Patent Publication Number: US-9416981-B2

Title: Temperature and low water monitoring for boiler systems

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to safety devices that automatically cut-off the burner operation of a hot water boiler. More specifically, the present invention relates to the type of boiler used in residential and light commercial heating applications that include a control system for monitoring both the temperature and level of the water in the boiler. The system allows these attributes to be measured through a single probe inserted into the boiler through a single tapping. 
     2. Description of Related Art 
     In conventional boilers of the type used in residential and light commercial heating the water level is monitored with a low water cutoff (LWCO) sensor. When the water level in the boiler drops below the level of the low water cutoff sensor, the burner is turned off until the water level is brought back up to a safe level. These controls are well known in the art. 
     One example is U.S. Pat. No. 6,390,027, issued to Lyons and Murray, entitled, “CYCLE CONTROL SYSTEM FOR BOILER AND ASSOCIATED BURNER,” which is incorporated by reference. In the &#39;027 design, a cycle control system is used with a boiler to determine the presence of an adequate level of fluid within the boiler. 
     In operation, an LWCO has a probe that extends into the boiler through a single tapping. Generally, the probe has two electrically conductive surfaces that are isolated from each other. An electrical signal is provided to one of these conductive surfaces. When the water level is above the level of the probe, the circuit between the conductive surfaces is closed by virtue of the conductivity of the water surrounding the probe. When the water level falls below the probe, there is no conductivity between the metal conductive surfaces. Thus, the circuit is open, and the control detects a low water condition. 
     Another component of monitoring boiler systems is information concerning the temperature of the water in the boiler. There are many temperature control systems in the art currently used to monitor water temperature in a boiler. Commercially available temperature controllers include, for example, the Honeywell L7224U Aquastat Relay. In these devices, a temperature sensing thermistor is inserted into a hollow well. The hollow well is then inserted within a tapping in the boiler and the boiler is filled with water. The thermistor is connected to a central control unit. The central control unit monitors the temperature gradient, and is typically programmed to shut down the burner to prevent the water in the boiler from exceeding a preset limit. The central control unit may also be programmed to turn the burner ON to maintain a minimum boiler temperature. 
     In U.S. Pat. No. 5,340,019, issued to Bohan, Jr., et al., entitled, “ELECTRONIC AQUASTAT IN IMMERSIBLE CAPSULE,” a liquid immersible electronic Aquastat is taught in which a temperature responsive element and substantially all associated electronic circuitry are arranged on a circuit board within a tubular capsule of liquid impervious material. The capsule or well houses a thermocouple, while conducting heat energy from the surface of the well to the temperature sensor. 
     A need exists to combine the two safety functions of monitoring for low water cutoff and temperature measurement in a single probe with supporting control circuitry to allow it to perform in existing boiler tappings, thus eliminating the need to drain the boiler to insert a new tapping. 
     In U.S. Pat. No. 5,111,691, issued to John, et al., entitled, “CONDUCTANCE/THERMAL LIMIT CONTROL APPARATUS AND METHOD,” a temperature probe is taught which mounts in a liquid container. The probe has a conductance electrode coupled to a conductance control circuit. A temperature sensor is combined with this low water cutoff probe. This control, however, does not allow for the ability to replace the sensor of an existing Aquastat such as the Honeywell devices described above without draining the boiler and possibly the entire heating system. Furthermore, this design only provides high temperature limit with no provision to turn the burner on to maintain a minimum boiler temperature, or to control the circulator pump on a call for heat. 
     One problem in the industry has been the reluctance to accommodate multiple tappings for water cutoff probes and temperature sensor probes. This requires expensive redesigns of boiler castings to accommodate a second hole in the boiler wall for the additional probe. It is desirable to combine the two measurement functions in a single probe, which can be inserted into a single well. It is further desirable to construct a probe/well design that can accomplish the multiple measurements in a single device that is interchangeable with existing well designs currently available in the industry. In this manner, it is not necessary to provide a new tapping or to drain existing boilers currently in operation in order to incorporate the present invention. In addition, it is desirable for the present invention to maintain a minimum boiler temperature. 
     Another problem that occurs is when the control circuitry is set to maintain a minimum water temperature and the temperature sensor is not in the boiler. In the prior art, the control circuitry would incorrectly determine that the water temperature is too low, and try to run the boiler, causing an unsafe, high temperature condition. This is generally referred to as a “run-away boiler” condition. In the present invention, if the dual probe sensor is connected to the control circuitry but not inserted into the well, the control circuitry will sense a low water condition, and not allow the burner to fire. 
