Patent Grant
11598533
The present disclosure relates generally to water heaters, and more particularly to controlling the availability of heated water for water heater operations for domestic and other uses.
Some water heaters provide heated water for domestic uses as well as hydronic heating uses. For example, domestic uses may include cooking, washing, bathing, etc. To illustrate, a water heater may provide heated water to faucets, shower heads, a dishwasher, a washing machine, etc. The use of heated water for hydronic heating may reduce the amount of heated water available for domestic use. Similarly, the use of heated water for domestic purposes may reduce the amount of water available for hydronic heating. In some cases, it may be desirable to control the amount of heated water that is provided by a water heater for different uses. For example, it may be desirable to reduce or stop the availability of heated water from a water heater for hydronic heating or other auxiliary uses when heated water from the water heater is being used for domestic purposes such as bathing, etc. In some cases, it may be desirable to reduce or stop the availability of heated water for domestic use when hydronic heating or other auxiliary use is needed or preferred. Thus, a solution that enables a control of the usage of heated water from a water heater among a domestic use and hydronic/auxiliary use may be desirable.
The present disclosure relates generally to water heaters, and more particularly to controlling water heater operations for domestic and hydronic/auxiliary usage. In some example embodiments, a water heater system includes a water heater having a first water outlet and a second water outlet. The water heater system further includes a flow detection device coupled to the first water outlet to detect a water flow through the first water outlet. The water heater system also includes a flow control valve fluidly coupled to the second water outlet. The flow control valve is configured to control a flow of water through the second water outlet based on whether the water flow through the first water outlet is detected by the flow detection device.
In some example embodiments, a heated water system includes a water heater system that includes a water heater having a first water outlet and a second water outlet. The water heater system further includes a flow detection device coupled to the first water outlet to detect a water flow through the first water outlet. The water heater system also includes a flow control valve fluidly coupled to the second water outlet and configured to control a flow of water through the second water outlet based on whether the water flow through the first water outlet is detected by the flow detection device. The heated water system further includes a pump fluidly coupled to the second outlet of the water heater to circulate water from the water heater through a hydronic heating system and back to the water heater through a recirculation water inlet of the water heater.
In some example embodiments, a water heater flow control method includes detecting, by a flow detection device, a water flow through a first water outlet of a water heater. The method further includes receiving, by a controller, a flow detection signal that indicates whether the water flow through the first water outlet is detected by the flow detection device. The method also includes controlling, by the controller, a flow control valve based on the flow detection signal, wherein the flow control valve is coupled to a second water outlet of the water heater.
These and other aspects, objects, features, and embodiments will be apparent from the following description and the claims.
Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The drawings illustrate only example embodiments and are therefore not to be considered limiting in scope. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or placements may be exaggerated to help visually convey such principles. In the drawings, the same reference numerals that are used in different drawings designate like or corresponding, but not necessarily identical elements.
In the following paragraphs, example embodiments will be described in further detail with reference to the figures. In the description, well-known components, methods, and/or processing techniques are omitted or briefly described. Furthermore, reference to various feature(s) of the embodiments is not to suggest that all embodiments must include the referenced feature(s).
Turning now to the figures, particular example embodiments are described.
In some example embodiments, the water heater 102 may include a water supply inlet 108, and a domestic-use water outlet 110. For example, the water heater 102 may receive cold water from a municipality or another water source through the water supply inlet 108 and heat the water. To illustrate, the heating of the cold water by the water heater 102 may be controlled by a thermostat setting of the water heater 102. The water heater 102 may include a heat exchanger and/or other components that may be included in and/or outside of the water heater 102 as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure. The water heater 102 may provide the heated water for domestic use through the domestic-use water outlet 110.
In some example embodiments, the water heater 102 may also include a hydronic-use water outlet 112 and a recirculation water inlet 114. For example, the water heater 102 may provide some of the heated water through the hydronic-use water outlet 112 for hydronic heating. The heated water that leaves the water heater 102 via the hydronic-use water outlet 112 may be recirculated back into the water heater 102 via the recirculation water inlet 114. In some case, the use of the heated water for hydronic use via the hydronic-use water outlet 112 may have a lower priority than the use of the heated water for domestic use via the domestic-use water outlet 110.
