Systems and Methods for Controlling Hybrid Gas Water Heater Systems Including a Gas Valve

TECHNICAL FIELD

The present disclosure is generally in the field of water heater systems. For example, systems and methods are provided herein for hybrid water heater systems with heat pump and gas heating systems.

BACKGROUND

Water heater systems heat large volumes of water contained in water tanks, for use in residential and/or commercial spaces. For example, a water heater system may include a gas heating system configured to heat a volume of water held in a water tank by transferring heat from the combustion of gas that rises via a flue extending vertically through the water tank. Other types of water heater systems include electric water heaters and heat pump water heaters.

Some water heater systems may be designed to include more than one type of heat source. Such water heaters with multiple types of heating sources are referred to as hybrid water heaters. For example, a single water heater may include a gas heating system and an electric heating system and may alternate between gas heating and heat pump heating to efficiently heat water in the water tank. In another example, a hybrid water heater may include a heat pump heating system and a gas heating system each having separate controllers.

Hybrid water heaters such as hybrid water heaters having a heat pump heating system and a gas heating system present a number of challenges relating to the control of water-heating operations and efficient temperature control. For example, determinations must be made as to whether gas heating or heating via the heat pump system is appropriate based on environmental conditions, system conditions, and/or desired temperature and heating preferences of one or more user(s). Further, as heat pump heating systems and gas heating systems typically have independent control, it is often difficult to manage the communication and coordination between the two distinct heating systems so as to ensure coordinated operation necessary to achieve desired temperatures in accordance with the heating preference of the user(s).

Accordingly, there is a need for improved systems and methods for controlling hybrid water heater systems including hybrid water heating systems including a heat pump heating system and a gas heating system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a hybrid water heater system in accordance with one or more example embodiments of the disclosure.

FIGS. 2A-2B are, respectively, side and cross-sectional views of a gas valve assembly in accordance with one or more example embodiments of the disclosure.

FIG. 3 is a schematic block diagram of a water heater system in accordance with one or more example embodiments of the disclosure.

FIG. 4 is a schematic block diagram of an integrated heat pump and gas valve control assembly in accordance with one or more example embodiments of the disclosure.

FIG. 5 is a schematic illustration of an example process flow for determining to activate gas heating in accordance with one or more example embodiments of the disclosure.

FIG. 6 is a schematic block diagram of a water heater system in accordance with one or more example embodiments of the disclosure.

DETAILED DESCRIPTION

Hybrid water heater systems have been developed which are capable of heating volumes of water held in water tanks using a gas heating system and a heat pump system. The gas heating system may include a burner in fluid communication with a gas line connected to a gas valve assembly and be configured to transfer heat to the water tank. The gas source may be in fluid communication with the gas line connected to the gas valve of a valve assembly. The heat pump system may additionally be configured to heat the water tank. The heat pump system may include a condenser, an evaporator, a compressor, and/or an expansion valve.

One or more temperature sensor(s), such as temperature probe(s) and/or thermistor(s), may be positioned in or on the water tank and may be in communication with the controller. The controller may be designed to facilitate heating of the water tank by determining a temperature setting for the water tank, requesting and/or receiving one or more tank temperature(s) determined by the one or more temperature sensor(s), and/or sending instructions to the gas valve assembly and/or the heat pump system to heat the water tank to a desired temperature. The computer-executable instructions sent to the valve assembly may transition the gas valve from a closed position to an open position to permit gas to traverse the gas line and enter the burner and ignite. The computer-executable instructions sent to the heat pump system may cause a refrigerant to flow into the compressor and expansion valve and through the condenser and the evaporator to activate the heat pump system.

Referring now to FIG. 1, an illustrative hybrid water heater system including a water tank, a gas heating system, a heat pump, and a controller is illustrated. As shown in FIG. 1, hybrid water heater system 100 may include water tank 102, gas heating system 104, heat pump system 106, and controller 108. The water tank 102 may be configured to hold a volume of water. The gas heating system 104 and the heat pump system 106 may each be configured to heat the water tank 102. The controller 108 may include memory configured to store computer-executable instructions and one or more processor(s) configured to access memory and execute the computer-executable instructions, which may facilitate the heating of the water tank 102. The controller may be any computing device having a processor.

The water tank 102 may include a generally cylindrical chamber that retains the volume of water and may include inner housing 145 and outer housing 103. The water tank 102 may be formed from materials common to the construction of water heaters (e.g., stainless steel, polymer, porcelain enamel, and/or glass). The water tank 102 may be configured to allow ingress of ambient air to provide air for combustion of gas at burner 110 (e.g., via through holes 115), as further described below. The water tank 102 may receive cold water from cold water inlet 125 and expel hot water from a hot water outlet 135. The hot water outlet 135 may be connected to a hot water line, which may, in turn, connect to valves of appliances, faucets, or other devices that conduct or use hot water.