     SUMMARY OF THE INVENTION 
     Bearing in mind the problems and deficiencies of the prior art, it is therefore an object of the present invention to provide a probe for sensing water level (low water cutoff) and temperature in a single unit. 
     It is another object of the present invention to provide a removable probe for sensing water level and temperature in a single unit that allows for integration into an existing tapping. 
     It is another object of the present invention to provide a slideably removable probe in a well that may accommodate sensing functions of low water cutoff and/or temperature measurement within the integration of an existing tapping. 
     It is yet another object of the present invention to provide a control unit that allows a user to set the limits for temperature and monitor low water conditions. 
     It is another object of the present invention to provide visual signals to the user to indicate which functions, temperature and low water, are currently active. 
     A further object of the present invention is to provide a safe condition when the probe sensor is connected to the control circuitry but not properly inserted within the well, which would otherwise cause a run-away boiler condition. 
     Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification. 
     The above and other objects, which will be apparent to those skilled in the art, are achieved in the present invention, which is directed to a removable probe insertable within a well in a boiler tapping comprising a removable low water cutoff sensor in electrical communication with the well interior by a resilient flexing connection, the low water cutoff sensor and the resilient flexing connection forming a slideably removable electrical connection. 
     The low water cutoff sensor includes a conductive member comprising a solidly-shaped conductive material, the solidly-shaped conductive material in electrical communication with the well interior, the solidly-shaped conductive member and the resilient flexing connection forming the slideably removable electrical connection without soldering or welding the conductive member to the interior of the well. 
     The low water cutoff sensor may further include a conductive nut for threadedly securing into the boiler tapping, the conductive nut in electrical communication with an interior wall of the boiler forming a conductive path between the interior wall of the boiler and the well when water within the boiler interior surrounds and contacts the well, the conductive path is open when the water within the boiler interior does not surround or contact the well. 
     In a second aspect, the present invention is directed to a removable probe insertable within a well in a boiler tapping comprising a low water cutoff sensor in electrical communication with the well interior, the electrical communication formed by a resilient flexing connection, the low water cutoff sensor including a conductive member comprising a solidly-shaped conductive material, the solidly-shaped conductive material in electrical communication with the well interior without soldering or welding the conductive member to the interior of the well, such that the low water cutoff sensor and the resilient flexing connection form a slideably removable electrical connection. 
     In a third aspect, the present invention is directed to system for monitoring low water cutoff and temperature in a boiler comprising: a temperature sensor within a housing inserted into a well within a boiler tapping; a slideably removable low water cutoff sensor in electrical communication with the well interior; a resilient flexible connector forming the electrical communication with the slideably removable low water cutoff sensor, such that the low water cutoff sensor senses a voltage potential of the well when in electrical communication with the resilient flexible connector; a conductive nut threaded for connection to the well and in electrical communication with the boiler interior wall; and a microcontroller including software for receiving and monitoring the temperature sensor and the low water cutoff sensor inputs. 
     The temperature sensor may include at least one thermistor. The microcontroller may include a high impedance resistor to shift the temperature sensor or the low water cutoff sensor inputs signals of approximately ±2.5 volts (p-p) or approximately 0-5 volts (p-p). 
     Software filtering is performed by the microcontroller at an approximate rate of 1/10 Hz, and approximately sixteen samples are measured and averaged. The software may be designed to perform a second, long-term average with a sixteen-sample averaged value. The software may compare an averaged value to predetermined threshold conditions including shorting, good or poor conductivity threshold, or an empty boiler condition. 
     The controller may perform boiler operations using calculations that include outdoor temperature, indoor temperature, boiler return temperature, or boiler supply temperature, or a combination of the same. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which: 
         FIG. 1  depicts an assembly drawing of a sensor well. 
         FIG. 2  depicts an assembly drawing of the well of  FIG. 1  with an elongated brass nut. 
         FIGS. 3A and 3B  depict a combined low water cutoff and Aquastat thermistor insert for installation into the proposed embodiments of  FIGS. 1 and 2 . 
         FIG. 4  is a wiring diagram for a control system. 
         FIG. 5  depicts the control system of the instant invention. 
         FIG. 6  depicts flow chart of one embodiment of the control system of the present invention. 
         FIG. 7  is an assembly drawing of a gas boiler control housing of the present invention having high/low temperature and low water cutoff indicators. 