In some example embodiments, a flow switch 116 may be coupled to the domestic-use water outlet 110. For example, the flow switch 116 may be fluidly or otherwise coupled to the domestic-use water outlet 110 to detect a water flow from the water heater 102 through the domestic-use water outlet 110. The flow switch 116 may be coupled to the controller 104 via an electrical connection 120 and may provide to the controller 104 a flow detection signal that indicates whether a flow of water through the domestic-use water outlet 110 is detected by the flow switch 116. The flow switch 116 may generate the flow detection signal in a manner known to those of ordinary skill in the art with the benefit of this disclosure.
In some example embodiments, a flow control valve 118 may be coupled to the hydronic-use water outlet 112. For example, the flow control valve 118 may be an electronic flow control valve as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure. The flow control valve 118 may be fluidly or otherwise coupled to the domestic-use water outlet 110 to control a flow of water through the hydronic-use water outlet 112 based on whether water flow through the domestic-use water outlet 110 is detected by the flow switch 116. To illustrate, the flow control valve 118 may be coupled to the controller 104 via an electrical connection 122 and may provide the control signal to the flow control valve 118 via the electrical connection 122.
In some examples, the controller 104 may control operations of the flow control valve 118 based on whether the flow detection signal from the flow switch 116 indicates a detection of a flow of water through the domestic-use water outlet 110. To illustrate, the controller 104 may determine from the flow detection signal that water is flowing through the domestic-use water outlet 110 from the water heater 102. In response to the detection of the water flow through the domestic-use water outlet 110, the controller 104 may use the control signal provided to the flow control valve 118 to close the flow control valve 118 or otherwise prevent a flow of water from the water heater 102 through the hydronic-use water outlet 112. For example, the flow control valve 118 may be an on-off flow control valve, such as an actuated ball valve. In response to determining that the flow detection signal from the flow switch 116 indicates that no water is flowing through the domestic-use water outlet 110, the controller 104 may use the control signal provided to the flow control valve 118 to open the flow control valve 118 or otherwise allow the flow of water through the hydronic-use water outlet 112.
In some alternative embodiments, instead of providing a control signal to fully close or open the flow control valve 118, the controller 104 may provide the control signal to the flow control valve 118 to adjust the flow of water through the hydronic-use water outlet 112. For example, in response to determining that the flow detection signal from the flow switch 116 indicates that water is flowing through the domestic-use water outlet 110, the controller 104 may use the control signal provided to the flow control valve 118 to reduce the flow of water through the hydronic-use water outlet 112. As another example, in response to determining that the flow detection signal from the flow switch 116 indicates that no water is flowing through the domestic-use water outlet 110, the controller 104 may use the control signal provided to the flow control valve 118 to increase the flow of water through the hydronic-use water outlet 112, for example, by increasing the opening of the flow control valve 118.
In some example embodiments, the controller 104 may include one or more microcontrollers, microprocessors, or another integrated circuit component (e.g., an FPGA) that execute a software code stored in one or more non-transitory memory devices to perform the functions of the controller 104. For example, the controller 104 may include or may be communicably coupled to a non-volatile memory device containing executable software code and data. In some example embodiments, the controller 104 may include other components such as an analog-to-digital converter, a digital-to-analog converter, etc. as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure.
By controlling the availability of heated water for hydronic heating based on the need for heated water for domestic use, the system 100 allows the domestic use of heated water to have a higher priority than the hydronic use of the heated water. To illustrate, by stopping or reducing the flow of heated water for hydronic heating purposes through the hydronic-use water outlet 112 when heated water is needed for domestic use, the system 100 may allow more heated water to be available for domestic use. By allowing or increasing the flow of heated water for hydronic heating purposes through the hydronic-use water outlet 112 when heated water is not needed for domestic use, the system 100 may allow more heated water to be available for hydronic heating.