The gas heating system 104 may include the burner 110 in fluid communication with gas line 112. Burner 110 may be any known gas burner configured to burn gas (e.g., natural gas) received from gas line 112. The gas line 112 may extend through the outer housing 103 of the water tank 102 to gas valve 114 that may be in fluid communication with the gas line 112 and may be designed to transition between an open position and a closed position to allow flow of gas through the gas line 112 to the burner 110. The burner 110 may ignite the gas, with contribution of the air from the ingress of ambient air, to produce heat via combustion in combustion chamber 142. Hot flue gas resulting from the combustion may rise from the combustion chamber 142 through flue 118 that extends vertically through the water tank 102. The hot flue gas may deliver heat to the wall of the flue 118 as the gas rises, thereby contributing heat to the volume of water held in the water tank 102.

Valve assembly 120 may include the gas valve 114, valve controller 122, and/or temperature probe 124. The valve assembly 120 may be connected to the hybrid water heater system 100 via the outer housing 103 (e.g., may extend through outer housing 103) of the water tank 102. The valve controller 122 may be in wired and/or wireless communication with the controller 108. The temperature probe 124 may be designed to extend into the water tank 102 and may generate one or more tank temperature(s) indicating the temperature of the water in water tank 102 at the location of temperature probe 124. The valve controller 122 may be configured to receive a request for the one or more tank temperature(s) from the controller 108, send the one or more tank temperature(s) to the controller 108, and/or actuate the gas valve 114 to transition the valve between the open position and the closed position. In the closed position, gas may not traverse gas valve 114 and in the open position, gas may traverse gas valve 114.

The heat pump system 106 may include compressor 126, evaporator 128, condenser 130, and/or expansion valve 132, each in fluid communication with one another via refrigerant line 134. Compressor 126 may be configured to pump a refrigerant (e.g., a gaseous refrigerant, such as a hydrofluorocarbon refrigerant, or other suitable refrigerant) from the compressor 126, thereby increasing the refrigerant's pressure and temperature and causing the heated refrigerant to flow through condenser 130, which may transfer thermal energy to the volume of water held in the water tank 102. As the refrigerant moves through condenser 130, it may condense to a liquid phase. Still under pressure provided by the condenser 130, the now-liquid refrigerant may flow from the condenser 130 to the expansion valve 132. The expansion valve 132 may depressurize the liquid refrigerant as the refrigerant enters the evaporator 128. Within the evaporator 128, the refrigerant may transition to a gaseous phase, drawing heat from air flowing over the evaporator 128, the heat being contributed by the ambient air and by the compressor 126. The gaseous refrigerant may return to the compressor 126, and the cycle may repeat. Fan 107 may direct airflow over evaporator 128 to facilitate heat transfer.

The controller 108 may include memory configured to store computer-executable instructions and at least one computer processor configured to access memory and execute the computer-executable constructions. The controller 108 may be in wired and/or wireless communication with the valve assembly 120 (e.g., via valve controller 122), remote controller 136, and/or server 138 (e.g., via a Wi-Fi, cellular network, Bluetooth, Bluetooth Low Energy (BLE) network, near field communication protocol, or the like). Server 138 may be one or more computing device with a processor (e.g., server, datastore, laptop, desktop, or the like).

Remote controller 136 may be any computing device (e.g., tablet, smartphone, laptop, desktop, wearable, or the like) and may be used to determine a temperature setting 140, which may be a desired temperature in the water tank 102. A user may use remote controller 136 to select a desired tank temperature and remote controller 136 may send the desired tank temperature to controller 108 and/or server 138. Server 138 may send the desired tank temperature to controller 108.

Controller 108 may send instructions to gas valve assembly 120 and may receive information (e.g., tank temperatures) from the valve assembly 120. For example, controller 108 may include instructions to transition the gas valve 114 between the closed position and the open position and/or instructions to generate a tank temperature using temperature probe 124. Controller 108 may further control heat pump system 106.

The controller 108 may receive the temperature setting 140 from the remote controller 136 and/or server 138 and may operate heat pump system 106 and/or gas heating system 104 based on temperature setting 140. Alternatively, or additionally, the controller 108 may receive the temperature setting 140 from a user interface on the hybrid water heater system 100 (e.g., a touch screen and/or buttons). Controller 108 may be powered by a power source, for example, an electrical power source in electrical communication with the controller 108.

Referring now to FIGS. 2A-2B, an illustrative valve assembly associated with a water heater system is illustrated. Specifically, gas valve assembly 200 may be associated with water heater system 214. Water heater system 214 may be the same as or similar to hybrid water heater system 100 of FIG. 1, water heater system 300 of FIG. 3, water heater system 400 of FIG. 4, and/or water heater system 601 of FIG. 6, or otherwise may be one or more of the water heater systems of FIG. 1 and/or FIGS. 3-6. Gas valve assembly 200 may be the same as or similar to valve assembly 120 of FIG. 1 or otherwise may be one or more of the valve assembly (or assemblies) of FIG. 1 and/or FIGS. 3-6. As shown in FIGS. 2A and 2B, gas valve assembly 200 may include on/off switch 202, adjustment device 204, communication port 206, valve controller 208, gas valve 210, and/or temperature probe 212.

