Abstract: A heating control system that includes a heating unit with a constant burner and a pulsed burner. The constant burner is configured to remain active during operation. The pulsed burner is configured to toggle between an active mode and an inactive mode. The heating control system further includes a memory operable to store a temperature map that maps temperatures to percentages of a period that the pulsed burner is active and a microprocessor operably coupled to the heating unit and the memory. The microprocessor is configured to transmit a first electrical signal to activate the constant burner, obtain a temperature set point, determine the percentage of the period that the pulsed burner is active using the temperature set point and the temperature map, and transmit a second electrical signal to toggle the pulsed burner based on the determination of the percentage of the period that the pulsed burner is active.

Abstract: A heating control method includes determining a first speed for an air circulation fan that corresponds with a temperature set point using a temperature map that maps temperatures to speeds of the air circulation fan and operating the air circulation fan at the first speed and a heating unit in a first configuration with at least one active burner from a plurality of burners where less than all of the burners are active when the heating unit is in the first configuration. The method further includes measuring a first temperature while operating the air circulation fan at the first speed, determining a temperature difference between the first temperature and the temperature set point, comparing the temperature difference to a temperature difference threshold, and updating the temperature map to map the first speed to the first temperature when the temperature difference is greater than the temperature difference threshold.

Abstract: A heating control device including input/output ports, a memory operable to store smoke output thresholds, and a microprocessor. The microprocessor is configured to transmit a first electrical signal to operate an air circulation fan at a first speed and a heating unit in a first configuration to burn a lubricant at a first temperature where less than all of the burners are active. The microprocessor is further configured to obtain a smoke output measurement for the first temperature, compare the smoke output measurement to the smoke output threshold, and transmit a second electrical signal to transition the air circulation fan to a second speed to burn the lubricant at a second temperature that is greater than the first temperature when the smoke output measurement is less than the smoke output threshold and is less than the first temperature when the smoke output measurement is greater than the smoke output threshold.

Abstract: A heating system comprising an air circulation fan, a heating unit, a memory that is operable to store a temperature map, and a microprocessor. The microprocessor is configured to operate the air circulation fan at a first speed and the heating unit in a first configuration. When the heating unit is in the first configuration, the heating unit is configured to achieve a first temperature and such that less than all of the burners are active. The microprocessor is also configured to receive a temperature set point and to determine a second speed for the air circulation fan using the temperature set point and the temperature map in response to receiving the temperature set point. Further, the microprocessor is configured to transition the air circulation fan from the first speed to the second speed in response to determining the second speed.

Abstract: A heating control system including an air circulation fan, a heating unit, a memory, and a microprocessor. The microprocessor is configured to operate the air circulation fan at a first speed and the heating unit in a first configuration where less than all of the burners are active. The microprocessor is further configured to determine a first temperature difference, compare the first temperature difference to a first temperature difference threshold, and transition the air circulation fan from the first speed to a second speed when the first temperature difference is less than the first temperature difference threshold. The microprocessor is further configured to determine a second temperature difference, compare the second temperature difference to a second temperature difference threshold, and transition the air circulation fan from the second speed to a third speed when the second temperature difference is less than the second temperature difference threshold.

Abstract: Retrofit assemblies and an HVAC unit including a retrofit assembly are disclosed herein. In one embodiment, the retrofit assembly includes: (1) a base plate, that is mountable to a face of a motor speed driver (MSD), having an attachment area, (2) a standoff bracket that is mountable to the attachment area of the base plate and having a configuration that secures the MSD in a position relative to an interior wall of the HVAC system and provides clearance between the interior wall of the HVAC system and the MSD such that wires can be routed between the MSD and the interior wall and (3) a control interface, electrically connectable between the MSD and a thermostat of the HVAC system, configured to differentiate thermostat calls from the thermostat and translate the thermostat calls to coordinate blower speeds for the blower motor via the MSD.

