 2223/20 (20200101) |
Current International
Class: |
F23N
5/20 (20060101); F23N 5/08 (20060101); F23n
005/08 () |
Field of
Search: |
;431/14,16,79 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Favors; Edward G.
Attorney, Agent or Firm: Hofgren, Wegner, Allen, Stellman
& McCord
Claims
We claim:
1. A burner control system comprising:
a. means providing a source of low voltage including a normally
closed safety switch,
b. a controlling relay element in circuit with the low voltage
source,
c. a thermostatic switch in circuit with said controlling relay
element adapted to close for conditioning the circuit responsive to
a call for heat,
d. a heater for the safety switch,
e. a normally nonconductive electronic switch in circuit with the
low voltage source and with the safety switch heater,
f. a circuit for triggering said electronic switch in circuit with
said low voltage source and said thermostatic switch,
g. a light-sensitive flame detector in the triggering circuit for
the electronic switch normally providing a relatively high
resistance to bias said switch to conduct in the absence of a
burner flame when the thermostatic switch is closed, and provide a
relatively low resistance in the presence of a burner flame to
reversely bias the switch to a nonconductive state when the burner
is lighted, and
h. an indicator energizable responsive to the triggering circuit
for the electronic switch during energization of the safety switch
heater.
2. A burner control system comprising:
a. means providing a source of low voltage including a normally
closed safety switch,
b. a controlling relay element in circuit with the low voltage
source,
c. a thermostatic switch in circuit with said controlling relay
element adapted to close for conditioning the circuit responsive to
a call for heat,
d. a first normally nonconductive electronic switch in circuit with
said controlling relay element and thermostatic switch for
energizing said controlling relay element,
e. a circuit for triggering said first electronic switch including
a second normally nonconductive electronic switch in circuit with
the low voltage source,
f. a heater for said safety switch in circuit with said second
electronic switch,
g. a circuit for triggering said second electronic switch in
circuit with said low voltage source and said thermostatic
switch,
h. a light-sensitive flame detector in the triggering circuit for
the second electronic switch normally providing a relatively high
resistance to bias said second electronic switch to conduct in the
absence of a burner flame when the thermostatic switch is closed
thereby to energize the safety switch heater and provide a
relatively low resistance in the presence of a burner flame to
reversely bias the second switch to a nonconductive state when the
burner is lighted, thereby to deenergize the heater, and
i. a visible indicator energizeable responsive to the triggering
circuit for the second electronic switch during energization of the
safety switch heater.
3. A burner control system as defined in claim 2, wherein the
visible indicator comprises a light emitting diode.
4. A burner control system as defined in claim 2, wherein the
second electronic switch comprises an asymmetrical switch rendered
conductive responsive only to a minimum breakover voltage.
5. A burner control system as defined in claim 2, wherein the
asymmetrical switch comprises a silicon asymmetrical trigger.
6. A burner control system comprising:
a. means providing a source of low voltage including a normally
closed safety switch,
b. a controlling relay element in circuit with the low voltage
source,
c. a thermostatic switch in circuit with said controlling relay
element adapted to close for conditioning the circuit responsive to
a call for heat,
d. an asymmetrical switch in circuit with said controlling relay
element and thermostatic switch for energizing said controlling
relay element responsive to a predetermined breakover voltage,
e. an operator for said safety switch,
f. a circuit for energizing said operator upon closure of said
thermostatic switch, and
g. a flame detector in the operator circuit for deenergizing the
operator on the establishment of a burner flame.
7. A burner control system comprising:
a. means providing a source of low voltage including a normally
closed safety switch,
b. a controlling relay element in circuit with the low voltage
source,
c. a thermostatic switch in circuit with said controlling relay
element adapted to close for conditioning the circuit responsive to
a call for heat,
d. a forward breakover switch in circuit with said controlling
relay element and thermostatic switch for energizing said
controlling relay element responsive only to a predetermined
minimum breakover voltage,
e. a circuit for triggering said breakover switch including a
second normally nonconductive electronic switch in circuit with the
low voltage source,
f. a heater for said safety switch in circuit with said second
electronic switch,
g. a circuit for triggering said second electronic switch in
circuit with said low voltage source and said thermostatic switch,
and
h. a light-sensitive flame detector in the triggering circuit for
the second electronic switch normally providing a relatively high
resistance to bias said second switch to conduct in the absence of
a burner flame when the thermostatic switch is closed, and provide
a relatively low resistance in the presence of a burner flame to
reversely bias the second switch to a nonconductive state when the
burner is lighted.
