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 fl
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.
대표청구항▼
1. A modulating burner apparatus, comprising: one and only one source of pressurized pre-mixed fuel and air mixture, the source including at least one variable speed blower;a multi-chamber burner configured to burn the pre-mixed fuel and air mixture, the burner including at least a first burner cham
1. A modulating burner apparatus, comprising: one and only one source of pressurized pre-mixed fuel and air mixture, the source including at least one variable speed blower;a multi-chamber burner configured to burn the pre-mixed fuel and air mixture, the burner including at least a first burner chamber and a second burner chamber; anda flow control valve including a valve member movable between a closed position restricting flow of fuel and air mixture to the second burner chamber, and an open position allowing flow of fuel and air mixture to the second burner chamber, the flow control valve further including a biasing spring biasing the valve member toward the closed position, such that fuel and air mixture is permitted to flow from the one and only one source to 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, wherein the valve member includes multiple flapper valve elements. 2. The apparatus of claim 1, wherein: the at least one variable speed blower includes one and only one blower. 3. The apparatus of claim 1, wherein: the at least one variable speed blower includes multiple blowers supplying a common source, the common source being the one and only one source. 4. The apparatus of claim 1, further comprising: a spring pre-load adjuster configured to adjust an opening force required to move the valve member from the closed position. 5. The apparatus of claim 1, wherein: the multi-chamber burner includes an interior wall at least partially separating the first burner chamber and the second burner chamber. 6. The apparatus of claim 1, wherein: the blower is a centrifugal blower having a blower output versus blower speed curve for a given flow restriction downstream of the blower; andthe first burner chamber defines a higher flow restriction and the first and second burner chambers together define a lower flow restriction, so that at the lower blower speeds when fuel and air mixture is provided to only the first burner chamber the blower output follows a first curve corresponding to the higher flow restriction, and at the higher blower speeds when fuel and air mixture is provided to both the first and second burner chambers the blower output follows a second curve corresponding to the lower flow restriction. 7. The apparatus of claim 6, wherein: an energy input to the burner can be continuously modulated over a lower input range modulation curve corresponding to operation of only the first burner chamber, and the energy input to the burner can be continuously modulated over a higher input range modulation curve corresponding to operation of both the first and second burner chambers together, there being an intermediate modulation curve between the lower and higher input range modulation curves, the intermediate modulation curve being steeper than the lower and higher input range modulation curves. 8. The apparatus of claim 6, wherein: the apparatus has an overall modulation range equal to a maximum energy input to the first and second burner chambers operating together at a maximum blower speed divided by a minimum energy input to the first burner chamber operating alone at a minimum blower speed, the overall modulation range being at least 16 to 1. 9. The apparatus of claim 8, wherein the overall modulation range is at least 25 to 1. 10. The apparatus of claim 1, further comprising: a mixing chamber upstream of the blower, the mixing chamber configured to at least partially pre-mix the fuel and air mixture prior to the fuel and air mixture entering an inlet of the blower. 11. The apparatus of claim 1, wherein: an energy input to the burner can be continuously modulated over a lower input range modulation curve corresponding to operation of only the first burner chamber, and the energy input to the burner can be continuously modulated over a higher input range modulation curve corresponding to operation of both the first and second burner chambers together, there being an intermediate modulation curve between the lower and higher input range modulation curves, the intermediate modulation curve being steeper than the lower and higher input range modulation curves. 12. The apparatus of claim 1, further comprising: a heat exchanger having a water side and a hot gas side, the burner being arranged so that hot combustion gases from the burner flow through the hot gas side of the heat exchanger to heat water flowing through the water side. 13. The apparatus of claim 12, wherein: the heat exchanger is a fire tube heat exchanger including a plurality of fire tubes through which the hot combustion gases flow, the fire tubes being surrounded by a water chamber defining the water side of the heat exchanger. 14. The apparatus of claim 1, wherein: the valve member is oriented to open in a downstream direction to allow flow of the fuel and air mixture in the downstream direction into the second burner chamber at the higher blower speeds. 15. The apparatus of claim 1, wherein: the multiple flapper valve elements include two flapper valve elements oriented such that both flapper valve elements pivot in a downstream direction from a horizontal orientation in the closed position to a vertical orientation in the open position of the valve member. 16. The apparatus of claim 1, wherein: the multiple flapper valve elements include two flapper valve elements arranged such that both flapper valve elements pivot in opposite rotational directions as the valve member moves from the closed position to the open position. 17. A method of modulating energy input to a multi-stage burner, the method comprising: (a) modulating blower speed of a variable speed blower within a lower speed range to modulate energy input to a first stage of the burner within a lower burner input range while a second stage of the burner is inoperative;(b) opening a valve and flowing fuel and air mixture in a downstream direction past the valve into the second stage of the burner, wherein the valve includes two flapper valve elements, and the opening of the valve includes pivoting both flapper valve elements in the downstream direction in opposite rotational directions; and(c) modulating blower speed of the variable speed blower within a higher speed range to modulate energy input to the combined first and second stages of the burner within a higher burner input range. 18. The method of claim 17, wherein: in step (b), the two flapper valve elements are a spring biased toward a closed position, and the valve opens as a result of outlet pressure from the blower acting on the two flapper valve elements valve and overcoming the biasing force from the spring. 19. The method of claim 17, wherein: during step (b), blower speed increases through a transition speed range separating the lower speed range from the higher speed range. 20. The method of claim 17, wherein: a highest end of the higher burner input range divided by a lowest end of the lower burner input range defines an overall turndown ratio of at least 16 to 1. 21. The method of claim 20, wherein the overall turndown ratio is at least 25 to 1. 22. The method of claim 17, wherein: in step (a), the blower speed is continuously modulated within the lower speed range; andin step (c), the blower speed is continuously modulated within the higher speed range. 