RADIANT HEATING ASSEMBLY AND METHOD OF OPERATING THE RADIANT HEATING ASSEMBLY

Abstract

A radiant heating assembly includes a fuel valve and a blower. A controller is configured to control the fuel valve and the blower according to one of a plurality of algorithms corresponding to one of a plurality of selectable modulation modes. An interface is in communication with the controller. One of the plurality of selectable modulation modes is selectable from the interface. The controller modulates at least one of the fuel valve and the blower according to the one of the plurality of algorithms corresponding to the one of the plurality of selectable modulation modes selected from the interface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The subject patent application claims priority to and all the benefits of U.S. Provisional Patent Application No. 61/443,615 which was filed on Feb. 16, 2011, which is expressly incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject invention generally relates to a radiant heating assembly as well as a method of operating the radiant heating assembly.

2. Description of the Related Art

Radiant heaters are widely utilized for a variety of heating purposes. One common type of radiant heater is a radiant tube heater including a burner and a heat tube extending from the burner. In the radiant tube heater, a gas valve provides gas into the burner while a blower motor provides air to the burner. The gas and the air are typically mixed and ignited in the burner. A flame and/or heated exhaust may pass from the burner to the heat tube such that the radiant tube heater emits radiant heat.

Attempts have been made in developing modulating systems for radiant tube heaters to improve control over the rates of the air and gas introduced into the burner. Modulating systems utilize variable-speed blower motors and electronically or pneumatically modulating gas valves. The modulating system typically provides electronic signals to the variable-speed blower motor and/or modulating gas valve. The modulating system varies the electronic signals to allow variations to the rates of the air and gas into the burner over a range not possible in multi-stage systems. Although such modulating systems allow variations to the rates of the air and gas into the burner, such modulating systems do not afford users of the radiant tube heater control over how and when the rates of the air and gas are varied. Rather, in such systems, modulation is triggered automatically and unbeknownst to users of the radiant tube heater.

Often, the same radiant tube heater may be used for different heating applications. For instance, the radiant tube heater may be installed at various different heights above a floor or subjected to a wide variety of environmental conditions. Additionally, users of the radiant tube heater may desire a balanced distribution of heat across a length of the heat tube by selectively increasing blower speed to force the air quickly across the length of the heat tube. Alternatively, users may desire to operate the radiant tube heater in a more thermally efficient manner by selectively reducing input of air and gas into the burner. Since the aforementioned radiant tube heaters do not provide user control over the rate of the air and/or gas, such radiant tube heaters may operate inconsistently with user expectations for different heating applications. As a result, such radiant tube heaters may operate inefficiently.

Accordingly, there remains an opportunity to provide a radiant tube heater that beneficially addresses the deficiencies set forth above. In other words, there remains an opportunity to provide a radiant tube heater which affords selective control over variable rates of the air and gas into the burner. Specifically, there remains an opportunity to provide a radiant tube heater which affords selective control over algorithms to control variable rates of the air and gas into the burner. Furthermore, there remains an opportunity to provide a radiant tube heater which exhibits increased operational efficiency over conventional modulating systems.

SUMMARY OF THE INVENTION AND ADVANTAGES

The present invention includes a method of operating a radiant heating assembly. The radiant heating assembly includes a fuel valve and a blower. The radiant heating assembly includes a controller configured to control at least one of the fuel valve and the blower according to one of a plurality of algorithms corresponding to one of a plurality of selectable modulation modes. The radiant heating assembly includes an interface in communication with the controller. The method includes the step of selecting one of the plurality of selectable modulation modes from the interface. The method includes the step of modulating at least one of the fuel valve and the blower by the controller according to the one of the plurality of algorithms corresponding to the one of the plurality of selectable modulation modes selected from the interface.

The method advantageously provides users of the radiant heating assembly selective control over variable rates of the air and/or gas into the burner. Specifically, the method provides users selective control over algorithms to control variable rates of the air and gas into the burner. Accordingly, users of the radiant heating assembly are provided the option of selecting one of the plurality of selectable modulation modes such that the radiant heating assembly operates consistently with user expectations for different heating applications. In effect, the radiant heating assembly further exhibits increased efficiency.

The present invention also includes the radiant heating assembly. The radiant heating assembly includes the burner for receiving the air and the fuel for combustion. The radiant heating assembly includes the elongated heat exchanger in communication with the burner. The radiant heating assembly includes the fuel valve for providing the fuel to the burner. The radiant heating assembly includes the blower for providing the air to the burner. The radiant heating assembly includes the controller configured to control the amount of the air and the fuel provided to the burner by modulating at least one of the fuel valve and the blower according to one of the plurality of algorithms corresponding to one of the plurality of selectable modulation modes. The radiant heating assembly includes the interface in communication with the controller. The one of the plurality of selectable modulation modes is selectable from the interface.

The radiant heating assembly advantageously provides selective control over variable rates of the air and/or gas into the burner. Specifically, users of the radiant heating assembly are provided the option of selecting one of the plurality of selectable modulation modes such that the radiant heating assembly operates consistently with user expectations for different heating applications. Selective control is conveniently provided to users of the radiant heat assembly by the interface.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of a radiant heating assembly including an elongated heat exchanger and a housing;

FIG. 2 is a perspective view, partially in phantom, of the radiant heating assembly including a burner, a fuel valve for providing fuel to the burner, a blower for providing air to the burner, and a controller configured to control the air and the fuel provided to the burner;

FIG. 3 is a front view of an interface of the radiant heating assembly including controls for facilitating selection of one of a plurality of selectable modulation modes from the interface;

FIG. 4 is a systematic diagram of the radiant heating assembly;

