Abstract: A combination boiler provides heated water to a boiler loop and heated domestic hot water (DHW) to a DHW loop. A primary heat exchanger is connected to the boiler loop. A burner provides heat to the primary heat exchanger and an input fan supplies a fuel and air mixture to the burner. A secondary heat exchanger transfers heat energy from the boiler loop to a domestic water loop. A controller determines a boiler loop flow rate. The controller measures an input temperature of the boiler loop, an output temperature of the boiler loop, and a DHW output temperature of the domestic water loop. The controller determines a DHW input temperature and estimates a DHW flow rate. The input fan speed is initiated or operated according to a required heat output of the burner corresponding to the DHW flow rate.

Abstract: A combination boiler provides heated water to a boiler loop and domestic hot water (DHW) to a domestic water loop. The combination boiler includes a primary heat exchanger (PHE) connected to the boiler loop and a burner to provide heat to the primary heat exchanger. A secondary heat exchanger (SHE) transfers heat energy from the boiler loop to the domestic water loop. A controller monitors a PHE inlet temperature and a DHW output temperature, obtains a pre-heat initialization temperature threshold and a pre-heat cancellation temperature threshold, and detects a low temperature condition. A pre-heat operation is initiated responsive to the low temperature condition by circulating heated water from the PHE to the SHE. The burner is selectively fired at least in part according to an outlet temperature of the PHE.

Abstract: A fluid heating system including a fluid supply subsystem having a fluid heating device, a fluid output subsystem, and an intermediary fluid device. The fluid heating system also includes a control device for the fluid supply subsystem, a first temperature sensor, a second temperature sensor, and a control circuit coupled to the control device. The control device is configured to control one selected from a group consisting of the fluid heating device and an amount of water input to the intermediary fluid device. The first and second temperature sensors are configured to output first and second temperature signals, respectively. The control circuit is configured to generate a first control signal based on the second temperature signal, determine a multiplier, generate a second control signal based on the first temperature signal, and send a main control signal to the control device based on the first and second control signals.

Abstract: A control system is provided for a modulated heating system including a plurality of modulating water heaters, which may be modulating boilers. A deadband control scheme provides for reduced cycling of the modulating heater when total system heat demand falls between the maximum output of one heater and the sum of the maximum output of that one point and the minimum firing point of the next subsequent heater. Condensation of flue gas products is prevented by monitoring flue exhaust temperature for each heater and controlling the modulation of each heater to maintain a minimum heater output sufficiently high to prevent condensation of flue gas products from that heater. Rapid reaction to changes in system heat demand is provided by sensing changes in flow rate in a primary loop of the system and anticipating resulting changes in temperature thus allowing for change in heater output prior to the time the change in flow rate has fully impacted system temperature.

Abstract: A combination boiler provides heated water to a boiler loop and domestic hot water (DHW) to a domestic water loop. The combination boiler includes a primary heat exchanger (PHE) connected to the boiler loop and a burner to provide heat to the primary heat exchanger. A secondary heat exchanger (SHE) transfers heat energy from the boiler loop to the domestic water loop. A controller monitors a PHE inlet temperature and a DHW output temperature, obtains a pre-heat initialization temperature threshold and a pre-heat cancellation temperature threshold, and detects a low temperature condition. A pre-heat operation is initiated responsive to the low temperature condition by circulating heated water from the PHE to the SHE. The burner is selectively fired at least in part according to an outlet temperature of the PHE.

Abstract: A hydronic water heating system heats water for various types of heat emitters. A boiler assembly includes a user interface which receives user-defined water temperature set point corresponding to a minimum outdoor temperature, and an integrated controller generates a nonlinear outdoor reset curve between the user-defined set point and a second set point corresponding to maximum outdoor temperature for which heating is required, and regulates the boiler to heat water to a temperature corresponding to a set point along the nonlinear output reset curve and based on a detected outdoor temperature. The nonlinear outdoor reset curve may be generated based on aggregated heat output functions for various types of heat emitters. A linear outdoor reset curve may be generated between a maximum water temperature set point and the user-defined set point, having a slope equal to an instantaneous slope of the nonlinear outdoor reset curve at the user-defined set point.

Abstract: A pre-mix burner apparatus includes a burner having a generally cylindrical burner surface, the burner having a generally circular burner inlet at one end of the burner, the burner inlet having an inlet diameter. A flow distribution member is arranged to distribute flow of fuel and air mixture into the burner. The flow distribution member includes a closed axially central portion configured to block flow of fuel and air mixture axially centrally into the burner. The flow distribution member includes a plurality of vanes extending radially outward from the closed axially central portion. The vanes are configured to generate a swirling flow of fuel and air mixture flowing past the vanes into the burner.