The valve assembly 200 may be connected to outer housing 220 of water tank 218. The temperature probe 212 of the valve assembly 200 may extend into the water tank 218 through the outer housing 220 and may generate a temperature reading and/or signal indicative of the temperature of water tank 218 at the location of temperature probe 212. It is understood that temperature probe 212 may be any well-known temperature sensor (e.g., thermometer, thermistor, etc.). The gas line 216 of the water heater system 214 may be in fluid communication with the valve assembly 200 via the gas valve 210.

The on/off switch 202 may be actuated or otherwise activated to turn power to the valve assembly 200 on or off. One or more component(s) of the water heater system 214 may be in wired (e.g., via the communication port 206) and/or wireless communication with one or more component(s) of the valve assembly 200. For example, the controller of the water heater system 214 may be in communication with the valve controller 208 of the valve assembly 200. The valve controller 208 may control actuation of gas valve 210 and/or may activate temperature probe 212 to cause temperature probe 212 to generate a reading. The controller may, for example, request a tank temperature from the temperature probe 212 via the valve controller 208 and/or send instructions to the valve controller 208 to transition the gas valve 210 between an open position and a closed position. Adjustment device 204 may optionally permit a user to adjust an amount of gas permitted to traverse valve assembly 200 in an open position. Adjustment device 204 may, for example, be or include a rotary-adjustment device or component such as a dial, a slide-adjustment device or component such as a slider switch, or any other adjustment device or component.

The valve assembly 200 may be a standalone assembly separate from water heater system 214. In such embodiments, the controller of the water heater system 214 may request and/or receive the temperature setting from a remote controller and/or a user interface and may further request and/or receive temperature measurements generated by temperature probe 212. Controller may compare the temperature measurement to the temperature setting and based on the comparison may send instructions to gas valve assembly 200 to actuate to open gas valve 210.

Referring now to FIG. 3, a schematic block diagram of an illustrative water heater system including one or more temperature sensor(s) disposed in or on a water tank and in communication with a controller and/or a gas valve controller is illustrated. Specifically, temperature sensor 302 may be positioned fully or partially within water tank 306 of water heater system 300 and may be in communication with controller 308 and/or gas valve controller 310 (which may be part of a valve assembly associated with a gas heating system). Water heater system 300 may be the same as or similar to hybrid water heater system 100 of FIG. 1, water heater system 214 of FIG. 2, water heater system 400 of FIG. 4, and/or water heater system 601 of FIG. 6, or otherwise may be one or more of the water heater systems of FIG. 1-2 and/or FIGS. 4-6.

Temperature sensors 302, 304, and/or 305 may be the same or different types of sensors, each configured to measure the tank temperature of the water tank 306, and may be variedly positioned with respect to the water tank 306. For example, temperature sensor 302 may be a temperature probe of a valve assembly that is adapted to extend into the water tank 306, while temperature sensors 304 and/or 305 may be thermistors disposed in the water tank 306. Temperature sensor 302 may be located on and/or extend into the water tank 306 at a different height than that where temperature sensor 304 is disposed in or on the water tank 306, for example, at a height below the location where temperature sensor 304 is disposed. Alternatively, or in addition, temperature sensor 305 may be disposed at a different height than temperature sensor 304, for example, at a height below temperature sensor 304. Accordingly, temperature sensors 302, 304, and/or 305 may measure temperatures at different locations in the tank and thus may record different tank temperatures of the water tank 306.

Temperature sensor 302 may be in wired or wireless communication with gas valve controller 310 as part of the valve assembly, while temperature sensors 302, 304, and/or 305 may be in wired or wireless communication with controller 308. Moreover, controller 308 may optionally be in communication with gas valve controller 310 via wired or wireless communication with the valve assembly. For example, temperature sensor 304 may determine a reference tank temperature of the water tank 306. Temperature sensors 302 and/or 305 may determine different tank temperatures of the water tank 306. The controller 308 may determine the reference tank temperature from temperature sensor 304 and may request and/or receive other tank temperatures generated by the temperature sensor 302 and/or temperature sensor 305.

Based, for example, on the reference tank temperature and/or another tank temperature of the water tank 306, the controller 308 may send instructions to the valve assembly to transition the gas valve from a closed position to an open position in order to facilitate heating of the water to an appropriate temperature (e.g., a temperature defined by a temperature setting). If the reference tank temperature and/or other tank temperature (e.g., from temperature sensor 302 and/or 305) satisfy a temperature setting (e.g., is/are at or above the temperature setting and/or a threshold value based on the temperature setting), then the controller 308 may send instructions to the valve assembly to transition the gas valve from the open position to the closed position.

The controller 308 may, additionally or alternatively, send further instructions associated with receiving the reference tank temperature and/or the other tank temperature. The further instructions may be sent before or after the temperature setting has been satisfied. For example, the controller 308 may send instructions to turn on a heat pump system of the water heater system 300 based on the reference tank temperature determined by temperature sensor 304 and/or the other tank temperature determined by temperature sensor 302 and/or 305. Accordingly, the controller 308 may facilitate heating of the water contained in the tank via the gas heating system and/or the heat pump system to achieve an appropriate tank temperature (e.g., the temperature defined by the temperature setting).

