U.S. patent number 3,906,221 [Application Number 05/423,168] was granted by the patent office on 1975-09-16 for proof of igniter and flame sensing device and system.
Invention is credited to Gary M. Mercier.
United States Patent |
3,906,221 |
Mercier |
September 16, 1975 |
**Please see images for:
( Certificate of Correction ) ** |
Proof of igniter and flame sensing device and system
Abstract
A single device for proving both the presence of an igniter and
flame in a fuel burner is provided, the device including means such
as a ceramic coating for both transmitting actinic radiation
emitted by the igniter and generating actinic radiation upon flame
excitation. The ceramic or other means is associated with an
actinic radiation transmitting element which delivers the radiation
to a photoresponsive element whereby a signal is provided which
triggers fuel delivery to the burner when the igniter is an
igniting mode or thereafter when flame is present. A method of
proving igniter and flame is also provided utilizing such device
and electronic circuitry adapted to prove its own integrity.
Inventors: |
Mercier; Gary M. (St. Louis
Park, MN) |
Family
ID: |
23677914 |
Appl.
No.: |
05/423,168 |
Filed: |
December 10, 1973 |
Current U.S.
Class: |
250/227.11;
340/578; 250/338.1; 359/350; 385/12 |
Current CPC
Class: |
F23N
5/082 (20130101); F23N 5/242 (20130101); F23Q
7/10 (20130101); F23N 2227/16 (20200101); F23N
2227/12 (20200101) |
Current International
Class: |
F23N
5/24 (20060101); F23Q 7/10 (20060101); F23N
5/08 (20060101); F23Q 7/00 (20060101); G02B
005/14 () |
Field of
Search: |
;250/227,239,212,238,338
;350/96R,16LC ;340/227R,252H |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
holzman, IBM Technical Disclosure Bulletin, Vol. 8, No. 1, June
1965, pp. 151, 152..
|
Primary Examiner: Stolwein; Walter
Attorney, Agent or Firm: Kirn, Jr.; Walter N.
Claims
What is claimed is:
1. A device for sensing the presence of a flame and an electrical
resistance igniter in the igniting mode in a fuel burner system in
combination with a photoresponsive element sensitive to infrared
radiation, said device comprising infrared radiation-conducting
means having a portion thereof adapted to be located directly
within said flame, ceramic cover means associated with and
substantially enclosing said portion of said infrared
radiation-conducting means, said ceramic cover means being heat
stable, visible light opaque, transparent to the passage of
infrared radiation emitted by said igniter through said cover means
whereby said igniter is sensed by said photoresponsive element and
further said cover means emitting infrared radiation upon
excitation by a flame whereby said flame is sensed by said
photoresponsive element.
2. The device of claim 1 wherein said infrared radiation conducting
means comprises quartz.
3. The device of claim 1 wherein said infrared radiation conducting
element comprises a quartz rod, a fiber optic bundle, and bonding
means for optically coupling said rod to said bundle.
4. The device of claim 1 wherein said cover means comprises a
ceramic composition adherably bonded to said infrared radiation
conducting means.
5. The device of claim 1 wherein said cover means comprises a
ceramic composition in infrared radiation transmitting relationship
to said conducting means.
6. The device of claim 1 wherein said infrared radiation conducting
means is in optically coupled relationship to said photoresponsive
element responsive to said infrared radiation.
7. The device of claim 6 wherein said photoresponsive element is
photoconductive.
8. The device of claim 6 wherein said photoresponsive element is
photovoltaic.
9. The device of claim 6 wherein a nematic liquid crystal is
operatively interposed between said conducting means and said
photoresponsive element.
10. The device of claim 3 wherein said optical bonding means
comprises an epoxy adhesive optically transmissive to said infrared
radiation.
Description
This invention relates to the art of detecting the presence of an
igniter and flame in a fuel burner system, and especially to a
system for sensing and proving both igniter and flame with a single
device.
There is a need for a reliable, inexpensive electric ignition and
flame detection system which can be applied to a broad range of
appliance burners. This need results from the inadequacies of
present ignition and flame sensing configurations.
The constant burning gas pilot is currently the most common means
of igniting the main burner in an appliance. The pilot itself must
be manually lit and it is proven by a thermocouple or mercury
expansion flame switch. The main burner flame is not proven.
There are several pilot relight systems commercially available.
