Patent Publication Number: US-2023160571-A1

Title: Control unit for detecting a flame in operation using flame monitors suitable for burners and flame monitoring system

Description:
The invention relates to a control unit for detecting a flame in operation using flame monitors for furnaces having a burner operated using a fuel, in particular oil or gas. Further, the invention relates to a flame monitoring system having such a control unit. 
     Such monitors being of the type having a flame sensing circuit with a flame sensor for monitoring the burner flame and switches for controlling the fuel supply. Various flame monitor constructions are known. As they are of considerable importance for the safe operation of furnaces and the like, it is known to use various control techniques. 
     In combustion plants such as burners, it is typical to assign each flame a so-called flame monitor, which is operatively associated with a fuel valve to permit or to stop flow of fuel to the burner. Such flame monitors comprise a radiation detector or flame sensor which generally detects the radiation originating from the flame root. The flame sensor produces a flame signal indicative of the existence of a flame at the burner. In the event of flame loss, the operation of the flame sensor causes switching means to close the fuel valve to stop fuel supply. The flame sensor is usually blacked out by a flame loss. 
     In view of the above, the radiation being indicative of the existence of a flame at the burner has to be discriminated against the background radiation which originates from the walls enclosing the combustion chamber. Optical flame monitors for such burners typically respond in a spectral range outside the spectrum of visible light. Known flame monitors with high sensitivity respond in the UVA range and are so-called UV tubes or semiconductor sensors based on silicon, GaN, GaP, or GaAsP diodes, which are followed by evaluation circuits having amplifiers. In general, the radiation intensity is evaluated via two thresholds, a prewarning threshold and a safety threshold. The flame monitors process flame sensor signals in such a way that a so-called flame relay is actuated, which, immediately after the flame is extinguished, triggers the safety measures then necessary. The oil burner control circuits usually comprise a number of relays and contacts which switch the components of the burner on and off different times, the components being actuated in particular during the switch-on phase of the burner. With respect to the relays it should be noted that they may be subject to a malfunction. 
     From DE 90 11 973 U1 it is known that for automatic protection against explosions in combustion plants, as well as for the control of optical combustion processes with the lowest possible pollutant emission, optical flame monitors are preferably used because of their reaction speed. These optical flame monitors use energy released during each combustion process in the form of electromagnetic radiation. This is because each flame has a particular radiation spectrum that depends on both the fuel, e.g., gas, oil, coal, etc., and the type of oxidation. In this context, the spectral radiation distribution ranges from extremely shortwave radiation (UV) through visible light to longwave infrared radiation. Blackbody radiation can be superimposed on this emission spectrum. 
     The flame monitor comprises a detector which therefore preferably responds in the wavelength range in which the radicals of a combustion process have their emission and absorption behavior. The detector therefore preferably responds in the wavelength range between 280 and 410 nm. The responsivity characteristic curve in relation to the wavelength has steep slopes, wherein these also taper off steeply in the lower range. The damping behavior ensures extensive elimination of the blackbody radiation and the radiation of combustion products other than radicals. For good evaluable amplification, the detector has a minimum responsivity between 0.015 and 0.035 (A/W), preferably 0.025 (A/W), and a response behavior in the range of microseconds, which define a threshold, the exceeding of which indicates the presence and/or the type of a flame. Preferably, these detectors are photoelectric sensors. If a GaP photodiode of the Schottky type having UV filter is used as the detector, the threshold value lies at a radiation intensity of approximately 1000 lux with a minimum short-circuit current of 0.18 μA. Such a detector shows a high responsivity essentially only in the wavelength range 280 to 410 nm. 
     All flames whether, e.g., gas, oil, coal, etc., are presented in this range with sufficient energy with respect to radiation and are detected in this wavelength range with a minimum responsivity of the responding detector of preferably 0.025 (A/W), eliminating the wavelengths outside the wavelength range of the radicals, amplified, and evaluated for the presence of a flame by comparison to predetermined thresholds for YES/NO responses. 
     From DE 197 46 786 C2 a flame monitor is known in which a detector with a spectral responsivity in a wavelength range, for example in the near ultraviolet, is used followed by an evaluation circuit, which influences a regulator for the fuel combustion air ratio according to the spectral distribution of the flame radiation. A photoelectric sensor is provided as a detector. An evaluation of the radiation received by the detector, with respect to whether the burner is burning and, in case that it is not burning, to switch off the fuel supply as immediately as possible, is not provided here. 