FIG. 5 is a comparative chart illustrating respective operational ranges of the fuel valve and the blower, and sample first and second modulation ranges of the fuel valve and the blower according to a first and second selectable modulation mode, as well as a high demand mode for each of the first and second selectable modulation modes for each of the fuel valve and the blower;

FIG. 6 is a flowchart illustrating a sample sequence of steps which may be practiced according to a method of operating the radiant heating assembly; and

FIG. 7 is a chart illustrating various sample operational results for each of the plurality of selectable modulation modes.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the Figures, wherein like numerals indicate like parts throughout the several views, a radiant heating assembly is generally shown at 10. As shown in FIG. 1, the radiant heating assembly 10 is typically suspended above an area to heat the area. The radiant heating assembly 10 may be installed in the interior or the exterior of any type of building or structure, such as a restaurant, factory, warehouse, arena, etc. Alternatively, the radiant heating assembly 10 may be independently suspended above any area such as a patio, and the like.

The radiant heating assembly 10 may include a housing 12 for accommodating various components of the radiant heating assembly 10. The housing 12 is typically formed of sheet metal but may be formed of any type of material without departing from the nature of the present invention. Furthermore, the housing 12 may have any suitable configuration for accommodating various components of the radiant heating assembly 10.

With reference to FIG. 2, the radiant heating assembly 10 includes a burner 14 for receiving air and fuel for combustion. The burner 14 typically has an inlet 16 for receiving the air and fuel. The air and fuel are typically mixed and ignited in the burner 14. However, it is to be appreciated that the air and fuel may be mixed before being received by the burner 14 according to any suitable method. The burner 14 typically combusts the air and fuel into exhaust. The burner 14 may include an outlet 18 for emitting exhaust generated by combustion of the air and fuel. Optionally, the radiant heating assembly 10 may include a plurality of burners 14. The burner 14 may have a venturi configuration but alternatively may have other configurations without departing from the nature of the present invention. The burner 14 is typically disposed at least partially within the housing 12.

The radiant heating assembly 10 includes an elongated heat exchanger 20 in communication with the burner 14. The elongated heat exchanger 20 typically has an inlet 22 for receiving the exhaust emitted by the outlet 18 of the burner 14. The burner 14 may be positioned adjacent the inlet 22 of the elongated heat exchanger 20. The exhaust emitted by the outlet 18 of the burner 14 passes through and heats the elongated heat exchanger 20 such that the elongated heat exchanger 20 emits radiant heat. The elongated heat exchanger 20 may be coupled to the housing 12 at one end. The elongated heat exchanger 20 may include a vent cap at another end to vent the exhaust passing through the elongated heat exchanger 20. Generally, the elongated heat exchanger 20 is mounted below a reflector 24 covering a significant portion of a length of the elongated heat exchanger 20. The reflector 24 directs radiant heat in a directional path towards the area to be heated to optimize the pattern of radiant heat emitted by the elongated heat exchanger 20.

The elongated heat exchanger 20 may have various lengths and shapes. Typically, the elongated heat exchanger 20 has a circular cross-section. However, the elongated heat exchanger 20 may have other cross-sections such as a rectangular cross-section, and the like. The elongated heat exchanger 20 may extend in any suitable path, such as a straight path, an L-shaped path, a U-shaped path, and the like. Additionally, the radiant heating assembly 10 may include a plurality of elongated heat exchangers 20 for receiving exhaust emitted by one or a plurality of burners 14.

The radiant heating assembly 10 includes a fuel valve 26 for providing the fuel to the burner 16. The fuel valve 26 may provide fuel directly to the inlet 16 of the burner 14. Alternatively, the fuel valve 26 may provide the fuel indirectly to the burner 14. For example, the fuel valve 26 may pass the fuel through a pre-mixing chamber before entering the burner 14. As illustrated at step 28 of FIG. 6, the fuel is provided to the fuel valve 26. Typically, the fuel valve 26 is coupled to a fuel source 30 which provides the fuel to the fuel valve 26. The fuel may be natural gas, although any suitable fuel, such as propane, may be received by the fuel valve 26. The fuel valve 26 may be disposed within the housing 12.

The fuel valve 26 is configured to provide the fuel according to a modulating operation. With respect to the fuel valve 26, the term “modulating,” is meant generally to describe operating the fuel valve 26 according to any given one of a plurality of fuel input rates defined within a predetermined range of fuel input rates. In the modulating operation, the fuel valve 26 may provide the fuel to the burner 14 according to one of the plurality of fuel input rates, as will be described below. It is to be appreciated that the fuel input rate may correspond to any suitable unit of measurement. The fuel valve 26 is generally capable of allowing between 0% to 100% of the fuel provided to the fuel valve 26 to pass to the burner 14. Said differently, the fuel valve 26 is capable of opening between 0% and 100% to provide various amounts of the fuel to the burner 14.

The radiant heating assembly 10 includes a blower 32 for providing the air to the burner 14. The blower 32 may receive the air and provide the air directly to the inlet 16 of the burner 14. Alternatively, the blower 32 may provide the air indirectly to the burner 14. For example, the blower 32 may pass the air through a pre-mixing chamber before entering the burner 14. As illustrated at a step 34, the air is provided to the blower 32. Typically, the blower 32 receives the air from an air source 36 such as ambient air. In particular, the blower 32 may draw the air through an aperture 38 defined in the housing 12 before providing the air to the burner 14. The blower 32 may be disposed within the housing 12 and in fluid communication with the elongated heat exchanger 20 for forcing the exhaust through the elongated heat exchanger 20.

In one embodiment, the blower 32 may force the air through the burner 14 and the exhaust through the elongated heat exchanger 20 by expelling the air away from the blower 32. Alternatively, the blower 32 may force the air through the burner 14 and the exhaust through the elongated heat exchanger 20 by pulling the air towards the blower 32.