8. A burner control system as defined in claim 7, wherein the
breakover switch comprises a silicon asymmetrical trigger.
9. A burner control system as defined in claim 7, including an
indicator energizable responsive to the triggering circuit for the
second electronic switch during energization of the safety switch
heater.
10. A burner control system comprising:
a. means providing a line voltage circuit including selectively
energizable burner means,
b. a first electronic switch in circuit with the burner means
including a gate for triggering said switch,
c. a light-sensitive element in circuit with the gate for rendering
the gate conductive,
d. means providing a source of low voltage,
e. a light emitting element for transmitting light to said
light-sensitive element,
f. a thermostat in circuit with said low voltage source and said
light emitting element for conditioning the circuit responsive to a
call for heat,
g. a forward breakover device in the circuit with said light
emitting element and thermostat for energizing said light emitting
element responsive to a predetermined breakover voltage,
h. a third normally nonconductive electronic switch in circuit with
the low voltage source for rendering the forward breakover device
conductive,
i. a circuit for triggering said third electronic switch in circuit
with said low voltage source and said thermostat, and
j. a light-sensitive flame detecting cell in circuit with the
triggering circuit for the third electronic switch normally
providing a relatively high resistance to trigger said third switch
in the absence of a burner flame when the thermostat is closed, and
provide a relatively low resistance in the presence of a burner
flame to render the third switch nonconductive when the burner is
lighted.
11. A burner control system as defined in claim 10, wherein the
forward breakover diode comprises a silicon asymmetrical
trigger.
12. A burner control system comprising:
a. means providing a line voltage circuit including selectively
energizable burner means,
b. a first electronic switch in circuit with the burner means
including a gate for triggering said switch,
c. a light-sensitive element in circuit with the gate for rendering
the gate conductive,
d. means providing a source of low voltage including a normally
closed safety switch,
e. a light emitting element for transmitting light to said
light-sensitive element,
f. a thermostat in circuit with said low voltage source and said
light emitting element for conditioning the circuit responsive to a
call for heat,
g. a second electronic switch in circuit with said light emitting
element and thermostat for energizing said light emitting element
including a gate for triggering said second electronic switch,
h. a third normally nonconductive electronic switch in circuit with
the low voltage source for rendering the last recited gate
conductive,
i. a heater for the safety switch in circuit with the third
electronic switch,
j. a gate for triggering said third electronic switch in circuit
with said low voltage source and said thermostat,
k. a light-sensitive flame detecting cell in circuit with the gate
for the third electronic switch normally providing a relatively
high resistance to trigger said third switch in the absence of a
burner flame when the thermostat is closed, and provide a
relatively low resistance in the presence of a burner flame to
render the third switch nonconductive when the burner is lighted,
and
l. a visible indicator energizable responsive to the gate circuit
for the second electronic switch during conductivity of the third
switch.
13. A burner control system comprising:
a. means providing a line voltage circuit,
b. burner means in the line voltage circuit adapted to be
selectively energized,
c. a first electronic switch in circuit with the burner means,
d. a circuit for triggering said switch including a controlled
relay element,
e. means providing a source of low voltage including a normally
closed safety switch,
f. a controlling relay element in circuit with the low voltage
source for controlling said controlled relay element,
g. a thermostat in circuit with said controlling relay element for
conditioning the circuit responsive to a call for heat,
h. a forward breakover device in circuit with said controlling
relay element and thermostat for energizing said controlling relay
element,
i. a circuit for triggering said breakover device including a third
electronic switch in circuit with the low voltage source,
j. a heater for said safety switch in circuit with said third
electronic switch,
k. a gate circuit for triggering said third electronic switch in
circuit with said low voltage source and said thermostat,
l. a light-sensitive flame detector in the gate circuit for the
third electronic switch normally providing a relatively high
resistance to trigger said third switch and the heater in the
absence of a burner flame when the thermostat is closed, and
provide a relatively low resistance in the presence of a burner
flame to render the third switch and the heater nonconductive when
the burner is lighted, and
m. a light emitting diode energizable during energization of the
third switch.