         FIGS. 8A and 8B  depict the temperature sensor assembly of the present invention. 
         FIG. 9  depicts the program flow for utilizing the dual probe design of the present invention. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT(S) 
     In describing the preferred embodiment of the present invention, reference will be made herein to  FIGS. 1-9  of the drawings in which like numerals refer to like features of the invention. 
     The present invention teaches a dual functionality of temperature control measurement and low water cut-off measurement within a single tapping in a boiler. This dual functionality combines a low water cut-off and temperature sensor into one control utilizing a sensing element suitable for use in an existing ¾″ tapping for typical boilers. The tappings generally comprise a threaded brass nut for insertion in a boiler housing wall, a hollow, cylindrical temperature/low water cutoff well for protecting and securing the sensors, and an insulator (dielectric), which electrically separates the brass nut from the cylindrical well. The sensor well allows a user to insert the temperature sensor and low water cutoff sensor without draining the system. Importantly, the sensor well may be used for both temperature and low-water cutoff measurements. In this manner, the dual function capability may be employed in boilers where only a single tapping is available. 
       FIG. 1  depicts an assembly drawing of a well  10  of the present invention. A brass well nut  1  is securely and circumferentially attached to the temperature/low water cutoff well or tube  3 . Insulator  4  extends circumferentially around a portion of well  3 , electrically isolating brass nut  1  from well  3 . In this manner, electrical connection between the well  3  and brass nut  1  is communicated only by the conductivity of surrounding water. If the water level is below well  3 , the electrical connection is broken, and a low water cutoff condition is realized. Typically, well  3  is made of copper, although other conductive metal combinations may be used with equal success. Importantly, well  3  extends through, but makes no contact with, brass nut  1 . Any contact would result in the electrical shorting of the low water cutoff circuitry. Brass well nut  1  may be any other suitable, non-brass material, provided it can survive the exposure requirements in adverse boiler environments, and lend suitable conductivity for the proper operation of the low water cutoff control circuitry. The electrical isolation between well  3  and brass nut  1  is controlled by insulator  4 . Insulator  4  is preferably made of a material that substantially resists electrical connection, such as a modified polyphenylene oxide resin (PPO), or the like. One such example is NORYL® N300X, which is a blend of polyphenylene ether (PPE) and polystyrene (PS). 
     Brass nut  1  includes a threaded portion, or some other appropriate means for connecting the probe assembly to the boiler. Importantly, brass nut  1  allows well  10  to be inserted within the wall of a boiler above the minimum water line, and remain there indefinitely by creating a watertight seal upon installation. The connection of brass nut  1  to the wall of the boiler also allows well  10  to be in electrical communication with the boiler interior wall. Generally, in operation, portions of well  3  and insulator  4  are exposed within the boiler interior to the water. Simultaneously, brass nut  1 , which is in electrical communication with the boiler interior wall, is also exposed to the water. When an electrical signal is applied to well  3 , it remains isolated from brass nut  1  as well as the boiler interior wall. In this manner, no electrical communication is established between well  3  and brass nut  1 . This is because insulator  4  prohibits electrical conductivity. Under normal operating conditions, the water level is high enough in the boiler to surround and encompass exposed portions of well  3  and brass nut  1 . The conductivity of the water effectively bypasses the operation of insulator  4  and completes the low water cutoff circuit, connecting well  3  to the boiler interior wall at brass nut  1 . When electrical connection is detected, the control circuitry connected to the probe determines that adequate water is in the boiler. When the water level is below well  10 , well  3  is no longer in electrical communication with the boiler interior wall at brass nut  1 . The absence of an electrical signal to complete the circuit, i.e., an open circuit, allows the system to determine that the water level is sufficiently low, and subsequently shuts down the burner. 
       FIG. 2  depicts an assembly drawing of a well  10   a  of the present invention with an elongated brass nut  11 . Electrically, the well  10   a  configuration of  FIG. 2  is the same as the well  10  configuration of  FIG. 1 . 