As with the fuel valve 26, the blower 32 is configured to provide the air according to a modulating operation. With respect to the blower 32, the term “modulating,” is meant generally to describe operating the blower 32 according to any given one of a plurality of blower input rates defined within a predetermined range of blower input rates. The blower 32 typically includes a variable speed motor capable of providing the air at various rates. More specifically, the variable speed motor may be an electrically commutated motor or a permanent-split capacitor motor. The blower 32 is generally capable of operating between 0 and 10,000 RPM. However, it is to be appreciated that the blower 32 may operate between any other suitable range. In the modulating operation, the blower 32 may provide the air to the burner 14 according to one of the plurality of blower input rates, as will be described below. The blower input rate may correspond to any suitable unit of measurement. For example, the blower input rate may correspond to a pressure differential measured at one or more locations within the blower 32, the burner 14, and the elongated heat exchanger 20, and the like. Specifically, the radiant heating assembly 10 may include a pressure sensor 39 for measuring the pressure differential and for providing a signal corresponding to the pressure differential measured.

As shown in FIGS. 2 and 4, the radiant heating assembly 10 includes a controller 40 configured to control the amount of the air and the fuel provided to the burner 14 by modulating at least one of the fuel valve 26 and the blower 32. The controller 40 may include a processing unit, such as a microcontroller for receiving inputs and processing and executing commands. Furthermore, the controller 40 may include logic, such as PID logic, and memory for monitoring information on past on/off heating cycles and optimizing on/off heating cycles based on the monitored information for increasing efficiency of the radiant heating assembly 10. The controller 40 may be disposed within the housing 12 and electrically connected to the fuel valve 26 and the blower 32. However, electrical connections between the controller 40, the fuel valve 26, and the blower 32 are generally not shown in the figures for simplicity in illustration.

The radiant heating assembly 10 may include an ignition controller 42. Typically, the ignition controller 42 is operatively connected between the burner 14 and the controller 40. Furthermore, an ignitor 44 may be disposed within or adjacent to the burner 14 for providing a flame for igniting the air and the fuel within the burner 14. The ignitor 44 may be controlled by the ignition controller 42. In addition, a flame sensor may be disposed adjacent the burner 14 for monitoring the flame within the burner 14. The ignition controller 42 regulates the flame provided by the ignitor 44 according to signals provided by the flame sensor. The ignition controller 42 is typically mounted in the housing 12. The ignition controller 42 may be configured to provide ignition sequencing and safety lock-out operations for the radiant heating assembly 10.

The controller 40 modulates the fuel valve 26 generally by providing a fuel control signal to the fuel valve 26 and varying the fuel control signal. More specifically, a waveform of the fuel control signal is varied as the fuel control signal is provided to the fuel valve 26. The fuel valve 26 varies fuel provided to the burner 14 according to variations of the waveform of the fuel control signal. The controller 40 may be configured to modulate the fuel valve 26 according to one of the plurality of fuel input rates. As such, in the modulation operation, the controller 40 electrically commands the fuel valve 26 to provide the fuel to the burner 14 according to one of the plurality of fuel input rates.

The controller 40 modulates the blower 32 generally by providing a blower control signal to the blower 32 and varying the blower control signal. In particular, a waveform of the blower control signal is varied as the blower control signal is provided to the blower 32. The blower 32 varies the air provided to the burner 14 according to variations of the waveform of the blower control signal. The controller 40 may be configured to modulate the blower 32 according to one of the plurality of blower input rates. Thus, in the modulation operation, the controller 40 electrically commands the blower 32 to provide the air to the burner 14 according to one of the plurality of blower input rates.

In some instances, the controller 40 may modulate the fuel valve 26 independent of the blower 32. That is, the controller 40 may provide the fuel control signal to the fuel valve 26 before or after providing the blower control signal to the blower 32. Similarly, the controller 40 may vary the fuel control signal before or after varying the blower control signal.

Alternatively, the controller 40 may simultaneously modulate the fuel valve 26 and the blower 32. Specifically, the controller 40 may provide the fuel control signal to the fuel valve 26 simultaneously while providing the blower control signal to the blower 32. Moreover, the controller 40 may vary the fuel control signal simultaneously while varying the blower control signal.

As illustrated in FIG. 4, the radiant heating assembly 10 may include a potentiometer 46 configured to control the one of the plurality of fuel input rates. Modulating the fuel valve 26 may be further defined as controlling one of the plurality of fuel input rates by the potentiometer 46. The potentiometer 46 may also be configured to control the one of the plurality of blower input rates. The potentiometer 46 may be operatively coupled to the controller 40. The potentiometer 46 may employ any suitable method for varying the fuel input rate or the blower input rate. For example, the potentiometer 46 may include a dial or knob operatively coupled to a variable-resistor for varying electrical current passed to the controller 40. Variations of the electrical current may correspond to any one of the plurality of fuel input rates or blower input rates.

The step of modulating the fuel valve 26 may be further defined as controlling one of the plurality of fuel input rates by a heat demand signal. The heat demand signal corresponds generally to a heating load request. The heating load request may be initiated by setting a desired room temperature. The radiant heating assembly 10 may include a temperature sensor for measuring an actual room temperature. If the desired room temperature is greater than the actual room temperature, the heat demand signal may be provided to the controller 40. The heat demand signal may trigger any one of the plurality of fuel input rates. However, the heat demand signal may correspond to any one of the plurality of blower input rates. It is to be appreciated that the controller 40 may also be configured to modulate at least one of the fuel valve 26 and the blower 32 according to the heat demand signal. Furthermore, the heat demand signal may be triggered by the potentiometer 46.