Description
BACKGROUND OF THE INVENTION
The present invention relates to controls for a heating system such
as an oil burner of the type utilized in residential buildings, for
example, wherein the burner is responsive to a call for heat by
thermostat, which is intended to energize a fuel supply means and
an igniter for lighting the fuel.
In systems of the type described, there is usually a relatively
delicate balance between fuel supply and air supply within which
clean, efficient combustion can be expected. If there is a fuel
supply without prompt ignition, or if combustion is initiated and
then discontinued inadvertently or unexpectedly, it is important
that the fuel supply be discontinued promptly in order to avoid
conditions which could be harmful to the equipment or dangerous to
property or personnel. Accordingly, it is important in burner
control systems to provide safe failure in the event the flame does
not start when desired, or goes out after starting.
In the past, control systems of the type described have often
utilized electro-mechanical controls including moving parts which
are subject to wear. As controls have become more complicated,
numerous moving parts have led to relatively short life and
expensive maintenance problems. Also, the controls have often been
incorporated in line voltage circuits which may be dangerous and
destructive of circuit components in event of malfunction.
Recently, there have been some controls utilizing electronic
components in low voltage circuits in an effort to improve safety
and reliability. For example, U.S. Pat. No. 3,624,407 relates to a
furnace control with electronic components in a low voltage
circuit, including a reed switch controlling the burner responsive
to separate energizing and holding coils. U.S. Pat. No. 3,672,811
relates to a burner control, in which all of the control components
are included in a line voltage circuit, and the fuel supply is
controlled by a light-sensitive relay responsive to both an
activating lamp and a holding lamp. U.S. Pat. No. 3,463,600 relates
to a burner control with two flame sensors, and a malfunction
indicator to signal when one of the sensors is not in working
order.
The prior application o Robert J. Lenski, Ser. No. 291,142 filed
Sept. 25, 1972, and assigned to the assignee of this application,
relates to an improved burner control system with control
components in a low voltage circuit with fail-safe capacity and
including an electronic switch for triggering a burner control
relay and remaining energized so long as the thermostat calls for
heat, without the need for separate energizing means and holding
means for the relay.
It is desirable to provide an improved burner control system with
control components in a low voltage circuit with means preventing
operation in event of inadequate line voltage, and with means for
indicating inoperation of the flame detection circuitry.
SUMMARY OF THE PRESENT INVENTION
The present invention relates to an improved burner control system
in which a thermostat, flame sensor and safety switch are connected
in a low voltage solid state circuit, completely isolated from the
commercial 110-volt AC power supply. Only a burner motor, for
supplying air and fuel, and an igniter, together with a control
switch for the motor and igniter, are included in a line voltage
circuit. When the thermostatic switch closes, calling for heat, the
controls in the low voltage control circuit function sequentially
to verify operation of a flame detector cell and a safety switch
before energizing the fuel supply and igniter means. If a flame is
not established in a short time, the safety switch opens the
control circuit to prevent energization of the fuel supply and
igniter, and the system cannot be placed in operation again without
manually resetting the safety switch.
In a preferred embodiment, the flame detection circuitry includes
an indicator light which is normally energized during the time when
the safety switch heater is energized to indicate that no flame has
been established, or that insufficient light has been sensed by the
flame detector, or that a break exists in the flame sensor
circuitry. In the event that a flame is established, the indicator
light is extinguished when the safety switch heater is
deenergized.