       FIGS. 3A and 3B  depict a combined low water cutoff and thermistor insert for installation into the proposed embodiments of  FIGS. 1 and 2 . The probe  20  contains preferably two thermistors per assembly (not shown), encased within a temperature sensitive thermoplastic (TPE) over-mold  23 . As illustrated in  FIGS. 3A and 3B , probe  20  is secured in well  3  by a resilient, compression-fit conductive member  24 , such as a wire having a spring constant, a shaped wire clip (shown), a peripheral or semi-peripheral resilient conductive band, or a solid-shaped conductive material capable of fitting within the well to ensure good electrical contact with the well interior wall, and which may provide a compressive force that simultaneously holds or pushes an adjacent temperature sensor against the well interior wall. If conductive member  24  is in the form of a resilient wire, it is preferably constructed of beryllium copper (BeCu). Conductive member  24  is configured to extend upward from the surface of probe  20 . Conductive member  24  terminates on a conductor within the assembly. In doing so, conductive member  24  makes electrical connection with well  3 , which is exposed to the boiler water environment. This connection allows a low water cutoff signal to propagate from the controller circuitry, making a circuit with well  3  and the electrically isolated brass nut  1  when conductive water is present. Conductive member  24  forms part of the contact path for the low water cutoff circuit. The water provides the connection from well  3  to brass nut  1 , thereby bypassing insulator  4 . When water is no longer present, the low water cutoff circuit is open, i.e., insulator  4  does not allow the signal to propagate, and a low water level is detected. The conductive member  24  secures the thermistor assembly within a well by forming a compression fit, while simultaneously providing a secure fitting for electrical contact for the low water cutoff signal. This design readily accommodates existing wells that were not otherwise constructed for this purpose. The probe of the present invention may be placed in a temperature sensor well design that is unable to accommodate a low water cutoff application. The supporting control circuitry will measure temperature, while the low water cutoff electrical signal monitors resistance. If the probe is in a temperature-sensor only well, the conductive member will sense zero ohms of resistance and temperature sensing will remain active while the low water cutoff function is inactive. This allows the present invention to replace an existing, non-dual function probe, and provide at least the same functionality as the probe it replaced. 
     The conductive member ensures that the probe of the present invention is inserted in the well. In contrast, if a probe is not inserted in the well, the temperature measurement cannot be sensing boiler temperature. This would cause a controller connected to a prior art probe to initiate a continuous firing of the boiler, otherwise known as a run-away boiler condition. However, in the present invention, a signal from the conductive member will ensure that the probe is inserted. Ensuring that the probe is installed in the well addresses this run-away boiler condition in a manner that is unique to the present invention. 
     In the preferred embodiment, the encapsulated thermistor 20 has a 30 K-ohm resistance at 25° C. with an operating temperature range on the order of −40° C. to +125° C. Clearly, these specifications are boiler dependent, and may be adjusted for specific applications. In operation, probe  20  is placed in well  3 . When inserted, conductor  24  is forced down into channel  26 . This ensures that conductive member  24  will remain in pressure contact with the interior wall of well  3 . The wires  28  connected to, and extending from, probe  20 , are covered by a heat-shrink wrap  30 . This heat-shrink wrap serves the dual function of insulating the wiring system from the environment, and also providing rigidity to the wire structure. For the preferred two-thermistor design, four conductors are used, such as 26 AWG 7/34 T.C., or the like, with insulation and an overall TPE cable jacket. The rigidity provided by the wrapping allows the thermistor assembly, including the compression-fit conductive member  24 , to be push-inserted within an existing well without collapsing onto itself. In contrast, the thermistor disclosed in U.S. Pat. No. 5,111,691 issued to John, teaches wires without any means for rigidity, mainly because the John disclosure does not suggest or teach using the thermistor assembly for replacement in wells that were not specifically designed for it. The &#39;691 patent also does not include a wire member assembly necessary to engage with the well simultaneously for a low water cutoff signal and temperature sensing signal. 
     Thus, the present invention allows for a dual probe combining temperature measurement and low water cutoff to be inserted within an existing well of a boiler without requiring a new tapping. The probe can be inserted within an existing well because of the rigidity of the wire system that allows the thermistor to be friction fit while providing for electrical connection for the low water cutoff signal. The control circuitry may then monitor safe operation of the boiler. However, dual sensing may be accommodated only if the existing well includes a dielectric spacer for the low water cutoff signal conductivity measurement. 
       FIG. 4  is a wiring diagram  40  for a control system. The wiring diagram depicts how a thermostat  42 , circulating pump  44 , burner  46 , and multi-zone controller  48  are connected in a preferred embodiment. 