If, after achieving an appropriate tank temperature, the reference tank temperature and/or another tank temperature (e.g., from a different temperature sensor than the one that generated the reference tank temperature) decrease below an acceptable temperature or threshold (e.g., the temperature setting and/or a threshold value based on the temperature setting), then the controller 308 may send instructions to the valve assembly to transition the gas valve from the closed position to the open position.

If the reference tank temperature and/or another tank temperature different than the reference tank temperature fail(s) to satisfy a temperature setting (e.g., remain(s) below the temperature setting and/or a threshold value based on the temperature setting), then the controller 308 may send instructions to the valve assembly to transition the gas valve from the open position to the closed position.

Referring now to FIG. 4, a schematic block diagram of an illustrative water heater system is illustrated. Specifically, water heater system 400 may include controller 402, user interface 404, and/or one or more component(s) and/or module(s). Controller 402 may be in communication with gas valve controller 406. The controller 402 and/or the gas valve controller 406 may receive power from power source 408. The water heater system 400 may be the same as or similar to hybrid water heater system 100 of FIG. 1, water heater system 214 of FIG. 2, water heater system 300 of FIG. 3, water heater system 601 of FIG. 6, or otherwise may be one or more of the water heater systems of FIGS. 1-3 and/or FIGS. 5-6.

The one or more component(s) of the water heater system 400 may include one or more tank thermistor(s) 410, leak sensor 412, shut-off valve 414, compressor relay 416, recirculation pump relay 418, fan 420, one or more heat pump thermistor(s) 422, current sensor 424, thermostat 426, electronic expansion valve (EXV) 427, and/or condensate sensor 428. The one or more module(s) of the water heater system 400 may include gas valve communication module 430, CTA-2045 communication module 432, Wi-Fi communication module 434, and/or anode monitoring communication module 436.

The controller 402 may receive and/or request data from and/or send instructions to the one or more component(s) to facilitate operation of the water heater system 400. The one or more module(s) of the water heater system 400 may facilitate communication between the controller 402, the one or more component(s) of the water heater system 400, and/or one or more external system(s) or component(s).

The user interface 404 may receive one or more user input(s) from a user of the water heater system 400. The user input(s) may be sent from the user interface 404 to the controller 402, which may send instructions to one or more other component(s) of the water heater system 400 to satisfy the user input(s). For example, a user may input a temperature setting and/or a heating preference for the water heater system 400 via the user interface 404 and/or the thermostat 426. The controller 402 may receive the temperature setting and/or heating preference from the user interface 404 and may send instructions one or more component(s) of the water heater system to achieve the temperature setting, for example, in accordance with the heating preference.

In some embodiments, for example, the controller 402 may request and/or receive one or more tank temperature(s) from the tank thermistor(s) 410 and/or the heat pump thermistor(s) 422. The tank temperature(s) determined by the tank thermistor(s) 410 and/or the heat pump thermistor(s) 422 may be compared to the temperature setting received from the user interface 404, and the controller 402 may determine to activate heating via, for example, a gas heating system and/or a heat pump system of the water heater system 400 if the tank temperature(s) is/are below the temperature setting.

The heating preference (e.g., a preference for an energy-saving heating operation) may inform selective activation of one or more component(s) via the controller 402. For example, the controller may selectively open or close the EXV 427 to facilitate or disable heating via the heat pump system. The anode monitoring communication module 436 may provide data received from one or more anode monitor(s) about the energy efficiency and performance of one or more anode cell(s) of the water heater system 400, which may inform the instructions sent by the controller 402.

The compressor relay 416 and/or the recirculation pump relay 418 may be configured to send instructions to perform one or more operation(s) from the controller 402 to, respectively, a compressor and/or a recirculation pump of a heat pump system of the water heater system 400. For example, the controller 402 may send instructions, via the compressor relay 416 and the recirculation pump relay 418, to turn on (or off) the compressor and the recirculation pump when a determination is made to initiate (or cease) heating via the heat pump system. Fan 420 may be configured to provide cooling functionality to portions of the water heater system 400 responsive to activation by the controller 402.

One or more sensor(s) may be in communication with the controller 402. For example, the current sensor 424 may determine an electrical current to one or more electrical component(s) of the water heater system 400 and send relevant current data to the controller 402 to, for example, optimize energy efficiency or respond to a loss of power from the power source 408. The condensate sensor 428 may determine a condensation level within the water heater system 400, which may cause the controller 402 to shut down the water heater system 400 to prevent an electrical hazard. The leak sensor 412 may send a notification to the controller 402 that a leak is detected within the water heater system 400, and the controller 402 may responsively turn off or otherwise modify the functionality of the water heater system 400. For example, the controller 402 may send instructions to activate the shut-off valve 414, which may restrict flow of water to or from the water heater system 400.

The user interface 404 may be a component of, for example, a remote controller in wireless communication with the controller 402 (e.g., via Wi-Fi communication module 434) and/or an input/output (IO) interface in wired communication with the controller 402 (e.g., via CTA-2045 communication module 432). One or more external component(s) may similarly be in wired and/or wireless communication with the controller 402. For example, gas valve controller 406 may be in wired or wireless communication with the controller 402 via the gas valve communication module 430. Gas valve controller 406 may communicate with temperature sensor 440 and flammable vapor (FV) sensor 442. Gas valve controller 406, temperature sensor 440, FV sensor 442, and/or gas valve 407 may receive power from power source 408 via transformer 444.