Preferably, an electronic switch in the form of a forward breakover
diode is used in circuit with a controlling relay and requires a
predetermined minimum voltage before operation, so that the control
circuit is incapable of operation under conditions where the line
voltage is inadequate to establish proper operation of the burner
igniter and burner motor.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a burner control circuit embodying the principles of
the present invention, utilizing a photoelectric coupling between a
low voltage control circuit and a line voltage burner circuit,
together with an indicating light for showing malfunction in the
flame detection circuitry.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
Referring now to the drawing, a line voltage circuit includes a
line 20 and line 21 connected across the primary winding of a
transformer 22. A burner motor 24 for supplying oil and air to a
combustion chamber is connected to the line 20 by wire 25 and
connected to the line 21 through a wire 27 and a triac switch T1.
An igniter 28 is connected in parallel with the motor 24 so that
the motor and the igniter are simultaneously energized.
The triac switch T1 includes a main terminal MT2 connected to the
wire 27, a main terminal MT1 connected to the line 21 and a gate G
connected to a control circuit for triggering the switch when there
is a call for heat by the thermostat. A resistor R2 is connected
between the triac terminals G and MT1 to eliminate false triggering
of the triac due to excessive leakage currents at high temperature
or due to electrically generated stray noise signals. A resistor R1
and a capacitor C1 are connected across the triac terminals MT2 and
MT1 to limit the rate of rise of voltage across the triac T1 to a
safe value when the triac switches from on to off.
The triac T1 is normally in its off or nonconducting state when the
thermostat is not calling for heat. The gate G of the triac T1 is
biased to render the triac conducting by means of a collector
current from a driver transistor T3. The collector of the
transistor T3 is connected to the triac gate G by a conductor 30
including a resistor R3. The resistor combination of R3 and R2
provides proper gate bias voltage and current for the triac T1. The
base of the transistor T3 is connected to the emitter of a
phototransistor T2 by a conductor 31, and the emitter of the
transistor T3 is connected by a conductor 32 to a conductor 33.
The base of the transistor T2 is connected by a capacitor C5 and
capacitor C6 to the conductor 33. The capacitors insure
stabilization of the high gain transistor pair T3 and T2. The
conductor 33 is connected by a conductor 36 and diode D1 to a tap
on the primary winding of the transformer 22. The collector of the
transistor T2 is connected to a resistor R4. The phototransistor T2
is arranged to respond to light from a light emitting diode D3 in a
low voltage control circuit responsive to the thermostat. Light
from the diode D3 striking the transistor T2 initiates a base
current flow in the transistor T2, as a result of which the
phototransistor conducts, amplifying the small light generated base
current into considerably more emitter current. The emitter current
from the transistor T2 flows into the base of the driver transistor
T3, causing it to saturate and conduct collector current to trigger
the triac T1.
Diode D1 and a capacitor C2 in the conductor 33 function as a
half-wave power supply for the gate trigger circuitry of
transistors T2 and T3. Resistor R4 acts as a current limit for
transistors T3 and T2.
A resistor R5 and a transistor R14 are connected between the
conductors 31 and 33. The resistors provide a finite resistance
shunt across the base-emitter junction of transistor T3 to drain
off leakage currents at high temperature.
A low voltage control circuit is connected across the secondary of
the transformer 22. The low voltage circuit includes a thermostat
incorporating a normally open thermostatic switch 40 which is
adapted to close responsive to decreasing ambient temperature to
call for heat. The low voltage circuit also includes a light
sensitive cadmium-type photoresistive flame detecting cell 42
located adjacent to a burner 43 so that the cell is responsive to
the presence or absence of a flame at the burner. The cell 42 has a
relatively high resistance, on the order of 50K ohms, in darkness
in the absence of a flame at the burner 43, and a relatively low
resistance, from 300 ohms to 2,000 ohms, depending upon the
distance of the cell from the flame, when the burner is
lighted.
Preferably, the burner control circuitry is incorporated in an
appropriate housing represented at 45, with only the burner motor
24, the igniter 28, the thermostat 40 and the cad cell 42 outside
the housing 45. In order to properly connect the control circuitry
to the external components of the system, the housing 45 includes a
terminal LG for connection to the power supply line 20, a terminal
L for connection to the power supply line 21, and a terminal M for
connection with the motor 24 and igniter 28. Additionally, the
housing 45 includes terminals T for connection of the thermostat,
and terminals F for connection of the flame detector cell 32.