These systems provide a spark to relight the pilot whenever it is
accidentally extinguished. A few types of electric resistance
igniters are also available. Two such devices are the molybdenum
disilicide igniter and the silicon carbide glow plug. Additionally,
there are some main burner ignition and flame detection systems
available. The majority of these systems provide ignition by means
of sparking electrodes. Some systems spark during the entire burner
cycle; others spark for a short duration at the beginning of every
cycle. Both types use one of the sparking probes or employ a
separate high temperature metal probe for sensing flame. These
systems use the properties of electrical conduction or
rectification and conduction through the flame to prove its
existence. Also, there are a limited number of systems which use
thermal bi-metal type switches for sensing burner flame. There are
significant drawbacks with each of these ignition and flame sensing
systems.
Main burner spark ignition systems suffer from probe degradation,
especially in high heat flux burners. The probe spark gap is
critical. Oxidation of the probes and condensation on the probes
can cause these systems to fail by preventing proper sparking or
improper biasing of the flame signal. The ceramic insulator can
cause problems by allowing water to condense in its pores,
presenting an alternate path for conduction. The ceramic itself can
begin to conduct at high temperatures and improperly bias the
system. Radio frequency interference caused by some spark igniter
systems is also undesirable.
The constant burning pilot system must be manually lit and usually
manually relit if it goes out. Pilots are continually on, and are
increasingly being criticized as a waste of energy. Pilots cannot
usually be employed with powered burners. Proof of pilot does not
necessarily assure proper and safe main burner operation.
The pilot relighter increases system reliability, but it has the
drawback of all spark systems and does not perform well under
conditions of high humidity. The pilot relighter is too costly for
the benefit it provides, with the possible exception of commercial
roof-top gas equipment.
Bi-metal flame sensing switches can only be applied to a limited
number of burner designs. For example, bi-metal systems have been
used for years on gas dryers, but the same systems cannot withstand
the conditions of a higher heat flux burner, nor can they respond
rapidly enough to meet ANSI Standards when applied on products such
as residential furnances which retain large quantities of residual
heat after flameout.
Electrical resistance igniters eliminate the problems of spark
ignition. However, the molybdenum disilicide igniter is very
fragile and cannot work at high flow rates or on high heat flux
burners. The silicon carbide igniter has been successfully applied
with a bi-metal sensor as a proof of ignition and flame system in
certain gas dryers. But the system is especially modified to a
specific burner design and has all the drawbacks previously
associated with bi-metal sensing systems.
It is an object of the present invention to provide a sensing
device which avoids the above-mentioned drawbacks.
A further object is the provision of a single sensing device which
proves both igniter and flame.
A still further object is to provide a sensing system which is fail
safe.
In one embodiment of this invention there is provided an optical
sensing device adapted for use with a photoresponsive element
sensitive to actinic radiation comprising an actinic radiation
conducting element, said conducting element being in energizing
relationship to said photoresponsive means, and cover means in
actinic radiation transmissive association with said conducting
element, said cover means being heat stable, ambient light opaque,
actinic radiation transmissive and actinic radiation emissive upon
subjection to flame energy.
In another embodiment, a process for detecting igniter and flame in
a burner system is provided comprising
1. arranging the above-defined optical sensing device in actinic
radiation receiving relationship to a fuel igniter, said fuel
igniter being adapted to emit actinic radiation when in the
igniting mode,
2. energizing said fuel igniter to said igniting mode wherein said
fuel igniter emits actinic radiation at a level capable of being
sensed by said device,
3. receiving said actinic radiation by said cover means associated
with said actinic radiation conducting element,
4. transmitting said actinic radiation to said photoresponsive
element via said actinic radiation conducting element whereby said
photoresponsive element provdes a signal for actuating a valve
means,
5. supplying fuel to said burner via said valve means for a time
sufficient to cause ignition of said fuel by said fuel igniter in
the igniting mode,
6. de-energizing said fuel igniter to a quiescent mode wherein said
fuel igniter does not emit actinic radiation at a level capable of
being sensed by said device,
7. arranging the device in a location providing direct contact
between said device and a flame from said burner,
8. flame heating said cover means to a thermally excited mode
wherein said cover means emits actinic radiation, and
9. transmitting said actinic radiation to said photoresponsive
element via said actinic radiation conducting element whereby said
photoresponsive element provides a signal maintaining said valve
means open so long as said cover means is in said thermally excited
mode.
These and other embodiments of this invention which will be
disclosed hereinafter are better understood by reference to the
accompanying drawings wherein:
FIG. 1 is a side elevational view of a burner system of this
invention;
FIG. 2 is a side elevational view in section of a preferred
embodiment of the sensing device of this invention;
FIG. 3 is a side elevational view in section of a portion of
another embodiment of the sensing device of this invention;
FIG. 4 is a side elevational view in section of another embodiment
of the sensing device of this invention;
FIG. 5 is a top plan view with block diagrams of the burner system
of FIG. 1 together with a schematic representation of a control
system usable therewith;
FIG. 6 is a schematic diagram of a circuit for use in conjunction
with the sensing device of this invention;
FIG. 7 is a logic diagram for a burner system utilizing the sensing
device of this invention; and
FIG. 8 is a schematic diagram of another circuit for use in
conjunction with the sensing device of this invention.
