Systems and methods for hybrid heating system control

Abstract

In accordance with various embodiments of the present disclosure, a control system for a hybrid air heating system is provided. In some embodiments, the hybrid air heating system has at least one electric heating element capable of generating an electric thermal output and at least one burner capable of generating a combustion thermal output. In some embodiments, the control system comprises a controller configured to, based on a desired total thermal output of the hybrid air heating system, determine an amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element and an amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner.

What is claimed is: 
     
         1 . A control system for a hybrid air heating system having at least one electric heating element capable of generating an electric thermal output and at least one burner capable of generating a combustion thermal output, the control system comprising:
 a controller configured to, based on a desired total thermal output of the hybrid air heating system, determine an amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element and an amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner.   
     
     
         2 . The control system of  claim 1 , wherein the controller is adapted to send a modulated signal to the at least one electric heating element corresponding to the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element and/or a modulated signal to the at least one burner corresponding to the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner. 
     
     
         3 . The control system of  claim 1 , wherein, when the desired total thermal output of the hybrid air heating system is less than a first threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element is 100 percent. 
     
     
         4 . The control system of  claim 3 , wherein the first threshold value is between a minimum combustion thermal output and a maximum electric thermal output. 
     
     
         5 . The control system of  claim 4 , wherein, when the desired total thermal output of the hybrid air heating system is greater than the first threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner is 100 percent. 
     
     
         6 . The control system of  claim 4 , wherein, when the desired total thermal output of the hybrid air heating system is greater than the first threshold value but less than a second threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element is the desired total thermal output of the hybrid air heating system minus the minimum combustion thermal output and the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner is the minimum combustion thermal output;
 wherein, when the desired total thermal output of the hybrid air heating system is greater than the second threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element is the maximum electric thermal output and the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner is the desired total thermal output of the hybrid air heating system minus the maximum electric thermal output; and   wherein the second threshold value is the first threshold value plus the maximum electric thermal output.   
     
     
         7 . The control system of  claim 1 , wherein the electric thermal output generated by the at least one electric heating element is increased during an air purge prior to startup of the at least one burner. 
     
     
         8 . A hybrid air heating system comprising:
 at least one electric heating element capable of generating an electric thermal output;   at least one burner capable of generating a combustion thermal output; and   a control system comprising a controller configured to, based on a desired total thermal output of the hybrid air heating system, determine an amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element and an amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner.   
     
     
         9 . The hybrid air heating system of  claim 8 , wherein the controller provides a modulated signal to the at least one electric heating element corresponding to the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element and/or a modulated signal to the at least one burner corresponding to the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner. 
     
     
         10 . The hybrid air heating system of  claim 8 , wherein, when the desired total thermal output of the hybrid air heating system is less than a first threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element is 100 percent. 
     
     
         11 . The hybrid air heating system of  claim 10 , wherein the first threshold value is between a minimum combustion thermal output and a maximum electric thermal output. 
     
     
         12 . The hybrid air heating system of  claim 11 , wherein, when the desired total thermal output of the hybrid air heating system is greater than the first threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner is 100 percent. 
     
     
         13 . The hybrid air heating system of  claim 11 , wherein, when the desired total thermal output of the hybrid air heating system is greater than the first threshold value but less than a second threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element is the desired total thermal output of the hybrid air heating system minus the minimum combustion thermal output and the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner is the minimum combustion thermal output;
 wherein, when the desired total thermal output of the hybrid air heating system is greater than the second threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element is the maximum electric thermal output and the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner is the desired total thermal output of the hybrid air heating system minus the maximum electric thermal output; and   wherein the second threshold value is the first threshold value plus the maximum electric thermal output.   
     
     
         14 . The hybrid air heating system of  claim 8 , wherein the electric thermal output generated by the at least one electric heating element is increased during an air purge prior to startup of the at least one burner. 
     
     
         15 . A method for controlling a hybrid air heating system having at least one electric heating element capable of generating an electric thermal output and at least one burner capable of generating a combustion thermal output, the method comprising:
 determining, based on a desired total thermal output of the hybrid air heating system, an amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element and an amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner.   
     
     
         16 . The method of  claim 15 , wherein, when the desired total thermal output of the hybrid air heating system is less than a first threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element is 100 percent. 
     
     
         17 . The method of  claim 16 , wherein the first threshold value is between a minimum combustion thermal output and a maximum electric thermal output. 
     
     
         18 . The method of  claim 17 , wherein, when the desired total thermal output of the hybrid air heating system is greater than the first threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner is 100 percent. 
     
     
         19 . The method of  claim 17 , wherein, when the desired total thermal output of the hybrid air heating system is greater than the first threshold value but less than a second threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element is the desired total thermal output of the hybrid air heating system minus the minimum combustion thermal output and the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner is the minimum combustion thermal output;
 wherein, when the desired total thermal output of the hybrid air heating system is greater than the second threshold value, the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one electric heating element is the maximum electric thermal output and the amount of the desired total thermal output of the hybrid air heating system to be generated by the at least one burner is the desired total thermal output of the hybrid air heating system minus the maximum electric thermal output; and 
 wherein the second threshold value is the first threshold value plus the maximum electric thermal output. 
 
     
     
         20 . The method of  claim 15 , wherein the electric thermal output generated by the at least one electric heating element is increased during an air purge prior to startup of the at least one burner.