At step 50, it may be determined whether or not a heating load request exists. At step 52, the controller 40 operates at least one of the fuel valve 26 and the blower 32 according to the heat demand signal provided to the controller 40. The heat demand signal may provide various fuel input signals and/or blower input signals to satisfy the heating load request. For instance, the heat demand signal may provide one of the plurality of fuel input signals to the controller 40 to operate the fuel valve 26 at a maximum rate during ignition. Furthermore, the heat demand signal may decrease the fuel input signal during a post-purge operation, and the like. At step 54, it may be determined whether or the heating load request has been satisfied, e.g., the actual room temperature is greater than or equal to the desired room temperature. Once the heating load request is satisfied, the controller 40 may cease operation of at least one of the fuel valve 26 and the blower 32 according to the heat demand signal.

In instances where the pressure sensor 39 measures pressure differential and provides a signal corresponding to the pressure differential measured, the signal provided by the pressure sensor 39 may be communicated to the controller 40. Specifically, the pressure sensor 39 may be electrically coupled to the controller 40. The controller 40 may process the signal from the pressure sensor 39 and modulate the blower 32 in accordance with the blower input rate corresponding to the signal from the pressure sensor 39.

The radiant heating assembly 10 includes an interface 56 in communication with the controller 40. Generally, the interface 56 includes any selectable control for facilitating communication between users of the radiant heating assembly 10 and the controller 40. In one embodiment, the interface 56 may be one or a plurality of manual electric and/or mechanical switches. For instance, the interface 56 may include dual in-line package (DIP) switches. Alternatively, as shown in FIGS. 3 and 4, the interface 56 may be a device including a display 58 and controls 60, including tactile keys. The interface 56 may include a processing unit for receiving inputs and processing and executing commands.

The interface 56 may be disposed external to the housing 12 to allow easy access to controls of the interface 56. Alternatively, the interface 56 may be integrated into the housing 12 or disposed within, or at least partially within, the housing 12. The interface 56 may be in direct electrical connection with the controller 40. For instance, the interface 56 may be in communication with the controller 40 through an electrical connection passing between the interface 56 and the controller 40. In addition, the interface 56 may be in communication with the controller 40 wirelessly.

The interface 56 may be configured to provide the heat demand signal to the controller 40. In particular, the heating load request may be initiated by utilizing the controls of the interface 56. That is, the desired room temperature may be set by the interface 56. The temperature sensor for measuring the actual room temperature may be electrically coupled to the interface 56. Alternatively, the temperature sensor may be disposed within the interface 56.

It is to be appreciated that the radiant heating assembly 10 may include more than one interface 56. More specifically, one interface 56 may override another interface 56, or vice-versa. For instance, the radiant heating assembly 10 may include both DIP switches and the device as shown in FIGS. 3 and 4. Communication to the controller 40 by DIP switches may be overridden pursuant to communication to the controller 40 by the device, or vice-versa.

As shown in FIG. 4, one or a plurality of interfaces 56 may be controlled by a control unit 61 which is coupled to one or the plurality of interfaces 44. The one or plurality of interfaces 56 may control one or a plurality of radiant heating assemblies 10. The control unit 61 may communicate with each of the interfaces 56 simultaneously or independently. Furthermore, the control unit 61 may be configured to provide the heat demand signal to each of the interfaces 44. In so doing, the control unit 61 provides a convenient way to control the heat demand signal to various radiant assemblies 10 in a building or structure, from a single position.

The controller 40 is configured to modulate at least one of the fuel valve 26 and the blower 32 according to one of a plurality of algorithms. It is to be appreciated that the controller 40 may modulate both the fuel valve 26 and the blower 32 according to one of the plurality of algorithms. As will be described below, each of the plurality of fuel input rates and/or each of the plurality of blower input rates may be determined by each one of the plurality of algorithms. The controller 40 may vary the fuel control signal or blower control signal according to each of the plurality of fuel input rates or blower input rates determined by each one the plurality of algorithms, respectively.

The controller 40 may be configured to control the fuel valve 26 according to each of the plurality of fuel input rates and the blower 32 according to one of the plurality of algorithms. In such instances, the fuel input rates may be controlled by the heat demand signal. More specifically, the fuel input rates may be controlled by the interface 56, the potentiometer 46, or the control unit 61. The blower input rates may be determined by each one of the plurality of algorithms.

Conversely, the controller 40 may be configured to control the fuel valve 26 according to one of the plurality of algorithms and the blower 32 according to the plurality of blower input rates. In such instances, each of the plurality of blower input rates may be controlled by the heat demand signal. Specifically, the blower input rate may be controlled by the interface 56, the potentiometer 46, or the control unit 61. The fuel input rates may be determined by each one of the plurality of algorithms. Furthermore, the controller 40 may be configured to control the fuel valve 26 and the blower 32 according to one of the plurality of algorithms.

Each one of the plurality of algorithms may be provided and/or stored by the controller 40 whereby the interface 56 is utilized to trigger each of the plurality of algorithms. Alternatively, each one of the plurality of algorithms may be provided and/or stored by the interface 56. In such instances, each one of the plurality algorithms is communicated to the controller 40 from the interface 56. It is to be appreciated that each one of the plurality of algorithms may be provided and/or stored by any other suitable medium not specifically recited herein.