     A radiation sensor having a radiation-sensitive diode for ultraviolet light is known from DE 41 15 255 A1. The spectral sensitivity is optimally adapted to the optical emission of blue burning flames of modern oil and gas burners, so that false light cannot appear to be a flame. The very small current, which is generated in a photoelectric manner by the radiation in the diode, is furthermore converted by means of an amplifier circuit into a voltage. The amplifier circuit comprises, for example, an operational amplifier which is fed back by means of a resistor and, if possible a capacitor. In addition to the inputs for connecting the diode, the amplifier circuit has connections for the supply voltage and for the ground and an output to which the output signal is applied. The abovementioned elements as a whole form the radiation sensor, which is arranged inside a hermetically sealed housing. 
     The known flame monitors provide an output signal when flame is present and no evaluation signal when there is a loss of flame. However, a statement indicative of the existence of a flame at the burner is particularly important for a flame sensing if intensity changes are to be recorded and evaluated. 
     A flame monitor at oil and gas burners is known from DE 29 32 129 A1, which is designed for self-monitoring in such a way that the flame monitor has self-monitoring, according to which the flame sensor switch is connected in parallel with a bridging switch for the fuel valve and, in the event of flame loss, can be connected with a circuit having two parallel connected alternately operated relays for switching the bridging switch and the element and a timing mechanism. As a result, the operation of the flame sensor and the bridging circuit, as well as the sensing switch, can be checked in a random sequence. 
     The above-described circuit units comprising flame monitors have the disadvantage that they do enable self-monitoring of the flame monitor with respect to its functionality, but the detection of a locality path of a flame area is not provided for. It has been presumed that it is sufficient to know that a flame having a radiation intensity has been detected at all. For burners with combustion chambers longer than 1 meter, the National Fire Protection Association (NFPA) USA has now stipulated safety regulations that at least one flame monitor is to be provided at each of the ends of a flame area to meet the safety requirements. 
     Accordingly, it is an object of the invention to provide a control unit for detecting a flame which, using at least two flame monitors, provides a control signal which is dependent on of a burner flame having radiation intensity and at the same time indicates the loss of a flame, and a flame monitoring system having such a control unit. 
     This object is achieved by the features of claims  1  and  15 . 
     Thus, a control unit for detecting the existence of a flame at the burner using a fuel with flame monitors and a flame monitoring system is provided, which is based on a sensor technology with several sensors, in particular a two-sensor technology. An intelligent subsystem having a logic functional wiring diagram is integrated to provide switching functions for detecting the presence of a flame and the loss/going out of a flame by means of flame monitors, and in particular for burners whose flame chambers exceed 1 m in length. 
     Combustion monitoring control units usually have control outputs for valves and ignition systems and an input for flame monitoring. Depending on the mechanism, this input is designed for connection of ionization electrodes, UV tubes, or relay contacts. The connection of at least one additional flame monitor requires the evaluation of several signals. On the one hand, the external light barrier has to trigger itself for external light monitoring of each flame monitor and, on the other hand, each flame monitor has to switch off safely during operation if the flame or a flame section goes out. 
     According to the invention, it is provided in a first operating state that the at least two outputs are sensed for flame light detection. As a switching function, an OR operation of the at least two flame monitoring outputs is provided. The parallel connection of closing contacts represents an OR element. A relay is energized when the closing contacts controlled by the first “or” the second flame monitoring output are closed. 
     According to the invention, it is further provided in a second operating state that for flame detection, each of the flame monitors has to detect the flame. In the event of failure/blacked out of a flame monitor, the system must switch off. As a switching function an AND operation of the at least two flame monitoring outputs is provided. The serial connection of closing contacts represents an AND element. A relay is energized when the contacts controlled by the first “and” the second flame monitoring output are closed. 
     According to the invention, it is further provided that a switching logic is provided for switching between the two operating states. Only one flame monitoring input of an evaluation circuit can be controlled by the switching logic. This can be done, for example, by a changeover relay with two changeover contacts. The changeover relay with two changeover contacts can be used to control a new output relay either in parallel or in series. The changeover relay should preferably be controlled via a fuel valve open—feedback signal. In this case, after the ignition, it is ensured that the at least two flame monitors were able to detect a flame. The fuel valve is a gas valve, for example. 
     The output of the new output relay can be designed in such a way that various automatic combustion systems can be used. On the one hand, a normal relay contact can be provided, and on the other hand, a resistor with a diode can be connected to an ionization input. 