In some example embodiments, the system 100 may include one or more other components without departing from the scope of this disclosure. For example, the system 100 may include a power supply to provide electrical power to the controller. In some example embodiments, the water heater 102 may be a tankless water heater. In some alternative embodiments, the water tank 102 may have a different shape than shown without departing from the scope of this disclosure. In some alternative embodiments, the inlets 108, 114 and the outlets 110, 112 may be at different locations than shown without departing from the scope of this disclosure. In some example embodiments, one or more of the inlets 108, 114 and the outlets 110, 112 may be have shorter or longer than shown without departing from the scope of this disclosure. For example, one or more of the inlets 108, 114 and the outlets 110, 112 may be flush with an outer shell 106 of the water heater 102. In some alternative embodiments, the controller 104 may be physically attached to the water heater 102.
In some example embodiments, the water heater 102 may provide heated water through the hydronic-use water outlet 112 for other purposes in addition to or instead of hydronic heating without departing from the scope of this disclosure. In some alternative embodiments, the recirculation water inlet 114 may be omitted, where the heated water that leaves the water heater 102 through the hydronic-use water outlet 112 is not recirculated back to the water heater 102. In some alternative embodiments, the flow switch 116 and the flow control valve 118 may have different shapes and may be at different locations relative to the shell 106 without departing from the scope of this disclosure. In some alternative embodiments, instead of the flow switch 116, a different type of a flow detection device may be used without departing from the scope of this disclosure.
In some example embodiments, the relay 206 may be hardwired as shown in
In some alternative embodiments, the flow switch 202 may be open when water flows through the domestic-use water outlet 110, and the flow switch 202 may be closed when is not flowing through the domestic-use water outlet 110. To illustrate, when the flow switch 202 is open, the polarity of the electrical power provided to the flow control valve 204 through the relay 206 may be such that the flow control valve 204 is closed, thus preventing heated water from flowing out from the water heater 102 through the hydronic-use water outlet 112. When the flow switch 202 is closed indicating that no water is flowing through the domestic-use water outlet 110, the polarity of the electrical power provided to the flow control valve 204 through the relay 206 may be such that the flow control valve 204 is open, thus allowing heated water to flow out from the water heater 102 through the hydronic-use water outlet 112.
In some alternative embodiments, instead of changing the polarity of the electrical power based on whether a flow of water through the domestic-use water outlet 110 is indicated by the flow switch 202, different voltage levels may be provided to the flow control valve 204 through the relay 206. For example, a first voltage level (e.g., 12 volts) may correspond to the detection of a flow of water through the domestic-use water outlet 110 and may result in the flow control valve 204 being closed and thus preventing the flow of heated water out of the hydronic-use water outlet 112. Another voltage level (0 volt) may correspond to no water flow through the domestic-use water outlet 110 and may result in the flow control valve 204 being open and thus allowing the flow of heated water out of the hydronic-use water outlet 112.
By controlling the availability of heated water for hydronic heating based on the need for heated water for domestic use, the system 200 allows the domestic use of heated water from the water heater 102 to have a higher priority than the hydronic use of the heated water.
In some example embodiments, the system 200 may include one or more other components without departing from the scope of this disclosure. In some alternative embodiments, instead of the flow switch 116, a different type of a flow detection device may be used without departing from the scope of this disclosure. In some example embodiments, the water heater 102 may provide heated water through the hydronic-use water outlet 112 for other purposes in addition to or instead of hydronic heating without departing from the scope of this disclosure.
In some example embodiments, the flow sensor 302 may be coupled to the controller 104 via the electrical connection 120 and may provide to the controller 104 a flow detection signal that is indicative of a volume of the water flow through the domestic-use water outlet 110. The flow detection signal may indicate the volume of the water flow through the domestic-use water outlet 110 in a manner readily understood by those of ordinary skill in the art with the benefit of this disclosure. For example, changes in the amplitude of the flow detection signal may indicate changes in the amount of water flowing through the domestic-use water outlet 110.
