Electronic Gas/Air Burner Modulating Control

A method of operating an electronic control system to modulate an air/gas rate and air/gas ratio of a burner comprising:

• providing a burner having a maximum heat output;
• providing a modulating gas valve upstream from the burner, wherein the gas valve has an adjustable position, wherein the position of the gas valve and gas flow are capable of being adjusted based on a variable electronic signal;
• providing a combustion air blower fan in communication with the burner that is capable of operating at a speed having a range of revolutions per minute and that is capable of being adjusted based on a variable electronic signal;
• providing an electronic control that receives an input signal from a thermostat control and outputs a variable electronic signal to the modulating gas valve and to the combustion air blower fan, wherein the electronic control comprises a processor, a memory and a software application stored within the memory, wherein voltage values for operating the gas valve and voltage values for operating the combustion air blower are stored in the memory, and wherein the thermostat control is either integrated with and is a component of the electronic control or is a separate component from the electronic control,
• adjusting the maximum heat output of the burner by:
• inputting a heat demand into the thermostat control;
• inputting the heat demand from the thermostat control into the electronic control;
• sending a signal from the electronic control to the gas valve and a return signal from the gas valve to the electronic control to verify the position of the gas valve;
• verifying and adjusting a position of the gas valve as necessary by sending a signal from the electronic control to the gas valve;
• sending a return signal from the gas valve to the electronic control indicating a new position of the gas valve;
• processing the return signal received from the gas valve with the electronic control to verify that the adjusted gas valve position is correct;
• upon verifying that the adjusted gas valve position is correct, sending a signal from the electronic control to the combustion air blower and a return signal from the combustion air blower to the electronic control to verify the speed of the combustion air blower and to determine whether a stall condition has occurred (blower speed is zero);
• verifying and adjusting the speed of the combustion air blower as necessary by sending a signal from the electronic control to the combustion air blower;
• sending a return signal from the combustion air blower to the electronic control indicating a new speed of the combustion air blower;
• determining with the processor of the electronic control whether a value of voltage required to attain a desired combustion air blower speed is different from the combustion air blower voltage value stored in the memory of the electronic control for a desired speed to achieve maximum heat output;
• and,
• storing a new voltage value in the memory corresponding to the speed of the combustion air blower if the voltage value for operating the combustion air blower at the desired speed to achieve maximum heat output has changed.