Referring to FIG. 1, sensor 1 is mounted in bracket 3 above and in
the flame region of burner 5 and also adjacent to and in actinic
radiation-receiving relationship to igniter 7. Burner 5 may be a
conventional burner providing a flame capable of thermally exciting
the sensor 1 as hereinafter described. Burner 5 may utilize
conventional fuels, especially gaseous fuels of hydrocarbon or
hydrogen composition. Situated atop burner 5 is a grate 9. Igniter
7, also mounted to bracket 3, includes lead attaching means 13,
ceramic housing 15 and igniter core 17 which holds ceramic spiral
18. Igniter 7 emits radiation which activates a photoresponsive
element hereinafter described. Igniter 7 is of the electrical
resistance or hot body type as opposed to the type of igniters
known as spark igniters. Upon sufficient excitation such an igniter
emits radiation in the visible and infrared wavelengths as well as
in the thermal region. A preferred igniter is a silicon carbide
igniter with a negative temperature coefficient and a power
consumption of approximately 100-350 watts. Such an igniter is
available under the tradename Carborundum.
Sensor 1 includes a forward portion 19 situated in close proximity
to igniter 7 and burner 5 and a rearward portion 21 situated
relatively remotely from the igniter and burner. Forward portion 19
is so located as to be directly within the flame of burner 5.
FIG. 2 depicts sensor 1 in greater detail. Sensor 1 includes an
elongated actinic radiation conductive element 25 which is
surrounded at forward portion by covering 29. Conductive element 25
includes a first segment 30 in the form of an integral, elongated
rod, and a second segment 33 optically coupled thereto by optical
coupling agent 37 to provide a path for actinic radiation received
by the sensor 1 to a photoresponsive element hereinafter described.
Surrounding actinic radiation conductive element 25 in the rearward
portion is a covering 41 which serves primarily to shield
conductive element 25 from thermal energy in the flame area and
specious radiation especially ambient light such as from sources
other than the burner and igniter which are out of the flame
area.
Suitable actinic radiation elements 25 may be composed of materials
such as quartz, sapphire, or optically transparent alumina or
combinations of the foregoing materials. Such materials should have
the ability to conduct actinic radiation, i.e., radiation to which
the photoresponsive element is responsive. For purposes of this
invention, actinic radiation is generally in the red visible and
infrared region. Additionally, such materials should be adapted to
function over prolonged periods of time at the temperatures to
which it is subjected, generally at 1,200.degree. F. or higher. It
should also be noted that the said conducting element will also
generate as well as transmit actinic radiation at the hot end.
Preferably, the first segment 30 of conductive element 25 is
composed of the foregoing materials in an integral rod form. The
second segment 33 may likewise be composed of the foregoing
materials or may be composed of a fiber optic bundle of quartz or
other suitable actinic radiation transmissive material. In the
former case, where the first and second segments are of the same
composition, conductive element 25 may be of a single unitary
construction. The advantage of the fiber optic bundle is that it
permits angular configurations of the second segment 33 so that the
path of actinic radiation transmission can be bent as needed to
conform to design demands of system. In particular, this allows the
photoresponsive element to be located in a relatively thermally
remote region to avoid deleterious thermal effects on the
photoresponsive element.
A preferred optical coupling agent 37 is a high temperature,
optical epoxy resin. The epoxy resin is stable at the elevated
temperatures encountered in use, and has generally been found
stable at temperatures in the order of 180.degree. C. or higher.
The epoxy resin is very clear with optical properties similar to
quartz and has high tensile and compressive strength. The
coefficients of expansion of the coupling agent and elements to be
optically coupled are sufficiently similar that the bond remains in
tact at the elevated temperatures encountered in operation. A
suitable epoxy resin is available commercially under the tradename
"Isochem."
Covering 29 is situated in actinic radiation-transmissive
relationship to element 25. In the embodiment of FIG. 2, covering
29 is adherably bonded to the surface of conductive element 25.