In some example embodiments, the controller 104 may control the flow control valve 118 based on the flow detection signal from the flow sensor 302. For example, when the flow detection signal indicates no water flow from the water heater 102 through the domestic-use water outlet 110, the controller 104 may use the control signal provided to the flow control valve 118 via the electrical connection 122 to fully open the flow control valve 118 or otherwise allow heated water to freely flow out from the water heater 102 through the hydronic-use water outlet 112. When the flow detection signal indicates some amount of water flow from the water heater 102 through the domestic-use water outlet 110, the controller 104 may use the control signal provided to the flow control valve 118 to correspondingly restrict the flow of heated water from the water heater 102 through the hydronic-use water outlet 112.
In some example embodiments, when the flow detection signal indicates a large volume of water flow from the water heater 102 through the domestic-use water outlet 110, the controller 104 may use the control signal to close the flow control valve 118 or otherwise prevent the flow of heated water from the water heater 102 through the hydronic-use water outlet 112. The relationship between the flow detection signal from the flow sensor 302 and the corresponding control of the flow control switch 118 may be set or adjusted, for example, based on a desired allocation of heater water for domestic use and hydronic use as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure.
By controlling the volume of heated water available for hydronic heating based on the level of domestic use of heated water, the system 300 allows the domestic use of heated water from the water heater 102 to have a higher priority than the hydronic use of the heated water.
In some example embodiments, the system 300 may include one or more other components without departing from the scope of this disclosure. In some alternative embodiments, instead of the flow sensor 302, a different type of flow detection device may be used without departing from the scope of this disclosure. In some example embodiments, the controller 104 may consider the amount of additional heat that can be used to further heat the water in the water heater 102 in controlling the flow control valve 118 to adjust the volume of heated water flow through the hydronic-use water outlet 112. In some example embodiments, the water heater 102 may provide heated water through the hydronic-use water outlet 112 for other purposes in addition to or instead of hydronic heating without departing from the scope of this disclosure.
In some example embodiments, cold water that enters the water heater 102 through the water supply inlet 108 may be heated by the water heater 102, and the heated water may be provided to the domestic-use system 402 and the hydronic-use system 404. For example, the domestic-use system 402 may include a kitchen sink, a bathroom sink, a dishwasher, a bathtub, a shower, etc., and the hydronic-use system 404 may include heat transfer piping, etc.
In some example embodiments, when heated water from the water heater 102 is used in the domestic-use system 402, the controller 104 may control the use of heated water by the hydronic-use system 404 by controlling the flow of heated water through the hydronic-use water outlet 112 in a similar manner as described with respect to the system 100 of
In some example embodiments, when the flow switch 116 indicates the flow of water from the water heater 102 to the domestic use system 402 through the domestic-use water outlet 110, the controller 104 may control flow control valve 118 to reduce, without stopping, the flow of heated water from the water heater 102 to the hydronic-use system 404 through the hydronic-use water outlet 112. When the flow switch 116 indicates no flow of water from the water heater 102 to the domestic use system 402 through the domestic-use water outlet 110, the controller 104 may control flow control valve 118 to increase the flow of heated water from the water heater 102 to the hydronic-use system 404 through the hydronic-use water outlet 112.
In some example embodiments, the controller 104 may control the operation of the pump 406. For example, when the controller 104 closes the flow control valve 118 or otherwise prevents the flow of heated water from the water heater 102 through the hydronic-use water outlet 112, the controller 104 may shut off the pump 406 to prevent dead heading that may occur if the recirculation piping does not include a bypass path. The controller 104 may also control the operations of the pump 406, for example, based on a thermostat that operates based on a temperature of a room that is heated hydronic use system 404.
In some alternative embodiments, the heated water system 400 may include the water heater system 200 of
In some alternative embodiments, the heated water system 400 may include the water heater system 300 of
In some alternative embodiments, the system 400 may include other components without departing from the scope of this disclosure. In some alternative embodiments, some of the heated water provided for domestic use may be recirculated without departing from the scope of this disclosure. In some alternative embodiments, a device other than the pump 406 may be used to control recirculation of water through the domestic-use system 404 without departing from the scope of this disclosure. In some example embodiments, the water heater 102 may provide heated water through the hydronic-use water outlet 112 for other purposes in addition to or instead of hydronic heating without departing from the scope of this disclosure.