     In case that the feedback signal—fuel valve open—is missing or is not connected, an additional forced switching can take place. This can be done via a timer module, which can be designed as a switch-on delay and can be activated when the power supply is switched on. The time delay can be adjustable in order to be able to represent corresponding specifications on the approval side for pre-ventilation and extraneous light control. 
     Further embodiments of the invention can be learned from the following description and the dependent claims. 
    
    
     
       The invention is explained in more detail below with reference to the embodiments shown in the accompanying figures. 
         FIG.  1    schematically shows a burner unit with a circuit diagram of a first embodiment of a flame monitoring system for burners, in particular oil or gas burners, 
         FIG.  2    schematically shows a parallel connection of two flame monitoring outputs of the flame monitoring system according to  FIG.  1   , 
         FIG.  3    schematically shows a series connection of two flame monitoring outputs of the flame monitoring system according to  FIG.  1   , 
         FIG.  4    schematically shows a circuit diagram of a second embodiment of a flame monitoring system for burners, in particular oil or gas burners. 
     
    
    
     As shown in  FIG.  1   , the invention relates to a flame monitoring system for sensing a presence or a loss of flame  1 , in particular of an axially extending flame area, at the burner  2  with combustion chamber lengths X of more than 1 m, wherein at least one flame monitor  3 ,  4  is provided on each of the two ends of the local extension of the flame  1 . The flame monitoring system further comprises a control unit  5  as a combustion monitoring device which connects the at least two flame monitors  3 ,  4  via preferably a control output  6  to an input  7  of a burner control unit  8 . The input  7  is thus the input for flame monitoring at the burner control unit, the burner control unit  8  preferably needs to have only one single input  7  for flame monitoring. 
     In a known manner, the burner control unit  8  further has control outputs  9 ,  10  for a valve-controlled air supply  1 , a gas supply  12  and an ignition system  13 . 
       FIG.  2    and  FIG.  3    show parts of the control unit  5  according to the invention for detecting the existence of a flame  1  with flame monitors  3 ,  4  for a burner  2  operated with a fuel. Each flame monitor  3 ,  4  comprises at least one sensor  31 ,  41  as operating means for detecting the radiation emission from a flame  1  as a visible reaction between fuel and oxidizing oxygen in a combustion region, and an evaluation circuit (not shown) associated with the at least one sensor  31 ,  41 . The evaluation circuit determines whether the radiation received by the sensor  31 ,  41  corresponds to that of a burning flame and, if the result is negative, generates a fuel supply switch-off signal. Such flame monitors  3 ,  4  are described, for example, in EP 2 439 451 B1 and U.S. Pat. No. 8,618,493 B2. Known usable flame monitors of high sensitivity respond in the UVA range and are so-called UV tubes or semiconductor sensors based on silicon, GaN, GaP or GaAsP diodes, which are followed by evaluation circuits with amplifiers. 
     The at least two flame monitors  3 ,  4  are connected in such a way that a basic electrical circuit  20 ,  21  is formed which processes the output signals of the at least two flame monitors  3 ,  4  via closing contacts  14 ,  15  in an OR operation  16  or via closing contacts  17 ,  18  in an AND operation  19 . Depending on which of at least two operating states of a flame detection system is assigned to the output signals of the flame monitors  3 ,  4 , processing of the output signals of the flame monitors  3 ,  4  is performed by a basic circuit control unit  22 . 
       FIG.  2    shows as OR element  16  a parallel connection of the at least two flame monitoring outputs. Both outputs have to be detected to perform flame detection, i.e., the at least two flame monitors  3 ,  4  must detect a flame  1  to ensure that an axially extending local area of the flame of more than 1 m distance is working completely. The parallel circuit according to  FIG.  2    is associated with a first operating state of a timing of detection of the presence of a flame. By means of the parallel circuit it is achieved that the function of a sensor  31 ,  41  or flame sensor of each flame monitor  3 ,  4  can in principle be checked at any time sequence, whereby the initial ignition is of particular importance. Notwithstanding this, it is also possible to switch back from the second operating state described below to the first operating state in order to increase the detection options by means of OR operation  16  of flame monitors  3 ,  4 . The number of flame monitors  3 ,  4  which can be used can vary between two and more, in particular up to ten. 