The light emitting diode D3 and the phototransistor T2 may be
appropriately characterized as a light relay generally designated
46, in which the diode D3 is a controlling relay element and the
transistor T2 is a controlled relay element.
In the low voltage control circuit, the light emitting diode D3 is
connected to be energized responsive to closure of the thermostatic
switch 40, provided that certain other conditions exist, as will
appear in the description of the circuitry.
The low voltage circuit includes a safety switch with normally
closed switch contacts 47 and a heater coil 48 arranged to cause
opening of the contacts 47 after a predetermined period on the
order of 15 to 45 seconds. After the switch contacts are opened,
they are latched in open condition and must be manually reset by
means of a button 49 accessible from the outside of the housing 45.
The physical construction of the safety switch may be on the order
of that shown and described in the aforementioned U.S. Pat. No.
3,624,407, but the present circuit obviates the need for a
temperature compensated switch which has generally been
necessary.
In order to provide for energization of the light emitting diode D3
when there is a call for heat, the diode is connected across the
secondary winding of the transformer 22 in a circuit including a
conductor 50 leeading from the transformer secondary (adjacent
ground) to the safety switch 47, a conductor 51 leading from the
safety switch 47 to the diode D3, a conductor 52 leading from the
diode, a conductor 54 leading from the conductor 52 to an
electronic switch T4 and resistance R10, diode D2, a conductor 55
including resistance R8 leading from the diode D2 to thermostat 40,
and a conductor 56 returning from the SCR T4 to the transformer
secondary.
The electronic switch T4 is a forward breakover device, such as
various silicon trigger devices. In a preferred circuit, the switch
T4 is a silicon asymmetrical AC trigger which is commercially
available as ST4. However, other devices may be used, such as a
silicon unilateral switch available as 2N4988.9, and a silicon
bilateral switch available as 2N4991.
As is conventional, the thermostat 40 includes an anticipator
heater element in the form of a very small resistance 58. When the
thermostat 40 closes responsive to a call for heat, power is
supplied from the transformer secondary winding (+ 12) through the
thermostat contacts and to the conductor 55 including resistors R8
and R7. The resistors are thus connected across the transformer
secondary winding via the safety switch contacts 47 and which are
normally closed. Under such conditions, the resistors draw
approximately 200 milliamps alternating current to operate the
thermostat anticipator element 58 which is commonly provided to
prevent overshooting of the thermostat.
Resistors R7 and R8, together with diode D2, provide a
predetermined bias voltage and charge path for a negative power
supply capacitor C3 in a conductor 59. On successive negative
half-cycle swings of the transformer secondary winding, capacitor
C3 charges in stepwise fashion to a negative steady state voltage,
controlled by the ratio of resistances R7 and R8, which is slightly
below the breakover voltage of the asymmetrical switch T4. Assuming
the switch T4 is nonconductive below a 7-volt differential across
the switch, the capacitor C3 could establish a negative voltage on
the order of 6.5 volts at the switch T4.
Triggering of the asymmetrical switch T4 is controlled by a silicon
controlled rectifier T5 which is connected to the conductor 56
leading from the transformer secondary. The SCR T5 is normally
nonconductive and is in circuit with heater 48 for the safety
switch contacts 47. When the SCR T5 is triggered, the cathode
voltage appears across a resistance R15 and a potentiometer R13.
The wiper arm of the potentiometer R13 couples part of the rising
cathode voltage across one terminal of the asymmetrical switch T4.
The other terminal of the switch T4 is held at negative supply
voltage established by capacitor C3 during negative half-cycle
excursions of the transformer. When the combination of these two
voltages exceeds the breakover voltage of switch T4, it switches
from the normally "off" mode to its "on" or conducting state. Thus,
at least one cycle of both positive and negative transformer
voltage is necessary to cause T4 to conduct, eliminating the
transient effects of thermostat contact closures. A capacitor C4 is
connected across the asymmetrical switch T4 an the resistance R10,
and a Capacitor C7 is connected across the SCR T5 and the heater
48, to eliminate noise spikes and false triggering of the
asymmetrical switch T4.