Each one of the plurality of algorithms corresponds to one of a plurality of selectable modulation modes. In particular, each one of the selectable modulation modes is selectable from the interface 56. The selectable modulation modes provide selective control over the fuel input rates and/or the blower input rates. Specifically, users of the radiant heating assembly 10 interact with controls of the interface 56 to select one of the selectable modulation modes from the interface 56. The interface 56 may communicate with the controller 40 and instruct the controller 40 to implement the selected algorithm. Accordingly, the controller 40 modulates at least one of the fuel valve 26 and the blower 32 according to the one of the plurality of algorithms corresponding to the one of the plurality of selectable modulation modes selected from the interface 56. The algorithm is initiated based upon user demand whereby users of the radiant heating assembly 10 exhibit control over which of the plurality of selectable modulation modes is best suited for a particular application, as will be described below.

Operation of the radiant heating assembly 10 according to any suitable operation, such as operation according to the heat demand signal, may be interrupted by modulation of the fuel valve 26 and/or the blower 32 according to selection of one of the selectable modulation modes selected from the interface 56. In such instances, the radiant heating assembly 10 may operate temporarily according to one of the selectable modulation modes. Specifically, as one of the selectable modulation modes is selected, the controller 40 may switch from operating the blower 32 and/or the fuel valve 26 according to the heat demand signal to modulating the blower 32 and/or the fuel valve 26 according to the algorithm corresponding to the selectable modulation mode selected. Alternatively, the radiant heating assembly 10 may continuously operate according to one of the selectable modulation modes. That is, operation of the radiant heating assembly 10 may continuously be in accordance with one of the selectable modulation modes. In other words, the radiant heating assembly 10 may operate in accordance with the selectable modulation mode selected before the heat demand signal is triggered.

Operation of the radiant heating assembly 10 according to one of the selectable modulation modes may be terminated by selecting from the interface 56 another one of the selectable modulation modes. In such instances, controls of the interface 56 may be utilized to switch directly from one of the selectable modulation modes to another.

It is to be appreciated that more than one radiant heating assembly 10 may be operatively coupled to one another. In particular, one radiant heating assembly 10 may operate as a master while another radiant heating assembly 10 operates as a slave operating in synchronization with the master. In such instances, one interface 56 may control the respective controllers 40 of each radiant heating assembly 10. That is, selection of one of the plurality of selectable modulation modes from the one interface 56 may enable the controllers 40 of each radiant heating assembly 10 to modulate each respective fuel valve 26 and/or blower 32. Modulation by each controller 40 occurs in accordance with the one of the plurality of algorithms corresponding to the one of the plurality of selectable modulation modes selected from the interface 56 in communication with the master.

In instances where there are the plurality of interfaces 56, the control unit 61 may enable simultaneous or independent selection of each of the selectable modulation modes from each interface 56. In so doing, the control unit 61 provides a convenient way to control the selectable modulation modes of various radiant assemblies 10 in a building or structure, from a single position.

As illustrated in FIG. 7, each one of the algorithms corresponding to each one of the selectable modulation modes is configured to produce an operational result for the radiant heating assembly 10. Said differently, the controller 40 modulates the fuel valve 26 and/or the blower 32 to achieve the operational result based upon instructions from each one of the algorithms corresponding to each one of the selectable modulation modes. More specifically, modulation of the fuel valve 26 and/or blower 32 may be implemented according to any suitable performance curve. That is, the fuel input rate or the blower input rate may vary according to any suitable linear or nonlinear performance curve or curves for each one of the selectable modulation modes.

For instance, there may be an immediate desire to have a balanced distribution of heat across a length of the elongated heat exchanger 20. Said differently, it may be desired to minimize temperature differentials across the length of the elongated heat exchanger 20. Accordingly, to achieve such result, one of the algorithms corresponding to one of the selectable modulation modes may provide one or the plurality of blower input rates at relatively increased rates as compared with the algorithm of another one of the selectable modulation modes. As such, the air may be forced quickly across the length of the elongated heat exchanger 20 thereby decreasing temperature near the burner 14 and increasing temperature near an end of the elongated heat exchanger 20 opposite the inlet 22. An example of the operational result produced by such a selectable modulation mode is illustrated by “Mode X” in FIG. 7.

Alternatively, there may be a need to operate the radiant heating assembly 10 in a thermally efficient manner. To achieve such result, one of the algorithms corresponding to one of the selectable modulation modes may provide relatively decreased fuel input rates as compared to the algorithm corresponding to another one of the plurality of selectable modulation modes. In effect, temperature may increase near the burner 14 and decrease near the end of the elongated heat exchanger 20 opposite the inlet 22. An example of the operational result produced by such a selectable modulation mode is illustrated by “Mode Z” in FIG. 7.

Furthermore, it may be desired to minimize temperature differentials across the length of the elongated heat exchanger 20 simultaneously while operating the radiant heating assembly 10 a thermally efficient manner. An example of the operational result produced by such a selectable modulation mode is illustrated by “Mode Y” in FIG. 7. According to “Mode Y,” temperature near the burner 14 may be greater than in “Mode X” but less than in “Mode Z.” Conversely, temperature near the end of the elongated heat exchanger 20 opposite the inlet 22 may be greater than “Mode Z” but less than “Mode X.” It is to be appreciated that the each one of the algorithms corresponding to each one of the selectable modulation modes may be configured to produce other suitable operational results for the radiant heating assembly 10 not specifically described herein.

In one embodiment, the plurality of selectable modulation modes may include a first selectable modulation mode operable according to a first algorithm and a second selectable modulation mode operable according a second algorithm. The first algorithm may include a first set of blower input rates. Each blower input rate of the first set may correspond to one of the plurality of fuel input rates. The second algorithm may include a second set of blower input rates different than the first set of blower input rates. Each blower input rate of the second set may correspond to one of the plurality of fuel input rates. The step of selecting one of the selectable modulation modes is further defined as selecting one of the first selectable modulation mode and the second selectable modulation mode. In this embodiment, the step of modulating at least one of the fuel valve 26 and the blower 32 is further defined as modulating the blower 32 according to the blower input rate of one of the first and second sets.