Covering 29 is actinic radiation transmissive and also capable of
generating actinic radiation in situ upon thermal excitation by the
flame from burner 5. In addition, covering 29 is heat stable and
opaque to ambient light. Covering 29 is preferably of a ceramic
composition. A preferred composition, especially for bonding
directly to conductive element 25, is a dry ceramic powder
available under the tradename "Ceramacast 511" mixed with silicon
carbide. It was found that 325 mesh silicon carbide improved the
bonding, opaqueness, and actinic radiation emissiveness of the
ceramic. The ceramic powder/silicon carbide mixture combined with
as little water as possible to attain a thick creamy consistency
and the mixture so obtained is then applied by rolling the
conductive element, generally in rod form, in the mixture and
thereafter curing the coated element at 1,000.degree. F. for 3
minutes. The silicon carbide may suitably be present in amounts of
from 10% to 65% and preferably 30% to 35% by volume of ceramic
powder.
Covering 29 is quite thin in cross-section, preferably on the order
of 0.8 - .16 cm. in the case of a bonded coating. In other forms,
such as a self-supporting case as depicted in FIG. 3, the thickness
is about .16 cm. Other suitable materials for covering 29 are
metals which are capable of withstanding the flame temperatures and
will exhibit the other properties mentioned above. Stainless steel
and inconel are two such suitable materials. As noted above, when
the covering 29 is subjected to flame from the burner 5, it emits
as well as transmits actinic radiation. This radiation includes
radiation in the red visible and infrared regions. The actinic
radiation so emitted is received by actinic radiation conductive
element 25 for transmission to the photoresponsive element.
Covering 41 may, but need not be, of the same composition as
covering 29, since actinic radiation transmission and emission are
not required for this element of the invention. Covering 41
generally performs the function of shielding conductive element 25
from harmful temperatures and specious light and for the latter
purpose is opaque to visible light. Suitable materials for covering
41 include ceramics, such as silicon carbide, silicon nitride,
alumina or graphite.
FIG. 3 illustrates another form of the sensor 1 of this invention.
Conductive element 25 is enclosed in a case 45 which in terms of
functional properties is essentially the same as covering 29 with
the exception that case 45 should be structurally self-supporting
whereas covering 30 should be bondable to conductive element 25.
The gap between conductive element 25 and case 45 is generally an
air gap sufficiently small to allow efficient transmission of
actinic radiation from case 45 to element 25. A gap of about .03
cm. has been found adequate. In this embodiment, it is seen that a
covering analogous to covering 41 is provided by case 45.
FIG. 4 depicts still another embodiment of the sensor 1. Conductive
element 25 includes first segment 30, second segment 33 and
coupling agent 37 as in previous embodiments. These elements are
enclosed in a metal case 49 having a shoulder portion 53. Case 49
is essentially the same functionally as case 45 of FIG. 3 and
covering 29 of FIG. 2. Shoulder portion 53 of case 49 is bored to
accept hardware to attach ceramic shield 61 (analogous in function
to covering 41 of FIG. 2) to case 49.
In FIG. 5, the system of FIG. 1 is integrated with a control system
depicted in block diagram form. In this system, thermostat 65
provides an exciting voltage, on lines 69 and 73, to sensing
circuit 77 and conventional timing circuit 81. Timing circuit 81
energizes the hot body igniter 7. As igniter 7 self-heats, it emits
radiation in visible and infrared wavelengths as well as in the
thermal region. Red and infrared radiation is absorbed by covering
29 at the forward portion 19 of sensor 1. This radiation is
transported through the sensor 1 via the first segment 30 of
actinic radiation-conducting element 25 to the second segment 33,
where it is transported to sensing circuit 77. Sensing circuit 77
energizes fuel valve 79, allowing fuel to enter burner 5, where
contact with igniter 7 produces flame. The flame impinges on
covering 29 sensor 1. After several seconds covering 29 begins to
emit actinic radiation which is also transported as above to
sensing circuit 77. Timing circuit 81 de-energizes igniter 7 which
cools to a state wherein the actinic radiation emission is
quantitatively insufficient to energize fuel valve 79. The sensing
circuit 77 maintains power to fuel valve 79 as long as the flame is
maintaining covering 29 in the excited state or until thermostat 65
disconnects the system.
Sensor 1 is connected as noted above in energizing relationship to
a photoresponsive element included in sensing circuit 77. The
photoresponsive element may be of a conventional type and may be
photoconductive or photovoltaic in operation. Suitable
photoconductive materials include cadmium selenide and cadmium
sulfide. Suitable photovoltaic elements include selenium, silicon,
and bismuth telluride. The photoresponsive element may be optically
coupled to conducting element 25 by conventional means. Preferably,
the second segment 33 of conductive element 25 is a fiber optic
bundle connected at a thermally remote location to the
photoresponsive element by an optical coupler such as the
above-described epoxy resin.