When the thermostat 40 closes, and there is no flame yet
established at the burner 43, the cad cell 42 remains in its "dark"
or high-resistance state. On positive half-cycle swings of the
transformer secondary winding, the high resistance of the cell 42
causes the gate-cathode junction of SCR T5 to be forward biased by
a bias network including resistor R6, resistor R5 and diode D4.
Enough gate current and voltage appear at SCR T5 to trigger T5 to
conduct sufficient holding current through the safety switch
heating element 48 so that the SCR remains conducting for the
duration of the positive half-cycle transformer voltage swing.
When the SCR T5 is triggered, it produces three results. (1) It
supplies heating current to the safety switch heater element 48
which ultimately will cause opening of the safety switch contacts
47 if a flame is not established at the burner 43 within a period
of time on the order of 15 to 45 seconds depending upon the
proximity of the cell 42 to the burner 43. (2) The rising cathode
voltage supplied to asymmetrical switch T4 through resistances R15
and R13 cause T4 to "breakover" and conduct current through the
light emitting diode D3 and resistor R10, thus calling for
energization of the burner motor 24 and igniter 28. (3) The rising
cathode voltage causes the cathode-gate junction of T5 to go into
"reverse breakdown" dumping a limited amount of current into the
resistor R9 and the light emitting diode D4, causing the diode D4
to emit visible light indicating that a flame condition has not yet
been established and that the control is operating in the trial
period, with the safety switch heater 48 energized.
The resistive heating element 48 in the safety switch, upon
receiving current from SCR T5, heats a bi-metallic element in the
safety switch which serves to open the safety switch contacts after
a predetermined time period. The switch is usually adjusted such
that it will open the safety contacts 47 after 15 to 45 seconds of
continuous heating by the element 48. If no flame is established in
such time period, while the thermostat 40 remains closed, calling
for heat, the contacts 47 open to remove power from the low voltage
control, thereby shutting down the entire burner control system.
Once the safety switch contacts open, they remain open, and it is
necessary to manually reset the safety switch.
Once triggered into the conducting state, the asymmetrical switch
T4 will remain in its conducting state, causing current to flow
through the light emitting diode D3 and the current limiting
resistor R10, until the commercial power is shut off, or the safety
switch contacts 47 open, or the thermostat contacts 40 open. As
long as T4 conducts, the light emitting diode D3 conducts, and
emits light to the base region of the phototransistor T2 for
energizing the burner motor 24 and the igniter 28. The wiper arm of
the potentiometer R13 is adjusted preferably so that the
asymmetrical switch T4 will not "breakover" and conduct for line
voltages less than approximately 90 volts. Thus, it is not possible
to energize the low voltage control when the line voltage is less
than that which is suitable for operating the burner motor 24 and
the igniter 28. Prior to adjustment of the potentiometer R13, the
resistor R15 serves to protect the asymmetrical switch T4 from
receiving excessive current in case the wiper arm of the
potentiometer R13 is randomly set, touching one of the extreme ends
of the potentiometer.
If a flame is established at the burner 43 during the 15 to 45
second trial period before the safety switch contacts 47 open, as
will normally occur if the control system functions properly, the
resistance in the flame detector cell 42 will be reduced to a low
volume between 300 and 2,000 ohms, depending upon the proximity of
the cell to the flame. The low resistance in the flame detector
cell reverse biases the gate-cathode junction of the SCR T5,
thereby turning off the SCR T5. When the switch T5 is not
conducting, no power is consumed by the heater element 48 in the
safety switch, so that it cools and the contacts 47 remain in the
normally closed position. As a result, the burner will continue to
operate as long as the thermostat calls for heat and the flame
detector cell reads flame condition.
The diagnostic indicator, light emitting diode D4 remains energized
while the heater 48 is energized. The flame detection circuitry is
thus monitored during such time period. Energization of the diode
D4 indicates that the safety switch heater 48 is energized and
timing out the trial period. During such trial period, if the diode
D3 is not energized, the absence of the light indicates that no
flame has been established, or insufficient light is reaching the
flame detector cell 42, or the flame detection circuitry is open.