In some example embodiments, cold water that enters the water heater 102 through the water supply inlet 108 may be heated by the water heater 102, and the heated water may be provided to the domestic-use system 402 and the hydronic-use system 404. In some example embodiments, when the flow switch 116 indicate the flow of heated water from the water heater 102 to the domestic-use system 402, the controller 104 may adjust the flow of heated water to the hydronic-use system 404 by controlling the flow control valve 118 in a similar manner as described above with respect to the system 100 of
As shown in
In some example embodiments, the controller 104 may control the flow control valve 502 based on the temperature sensed by the temperature sensor 504 to adjust the flow of heated
water from the water heater 102 through the domestic-use water outlet 110. For example, the controller 104 may provide a control signal to the flow control valve 502 via an electrical connection 510 to control the operations of the flow control valve 502. The controller 104 may also control the flow control valve 118 based on the temperature sensed by the temperature sensor 504 to adjust the flow of heated water from the water heater 102 through the hydronic-use water outlet 112. To illustrate, if the temperature sensor 504 senses a temperature that is below a threshold temperature (e.g., 33° F.), the controller 104 may control the flow control valve 502 to decrease the flow of heated water through the domestic-use water outlet 110 and may control the flow control valve 118 to increase the flow of heated water through the hydronic-use water outlet 112. By increasing the water flow through the hydronic-use water outlet 112 based on the temperature information provided by the temperature sensor 504, the freezing of water in or after the hydronic-use 404, which can result in damages to various components, may be avoided.
In some example embodiments, the controller 104 may control the flow control valve 502 and/or the control valve 118 based on the temperature sensed by a temperature sensor 506 instead of or in addition to the temperature sensed by the temperature sensor 504. For example, the temperature sensor 506 may be located proximal to the water supply inlet 108 and may sense the temperature of the supply water that is provided to the water heater 102 via the water supply inlet 108. To illustrate, the controller 104 may control flow the control valve 118 to decrease or increase the flow of heated water through the hydronic-use water outlet 112 based on the temperature sensed by the temperature sensor 506. The controller 104 may alternatively or in addition control flow the control valve 502 to decrease or increase the flow of heated water through the domestic-use water outlet 110 based on the temperature sensed by the temperature sensor 506.
In some example embodiments, the controller 104 may control the flow control valves 118, 502 to adjust the flows of heated water through the domestic-use water outlet 110 and the hydronic-use water outlet 112 only if the water heater 102 cannot provide additional heated water to the domestic-use system 402 or to the hydronic-use system 404 without reducing the volume of heated water provide to one of the two systems. 402, 404. In some example embodiments, when the temperature sensed by the temperature sensor 504 is below a threshold temperature (e.g., 35° F., 40 F, etc.), the controller 104 may reduce the volume of heated water that is provided to the hydronic-use system 404 even when no domestic use of heated water is detected by the flow switch 116 (or by the flow sensor 302 or another flow detection device).
In some alternative embodiments, the system 500 may include other components without departing from the scope of this disclosure. In some alternative embodiments, some of the heated water provided for domestic use may be recirculated without departing from the scope of this disclosure. In some alternative embodiments, a device other than the pump 406 may be used to control recirculation of water through the domestic-use system 404 without departing from the scope of this disclosure. In some example embodiments, the water heater 102 may provide heated water through the hydronic-use water outlet 112 for other purposes in addition to or instead of hydronic heating without departing from the scope of this disclosure.
In some example embodiments, cold water that enters the water heater 102 through the water supply inlet 108 may be heated by the water heater 102, and the heated water may be provided to the domestic-use system 402 and the hydronic-use system 404. In some example embodiments, when the flow switch 116 indicate the flow of heated water from the water heater 102 to the domestic-use system 402, the controller 104 may adjust the flow of heated water to the hydronic-use system 404 by controlling the flow control valve 118 in a similar manner as described above with respect to the systems 100, 400, 500. In some alternative embodiments, the system 500 may operate to control the flow of heated water through the hydronic-use water outlet 112 in a similar manner as described with respect to the systems 300, 400, 500 when the system 600 includes the flow sensor 302 instead of the flow switch 116. In some example embodiments, the controller 104 may control the operation of the pump 406 in a similar manner as described above.