23. The method of claim 17, wherein: in step (a), the blower speed is non-continuously modulated within the lower speed range; andin step (c), the blower speed is non-continuously modulated within the higher speed range. 24. A modulating burner apparatus, comprising: a variable speed blower, the blower including a blower outlet;a multi-chamber burner configured to burn a pre-mixed fuel and air mixture, the burner including at least a first burner chamber and a second burner chamber, the second burner chamber being located adjacent the first burner chamber so that the second burner chamber can be ignited by the first burner chamber;a supply manifold communicating the blower with the burner, the supply manifold including a first passage portion communicated with the blower outlet, a second passage portion communicating the first passage portion with the first burner chamber, and a third passage portion communicating the first passage portion with the second burner chamber;a valve between the first passage portion and the third passage portion, the valve being configured such that as the blower speed increases from a lower speed range through a transition speed range to a higher speed range, the valve moves from a closed position when blower-speed is in the lower speed range to an open position when blower speed is in the higher speed range,wherein the valve includes a valve member movable between a closed position and an open position, and a biasing spring biasing the valve member toward the closed position;wherein the valve member includes multiple flapper elements; andwherein the biasing spring includes at least one tension spring connected to the flapper elements. 25. The apparatus of claim 24, wherein: the biasing spring is configured such that as the blower speed increases through the transition speed range, pressure from the blower acting on the valve member overcomes the biasing spring to move the valve member to the open position. 26. The apparatus of claim 25, further comprising: a spring pre-load adjuster configured to adjust an opening force required to open the valve member against the biasing spring. 27. The apparatus of claim 24, wherein: the blower is a centrifugal blower having a blower output versus blower speed curve for a given flow restriction downstream of the blower outlet; andthe first burner chamber defines a higher flow restriction and the first and second burner chambers together define a lower flow restriction, so that when the valve is in the closed position the blower output follows a first curve corresponding to the higher flow restriction, and when the valve is in the open position the blower output follows a second curve corresponding to the lower flow restriction. 28. The apparatus of claim 27, wherein: an energy input to the burner can be continuously modulated between a first energy input value and a second energy input value corresponding to the lower speed range of the blower;the energy input to the burner can be continuously modulated between a third energy input value and a fourth energy input value corresponding to the higher speed range of the blower; andthe fourth energy input value divided by the first energy input value defines an overall modulation range of the heater apparatus, the overall modulation range being at least 16 to 1. 29. The apparatus of claim 28, wherein the overall modulation range is at least 25 to 1. 30. The apparatus of claim 28, wherein: as the valve opens the blower output follows an intermediate modulation curve steeper than the first and second curves. 31. The apparatus of claim 24, further comprising: a mixing chamber upstream of the blower, the mixing chamber configured to at least partially pre-mix the fuel and air mixture prior to the fuel and air mixture entering an inlet of the blower. 32. The apparatus of claim 24, wherein: during operation of the first burner chamber when blower speed is in the lower speed range, a positive pressure differential exists across the valve from the first passage portion to the third passage portion, thereby preventing backflow through the second burner chamber. 33. An apparatus for heating water, comprising: a water conduit having an inlet and an outlet;a heat exchanger having a water side defining a portion of the water conduit;a pre-mix burner configured to burn a pre-mixed fuel-air mixture, the burner operatively associated with the heat exchanger to heat water in the water side of the heat exchanger, the burner including a first plenum communicated with a first foraminous burner surface, and a second plenum communicated with a second foraminous burner surface, the first and second foraminous burner surfaces being sufficiently close to each other so that flame from the first foraminous burner surface will ignite fuel-air mixture exiting the second foraminous burner surface;a variable flow blower having a blower outlet communicated with the first and second plenums;a damper located between the second plenum and the blower outlet, the damper including multiple flapper valve elements; anda biasing spring biasing the damper toward a closed position, the damper being movable toward an open position when fluid pressure from the blower acting on the damper overcomes the biasing spring. 34. The apparatus of claim 33, further comprising: a spring pre-load adjuster configured to adjust an opening force required to move the damper from the closed position. 35. The apparatus of claim 33, wherein: the blower is a centrifugal blower having a blower output versus blower speed curve for a given flow restriction downstream of the blower outlet; andthe first foraminous burner surface defines a higher flow restriction and the first and second foraminous burner surfaces together define a lower flow restriction, so that when the damper is in the closed position the blower output follows a first curve corresponding to the higher flow restriction, and when the damper is in the open position the blower output follows a second curve corresponding to the lower flow restriction. 36. The apparatus of claim 33, further comprising: one and only one ignition element adjacent the first foraminous burner surface. 37. The apparatus of claim 33, further comprising: one and only one flame sensor adjacent the first foraminous burner surface. 38. A modulating burner apparatus, comprising: one and only one source of pressurized pre-mixed fuel and air mixture, the source including at least one variable speed blower;a multi-chamber burner configured to burn the pre-mixed fuel and air mixture, the burner including at least a first burner chamber and a second burner chamber; anda flow control valve including a valve member movable between a closed position restricting flow of fuel and air mixture to the second burner chamber and an open position allowing flow of fuel and air mixture to the second burner chamber, the flow control valve being a positive control valve including an actuator configured to positively control the position of the valve member;a blower speed sensor; andan electronic controller receiving a blower speed signal from the blower speed sensor, the electronic controller configured to control the actuator in response to the blower speed signal. 39. The apparatus of claim 23, wherein: the multi-chamber burner includes an interior wall at least partially separating the first burner chamber and the second burner chamber. 40. The apparatus of claim 23, wherein: the actuator is an electrically driven actuator.
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