The temperature sensor 440 may be designed to determine one or more temperature(s) indicative of the temperature in the water tank. For example, the temperature sensor 440 may be a temperature probe adapted to extend into a water tank of the water heater system 400 and may be designed to determine one or more tank temperature(s) of the water tank. The FV sensor 442 may be designed to determine the presence of a flammable vapor proximate to the gas valve 407, which may pose a safety hazard (e.g., a gas leak). The temperature sensor 440 and/or the FV sensor 442 may be in communication with the gas valve controller 406 and/or the controller 402 via the gas valve communication module 430. Accordingly, the controller 402 may receive the tank temperature(s) generated by the temperature sensor 440 and/or the presence of a flammable vapor via the FV sensor 442 and send instructions to activate or deactivate the gas valve 407 as appropriate.

The power source 408 may provide power (e.g., electrical power) to the controller 402 and/or the gas valve 406 via the transformer 444. The transformer 444 may be required to provide power from the power source 408 to the gas valve 406 because the gas valve 406 may require a different voltage than the controller 402 to operate. For example, the gas valve controller 406, but not the controller 402, may operate at a different voltage than the 120-volt electricity supplied in a typical household setting.

Referring now to FIG. 5, example process flow 500 for determining to activate gas heating based on the temperature of water in a water tank and/or a heating setting or preference is illustrated. The water heater system in process flow 500 may be the same as or similar to hybrid water heater system 100 of FIG. 1, water heater system 214 of FIG. 2, water heater system 300 of FIG. 3, water heater system 400 of FIG. 4, and/or water heater system 601 of FIG. 6, or otherwise may be one or more of the water heater systems of FIGS. 1-5 and/or FIG. 6.

While example embodiments of the disclosure may be described in the context of a controller, it should be appreciated that the disclosure is more broadly applicable to various types of computing devices as well as a controller in combination with a computing device, such as gas valve controller, a server and/or smartphone. Some or all of the blocks of the process flows in this disclosure may be performed in a distributed manner across any number of devices. The operations of process flow 500 may be optional and may be performed in a different order.

At block 502, computer-executable instructions stored on a memory of a device, such as a controller, may be executed to determine a temperature setting. For example, the temperature setting may be requested and/or received from a remote controller or a user interface (e.g., touch screen) on the water heater system. The temperature setting may be indicative of a preferred temperature of water contained in a water tank of a water heater system.

At block 504, computer-executable instructions stored on a memory of a device, such as a controller, may be executed to determine the temperature of the water in the water tank. For example, the controller may instruct the gas valve controller to generate a temperature reading using a temperature probe of the gas valve assembly and the gas valve controller may send the temperature reading to the controller. Alternatively, or additionally, the controller may determine a temperature reading from a thermistor. The temperature may be above, below, or equal to the temperature setting determined at block 502. The controller may compare the temperature reading (e.g., measurement) to the temperature setting and/or to a threshold value based on the temperature setting (e.g., 0.9× temperature setting) and may determine the temperature reading does not satisfy the temperature setting (e.g., temperature reading may be below the temperature setting and/or threshold).

At block 506, computer-executable instructions stored on a memory of a device, such as a controller, may be executed to determine to activate gas heating based on the temperature of the water in the water tank and/or a heating preference, setting and/or threshold. For example, if the temperature of the water in the water tank determined at block 504 is below the temperature setting determined at block 502, a determination may be made to activate gas heating in order to heat the water in the water tank, thereby increasing the temperature of the water to a temperature equal to or above the temperature setting. Alternatively, a heating preference may be received, which may inform the determination to activate gas heating. For example, the heating preference may indicate a preference for an energy-saving mode of gas heating (i.e., instead of heat pump heating) or for achieving the temperature setting in the shortest amount of time via gas heating.

At block 508, computer-executable instructions stored on a memory of a device, such as a controller, may be executed to send instructions to the valve assembly to activate gas heating. The gas heating may be performed by a gas heating system, which may include a burner in fluid communication with a gas line. The gas line may further be in fluid communication with a gas valve of a valve assembly. Activating the gas heating may be achieved by transitioning the gas valve to an open position, thereby facilitating burning of gas contained in the gas line by the burner.

It is understood that standalone gas valve assemblies may be actuated by one or more signal(s) that facilitate one or more software protocol(s) associated with the valve assemblies. For example, standalone gas valve assemblies may allow for the movement of gas through a gas valve of the valve assembly once a signal indicating that a damper of a gas heating system has been opened. In certain embodiments described herein, however, one or more existing software protocol(s) may be leveraged by, for example, replacing the signal indicating that the damper is open with a signal from a controller to activate gas heating. Accordingly, the response of the gas heating system to the signal from the controller to activate gas heating is the same as or similar a signal indicating that the damper of a traditional gas heating system had been opened, resulting in the same result, actuating the gas valve to transition from a closed to an open position.