In another embodiment, the plurality of selectable modulation modes may include the first selectable modulation mode operable according to the first algorithm and the second selectable modulation mode operable according the second algorithm. The first algorithm may include the first set of blower input rates. The second algorithm may include the second set of blower input rates different than the first set of blower input rates. Each one of the plurality of fuel input rates may correspond to one of the blower input rates of the first set and to one of the blower input rates of the second set. The one of the blower input rates of the first set is different than the one of the blower input rates of the second set. The step of selecting one of the selectable modulation modes is further defined as selecting one of the first selectable modulation mode and the second selectable modulation mode. In this embodiment, step of modulating at least one of the fuel valve 26 and the blower 32 is further defined as modulating the blower 32 according to the one of the blower input rates of one of the first and second sets.

In the aforementioned embodiments, it is to be appreciated that the first algorithm may define a first set of fuel input rates and the second algorithm may define a second set of fuel input rates different than the first set. In such instances, the step of modulating at least one of the fuel valve 26 and the blower 32 may be further defined as modulating the fuel valve 26 according to the fuel input rate of one of the first and second sets.

In yet another embodiment, the plurality of selectable modulation modes may include the first selectable modulation mode operable according to the first algorithm and the second selectable modulation mode operable according the second algorithm. As illustrated in FIG. 5, the first algorithm may define a first modulation range 62 of the blower 32. The second algorithm may define a second modulation range 64 different than the first modulation range 62 of the blower 32. The step of selecting one of the selectable modulation modes is further defined as selecting one of the first selectable modulation mode and the second selectable modulation mode. In this embodiment, the step of modulating at least one of the fuel valve 26 and the blower 32 is further defined as modulating the blower 32 within one of the first and second modulation ranges 62, 64.

As illustrated in FIG. 5, it is to be appreciated that the first algorithm may define a first modulation range 66 for the fuel valve 26 and the second algorithm may define a second modulation range 68 for the fuel valve 26. In such instances, the step of modulating at least one of the fuel valve 26 and the blower 32 may be further defined as modulating the fuel valve 26 within one of the first and second modulation ranges 66, 68 of the fuel valve 26.

At steps 70 and 72, it may be determined whether or not the first selectable modulation mode or second selectable modulation mode was selected from the interface 56, respectively. As mentioned above, each one of the plurality of algorithms corresponding to each one of the plurality of selectable modulation modes may provide different blower input rates, different sets of blower input rates, and/or different modulation ranges for the blower 32 and/or fuel valve 26. At steps 74 and 76, respectively, the controller 40 modulates the fuel valve 26 and/or the blower 32 according to the first algorithm corresponding to the first selectable modulation mode or the second algorithm corresponding to the second selectable modulation mode.

The controller 40 is configured to operate the fuel valve 26 and the blower 32 according to a high demand mode. The high demand mode provides capability to operate the radiant heating assembly 10 in an “over-fire” manner for any given period of time to handle various environmental demands, such as a strong influx of cold wind near the radiant heating assembly 10.

Specifically, as illustrated in FIG. 5, an operational range 78 of the blower 32 is defined generally between a blower minimum 80 and a blower maximum 82. An operational range 84 of the fuel valve 26 is defined generally between a fuel minimum 86 and a fuel maximum 88. The operational range 78 of the blower 32 is generally independent of the first or second modulation ranges 62, 64 of the blower 32. Similarly, the operational range 84 of the fuel valve 26 is generally independent of the first or second modulation ranges 66, 68 of the fuel valve 26. More specifically, the operational ranges 78, 84 are generally meant to represent the range that the fuel valve 26 and blower 32 may operate given the specific output characteristics of the radiant heating assembly 10 in general. Alternatively, the first or second modulation ranges 62, 64 of the blower 32 or the first or second modulation ranges 66, 68 of the fuel valve 26 are generally dependent upon selection of the selectable modulation modes and may fluctuate within each respective operational range 78, 84.

The radiant heating assembly 10 may include a stated BTU range of the radiant heating assembly 10. In the high demand mode, the radiant heating assembly 10 may operate in excess of the stated BTU range of the radiant heating assembly 10. For example, if the radiant heating assembly 10 includes the stated BTU range between 120-150 MBH, the radiant heating assembly 10 may operate in the high demand mode between 151-180 MBH or at 180 MBH.

The controller 40 operates at least one of the fuel valve 26 and blower 32 according to the high demand mode. Specifically, the controller 40 may provide at least one of a high demand blower control signal to the blower 32 such that the blower 32 provides the air at the blower maximum 82 and a high demand fuel control signal to the fuel valve 26 such that the fuel valve 26 provides the fuel at the fuel maximum 88. The controller 40 may provide the high demand fuel control signal and the high demand blower control signal simultaneously or independently.

In embodiments where the first algorithm defines the first modulation range 62 of the blower 32 and the second algorithm defines the second modulation range 64 of the blower 32, the blower 32 may operate beyond the first or second modulation ranges 62, 64 in the high demand mode. In such instances, as illustrated in FIG. 5, the blower 32 may operate above the first or second modulation range 62, 64 of the blower 32 and below the blower maximum 82. Similarly, the fuel valve 26 may operate above the first or second modulation ranges 66, 68 of the fuel valve 26 and below the fuel maximum 88.

The controller 40 may modulate at least one of the fuel valve 26 and the blower 32 in the high demand mode. Specifically, the fuel valve 26 may operate according to a plurality of fuel input rates in attempt to reach the fuel maximum 88. Similarly, the blower 32 may operate according to a plurality of blower input rates in attempt to reach the blower maximum 82.

