Furnace Header Box with Single-Sensor Blocked Condensation Detection
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Solution Overview
Problem
Conventional furnaces require multiple pressure sensing devices and relocation of pressure tubes to properly sense water build-up and protect equipment from condensation, especially when installed in different positions, leading to inefficiencies and increased complexity.
Innovation Solution
A furnace design with a Cold End Header Box (CEHB) that includes integrated blocked condensation protection, using a single pressure sensing device to monitor combustion pressure and shut off fuel supply when condensation drainage is blocked, eliminating the need for multiple switches and rerouting of pressure tubes across different positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional furnaces use multiple pressure sensing devices and relocate pressure tubes for different installation positions, then they can properly sense water build-up and protect equipment from condensation, but the device complexity and installation difficulty increase
Solution Approach 1:
The single pressure sensing device is designed to perform multiple functions: it monitors combustion pressure through the heat exchanger and simultaneously detects blocked condensation drainage by measuring pressure differential between the first and second channels. This multi-functional design eliminates the need for multiple separate sensing devices and pressure tubes, reducing system complexity while maintaining comprehensive protection capability across different installation positions.
Solution Approach 2:
The patent combines the functions of multiple pressure sensing devices into a single integrated pressure sensing device with multiple inputs. The first input monitors combustion pressure through the heat exchanger, while the second input monitors pressure in the second channel that is in fluid communication with the first channel. This merging approach reduces the number of components and simplifies installation while maintaining the ability to detect various fault conditions.
2Adaptability or versatility
If conventional furnaces relocate pressure tubes for different installation positions, then they can adapt to various positions, but the ease of operation and installation time increase
Solution Approach 1:
The pressure sensing device and header box are designed with universal functionality that works across different installation positions (horizontal, vertical, angled) without requiring relocation of pressure tubes. The first channel with supply port and the second channel with supply port and pressure reference inlet are configured to maintain proper fluid communication regardless of orientation, allowing the single pressure sensing device to adapt to various positions while simplifying installation procedures.
3Device complexity
If a single pressure sensing device is used to monitor combustion pressure and detect blocked condensation, then the device complexity reduces, but the measurement precision may be compromised
Solution Approach 1:
The single pressure sensing device is segmented into multiple independent inputs: a first input coupled to the first channel for monitoring combustion pressure and a second input coupled to the second channel for monitoring pressure under blocked condensation conditions. This segmentation allows each input to independently measure specific pressure parameters, maintaining high measurement precision for detecting zero pressure differential that indicates blocked condensation drainage.
Solution Approach 2:
The header box acts as an intermediary structure that creates distinct fluid communication paths (first channel and second channel) leading to the pressure sensing device. The first channel provides a reference pressure path while the second channel provides the monitored pressure path. This intermediary structure enables the single pressure sensing device to accurately detect pressure differentials by comparing pressures from two separately configured channels.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively protects the furnace from blocked condensation drainage by using a single pressure sensing device to detect zero pressure differential, reducing the number of safety switches needed and simplifying installation across various positions without relocating monitoring equipment.
Implementation Method 1
the pressure sensing device configured to turn off a fuel supply to the heat exchanger when determining a pressure differential between the first channel and the second channel is about zero
Implementation Method 2
the second channel in fluid communication with the first channel and configured to have about a same pressure as the first channel when the pressure reference inlet is blocked
Data Source
AI summary
A header box, a furnace and a blocked condensation protection system are disclosed herein. In one embodiment, the header box includes: (1) a first channel having a first channel supply port positioned to be in fluid communication with an inlet of a combustion air blower and a first pressure port couplable to a first input of a pressure sensing device, the combustion air blower and the pressure sensing device associated with the cold end header box and (2) a second channel having a second channel supply port positioned to be in fluid communication with the inlet of the combustion air blower, a second pressure port couplable to a second input of the pressure sensing device and a pressure reference inlet, the second channel in fluid communication with the first channel and configured to have about a same pressure as the first channel when the pressure reference inlet is blocked.