Abstract: An HVAC system includes a blower configured to provide a flow of air into a conditioned space. A temperature sensor measures a discharge air temperature of the flow of air provided to the conditioned space. The blower provides the flow of air at a predefined flow rate. The controller determines that the measured discharge air temperature satisfies predefined stability criteria associated with a change in the discharge air temperature during a first period of time being less than a threshold value. If the stability criteria are satisfied, a temperature offset is determined between the discharge air temperature and an indoor temperature. The temperature offset is stored in a memory and is associated with the flow rate of air provided by the blower and the outdoor temperature.

Abstract: An HVAC system includes a heating element, a discharge air temperature sensor, and a return air temperature sensor. A controller of the HVAC system determines that the HVAC system has been operating in the heating mode for at least a predefined amount of time. The controller receives measurements of the discharge air temperature and the return air temperature. A temperature rise value is determined using the discharge air temperature and return air temperature. If the temperature rise value is less than a predefined minimum threshold value, the controller determines that a first fault of the HVAC system is detected and provides a corresponding alert. If the temperature rise value is greater than a predefined maximum threshold value, the controller determines that a second fault of the HVAC system is detected and provides a corresponding alert.

Abstract: A burner assembly according to aspects of the disclosure includes a burner surface carried by a burner, the burner surface extending outward from a front side of the burner, a housing coupled to the burner on a side opposite the front side of the burner, a gasket disposed between the burner and the housing, a thermally anisotropic protective covering located on the front side of the burner and surrounding a perimeter of the burner surface, and an igniter positioned adjacent to the burner surface.

Abstract: A clamshell heat exchanger for use in a combustion furnace of an HVAC system is presented that includes in one instance two passageways coupled by a turnaround passageway. The first passageway that receives the combustion products diverges. A cross section of the first passageway resembles a tear drop or air foil with the widest portion closest to the second passageway. The second passageway also diverges from the turnaround portion towards the outlet. The second passageway may include a baffle that forms two flow streams. Other embodiments are presented.

Abstract: A method of monitoring a HVAC system to detect erroneous sensor installation. The method includes determining whether a circulation fan has been operational for a first predetermined time interval. If the circulation fan has been operational for the first predetermined time interval, determining whether a cooling demand is present. If the cooling demand is present, determining whether the HVAC system has been conditioning air for the first predetermined time interval responsive to the cooling demand. If the HVAC system has been conditioning the air for the first predetermined time interval, determining whether a difference between an indoor air temperature value corresponding to an enclosed space and an air temperature value from a discharge air temperature (DAT) sensor is greater than a predetermined temperature value.

Abstract: An HVAC system includes a heating element, a discharge air temperature sensor, and a return air temperature sensor. A controller of the HVAC system determines that the HVAC system has been operating in the heating mode for at least a predefined amount of time. The controller receives measurements of the discharge air temperature and the return air temperature. A temperature rise value is determined using the discharge air temperature and return air temperature. If the temperature rise value is less than a predefined minimum threshold value, the controller determines that a first fault of the HVAC system is detected and provides a corresponding alert. If the temperature rise value is greater than a predefined maximum threshold value, the controller determines that a second fault of the HVAC system is detected and provides a corresponding alert.

Abstract: An HVAC system includes a heating element, a discharge air temperature sensor, and a return air temperature sensor. A controller of the HVAC system determines that the HVAC system has been operating in the heating mode for at least a predefined amount of time. The controller receives measurements of the discharge air temperature and the return air temperature. A temperature rise value is determined using the discharge air temperature and return air temperature. If the temperature rise value is less than a predefined minimum threshold value, the controller determines that a first fault of the HVAC system is detected and provides a corresponding alert. If the temperature rise value is greater than a predefined maximum threshold value, the controller determines that a second fault of the HVAC system is detected and provides a corresponding alert.

Abstract: A burner assembly according to aspects of the disclosure includes a burner surface carried by a burner, the burner surface extending outward from a front side of the burner, a housing coupled to the burner on a side opposite the front side of the burner, a gasket disposed between the burner and the housing, a thermally anisotropic protective covering located on the front side of the burner and surrounding a perimeter of the burner surface, and an igniter positioned adjacent to the burner surface.

Abstract: An HVAC system includes a heating element, a discharge air temperature sensor, and a return air temperature sensor. A controller of the HVAC system determines that the HVAC system has been operating in the heating mode for at least a predefined amount of time. The controller receives measurements of the discharge air temperature and the return air temperature. A temperature rise value is determined using the discharge air temperature and return air temperature. If the temperature rise value is less than a predefined minimum threshold value, the controller determines that a first fault of the HVAC system is detected and provides a corresponding alert. If the temperature rise value is greater than a predefined maximum threshold value, the controller determines that a second fault of the HVAC system is detected and provides a corresponding alert.

Abstract: An HVAC system includes a blower configured to provide a flow of air into a conditioned space. A temperature sensor measures a discharge air temperature of the flow of air provided to the conditioned space. The blower provides the flow of air at a predefined flow rate. The controller determines that the measured discharge air temperature satisfies predefined stability criteria associated with a change in the discharge air temperature during a first period of time being less than a threshold value. If the stability criteria are satisfied, a temperature offset is determined between the discharge air temperature and an indoor temperature. The temperature offset is stored in a memory and is associated with the flow rate of air provided by the blower and the outdoor temperature.