Abstract: A combination boiler provides heated water to a boiler loop and heated domestic hot water (DHW) to a DHW loop. A primary heat exchanger is connected to the boiler loop. A burner provides heat to the primary heat exchanger and an input fan supplies a fuel and air mixture to the burner. A secondary heat exchanger transfers heat energy from the boiler loop to a domestic water loop. A controller determines a boiler loop flow rate. The controller measures an input temperature of the boiler loop, an output temperature of the boiler loop, and a DHW output temperature of the domestic water loop. The controller determines a DHW input temperature and estimates a DHW flow rate. The input fan speed is initiated or operated according to a required heat output of the burner corresponding to the DHW flow rate.

Abstract: A fluid heating system including a fluid supply subsystem having a fluid heating device, a fluid output subsystem, and an intermediary fluid device. The fluid heating system also includes a control device for the fluid supply subsystem, a first temperature sensor, a second temperature sensor, and a control circuit coupled to the control device. The control device is configured to control one selected from a group consisting of the fluid heating device and an amount of water input to the intermediary fluid device. The first and second temperature sensors are configured to output first and second temperature signals, respectively. The control circuit is configured to generate a first control signal based on the second temperature signal, determine a multiplier, generate a second control signal based on the first temperature signal, and send a main control signal to the control device based on the first and second control signals.

Abstract: A water heater apparatus includes an elongated radial burner extending along a longitudinal central axis of the apparatus. First and second concentric rows of longitudinally extending fin tubes around the radial burner. The fin tubes may have multiple wiped circumferentially laterally portions allowing close packing of the fin tubes for improved efficiency and reduced footprint.

Abstract: A control system is provided for a modulated heating system including a plurality of modulating water heaters, which may be modulating boilers. A deadband control scheme provides for reduced cycling of the modulating heater when total system heat demand falls between the maximum output of one heater and the sum of the maximum output of that one point and the minimum firing point of the next subsequent heater. Condensation of flue gas products is prevented by monitoring flue exhaust temperature for each heater and controlling the modulation of each heater to maintain a minimum heater output sufficiently high to prevent condensation of flue gas products from that heater. Rapid reaction to changes in system heat demand is provided by sensing changes in flow rate in a primary loop of the system and anticipating resulting changes in temperature thus allowing for change in heater output prior to the time the change in flow rate has fully impacted system temperature.

Abstract: A modulating burner apparatus includes a burner and a blower placed upstream of the burner. A venturi is placed upstream of the blower. A damper valve is placed upstream of the venturi. The damper valve has an open position and a restricted position. A smaller gas valve and a larger gas valve are communicated with the venturi. A controller is operably associated with the system to select a position of the damper valve and to select the appropriate one of the gas valves so as to provide a low output operation mode and a high output operation mode, which in combination provide an overall turndown ratio of at least 25:1.

Abstract: A modulating burner apparatus includes a burner and a blower placed upstream of the burner. A venturi is placed upstream of the blower. A damper valve is placed upstream of the venturi. The damper valve has an open position and a restricted position. A smaller gas valve and a larger gas valve are communicated with the venturi. A controller is operably associated with the system to select a position of the damper valve and to select the appropriate one of the gas valves so as to provide a low output operation mode and a high output operation mode, which in combination provide an overall turndown ratio of at least 25:1.

Abstract: A modulating burner apparatus includes a variable speed blower feeding a multi-chamber burner having first and second burner chambers. A manifold system communicates the blower with the burner, and a flow control valve member is located between the blower and the second chamber of the burner. The flow control valve is configured to provide fuel and air mixture from the blower to only the first burner chamber at lower blower speeds of the blower and to both the first and second burner chambers at higher blower speeds of the blower.

Abstract: A modulating burner apparatus includes a burner and a blower placed upstream of the burner. A venturi is placed upstream of the blower. A damper valve is placed upstream of the venturi. The damper valve has an open position and a restricted position. A smaller gas valve and a larger gas valve are communicated with the venturi. A controller is operably associated with the system to select a position of the damper valve and to select the appropriate one of the gas valves so as to provide a low output operation mode and a high output operation mode, which in combination provide an overall turndown ratio of at least 25:1.

Abstract: A dual chamber burner assembly provides a header, a first burner chamber adjacent the header, and a second burner chamber on an opposite side of the first burner chamber from the header. The second burner chamber is provided with a flame sensor portion extending back through the first burner chamber toward the header so that first and second flame sensors may be utilized to detect flame in the first and second chambers, respectively.

Abstract: A control system is provided for a modulated heating system including a plurality of modulating water heaters, which may be modulating boilers. A deadband control scheme provides for reduced cycling of the modulating heater when total system heat demand falls between the maximum output of one heater and the sum of the maximum output of that one point and the minimum firing point of the next subsequent heater.

Abstract: A fire tube heater apparatus includes a shell, with a tube bundle received in the shell and a burner section communicated with the tube bundle. The tubes in the tube bundle have circular inlet and outlet end portions with a flattened, serpentine intermediate portion. The intermediate portion has a width greater than the inlet outside diameter and a tube thickness transverse to the width less than the inlet outside diameter.