FIG. 6 depicts a sensing circuit for performing the sensing
operations described in connection with FIG. 5. This FIGURE
represents the first of two embodiments of this sensing circuit.
Since the timing sequence can be performed well by any number of
conventional means, this has been left out of the detailed circuit
schematics and its position relative to the sensing circuit as
shown in FIG. 5. The function of the timing circuit is merely to
de-energize the igniter 7 when the system is to begin its flame
sensing mode.
Thermostat 65 provides 60 Hertz AC voltage at lines 69 and 73. The
sensing circuit provides means for actuating fuel valve 79. The
valve is energized by the control A1 of relay A. Relay A is turned
on by the discharge of capacitor 89 and then held on by PUT 94,
resistor 167 and resistor l05. The PUT 94 is triggered into
conduction when the anode voltage exceeds the gate voltage by 0.2
to 0.6 volts. By design of the triggering elements, which consist
of reference photoconductor 101, resistor 113, sensing
photoconductor 85, resistors 121, 105 and 109, triggering is
accomplished when the sensing photoconductor 85 receives sufficient
actinic radiation. The actinic radiation level is sufficient when
it is indicative that the igniter 7 has reached a state capable of
igniting the fuel to be employed. By requiring photoresponsive
element 85 to be less than the reference element 101 in resistance
for the PUT 94 to trigger, several functions are accomplished.
The reference element 101 serves the function of setting the
required level of actinic radiation to be received by
photoresponsive element 85, as well as offsetting the effect of
changes in the energizing voltage and the effect of temperature on
the photoresponsive element 85. This is accomplished by
illuminating the reference element 101 with sufficient radiation to
establish a reference resistance (R.sub.101). The amount of
illumination is selected such that the resistance R.sub.101 will be
at a value slightly greater than the resistance R.sub.85 of the
photoresponsive element 85 when the igniter 7 is in an igniting
mode. The illumination is provided by lamp 139, the brilliance of
which is controlled by resistor 143 and varible resistor 147.
Reference element 101 also compensates for variations in input
voltage since any variations will directly proportionately affect
the brilliance of lamp 139 just as it will affect the igniter 7.
While the effect on the igniter 7 and brilliance of lamp 139 will
not in practice be precisely the same, the difference will not be
significant in terms of operation of the circuit. Insofar as
temperature effect on the resistance R.sub.85 is concerned, this
too will be effectively compensated for by reference element 101
since the latter is of the same type as photoresponsive element 85
and reference element 101 is so physically situated that it will
experience substantially the same temperature environment as
photoresponsive element 85.
Resistors 105 and 109 are of equal value. This requires resistors
101 and 113 to be greater than resistors 85 and 121. Resistors 113
and 121 are also set equal and this in effect requires the sensing
element 85 to be more conductive than the reference element 101 if
the voltage at A (the programmable unijunction transistor anode) is
to be greater than the voltage established by the photoresponsive
elements at B (the PUT 94 gate terminal).
In order for fuel valve 79 to be energized, the cirlcuit must store
enough energy in capacitor 89 to turn relay A on when it is
discharged by transistor 99 and PUT 94. These transistors are
brought into conduction by the previously explained triggering
elements. Diode 129, resistors 151, 155 and 169 determine the final
charge level and the time required for the charge to be
established. Failure of key triggering components such as the
photoresponsive elements or the transistors will cause premature
discharge of capacitor 89 and the fuel valve 79 will not be
energized. If such failures occur in the previous system cycle or
during the timing period (i.e., when capacitor 89 is charging), the
system will be protected from unsafe operation.
Capacitor 163, at the base of transistor 99, will charge more
quickly than capacitor 89 to assure that transistor 99 will not
discharge on negative half cycles due to the emitter voltage of
transistor 99 being greater than the base voltage. Resistors 164
and 165 provide charging for capacitor 163.
In operation, after some predetermined time T, capacitor 89 will
have reached an energy level sufficient to energize flame relay A.
After some time greater than T, igniter 7 will provide a signal to
photoresponsive element 85 causing it to become electrically
conductive, thereby triggering unijunction 94, which will cause
transistor 99 to saturate, thereby discharging capacitor 89 into
the solenoid of the flame relay A. The flame relay A energizes and
closes its contact A1. The photoresponsive element 85 continues
conducting and PUT 94 is allowed to conduct current every positive
half cycle. this alternating current is sufficient to hold flame
relay A in the active or energized state by resistors 105 and 167.
Diode 168 serves as a holding diode for flame relay A during
negative half cycles.