The high demand mode may interrupt modulation of at least one of the fuel valve 26 and blower 32 according to one of the plurality of algorithms corresponding to one of the plurality of selectable modulation modes. As the high demand mode is initiated, the blower 32 may cease operating according to the blower input rate defined by one of the algorithms corresponding to one of the selectable modulation modes and operate at the blower maximum 82. Similarly, the fuel valve 26 may cease operating according to the fuel input rate defined by one of the algorithms corresponding to one of the selectable modulation modes and operate at the fuel maximum 88. Furthermore, operation of at least one of the fuel valve 26 and the blower 32 according to the heat demand signal by the controller 40 may be interrupted by initiation or selection of the high demand mode.

It is to be appreciated that the blower 32 may cease operating according to the blower input rate defined by the heat demand signal provided from the interface 56, potentiometer 46, or control unit 61, and operate at the blower maximum 82. Likewise, the fuel valve 26 may cease operating according to the fuel input rate defined by the heat demand signal and operate at the fuel maximum 88.

The high demand mode may be selectable from the interface 56. At step 90, it may be determined whether or not the high demand mode was selected from the interface 56. In such instances, the high demand mode is initiated at-will by selection of the high demand mode from the interface 56. Specifically, users of the radiant heating assembly 10 interact with controls of the interface 56 to select the high demand mode from the interface 56. Thereafter, the interface 56 may communicate with the controller 40. At step 92, the controller 40 operates at least one of the fuel valve 26 and the blower 32 according to instructions corresponding to the high demand mode.

Alternatively, the high demand mode may be initiated by a sensor input signal. Specifically, as illustrated in FIG. 4, the radiant heating assembly 10 may include a sensor 94 for providing the sensor input signal. The sensor 94 may be any suitable sensor including, but not limited to, a thermistor or other temperature sensor, humidity sensor, wind speed sensor, and the like. The sensor 94 may be electrically coupled to the controller 40 and/or the interface 56. Furthermore, the sensor 94 may be attached to or spaced from the radiant heating assembly 10. The sensor 94 may detect the presence of environmental conditions requiring the high demand mode. Thereafter, the sensor input signal is communicated in order to initialize the high demand mode. The sensor input signal may be communicated to the controller 40 and/or the interface 56. In the absence of environmental conditions requiring the high demand mode, the sensor input signal may be provided to terminate the high demand mode. However, it is to be appreciated that the high demand mode in such embodiments may be terminated in various other manners not specifically recited herein. It is also to be appreciated that the high demand mode may be initiated and/or terminated though any combination of the interface 56 and/or the sensor input signal and sensor 74.

The high demand mode may be terminated at-will by selection of the high demand mode once again from the interface 56. Accordingly, as with the selectable modulation modes, the control over the fuel input rate and the blower input rate is triggered based upon user demand whereby users exhibit control over selection of the high demand mode. It is to be appreciated that upon selection, the high demand mode may operate for any period of time. The period of time may be predetermined and selectable from the interface 56. The high demand mode may terminate when the period of time lapses. At step 96, it may be determined whether or not the high demand mode has been deselected or whether the period of time has lapsed. If so, the high demand mode will cease and modulation continues according to one of the plurality of selectable modulation modes or operation continues according to the heating load request, as shown at step 96.

The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.

Claims

1. A method of operating a radiant heating assembly, the radiant heating assembly including a fuel valve, a blower, a controller configured to control at least one of the fuel valve and the blower according to one of a plurality of algorithms corresponding to one of a plurality of selectable modulation modes, and an interface in communication with the controller, the method comprising the steps of:

selecting one of the plurality of selectable modulation modes from the interface; and

modulating at least one of the fuel valve and the blower by the controller according to the one of the plurality of algorithms corresponding to the one of the plurality of selectable modulation modes selected from the interface.

2. The method of claim 1 wherein the step of modulating at least one of the fuel valve and the blower is further defined as modulating the fuel valve according to one of a plurality of fuel input rates.

3. The method of claim 2 wherein the plurality of selectable modulation modes include a first selectable modulation mode operable according to a first algorithm including a first set of blower input rates, each blower input rate of the first set corresponding to one of the plurality of fuel input rates, and a second selectable modulation mode operable according a second algorithm including a second set of blower input rates different than the first set of blower input rates, each blower input rate of the second set corresponding to one of the plurality of fuel input rates, wherein the step of selecting one of the selectable modulation modes is further defined as selecting one of the first selectable modulation mode and the second selectable modulation mode.

4. The method of claim 3 wherein the step of modulating at least one of the fuel valve and the blower is further defined as modulating the blower according to the blower input rate of one of the first and second sets.

5. The method of claim 2 wherein the plurality of selectable modulation modes include a first selectable modulation mode operable according to a first algorithm including a first set of blower input rates and a second selectable modulation mode operable according a second algorithm including a second set of blower input rates different than the first set of blower input rates, wherein each one of the plurality of fuel input rates corresponds to one of the blower input rates of the first set and to one of the blower input rates of the second set, and the one of the blower input rates of the first set is different than the one of the blower input rates of the second set, wherein the step of selecting one of the selectable modulation modes is further defined as selecting one of the first selectable modulation mode and the second selectable modulation mode.

6. The method of claim 5 wherein the step of modulating at least one of the fuel valve and the blower is further defined as modulating the blower according to the one of the blower input rates of one of the first and second sets.

7. The method of claim 1 wherein the plurality of selectable modulation modes include a first selectable modulation mode operable according to a first algorithm defining a first modulation range of the blower, and a second selectable modulation mode operable according a second algorithm defining a second modulation range different than the first modulation range of the blower, and wherein the step of selecting one of the selectable modulation modes is further defined as selecting one of the first selectable modulation mode and the second selectable modulation mode.