At block 510, computer-executable instructions stored on a memory of a device, such as a controller, may be executed to determine the temperature of the water contained in the water tank. Again, the controller may instruct the gas valve controller to generate a temperature reading using a temperature probe of the gas valve assembly and the gas valve controller may send the temperature reading to the controller. Alternatively, or additionally, the controller may determine a temperature reading from a thermistor.

At decision 512, computer-executable instructions stored on a memory of a device, such as a controller, may be executed to determine whether the temperature of the water in the water tank satisfies the temperature setting and/or threshold (e.g., similar to block 506). For example, the gas heating activated at block 508 may heat the water contained in the water tank such that the temperature of the water is above the temperature setting and/or threshold value determined at block 502.

If the temperature of the water tank satisfied the temperature setting and/or threshold is satisfied, at block 514, computer-executable instructions stored on a memory of a device, such as a controller, may be executed to send instructions to the valve assembly (e.g., to the gas valve controller) to deactivate gas heating. For example, instructions may be sent to the valve assembly (e.g., to the gas valve controller) to deactivate the gas heating. Deactivating the gas heating may be achieved by transitioning the gas valve to a closed position, thereby restricting the burner from burning the gas contained in the gas line. However, if the temperature of the water in the tank (e.g., the tank temperature) does not satisfy the temperature setting and/or threshold value determined at block 502, then block 510 may be repeated (e.g., after waiting a set period of time).

Referring now to FIG. 6, a schematic block diagram of an illustrative controller of a water heater system with a gas heating system and a heat pump is illustrated. Specifically, controller 600 may be incorporated into water heater system 601 and/or may communicate with water heater system 601, in accordance with one or more example embodiments of the disclosure. Controller 600 may be the same as or similar to controller 108 of FIG. 1, controller 308 of FIG. 3, and/or controller 402 of FIG. 4 or otherwise may be one or more of the controllers of FIGS. 1-5. Water heater system 601 may be the same as or similar to water heater system 100 of FIG. 1.

Controller 600 may be configured to communicate with one or more remote controllers, gas valve controllers, servers, mobile devices, user devices, other systems, or the like. Controller 600 may be configured to communicate via one or more networks. Such network(s) may include, but are not limited to, any one or more different types of communications networks such as, for example, cable networks, public networks (e.g., the Internet), private networks (e.g., frame-relay networks), wireless networks, cellular networks, telephone networks (e.g., a public switched telephone network), or any other suitable private or public packet-switched or circuit-switched networks.

In an illustrative configuration, controller 600 may include one or more processor(s) 602, one or more memory device(s) 604 (also referred to herein as memory 604), one or more input/output (I/O) interface(s) 606, one or more network interface(s) 608, one or more transceiver(s) 610, one or more antenna(s) 634, and data storage 620. The controller 600 may further include one or more bus(es) 618 that functionally couple various components of the controller 600.

The bus(es) 618 may include at least one of a system bus, a memory bus, an address bus, or a message bus, and may permit exchange of information (e.g., data (including computer-executable code), signaling, etc.) between various components of the controller 600. The bus(es) 618 may include, without limitation, a memory bus or a memory controller, a peripheral bus, an accelerated graphics port, and so forth. The bus(es) 618 may be associated with any suitable bus architecture.

The memory 604 may include volatile memory (memory that maintains its state when supplied with power) such as random-access memory (RAM) and/or non-volatile memory (memory that maintains its state even when not supplied with power) such as read-only memory (ROM), flash memory, ferroelectric RAM (FRAM), and so forth. Persistent data storage, as that term is used herein, may include non-volatile memory. In various implementations, the memory 604 may include multiple different types of memory such as various types of static random-access memory (SRAM), various types of dynamic random access memory (DRAM), various types of unalterable ROM, and/or writeable variants of ROM such as electrically erasable programmable read-only memory (EEPROM), flash memory, and so forth.

The data storage 620 may include removable storage and/or non-removable storage including, but not limited to, magnetic storage, optical disk storage, and/or tape storage. The data storage 620 may provide non-volatile storage of computer-executable instructions and other data. The memory 604 and the data storage 620, removable and/or non-removable, are examples of computer-readable storage media (CRSM) as that term is used herein. The data storage 620 may store computer-executable code, instructions, or the like that may be loadable into the memory 604 and executable by the processor(s) 602 to cause the processor(s) 602 to perform or initiate various operations. The data storage 620 may additionally store data that may be copied to memory 604 for use by the processor(s) 602 during the execution of the computer-executable instructions. Moreover, output data generated as a result of execution of the computer-executable instructions by the processor(s) 602 may be stored initially in memory 604, and may ultimately be copied to data storage 620 for non-volatile storage.

The data storage 620 may store one or more operating system(s) (O/S) 622; one or more optional database management system(s) (DBMS) 624; and one or more program module(s), applications, engines, computer-executable code, scripts, or the like such as, for example, one or more implementation module(s) 626, one or more temperature control module(s) 627, one or more valve actuation module(s) 629, and one or more communication module(s) 628. Some or all of these modules may be sub-modules. Any of the components depicted as being stored in data storage 620 may include any combination of software, firmware, and/or hardware. The software and/or firmware may include computer-executable code, instructions, or the like that may be loaded into the memory 604 for execution by one or more of the processor(s) 602. Any of the components depicted as being stored in data storage 620 may support functionality described in reference to correspondingly named components earlier in this disclosure.