Abstract: A heating control system including an air circulation fan, a heating unit, a memory, and a microprocessor. The microprocessor is configured to operate the air circulation fan at a first speed and the heating unit in a first configuration to achieve a first temperature rise where less than all of the burners are active. The microprocessor is further configured to compare the first temperature rise to a first temperature rise threshold and transition the air circulation fan to a second speed to achieve a second temperature rise when the first temperature rise is less than the first temperature rise threshold. The microprocessor is further configured to compare the second temperature rise to a second temperature rise threshold and transition the air circulation fan to a third speed when the second temperature rise is greater than the second temperature rise threshold.

Abstract: A heating control device comprising input/output ports, a memory, and a microprocessor. The microprocessor is configured to transmit a first electrical signal to operate an air circulation fan at a first speed and a heating unit in a first configuration to achieve a first temperature rise where less than all of the burners are active. The microprocessor is further configured to obtain a return air temperature, obtain a room air temperature, and determine a temperature difference between the return air temperature and the room air temperature. The microprocessor is further configured to compare the temperature difference to a temperature rise threshold and transmit a second electrical signal to transition the air circulation fan from the first speed to a second speed to achieve a second temperature rise that is less than the first temperature rise when the temperature difference is greater than the temperature rise threshold.

Abstract: A heating control system including an air circulation fan, a heating unit, a memory, and a microprocessor. The microprocessor is configured to operate the air circulation fan at a first speed and the heating unit in a first configuration to achieve a first temperature rise where less than all of the burners are active. The microprocessor is further configured to compare the first temperature rise to a first temperature rise threshold and transition the air circulation fan to a second speed to achieve a second temperature rise when the first temperature rise is less than the first temperature rise threshold. The microprocessor is further configured to compare the second temperature rise to a second temperature rise threshold and transition the air circulation fan to a third speed when the second temperature rise is greater than the second temperature rise threshold.

Abstract: A heating control system that includes a heating unit with a constant burner and a pulsed burner. The constant burner is configured to remain active during operation. The pulsed burner is configured to toggle between an active mode and an inactive mode. The heating control system further includes a memory operable to store a temperature map that maps temperatures to percentages of a period that the pulsed burner is active and a microprocessor operably coupled to the heating unit and the memory. The microprocessor is configured to transmit a first electrical signal to activate the constant burner, obtain a temperature set point, determine the percentage of the period that the pulsed burner is active using the temperature set point and the temperature map, and transmit a second electrical signal to toggle the pulsed burner based on the determination of the percentage of the period that the pulsed burner is active.

Abstract: A heating control device comprising input/output ports, a memory, and a microprocessor. The microprocessor is configured to transmit a first electrical signal to operate an air circulation fan at a first speed and a heating unit in a first configuration to achieve a first temperature rise where less than all of the burners are active. The microprocessor is further configured to obtain a return air temperature, obtain a room air temperature, and determine a temperature difference between the return air temperature and the room air temperature. The microprocessor is further configured to compare the temperature difference to a temperature rise threshold and transmit a second electrical signal to transition the air circulation fan from the first speed to a second speed to achieve a second temperature rise that is less than the first temperature rise when the temperature difference is greater than the temperature rise threshold.

Abstract: A heating control system including an air circulation fan, a heating unit, a memory, and a microprocessor. The microprocessor is configured to operate the air circulation fan at a first speed and the heating unit in a first configuration where less than all of the burners are active. The microprocessor is further configured to determine a first temperature difference, compare the first temperature difference to a first temperature difference threshold, and transition the air circulation fan from the first speed to a second speed when the first temperature difference is less than the first temperature difference threshold. The microprocessor is further configured to determine a second temperature difference, compare the second temperature difference to a second temperature difference threshold, and transition the air circulation fan from the second speed to a third speed when the second temperature difference is less than the second temperature difference threshold.