     By means of the OR element  16  shown in  FIG.  2   , it is preferably only possible to switch to a second operating state in case a flame  1  of a burner  2  has ignited correctly in view of time steps, as shown in  FIG.  3   . The second operating state is then the continuous monitoring for the existence of the flame  1 . 
       FIG.  3    shows as an AND operation  19  a series connection of the at least two flame monitoring outputs. Each of the flame monitors  3 ,  4  have to be detected. In the event of failure of a flame monitor  3 ,  4 , the system has to switch off as part of the flame detection process that has been carried out. According to a time schedule for the detection of the presence of a flame the series connection according to  FIG.  3    is associated to a second operating state. By this series connection it is achieved that the function of a sensor  31 ,  41  or flame scanner of each flame monitor  3 ,  4  provides an electrical current interruption in the basic circuit  21  in case of flame loss. 
       FIG.  4    shows an embodiment in which the basic circuit  20 ,  21  combines the OR element  16  and AND element  19  to a logic function circuit with a switching logic  24  for switching between the at least two operating states for detecting the existence of a flame  1 . The switching logic  24 , for example in the form of a changeover relay  25  with two changeover contacts  27 ,  28 , allows an output relay  23  to be controlled either in parallel via the basic circuit  20  or in series via the basic current circuit  21 . Consequently, the switching logic  24  links the parallel and serial connection of the flame monitoring outputs as an intelligent subsystem with a logic function plan. Preferably, the switching logic  24  is to be controlled by a feedback signal  26 —fuel valve open. In this case, after the ignition, it is ensured that the at least two flame monitors  3 ,  4  have to detect the flame  1 . The fuel valve can be a gas valve, for example. 
     The contacts  17 ,  18 , shown in  FIG.  3   , used to define an AND operation  19  are made by changeover contacts  27 ,  28 , since in combination with the OR operation  16  the AND operation is arranged in a subordinate position. In the combination of OR operation  16  and AND operation  19 , the outputs of the at least two flame monitors  3 ,  4  are connected to the make contacts  14 ,  15  of the OR operation. 
     The output of the new output relay  23  can be designed so that various automatic burner controls can be used. On the one hand, a normal relay contact can be provided, which is connected via a line  32  to the flame monitoring input  7  on the burner control unit  8 . Alternatively or additionally, connection to an ionization input of the basic circuit control unit  22  is also possible via a resistor  29  with diode  30 . The basic circuit control unit  22  can also be integrated in the burner control unit  8  (see  FIG.  1   ). 
     In the event that the feedback signal  26 —fuel valve open—fails to appear or is not connected, a forced switchover can also be performed. This can be done via a timer module  33 , which can be designed as a switch-on delay and can be activated when the voltage supply  34  is switched on. The time delay can be adjustable in order to be able to represent corresponding specifications on the approval side for pre-ventilation and extraneous light control. 
       FIG.  1    to  FIG.  4    show further preferred embodiments. 
     The output signals of the at least two flame detectors  3 ,  4  each switch on/off closing contacts  14 ,  15 ;  17 ,  18 , which can also be designed as relays. The output signals are optionally processed in an OR operation for a first operating state of the flame detector or an AND operation for a second operating state of the flame detector. Both combinations are implemented additively in the basic circuit  20 ,  21 , but selectively connected by means of the switching logic  24 . 
     With OR operation  16  for the first operating state, the outputs of the at least two flame monitors  3 ,  4  are individually detectable by means of a current meter comprised by the control unit  22 , for example, if not all flame monitors  2 ,  3  provide an output signal. 
     In the AND operation  19  for the second operating state, the outputs of the at least two flame monitors are individually checked and an interruption of the basic circuit can be evaluated by the control unit  22 . 
     The AND operation  19  is preferably a serial connection of the outputs of the flame detectors  3 ,  4  and the OR operation  16  is preferably a parallel connection of the outputs of the flame monitors  3 ,  4 . The operations can also be replaced by binary elements. 
     The at least two flame monitors  3 ,  4  can have binary and/or analog sensors as flame sensors, in particular photosensors. 
     Burner control  8  may be designed to optimize a mixing ratio of gas and air. 
     For switching between the at least two operating states, a switching logic  24  is provided. This switching logic  24  combines an intelligent subsystem comprising closing contacts  14 ,  15 ,  17 ,  18 , OR element  16 , basic electric circuit  20 ,  21 , and AND element  19  with a logic function plan comprising changeover relays  25  and changeover contacts  27 ,  28 . 
     All publications and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference. 
     The invention now being fully described, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the appended claims.