Referring now to other illustrative components depicted as being stored in the data storage 620, the O/S 622 may be loaded from the data storage 620 into the memory 604 and may provide an interface between other application software executing on the controller 600 and hardware resources of the controller 600. More specifically, the O/S 622 may include a set of computer-executable instructions for managing hardware resources of the controller 600 and for providing common services to other application programs (e.g., managing memory allocation among various application programs). In certain example embodiments, the O/S 622 may control execution of the other program module(s) to for content rendering. The O/S 622 may include any operating system now known or which may be developed in the future including, but not limited to, any server operating system, any mainframe operating system, or any other proprietary or non-proprietary operating system.

The optional DBMS 624 may be loaded into the memory 604 and may support functionality for accessing, retrieving, storing, and/or manipulating data stored in the memory 604 and/or data stored in the data storage 620. The DBMS 624 may use any of a variety of database models (e.g., relational model, object model, etc.) and may support any of a variety of query languages. The DBMS 624 may access data represented in one or more data schemas and stored in any suitable data repository including, but not limited to, databases (e.g., relational, object-oriented, etc.), file systems, flat files, distributed datastores in which data is stored on more than one node of a computer network, peer-to-peer network datastores, or the like.

The optional input/output (I/O) interface(s) 606 may facilitate the receipt of input information by the controller 600 from one or more I/O devices as well as the output of information from the controller 600 to the one or more I/O devices. The I/O devices may include any of a variety of components such as a display or display screen having a touch surface or touchscreen; an audio output device for producing sound, such as a speaker; an audio capture device, such as a microphone; an image and/or video capture device, such as a camera; and so forth. Any of these components may be integrated into the controller 600 or may be separate.

The controller 600 may further include one or more network interface(s) 608 via which the controller 600 may communicate with any of a variety of other systems, platforms, networks, devices, and so forth. The network interface(s) 608 may enable communication, for example, with one or more wireless routers, one or more host servers, one or more web servers, and the like via one or more of networks.

The antenna(s) 634 may include any suitable type of antenna depending, for example, on the communications protocols used to transmit or receive signals via the antenna(s) 634. Non-limiting examples of suitable antennas may include directional antennas, non-directional antennas, dipole antennas, folded dipole antennas, patch antennas, multiple-input multiple-output (MIMO) antennas, or the like. The antenna(s) 634 may be communicatively coupled to one or more transceivers 610 or radio components to which or from which signals may be transmitted or received. Antenna(s) 634 may include, without limitation, a cellular antenna for transmitting or receiving signals to/from a cellular network infrastructure, an antenna for transmitting or receiving Wi-Fi signals to/from an access point (AP), a Global Navigation Satellite System (GNSS) antenna for receiving GNSS signals from a GNSS satellite, a Bluetooth antenna for transmitting or receiving Bluetooth signals including BLE signals, a Near Field Communication (NFC) antenna for transmitting or receiving NFC signals, a 900 MHz antenna, and so forth.

The transceiver(s) 610 may include any suitable radio component(s) for, in cooperation with the antenna(s) 634, transmitting or receiving radio frequency (RF) signals in the bandwidth and/or channels corresponding to the communications protocols utilized by the controller 600 to communicate with other devices. The transceiver(s) 610 may include hardware, software, and/or firmware for modulating, transmitting, or receiving-potentially in cooperation with any of antenna(s) 634—communications signals according to any of the communications protocols discussed above including, but not limited to, one or more Wi-Fi and/or Wi-Fi direct protocols, as standardized by the IEEE 802.11 standards, one or more non-Wi-Fi protocols, or one or more cellular communications protocols or standards. The transceiver(s) 610 may further include hardware, firmware, or software for receiving GNSS signals. The transceiver(s) 610 may include any known receiver and baseband suitable for communicating via the communications protocols utilized by the controller 600. The transceiver(s) 610 may further include a low noise amplifier (LNA), additional signal amplifiers, an analog-to-digital (A/D) converter, one or more buffers, a digital baseband, or the like.

Referring now to functionality supported by the various program module(s) depicted in FIG. 6, the implementation module(s) 626 may include computer-executable instructions, code, or the like that responsive to execution by one or more of the processor(s) 602 may perform functions including, but not limited to, overseeing coordination and interaction between one or more modules and computer executable instructions in data storage 620, determining user selected actions and tasks, determining actions associated with user interactions, determining actions associated with user input, initiating commands locally or at remote devices, and the like.

The temperature control module(s) 627 may include computer-executable instructions, code, or the like that, responsive to execution by one or more of the processor(s) 602, may perform functions including, but not limited to, requesting and/or receiving one or more temperature measurements of the water tank (e.g., from a temperature probe and/or thermistor) and sending instructions to turn on the heat pump system in order to achieve a temperature setting for the water tank.