If either resistor 109 becomes open circuited, or resistors 105 or
167 should short, there is not enough current present to turn on
the flame relay A. The circuit is failsafe; any component can fail
during a cycle, and the circuit will be safe on the succeeding
cycle.
Under normal operation capacitor 89 charges. The igniter 7 reaches
full brilliance. This brilliance is sufficient for the
photoresponsive element 85 to be made more conductive than the
photoresponsive element 101. The PUT 94 triggers into
conduction--so too does transistor 99 trigger into conduction.
Capacitor 89 is discharged into relay A and resulting in actuation
of valve 79. The igniter 7 continues to glow thereby containing the
triggering of PUT 94 on successive positive half cycles. The timing
circuit 81 de-energizes igniter 7. If the burner system was
functioning, the fuel ignited on contact with igniter 7 and the
resultant flame was allowed to contact the sensing probe 1 during
the time igniter 7 was left on.
After the burner flame impinges on covering 29 of sensor 1 for
several seconds, the covering 29 will emit actinic radiation in
situ which will further increase the conductivity of
photoresponsive element 85. Hence, the triggering process will
continue and fuel valve 79 will remain energized. When timing
circuit 81 de-energizes igniter 7, radiation from the
flame-activated sensor 1 will be sufficient to maintain triggering.
Flame-out will cause the actinic radiation emission of sensor 1 to
fall below the threshold amount needed to operatively actuate
photoresponsive element 85 (i.e., the photoconductor will return to
a relatively non-conducting state). The triggering process will
stop, thereby de-energizing flame relay A and de-energizing fuel
valve 79 by opening contact A1. Consequently, the fuel supply to
burner 5 will be interrupted and the system will not automatically
initiate another cycle.
The operation of the circuit of FIG. 6 can be further understood by
reference to the logic diagram of FIG. 7. The symbols employed in
the diagram have the following meaning: R.sub.85 is the resistance
of the photoresponsive element 85; R.sub.101 is the resistance of
the reference photoresponsive element 101; t.sub.0 is the time at
which the system is energized; and t.sub.1 is the time allowed to
test the photoresponsive element 85.
At the outset, a 60 Hertz AC voltage is applied by thermostat 79 to
lines 69 and 73 of the sensing circuit 77 (Box 600). This occurs at
time t.sub.0. Within a time t.sub.1 after t.sub.0, the resistance
of photoresponsive element 85 undergoes testing. If R.sub.85 is
less than the resistance R.sub.101 of the reference element 101
(Box 601), this means that element 85 is not working properly
because it is in a radiation receiving state before the time when
igniter 7 could reach its igniting mode. This condition is
considered an unsafe failure condition and the circuit will lock
out (Box 602) with the valve 79 off and the igniter 7 on. As a
result the system will be de-energized (Box 603) and the system is
then turned off (Box 604). This lockout occurs because the PUT 94
is triggered too early and continues to be triggered into
conduction every positive half cycle. It receives its triggering
voltage from the bridge circuit 125 composed of elements 105, 109,
101, 113, 85 and 121. The conductive paths to the flame relay A
which include resistors 105 and 25, as well as resistors 151 and
159, are not sufficient to turn the flame relay A on.
If the photoresponsive element 85 is properly functioning, the
resistance R.sub.85 is higher than the resistance R.sub.101 (Box
605). Thus, PUT 94 is not in a conducting or triggering mode.
If the photoresponsive element 85 has the proper resistance
R.sub.85 (Box 605), lockout will occur (Box 602) if either one of
two situations prevail: the signal from igniter 7 is insufficient
(Box 606), or the signal from igniter 7 or from any other source,
while sufficient, occurs at a time t prior to t.sub.1 (Box
607).
If a sufficient signal is received by the photoresponsive element
85 at a time t after t.sub.1 (Box 608), element 85 will drop in
resistance below the value R.sub.101. Triggering of the PUT 94 will
occur when the voltage at point A is 0.2 to 0.6 volts greater than
the voltage at B. Since resistor 105 is of equal value to resistor
109, and since the input voltage is always much greater than 0.6
volts, this differential voltage is established by the
photoresponsive element 85 being only slightly less resistance than
reference photoconductor 101. This triggering point will be voltage
dependent as is seen by the equation:
V.sub.AB = V/2 - V(R.sub.85 + R.sub.121)/(R.sub.85 + R.sub.121 +
R.sub.101 + R.sub.133)
where V is the input voltage and V.sub.AB is the voltage at point A
relative to point B. As V increases, the resistance R.sub.85 at
which V.sub.AB equals 0.2 to 0.6 volts (triggering voltage) is
higher. This is offset by the increased brilliance of lamp 139 at
the higher voltage. This causes reference photoconductor 101 to be
at a lower resistance because the lamp is brighter thereby
requiring the same of the photoresponsive element 85 and cancelling
out the effect of increasing voltage. The same thing holes true in
reverse for low voltage. Also, since the igniter will glow more
brilliantly at higher voltages, the increased brilliance of the
lamp at these higher voltages makes it a good match for the effects
of varying voltage on the igniter.