       FIG. 5  depicts the control system  50  of the instant invention. Control system  50  has controls that allow for adjusting the low temperature setting  52 , high temperature setting  54 , and the temperature differential  56 . A display  58  is used for indicating the water temperature to the user or technician. Diagnostic lights  51 ,  53 ,  55 , and  57  indicate active temperature, high temperature, active low water cutoff, and low water, respectively. 
     In operation, a temperature control circuit is used in conjunction with the temperature sensor. The temperature sensor inputs a temperature signal for sensing a high temperature range with adjustable differential. The measured temperature is used to determine the operation of the burner through comparator circuitry and relays for the safety functioning of the burner, e.g., a high temperature condition may require burner shut-off and a low temperature condition may require the burner to be turned on. A thermostat signal is also used as an input to allow for a “demand heat” condition. 
     A conductance sensor is used for measuring the variable conductivity of the water in the boiler. The sensor receives an AC source signal and provides a variable resistance to the signal based on the conductivity of the water. The variable resistance forms a resistor divider network with a predetermined series resistance. The AC source signal (rail voltage) is preferably a 5 volt signal operating at approximately 400-500 Hz. The probe input is on the order of 100 mV of the rail. Specifically, the source signal is preferably sinusoidal with an amplitude span of approximately +2.5 volts to −2.5 volts (peak-to-peak). Generally, there are no active electronics within the sensor, although the present design does not preclude the addition of such devices. The resistance divider formed by a series resistor and a variable resistance, which represents the measured water conductance, acts to attenuate the source signal in an amount proportional to the water conductivity. 
     Referring to  FIG. 6 , the probe input  61  is then directed to a unity buffer  62 , which provides a high impedance for interfacing with the analog input of the microprocessor  63 . The signal is biased at +2.5 volts through a high impedance resistor. This shifts the signal from ±2.5 volts (p-p) to 0-5 volts (p-p), which enables it to be received properly at the analog input of microprocessor  63 . No amplification is performed during this biasing. The probe input port is voltage surge protected by a diode. 
     Microprocessor  63  receives the buffered probe signal at an analog input  64  to microprocessor  63 . The analog input signal is normally sampled in sequence with a drive signal (AC source signal). Microprocessor  63  performs a sample-and-hold function for a high output drive signal and a low output drive signal, respectively. The signal&#39;s peak-to-peak voltage is then measured. Internal to the microprocessor is an analog-to-digital (A/D) converter that converts the bias signal returned from the probe into a digital value with 8-bit resolution (0-255). 
     Software filtering is performed by the microprocessor at a preferred rate of approximately 1/10 Hz. Sixteen samples are measured and averaged in order to eliminate or account for externally induced noise. A second average (long-term average) is performed with the sixteen-sample averaged value. The resultant averaging function filters out adverse effects due to air bubbles and probe-induced or probe-coupled transients. The measured, averaged value is then compared via software to threshold conditions such as: a) shorting; b) good/poor conductivity threshold; and c) an empty boiler condition. As the measurement software loop progresses, the resultant determination (short, good conductor, etc.) must be shown to persist for a predetermined number of cycles before a declaration may be made and action taken. If the measurement condition is removed before the predetermined number of cycles is accumulated, a counter is reset and the measurement cycle is repeated. Once an actionable condition is determined, the user is notified by a series of LED indicators  65  and appropriate action is taken, e.g., the boiler may be shut down for a “no water” condition. 
     The action taken by the controller includes toggling a burner relay  66 . Relay  66  is turned on or driven by a relay driver circuit  67  which requires redundant burner signals to ensure that any action affecting burner operation is not based on faulty circuitry. 
     Preferably, four settings are available for the temperature display  68  of the present invention: high temperature  69 ; low temperature  70 ; high temperature plus differential  71 ; and low temperature plus differential  72 . The high temperature settings  69  and  71  limit the boiler water temperature to a safe operating temperature. The low temperature settings  70  and  72  maintain a minimum temperature in the boiler. In a cold start condition, the burner does not fire unless there is a call for heat from the system thermostat  73 . In the low temperature sensor limit of the present invention, turning the temperature control setting to off, turns the controller into a cold start apparatus. 
       FIG. 7  is an assembly drawing of a gas control housing  74  of the present invention having high/low temperature and low water cutoff indicators  75 . Probe well  76  is shown drawn to approximate scale. Housing  74  comprises a lower module  77 , a printed circuit board assembly  78 , and a housing cover  79 . Circuit board assembly  78  includes electronics, the high temperature and low water indicators, a temperature probe check (HT active), a water probe check (LW active), high temperature settings, high temperature differential, and burner firing signals. 
