Control method for gas burners

1. A control method for providing a gas flow and a combustion air flow in a gas-air mixture to a burner to produce a burner flame, and for using a sensor that produces an ionization signal to adapt the gas-air mixture to different gas qualities, the method comprising the steps of:

optically determining when the burner flame sweeps over the sensor;

using the ionization signal of the sensor for setting a mixing ratio of the gas-air mixture when the burner flame sweeps over the sensor; and

setting the mixing ratio of the gas-air mixture based on the gas flow and the combustion air flow when the burner flame does not sweep over the sensor.

2. A control method according to claim 1 wherein the ionization signal of the sensor is used for setting the mixing ratio of the gas-air mixture when the burner flame completely sweeps over the sensor, and the mixing ratio of the gas-air mixture is set based on the gas flow and the combustion air flow when the burner flame does not completely sweep over the sensor.

3. A controller for controlling a gas flow and a combustion air flow in a gas-air mixture for a gas burner to produce a burner flame, the gas burner including a sensor adjacent the gas burner, the controller receiving an ionization signal from the sensor and sets the gas-air mixture based, at least in part, on the ionization signal when the burner flame sweeps over the sensor, and sets the gas-air mixture based on the gas flow and the combustion air flow when the burner flame does not sweep over the sensor, the controller further including an optical flame monitor for monitoring when the burner flame does or does not sweep over the sensor.

4. A control method according to claim 1 wherein the ionization signal of the sensor is used for setting the mixing ratio of the gas-air mixture when the burner flame completely sweeps over the sensor, and said mixing ratio is used to control the gas-air mixture when the burner flame does not completely sweep over the sensor.

5. A combustion burner controller that adapts a gas-air mixture to different gas qualities, the controller comprising:

a combustion burner providing gas and air flow to a burner to produce a flame;

a sensor that provides an ionization signal based on the combustion process in the burner, the sensor positioned adjacent the burner flame such that when the burner is in a first operating state, the flame sweeps completely over the sensor and when the burner is in a second operating state, the flame does not sweep completely over the sensor;

an optical monitor positioned adjacent the flame, the optical monitor providing a signal indicating the burner flame is or is not sweeping over the sensor;

a controller that sets a gas-air mixture ratio based on the ionization signal, wherein the gas-air mixture is dependent at least in part on the gas quality;

wherein the controller sets the gas-air mixture ratio when the burner is in the first operating state, and uses that gas-air mixture ratio when the burner is in the second operating state.

6. A control method for providing a gas flow and a combustion air flow in a gas-air mixture to a burner to produce a burner flame, and for using a sensor that produces an ionization signal to adapt the gas-air mixture to different gas qualities, the method comprising the steps of:

optically determining when the burner flame completely sweeps over the sensor;

using the ionization signal of the sensor for setting a mixing ratio of the gas-air mixture when the burner flame completely sweeps over the sensor; and

setting the mixing ratio of the gas-air mixture based on the gas flow and the combustion air flow when the burner flame does not sweep over the sensor.

7. A control method for providing a gas flow and a combustion air flow in a gas-air mixture to a gas burner to produce a burner flame, the method comprising the steps of:

optically determining when an operating load of the burner is in a first state and when the operating load is in a second state;

accepting an ionization signal from a sensor, wherein the sensor is positioned in the burner flame when the operating load of the burner is in a first state and at least not completely positioned in the burner flame when the operating load of the burner is in a second state;

using, at least in part, the ionization signal of the sensor for controlling the gas-air mixture to the burner when the operating load is in the first state; and

using a measure of the gas flow and combustion air flow for controlling the gas-air mixture to the burner when the operating load is in the second state.

8. A control method according to claim 7 wherein, in the first state, the burner flame completely sweeps over the sensor, and in the second state, the burner flame does not completely sweep over the sensor.

9. A control method according to claim 7 wherein the determining step determines when the operating load of the burner is in the first state by determining when the burner flame completely sweeps over the sensor.

10. A control method according to claim 9 wherein the determining step determines when the operating load of the burner is in the second state by determining when the burner flame does not completely sweep over the sensor.

11. A method for managing the combustion of fuel in a gas burner in which a controller controls the mixture of gas and air to produce a burner flame, the method comprising the steps of:

providing an ionization sensor positioned such that when the burner is in a first operating state, the burner flame sweeps over the sensor, and when the burner is in a second operating state, the burner flame does not completely sweep over the sensor;

providing an optical flame monitor coupled to the controller for monitoring when the burner flame does or does not completely sweep over the sensor;

providing an ionization signal to the controller when the burner is in the first operating state; and

using the ionization signal to set a mixing ratio for a gas-air mixture;

wherein when the burner is in the second operating state, maintaining the mixing ratio set when the burner was in the first operating state.

12. The method of claim 11 , wherein the ionization signal is only used to set a mixing ratio for a gas-air mixture when the burner is in the first operating state.