As previously explained, when the voltage at point A becomes
slightly greater than that at B by the increased conduction of
photoresponsive element 85, PUT 94 conducts on every positive half
cycle. This causes charged capacitor 89 to discharge its energy
into the solenoid of relay A, thereby turning relay A on. The
continuation of photoresponsive element 85 in the low resistance
state causes PUT 94 to conduct every positive cycle thereby holding
relay A in the energized state through the conductive path of
resistor 170 and resistor 105. The flame relay A turns the gas
valve 79 on (Box 609) and holds it on as long as either the igniter
or flame signal is received by the photoresponsive element 85.
After allowing time for the sensor 1 to emit radiation upon flame
excitation, the timer 81 turns the igniter off (Boxes 610, 611). If
ignition did not occur (Box 612) or the flame is of insufficient
intensity (Box 613), the circuit will again lockout (Box 614) and
return to the nontriggering mode causing the valve 79 to be
de-energized. The igniter 7 will remain off and the circuit locked
out until the entire system is recycled by removing power and
reapplying it after a few seconds (Boxes 604, 600). If the flame is
sufficient (Box 615), the valve 79 will remain on (Box 616) until
the thermostat 69 de-energizes the circuit (Box 603) or until
flameout occurs (Box 617).
FIG. 8 illustrates another sensing circuit for use in the
invention. Certain elements common to the circuits of FIGS. 6 and 8
are designated by like numerals.
The circuit is energized by applying 60 Hertz A.C. voltage at lines
69 and 73. The circuit can be designed to operate at any of the
conventional voltages 24, 110, 117, 208, 240. Proper sizing of the
elements is all that is required. Fuse 211 allows resistor 171 and
diode 207 to charge capacitor 175. The R C time constant is chosen
to provide some delay less than the minimum time for the igniter 7
to reach its glowing state. Resistors 183 and 187 are so large
relative to resistor 171 that they do not effect the charging level
or rate significantly. The purpose of resistor 183 and 187 is to
provide a discharge path for capacitor 175 so that the circuit will
reset in a few seconds after being de-energized by the total
discharge of capacitor 175.
If resistor 171 short circuits it would fail to provide the
required timing interval since capacitor 175 will reach its peak
value almost instantaneously. If the resistor 171 short circuits,
diode 204 will cause heavy conduction through fuse 211 and it will
blow thereby de-energizing the circuit.
Capacitor 175 must fully charge before the proper operational
sequence leading to the opening of fuel valve 79 can take place. If
any key triggering elements 85, such as photoresponsive element
reference photoconductor 101, or SCR 199 have failed in the
preceding cycle or fail during the test period, the capacitor 175
will not charge if these elements have failed in a nonsafe mode.
The nonsafe mode is such that triggering of SCR 199 to the on start
would occur without the presence of actinic radiation. This nonsafe
mode causes early triggering thereby discharging capacitor 175
prematurely, and thus, causing circuit lockout because insufficient
energy had been stored in the capacitor 175. Capacitor 175 must
charge to sufficient voltage to energize flame relay 179 by its
discharge into the relay.
If the circuit elements are in a safe operating mode, capacitor 175
will become fully charged. When igniter 7 reaches full brilliance,
the sensing photoconductor 85 will be at the critical value
R.sub.101 set by lamp 139 and the reference photoconductor 101.
This critical value is the resistance expected for the
photoresponsive element 85 when it receives actinic radiation from
the igniter 7. Resistor 143 is of the proper value to set lamp 139
at the proper radiation level to cause the reference photoconductor
101 to have a resistance value R.sub.101. The values of resistors
215, 219, 235 and 205 are such that the diac 195 will break into
conduction when the photoresponsive element 85 is at the R.sub.101
resistance level. The resistors 215, 219, 235 and 205, in
combination with the diac 195 and the photoresponsive elements 85
and 101, make up the triggering circuit which can cause SCR 199 to
conduct. This triggering circuit receives energy on negative half
cycles. Thus, it is on negative half cycles when the SCR can be
brought into the conductive state. When the diac 195 breaks into
conduction, it allows capacitor 101 to discharge through capacitor
205 and across the SCR gate biasing resistor 237. This effects a
positive voltage at the gate of SCR 199 sufficient to cause SCR 199
to conduct. This conduction discharges capacitor 175 into relay 179
causing the contact A1 of said relay to close. The closing of
contact A1 energizes fuel valve 79 and the highly conductive path
of diode 203. The conductive path allows capacitor 175 to charge
each positive cycle. During each positive cycle diode 239 acts as a
holding diode for the coil of relay 179 preventing chattering of
said relay. During each negative cycle SCR 199 will be triggered
into conduction again causing discharge of capacitor 175 into relay
171. This charge, trigger, discharge sequence will continue as long
as the sensing photocell is receiving sufficient actinic
radiation.