In some example embodiments, the controller 104 may control the flow control valve 502 based on the temperature sensed by the temperature sensor 504 and/or the temperature sensed by the temperature sensor 506 to adjust the flow of heated water through the domestic-use water outlet 110 in a similar manner as described with respect to the system 500 of
As shown in
In some example embodiments, the controller 104 may control the flow control valves 118, 502 to adjust the flows of heated water through the domestic-use water outlet 110 and the hydronic-use water outlet 112 only if the water heater 102 cannot provide additional heated water to the domestic-use system 402 or to the hydronic-use system 404 without reducing the volume of heated water provide to one of the two systems. 402, 404. In some example embodiments, when the flow of heated water from the water heater 102 increases to a total volume that exceeds the maximum volume of adequately heated water that can be provided by the water heater 102, the controller 104 may reduce the volume of heated water that is provided to the domestic-use system 402, the hydronic-use system 404, or both. In some example embodiments, when the temperature sensed by the temperature sensor 504 is below a threshold temperature (e.g., 35° F., 40 F, etc.), the controller 104 may reduce the volume of heated water that is provided to the hydronic-use system 404 even when no domestic use of heated water is detected by the flow switch 116 (or by the flow sensor 302 or another flow detection device).
In some alternative embodiments, the system 600 may include other components without departing from the scope of this disclosure. In some alternative embodiments, some of the heated water provided for domestic use may be recirculated without departing from the scope of this disclosure. In some alternative embodiments, a device other than the pump 406 may be used to control recirculation of water through the domestic-use system 404 without departing from the scope of this disclosure. In some example embodiments, the water heater 102 may provide heated water through the hydronic-use water outlet 112 for other purposes in addition to or instead of hydronic heating without departing from the scope of this disclosure.
In some example embodiments, at step 706, the method 700 may include controlling, by the controller 104, a flow control valve, such as the flow control valve 118, based on the flow detection signal. As described above, the flow control valve is coupled to hydronic-use water outlet 112 of the water heater 102. The controller 102 may control the flow control valve 118 based on the flow detection signal by providing a command to the flow control valve to close the flow control valve 118 if the flow detection signal indicates a detection of the water flow through the domestic-use water outlet 110. The flow control valve 118 may prevent a flow of water through the hydronic-use water outlet 112 when the flow control valve 118 is closed.
In some example embodiments, the method 700 may include controlling, by the controller 102, the flow control valve 118 based on the flow detection signal by providing a command to the flow control valve 118 to open the flow control valve 118 if the flow detection signal from the flow detection device indicates that water flow through the domestic-use water outlet 110 is not detected. The method 700 may also include controlling, by the controller 102, a second flow control valve (e.g., the flow control valve 502) fluidly coupled to the flow detection device at least based on a temperature of hydronic-use water returning to the water heater through the recirculation water inlet 114.
In some example embodiments, the method 700 may include controlling, by the controller 104, the flow of heated water through the first water outlet, such as the domestic-use water outlet 110, based on the temperature of the of hydronic-use water returning to the water heater 102 through the recirculation water inlet 114. The controller 104 may also control the flow of heated water through the hydronic-use water outlet 112 based on the temperature of the of hydronic-use water returning to the water heater 102 through the recirculation water inlet 114.
In some example embodiments, one or more steps of the method 700 may be omitted without departing from the scope of this disclosure. In some example embodiments, the method 700 may include additional steps without departing from the scope of this disclosure. In some example embodiments, some of the steps of the method 700 may be performed in a different order than described above without departing from the scope of this disclosure.
Although example embodiments are described herein, it should be appreciated by those skilled in the art that various modifications are well within the scope and spirit of this disclosure. Those skilled in the art will appreciate that the example embodiments described herein are not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments using the present disclosure will suggest themselves to practitioners of the art. Therefore, the scope of the example embodiments is not limited herein.
The present application is a continuation of, and claims priority to, U.S. patent application Ser. No. 16/528,369, filed 31 Jul. 2019, the entire content of which is incorporated herein by reference.
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