       FIGS. 8A and 8B  depict the temperature sensor assembly  80  of the present invention. The conductors  82  from each of two thermistors  84  are wrapped in semi-rigid heat shrink tubing  86  and terminated with connectors  88 , preferably using terminals such as AMP P/N 770666, or the like, and a corresponding connector, such as AMP P/N 770602-4, or the like. The heat shrink tubing is preferably a polyolefin heat shrink sleeve or equivalent. The thermistors are housed in a plastic or metal housing  81 . In one embodiment the thermistors are first encapsulated in a resin, such as blue hysol or the like. Conductors  82  are soldered to each thermistor lead. The solder joints are protected by an adhesive lined polyolefin sleeve, preferably a sleeve with a temperature rating on the order of 135° C. Sharing the same housing is beryllium copper conductor clip  83 , which connects to its own dedicated conductor  85 . Clip  83  extends outside of housing  81  in order to make contact with the metal interior wall of the well. Clip  83  may be formed from  22  AWG wire or other resilient material. Clip  83  helps position the thermistors  84 , which are opposite the clip, against the well. 
     Many different versions of temperature probes are suitable for use in the present invention. In one embodiment, a preferred probe includes epoxy coated point matched disc thermistors with nickel PTFE insulated lead wires. One such probe may be comprised of NTC thermistors from GE. These probes have a solid-state sensor, strong mechanical strength, and a wide operating temperature range of about −50° C. to 150° C. Another such sensor is a Betatherm Corporation sensor, which is also a ceramic chip NTC thermistor design with nickel plated CP wire, and glass encapsulating material. These probes are representative of the types of probes which may be used in the present invention; however, the present invention may accommodate other probe designs, and is not limited to the probes identified above, provided each probe meets the physical restraints of the well design, and the environmental restrictions on boiler operation. 
       FIG. 9  depicts the program flow  90  for utilizing the dual probe design of the present invention. Upon initiating the power up sequence  91 , the burner  92  and circulator  94  are off. The water sensor is first initiated  96 . For a low water condition, the low water LED is activated  98  and burner  92  and circulator  94  are turned off or kept off. For a high water condition, the low water LED is either switched off or kept off  100 . A temperature measurement is made  102 . If the temperature is low, the circulator is turned off or kept off  104 . The high temperature LED is turned off or kept off  106 , as the case may be, and the burner is activated or turned on  108 . If the temperature measurement  102  is not low, the thermostat input is monitored for a call for heat  110 . If there is no call for heat, the maximum temperature limit is checked  112 . If the maximum temperature is reached, the high temperature LED is turned on  114  and the burner  92  and circulator  94  are turned off. If the maximum temperature limit  112  is not attained, the high temperature LED  116  remains off, and again the burner  92  and circulator  94  also remain off. If the thermostat input  110  calls for heat, the circulator is turned on  118 . The maximum temperature limit is monitored  120 . When the maximum temperature is reached, the high temperature LED is turned on  122 , and the burner is turned off  124 . The water sensor is then monitored  96 . If Maximum temperature is not reached, the high temperature LED  106  is turned off or kept off and the burner  108  is turned on or kept on. The water sensor  96  is then monitored. 
     Importantly, the present invention&#39;s controller allows for external temperature inputs as well as various boiler system temperature inputs. This would include outdoor temperature, boiler return temperature, boiler supply temperature, indoor temperature, and the like. This allows for efficient burner operation under various environmental and system conditions. For example, in this manner, an outside temperature or call for heat is monitored, and the boiler is limited to the outdoor reset controller conditions. Thus, the dual function sensors are integrated with a controller that monitors external environmental temperature. If the controller system monitors a high outside temperature, it would regulate its temperature accordingly. Otherwise, the system would not distinguish between a moderate 50° day and a cold 10° day, insomuch as it will work all the time as if it is in an environment of a cold day all year long. It will consistently heat the water to a maximum temperature without regard for the outside temperature. By incorporating boiler system and environmental temperature measurements, the system can provide significant energy efficiency. 
     One feature of the present invention is the ability to replace sensors from existing controllers without replacing the wells, that is, it has the unique ability to be interchangeable with current systems. In some systems, it is possible that the interchange of the present sensor system into an existing system will not allow the dual function of the present invention to be completely activated. In these circumstances, only temperature function may be employed. Indicator lights will signal which functions are active. 
     While the present invention has been particularly described, in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.