Reference cell 101 provides much the same voltage and temperature
compensation as it did in the circuit of FIG. 6. When the voltage
to the circuit of FIG. 8 increases, the voltage across the diac
increases proportionally. However, the increased voltage also
causes lamp 139 to glow more brilliantly. This causes the back
biasing voltage to diac 95 to increase. The net effect negates the
voltage increase and allows the diac to trigger at the same
photoresponsive element 85 resistance regardless of the voltage
variations across the otherwise voltage-sensitive triggering
circuit.
Most important, however, is the temperature compensation afforded
by the photoresponsive reference element 101. The resistance of
this element changes with temperature during its actinic
radiation-receiving mode. This allows the voltage across the diac
to be unaffected by the temperature effects of the sensing
photocell resistance.
The safety of flame sensing may be enhanced by the addition of a
nematic liquid crystal between the secondary conducting element 33
and photoresponsive element 85. This junction area could be
temperature controlled to give both the photoresponsive element 85
and the liquid crystal further stability. Also, the liquid crystal
can be used as a shutter to generate a pulsating signal to the
photoresponsive element 85. Such a signal will assure immediate
detection of the failure of photoresponsive element 85 by the lack
of its continually changing resistance, the frequency of which is
controlled by the liquid crystal shutter and its associated shutter
control circuit.
The flame detection circuitry of this invention proves its own
integrity at the beginning of each operating cycle, proves the
igniter during the proof of ignition mode and then provides main
burner proof of flame. This system provides greater safety in all
functional modes than any system currently available for
application to residential and commercial appliances.
A preferred sensor of the type depicted in FIG. 2 includes a 3 inch
length of 2.4 MM quartz rod as the first segment of the actinic
radiation-conductive element. The quartz rod can withstand
temperatures in excess of 1,100.degree.C. and is very transparent
in the visible and near infrared spectrum, but opaque to the
infrared beyond 7.0 microns. The quartz rod is bonded to a fiber
optic bundle with a high temperature, optical epoxy. The epoxy can
operate to 180.degree.C. It is very clear with optical properties
similar to quartz. It has high tensile and compressive strength.
The fiber optics passes radiation between 0.44 microns and 1.3
microns and with an additional narrow passband around 1.5 microns.
The junction at the fiber optic end and all but 1 inch of quartz
are sheathed with a ceramic tube. The exposed quartz is coated with
a thin coating of a ceramic cement. The cement is not transparent
to visible light. The cement can maintain high operating
temperature without deterioration. Since the coefficients of
expansion of the quartz and cement are close, the cement adheres
despite the rapid heating in a flame. Although the ceramic expands
more than the quartz, its expansion is very small, and the
structure of the ceramic allows this to occur without hazard to the
bonding properties or to the ceramic itself.
When the probe is inserted in a flame, the thin ceramic coating
begins to emit broadband radiation. The radiation travels down the
quartz rod through the fiber optic bundle and is received by a
photoresponsive device.
The system of this invention can withstand the severe environment
of a high heat flux powered burner and also reliably prove flame in
a much lower heat flux burner. It is sensitive enough to prove
flame for a rangetop burner over a reasonable ambient temperature
range using the sensor of FIG. 2 or FIG. 4.
The system of this invention enables proof of ignition source as
well as proof of flame. It is applicable in any type of burner. It
can easily be used on a ceramic burner tile which does not provide
the ground return required by many conduction systems. It can be
used from 20,000-2,000,000 BTU/HR/FT.sup.2 of burner surface. The
system can get enough signal from burners as small as a 250 BTU/HR
pilot burner. The resistance igniter is not affected by moisture
and is not as position sensitive as a sparking igniter. The system
is low in cost, simple and reliable. The system eliminates probe
deterioration and probe gap problems prevalent in spark ignition
systems. Carbon deposits which can prevent ignition and bias flame
sensing on other systems do not effect this system.
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