Thus, at the time of the trial period, a service man is able to
immediately ascertain what is happening in the flame detection
circuitry. When a flame is appropriately established at the burner
43 within the trial period, the light emitting diode D4 is
deenergized when the safety switch heater 48 is deenergized.
Preferably, the light emitting diode D3 and the phototransistor T2
are combined in a single commercially available integrated circuit
such as Monsanto Company's photocoupler MCT26.
The switching devices T1 and T3-T5 may be of the type identified by
various manufacturers as follows:
T1 -- 64149 special
t3 -- 2n5305
t4 -- st-4
t5 -- c103y, tic-44
the diodes D1, D2 and D4 may be of the type identified by
manufacturers as follows:
D1 -- 1n4002
d2 -- 1n4148
d4 -- rl-50
the capacitors C1-C7 have values generally as follows:
C1 -- 0.1 mf, 400v
c2 -- 220 mf, 25v
c3 -- 220 mf, 16v
c4 -- 0.1 mf, 25v
c5 -- 270pf to 390 PF, 25V
C6 -- 270pf to 390 PF, 25V
C7 -- 0.1 mf, 50v
the resistances R1-R15 have values approximately as follows:
R1 -- 100 ohm 1/2W
R2 -- 820 ohm 1/2W
R3 -- 68 ohm 1W
R4 -- 1.8k ohm 1/2W
R5 -- 33k ohm 1/2W
R6 -- 18k ohm 1/2W
R7 -- 22 ohm 3W. 5 percent
R8 -- 40 ohm 3W. 5 percent
R9 -- 390 ohm 1/2W
R10 -- 150 ohm 1/2W
R11 -- 820 ohm 1/2W
R12 -- 820 ohm 1/2W
R13 -- 100k ohm POT
R14 -- 33k ohm 1/2W
R15 -- 4.7k ohm 1/2W
To summarize the operation, when there is no call for heat, the
thermostatic switch contacts 40 are normally open, and the
components of the system are at rest. When the thermostatic switch
is closed, a circuit is completed to the gate for the SCR T5. If
the flame detector cell 42 is functioning properly, and there is no
flame, the high resistance at the cell causes the SCR T5 to
conduct. When the SCR T5 conducts, a circuit is completed through
the safety switch heater 48 to start the trial period. At the same
time, the indicator diode D4 is energized. Conduction in the SCR T5
results in triggering the asymmetrical switch T4, completing a
circuit to energize the light emitting diode D3 to transmit light
to the phototransistor T2. The emitted current from the
phototransistor T2 causes the transistor T3 to conduct. The
collector current from the transistor T3 biases the gate G of the
triac T1 so that the latter is rendered conducting, to energize the
burner motor 24 and the igniter 28. The motor drives a pump for
supplying fuel oil to the burner 43 and the igniter causes ignition
of such fuel. The existence of a flame reduces the resistance in
the flame detector cell 42, rendering the SCR T5 nonconducting. The
indicator diode D4 is deenergized. The heater coil 48 is
deenergized, and the safety switch contacts 47 remain closed.
If, for some reason, the normally expected cycle of operation
described above is not completed, no flame is established at the
burner 43, the high resistance in the unlighted flame detector cell
42 will maintain the SCR T5 conducting until the heater element 48
opens the safety switch contacts 47, thereby shutting the system
down until it receives manual attention.
The arrangement provides for safe failure. If a malfunction
condition exists such that the thermostat terminals T are shorted,
and the flame sensor terminals F are open, the burner control may
turn on, but it will not operate longer than the time required for
the heater to open the safety switch contacts 47, because there
will be no reduction of resistance to render the SCR T5
nonconducting. If the flame sensor terminals F are shorted, the
burner control will never start, because the SCR T5 will be
nonconducting. If the safety switch heater element 48 is open
circuited, the SCR T5 will not receive sufficient holding current
to conduct, as a result of which the asymmetrical switch T4 will
remain off and the control will not start.
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