8. The method of claim 7 wherein the step of modulating at least one of the fuel valve and the blower is further defined as modulating the blower within one of the first and second modulation ranges.

9. The method of claim 2 further comprising providing a heat demand signal, and wherein the step of modulating the fuel valve is further defined as controlling the one of the plurality of fuel input rates by the heat demand signal.

10. The method of claim 2 wherein the radiant heating assembly includes a potentiometer, and wherein the step of modulating the fuel valve is further defined as controlling the one of the plurality of fuel input rates by the potentiometer.

11. The method of claim 1 wherein an operational range of the blower is defined between a blower minimum and a blower maximum and an operational range of the fuel valve is defined between a fuel minimum and a fuel maximum, and further comprising the step of operating at least one of the fuel valve and blower by the controller according to a high demand mode by providing at least one of a high demand blower control signal to the blower such that the blower provides the air at the blower maximum and a high demand fuel control signal to the fuel valve such that the fuel valve provides the fuel at the fuel maximum.

12. The method of claim 11 further comprising the step of selecting the high demand mode from the interface to initiate the high demand mode according to selection of the high demand mode from the interface.

13. The method of claim 11 wherein the step of operating at least one of the fuel valve and blower by the controller according to the high demand mode is further defined as interrupting modulation of at least one of the fuel valve and blower according to one of the plurality of selectable modulation modes.

14. The method of claim 1 further comprising providing a heat demand signal and wherein the step of modulating at least one of the fuel valve and the blower is further defined as interrupting operation of at least one of the fuel valve and the blower according to the heat demand signal.

15. The method of claim 1 wherein the step of modulating at least one of the fuel valve and blower is further defined as providing at least one of a fuel control signal to the fuel valve and varying the fuel control signal and providing a blower control signal to the blower and varying the blower control signal.

16. A method of operating a radiant heating assembly, the radiant heating assembly including a fuel valve, a blower, a controller configured to control the fuel valve according to one of a plurality of fuel input rates and the blower according to one of a plurality of algorithms corresponding to one of a plurality of selectable modulation modes, and an interface in communication with the controller, the method comprising the steps of:

providing fuel to the fuel valve;

providing air to the blower;

selecting one of the plurality of selectable modulation modes from the interface;

modulating the fuel valve by the controller according to one of the plurality of fuel input rates; and

modulating the blower by the controller according to the one of the plurality of algorithms corresponding to the one of the plurality of selectable modulation modes selected from the interface.

17. The method of claim 16 wherein the plurality of selectable modulation modes include a first selectable modulation mode operable according to a first algorithm including a first set of blower input rates and a second selectable modulation mode operable according a second algorithm including a second set of blower input rates different than the first set of blower input rates, wherein each one of the plurality of fuel input rates corresponds to one of the blower input rates of the first set and to one of the blower input rates of the second set, and the one of the blower input rates of the first set is different than the one of the blower input rates of the second set, wherein the step of selecting one of the selectable modulation modes is further defined as selecting one of the first selectable modulation mode and the second selectable modulation mode.

18. The method of claim 17 wherein the step of modulating at least one of the fuel valve and the blower is further defined as modulating the blower according to the one of the blower input rates of one of the first and second sets.

19. A radiant heating assembly comprising:

a burner for receiving air and fuel for combustion;

an elongated heat exchanger in communication with said burner;

a fuel valve for providing the fuel to said burner;

a blower for providing the air to said burner;

a controller configured to control the amount of the air and the fuel provided to said burner by modulating at least one of said fuel valve and said blower according to one of a plurality of algorithms corresponding to one of a plurality of selectable modulation modes; and

an interface in communication with said controller wherein said one of said plurality of selectable modulation modes is selectable from said interface.

20. The radiant heating assembly of claim 19 wherein said controller is configured to control said fuel valve according to one of a plurality of fuel input rates.

21. The radiant heating assembly of claim 20 wherein said plurality of selectable modulation modes include a first selectable modulation mode operable according to a first algorithm including a first set of blower input rates, each blower input rate of said first set corresponding to one of said plurality of fuel input rates, and a second selectable modulation mode operable according a second algorithm including a second set of blower input rates different than said first set of blower input rates, each blower input rate of said second set corresponding to one of said plurality of fuel input rates.

22. The radiant heating assembly of claim 20 wherein said plurality of selectable modulation modes include a first selectable modulation mode operable according to a first algorithm including a first set of blower input rates and a second selectable modulation mode operable according a second algorithm including a second set of blower input rates different than said first set of blower input rates, wherein each one of said plurality of fuel input rates corresponds to one of said blower input rates of said first set and to one of said blower input rates of said second set, and said one of said blower input rates of said first set is different than said one of said blower input rates of said second set.

23. The radiant heating assembly of claim 19 wherein an operational range of said blower is defined between a blower minimum and a blower maximum and an operational range of said fuel valve is defined between a fuel minimum and a fuel maximum, and wherein said controller is configured to operate at least one of said fuel valve and said blower according to a high demand mode by providing at least one of a high demand blower control signal to said blower such that said blower provides the air at said blower maximum and a high demand fuel control signal to said fuel valve such that said fuel valve provides the fuel at said fuel maximum.

24. The radiant heating assembly of claim 23 wherein said high demand mode is selectable from said interface and initiated by selection of said high demand mode from said interface.

25. The radiant heating assembly of claim 19 including a housing wherein said fuel valve and said blower and said controller are disposed within said housing and said elongated heat exchanger is coupled to said housing, and wherein said interface is disposed external to said housing.

26. The radiant heating assembly of claim 20 further including a potentiometer configured to control said one of said plurality of fuel input rates.