Abstract: A burner assembly according to aspects of the disclosure includes a burner surface carried by a burner, the burner surface extending outward from a front side of the burner, a housing coupled to the burner on a side opposite the front side of the burner, a gasket disposed between the burner and the housing, a thermally anisotropic protective covering located on the front side of the burner and surrounding a perimeter of the burner surface, and an igniter positioned adjacent to the burner surface.

Abstract: An HVAC system includes a blower configured to provide a flow of air into a conditioned space. A temperature sensor measures a discharge air temperature of the flow of air provided to the conditioned space. A controller of the HVAC system determines that heating or cooling mode operation is not requested. Following this determination, the blower provides the flow of air at a predefined flow rate. The controller determines that the measured discharge air temperature satisfies predefined stability criteria associated with a change in the discharge air temperature during the first period of time being less than a threshold value. If the stability criteria are satisfied, a temperature offset is determined between the discharge air temperature and an indoor temperature. The temperature offset is stored in a lookup table such that the temperature offset is associated with the flow rate of air provided by the blower and the outdoor temperature.

Abstract: An HVAC system includes a blower configured to provide a flow of air into a conditioned space. A temperature sensor measures a discharge air temperature of the flow of air provided to the conditioned space. A controller of the HVAC system determines that heating or cooling mode operation is not requested. Following this determination, the blower provides the flow of air at a predefined flow rate. The controller determines that the measured discharge air temperature satisfies predefined stability criteria associated with a change in the discharge air temperature during the first period of time being less than a threshold value. If the stability criteria are satisfied, a temperature offset is determined between the discharge air temperature and an indoor temperature. The temperature offset is stored in a lookup table such that the temperature offset is associated with the flow rate of air provided by the blower and the outdoor temperature.

Abstract: Provided herein are embodiments of, a multistage gas furnace, a controller therefor and a computer-usable medium having non-transitory computer readable instructions stored thereon for execution by a processor to perform a method for operating a gas furnace. In one embodiment, the gas furnace includes: (1) a burner, (2) a circulation fan and (3) a furnace controller. The furnace controller having: (3A) an interface configured to receive heating calls and a blower control signal, the blower control signal corresponding to an operating speed of the circulation fan and (3B) a processor configured to respond to the heating calls and the blower control signal by setting and adjusting a gas input rate for the burner that is based on the blower control signal and that corresponds to a discharge air temperature determined by a dedicated discharge air sensor associated with the furnace.

Abstract: A flue shield and mesh baffle are described for use within HVAC systems and inside of a combustion chamber. The shield or baffle can be installed around the burner and within the combustion chamber to help dissipate heat that builds up as a result of the combustion of gas and air. An air gap is created between the flue shield and the inner surfaces of the combustion chamber and heat exchanger tubes. A mesh baffle can provide heat insulation and noise dampening. Installation of a flue shield or mesh baffle provides better efficiency than insulation solutions, reduces stresses on the heat exchanger, and provides safety benefits.

Abstract: A method of monitoring a HVAC system to detect erroneous sensor installation. The method includes determining whether a circulation fan has been operational for a first predetermined time interval. If the circulation fan has been operational for the first predetermined time interval, determining whether a cooling demand is present. If the cooling demand is present, determining whether the HVAC system has been conditioning air for the first predetermined time interval responsive to the cooling demand. If the HVAC system has been conditioning the air for the first predetermined time interval, determining whether a difference between an indoor air temperature value corresponding to an enclosed space and an air temperature value from a discharge air temperature (DAT) sensor is greater than a predetermined temperature value.

Abstract: A method of monitoring a HVAC system to detect erroneous sensor installation. The method includes determining whether a circulation fan has been operational for a first predetermined time interval. If the circulation fan has been operational for the first predetermined time interval, determining whether a cooling demand is present. If the cooling demand is present, determining whether the HVAC system has been conditioning air for the first predetermined time interval responsive to the cooling demand. If the HVAC system has been conditioning the air for the first predetermined time interval, determining whether a difference between an indoor air temperature value corresponding to an enclosed space and an air temperature value from a discharge air temperature (DAT) sensor is greater than a predetermined temperature value.

Abstract: A flue shield is described for use within HVAC systems and inside of a combustion chamber. The flue shield can be installed around the burner and within the combustion chamber to help dissipate heat that builds up as a result of the combustion of gas and air. Extensions from the flue shield extend through holes in the combustion chamber and into tubes of a heat exchanger. An air gap is created between the flue shield and the inner surfaces of the combustion chamber and heat exchanger tubes. Installation of a flue shield provides better efficiency than insulation solutions, reduces stresses on the heat exchanger, and provides safety benefits.

Abstract: Systems and methods are described related to a premix combustion system used in a furnace system. Prior systems have to create a negative pressure in the premix chamber to draw gas into the chamber. Embodiments under the current disclosure can use an amplifier that is pneumatically coupled to an air supply and a secondary location (besides the gas valve). Coupling to the amplifier to a location apart from the gas valve allows the system to avoid a negative pressure in the mixing chamber. The amplifier can apply an amplified pressure or signal to a gas valve regulator and thereby raise the gas pressure so that the gas supply is driven into the premix chamber.

Abstract: Systems and methods are described for a screen assembly for gas-air mixers in HVAC systems, such as for furnaces. A screen assembly can comprise a mesh screen, a housing, and a pressure tap. The mesh screen can allow for the intake of an air supply while also blocking unwanted foreign matter such as dust or leaves. The housing can receive the air supply and direct it into a gas-air mixer or other component. The pressure tap can be coupled to a gas valve or regulator in order to modulate the flow of gas when air flow is restricted.