Abstract: A heating control method includes determining a first speed for an air circulation fan that corresponds with a temperature set point using a temperature map that maps temperatures to speeds of the air circulation fan and operating the air circulation fan at the first speed and a heating unit in a first configuration with at least one active burner from a plurality of burners where less than all of the burners are active when the heating unit is in the first configuration. The method further includes measuring a first temperature while operating the air circulation fan at the first speed, determining a temperature difference between the first temperature and the temperature set point, comparing the temperature difference to a temperature difference threshold, and updating the temperature map to map the first speed to the first temperature when the temperature difference is greater than the temperature difference threshold.

Abstract: A heating system comprising an air circulation fan, a heating unit, a memory that is operable to store a temperature map, and a microprocessor. The microprocessor is configured to operate the air circulation fan at a first speed and the heating unit in a first configuration. When the heating unit is in the first configuration, the heating unit is configured to achieve a first temperature and such that less than all of the burners are active. The microprocessor is also configured to receive a temperature set point and to determine a second speed for the air circulation fan using the temperature set point and the temperature map in response to receiving the temperature set point. Further, the microprocessor is configured to transition the air circulation fan from the first speed to the second speed in response to determining the second speed.

Abstract: A heating control device including input/output ports, a memory operable to store smoke output thresholds, and a microprocessor. The microprocessor is configured to transmit a first electrical signal to operate an air circulation fan at a first speed and a heating unit in a first configuration to burn a lubricant at a first temperature where less than all of the burners are active. The microprocessor is further configured to obtain a smoke output measurement for the first temperature, compare the smoke output measurement to the smoke output threshold, and transmit a second electrical signal to transition the air circulation fan to a second speed to burn the lubricant at a second temperature that is greater than the first temperature when the smoke output measurement is less than the smoke output threshold and is less than the first temperature when the smoke output measurement is greater than the smoke output threshold.

Abstract: An inverter controller, a method of operating a controller and a field-installable kit. In one embodiment, the controller includes: (1) a thermostat interface configured to receive conventional thermostat signals providing for a ventilation mode, first- and second-stage cooling modes and at least one heating mode and provide relay control signals for an inverter forward start relay, first- and second-stage cooling speed select relays and at least one heating relay and (2) an inverter controller coupled to the thermostat interface and configured to receive the relay control signals and provide an inverter forward start signal, an inverter high speed set, an inverter medium speed set and an inverter ventilation speed set.

Abstract: Retrofit assemblies and an HVAC unit including a retrofit assembly are disclosed herein. In one embodiment, the retrofit assembly includes: (1) a base plate, that is mountable to a face of a motor speed driver (MSD), having an attachment area, (2) a standoff bracket that is mountable to the attachment area of the base plate and having a configuration that secures the MSD in a position relative to an interior wall of the HVAC system and provides clearance between the interior wall of the HVAC system and the MSD such that wires can be routed between the MSD and the interior wall and (3) a control interface, electrically connectable between the MSD and a thermostat of the HVAC system, configured to differentiate thermostat calls from the thermostat and translate the thermostat calls to coordinate blower speeds for the blower motor via the MSD.

Abstract: An inverter controller, a method of operating a controller and a field-installable kit. In one embodiment, the controller includes: (1) a thermostat interface configured to receive conventional thermostat signals providing for a ventilation mode, first- and second-stage cooling modes and at least one heating mode and provide relay control signals for an inverter forward start relay, first- and second-stage cooling speed select relays and at least one heating relay and (2) an inverter controller coupled to the thermostat interface and configured to receive the relay control signals and provide an inverter forward start signal, an inverter high speed set, an inverter medium speed set and an inverter ventilation speed set.

Abstract: A tubular heat exchanger has at least one pair of dimples which are extruded into at least one tube of the heat exchanger by deforming the tube wall inwardly. The dimples of each pair are in generally facing relationship, but are offset with respect to each other along a longitudinal axis of the tube, which slows down the flow of flue gas in the tube when the heat exchanger is in operation and increases the turbulence of the gas, thereby enhancing the transfer of heat from the flue gas to air flowing across the outer surfaces of the heat exchanger. The offset design allows each dimple to protrude beyond the centerline of the tube, which alters the direction of the flue gas flowing in the tube.