The communication module(s) 628 may include computer-executable instructions, code, or the like that, responsive to execution by one or more of the processor(s) 602, may perform functions including, but not limited to, communicating with one or more devices, for example, via wired or wireless communication, communicating with remote controllers, mobile devices, communicating with servers (e.g., remote servers), communicating with remote datastores and/or databases, sending or receiving notifications or commands/directives, communicating with cache memory data, communicating with user devices, and the like.

The valve actuation module(s) 629 may include computer-executable instructions, code, or the like that, responsive to execution by one or more of the processor(s) 602, may perform functions including, but not limited to, communicating with the valve assembly and/or gas valve controller to cause the valve to transition from a closed position to an open position to permit gas to flow through the valve and into the burner.

Although specific embodiments of the disclosure have been described, one of ordinary skill in the art will recognize that numerous other modifications and alternative embodiments are within the scope of the disclosure. For example, any of the functionality and/or processing capabilities described with respect to a particular device or component may be performed by any other device or component. Further, while various illustrative implementations and architectures have been described in accordance with embodiments of the disclosure, one of ordinary skill in the art will appreciate that numerous other modifications to the illustrative implementations and architectures described herein are also within the scope of this disclosure.

Certain aspects of the disclosure are described above with reference to block and flow diagrams of systems, methods, apparatuses, and/or computer program products according to example embodiments. It will be understood that one or more blocks of the block diagrams and flow diagrams, and combinations of blocks in the block diagrams and the flow diagrams, respectively, may be implemented by execution of computer-executable program instructions. Likewise, some blocks of the block diagrams and flow diagrams may not necessarily need to be performed in the order presented, or may not necessarily need to be performed at all, according to some embodiments. Further, additional components and/or operations beyond those depicted in blocks of the block and/or flow diagrams may be present in certain embodiments.

Accordingly, blocks of the block diagrams and flow diagrams support combinations of means for performing the specified functions, combinations of elements or steps for performing the specified functions, and program instruction means for performing the specified functions. It will also be understood that each block of the block diagrams and flow diagrams, and combinations of blocks in the block diagrams and flow diagrams, may be implemented by special-purpose, hardware-based computer systems that perform the specified functions, elements or steps, or combinations of special-purpose hardware and computer instructions.

Program module(s), applications, or the like disclosed herein may include one or more software components, including, for example, software objects, methods, data structures, or the like. Each such software component may include computer-executable instructions that, responsive to execution, cause at least a portion of the functionality described herein (e.g., one or more operations of the illustrative methods described herein) to be performed.

A software component may be coded in any of a variety of programming languages. An illustrative programming language may be a lower-level programming language such as an assembly language associated with a particular hardware architecture and/or operating system platform. A software component comprising assembly language instructions may require conversion into executable machine code by an assembler prior to execution by the hardware architecture and/or platform.

Another example programming language may be a higher-level programming language that may be portable across multiple architectures. A software component comprising higher-level programming language instructions may require conversion to an intermediate representation by an interpreter or a compiler prior to execution.

Other examples of programming languages include, but are not limited to, a macro language, a shell or command language, a job control language, a script language, a database query or search language, or a report writing language. In one or more example embodiments, a software component comprising instructions in one of the foregoing examples of programming languages may be executed directly by an operating system or other software component without having to be first transformed into another form.

A software component may be stored as a file or other data storage construct. Software components of a similar type or functionally related may be stored together such as, for example, in a particular directory, folder, or library. Software components may be static (e.g., pre-established or fixed) or dynamic (e.g., created or modified at the time of execution).

Software components may invoke or be invoked by other software components through any of a wide variety of mechanisms. Invoked or invoking software components may comprise other custom-developed application software, operating system functionality (e.g., device drivers, data storage (e.g., file management) routines, other common routines, and services, etc.), or third-party software components (e.g., middleware, encryption, or other security software, database management software, file transfer or other network communication software, mathematical or statistical software, image processing software, and format translation software).

Software components associated with a particular solution or system may reside and be executed on a single platform or may be distributed across multiple platforms. The multiple platforms may be associated with more than one hardware vendor, underlying chip technology, or operating system. Furthermore, software components associated with a particular solution or system may be initially written in one or more programming languages, but may invoke software components written in another programming language.

Computer-executable program instructions may be loaded onto a special-purpose computer or other particular machine, a processor, or other programmable data processing apparatus to produce a particular machine, such that execution of the instructions on the computer, processor, or other programmable data processing apparatus causes one or more functions or operations specified in the flow diagrams to be performed. These computer program instructions may also be stored in a CRSM that upon execution may direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means that implement one or more functions or operations specified in the flow diagrams. The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational elements or steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process.

Additional types of CRSM that may be present in any of the devices described herein may include, but are not limited to, programmable random access memory (PRAM), SRAM, DRAM, RAM, ROM, electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, compact disc read-only memory (CD-ROM), digital versatile disc (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the information and which can be accessed. Combinations of any of the above are also included within the scope of CRSM. Alternatively, computer-readable communication media (CRCM) may include computer-readable instructions, program module(s), or other data transmitted within a data signal, such as a carrier wave, or other transmission. However, as used herein, CRSM does not include CRCM.

Although embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the disclosure is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the embodiments. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.

Systems and Methods for Controlling Hybrid Gas Water Heater Systems Including a Gas Valve

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