Patent Application
20190024944
Embodiments relate to water heaters.
Water heating systems may include a hot water storage tank, an external heater, a circulation pump, and a tank thermostat. Some external heaters include tank thermostats that are set below the setpoint of the external heater by a set number (for example, 10° F.). This method may not provide optimal tank temperature regulation. For example, when there is a hot water draw, depending on the location of the tank thermostat, the circulation pump may be activated quickly even if the majority of the storage tank is full of hot water. When the amount of hot water discharge is small, the external heater would rapidly turn off. This may result in short cycling both the pump and the external heater. In addition, depending on the setpoint of the external heater, hot water may enter the inlet of the external water heater, reducing energy efficiency.
Therefore, in one embodiment, the application provides a water heater including a storage tank including a water inlet and a water outlet, a pump, an upper temperature sensor configured to sense an upper temperature related to an upper area of the tank and output an upper temperature signal corresponding to the upper temperature, a lower temperature sensor configured to sense a lower temperature related to a lower area of the tank and output a lower temperature signal corresponding to the lower temperature, and an electronic processor. The electronic processor is configured to receive an upper temperature signal and a lower temperature signal, compare the upper temperature signal to a sum of a setpoint temperature threshold minus a temperature differential, and compare the lower temperature signal to a high limit temperature threshold. The electronic processor is further configured to activate the pump in response to the first upper temperature signal being less than the sum of the setpoint temperature threshold minus the temperature differential and the first lower temperature signal being less than the predetermined high limit temperature threshold.
In another embodiment, the application provides a method of operating a water heater including a storage tank including a water inlet and a water outlet, a pump, an upper temperature sensor configured to sense an upper temperature related to an upper area of the tank and output an upper temperature signal corresponding to the upper temperature, and a lower temperature sensor configured to sense a lower temperature related to a lower area of the tank and output a lower temperature signal corresponding to the lower temperature. The method includes receiving a first upper temperature signal and a first lower temperature signal, comparing the first upper temperature signal to a sum of a setpoint temperature threshold minus a temperature differential, comparing the first lower temperature signal to a high limit temperature threshold, and activating the pump in response to the first upper temperature signal being less than the sum of the setpoint temperature threshold minus the temperature differential and the first lower temperature signal being less than the predetermined high limit temperature threshold.
Other aspects of the application will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the application are explained in detail, it is to be understood that the application is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawing. The application is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
The water heater system 100 may further include a cold water inlet opening 120, a hot water inlet opening 125, a water t-valve 126, a hot water outlet 127, an upper temperature sensor 130, a lower temperature sensor 135, an external heater 140, a circulation pump (or valve) 145, and a controller 150. A cold water source 155 provides cold water to the water tank 105 through the cold water inlet opening 120. The cold water source 155 also delivers cold water to the external heater 140 through the circulation pump 145. The circulation pump 145 may be controlled by the controller 150. When the circulation pump 145 is active, the external heater 140 receives the cold water and heats the cold water to a predetermined temperature. From the external heater 140, the water is then delivered to the water t-valve 126, which directs the water to the water tank 105, via hot water inlet opening 125, or to a user, via hot water outlet 127.
The upper temperature sensor 130 may be positioned in the upper portion of the water tank 105 to determine a temperature of the water stored in the upper portion of the water tank 105. Analogously, the lower temperature sensor 135 may be positioned in the lower portion of the water tank 105 to determine a temperature of the water in the lower portion of the water tank 105. The upper temperature sensor 130 and the lower temperature sensor 135 may be attached to the water tank 105, and may include, for example, thermistor type sensors. The upper temperature sensor 130 and the lower temperature sensor 135 may be electrically and/or communicatively coupled to the controller 150 to periodically provide the sensed temperatures to the controller 150. In some embodiments, the water tank 105 may include more temperature sensors to provide a more accurate indication of the temperature of water inside the water tank 105. For example, the water tank 105 may be divided into three or more portions and a temperature sensor may be positioned in each portion. The distance between the upper temperature sensor 130 and the lower temperature sensor 135 may be determined based on the geometry of the tank, a desired tank recovery, and the water stratification pattern inside the water tank 105. In some embodiments, the shorter the distance between sensors 130 and 135, the sooner the external heater 140 and circulation pump 145 may activate (when implementing a control method 300 described in
The controller 150 is electrically and/or communicatively coupled to the upper temperature sensor 130, the lower temperature sensor 135, and the circulation pump 145. In some embodiments, the controller 150 is also electrically and/or communicatively coupled to the external heater 140. The controller 150 receives the temperature signals from the upper temperature sensor 130 and the lower temperature sensor 135. Based on the received temperature signals, the controller 150 may control the operation of the external heater 140 and/or the circulation pump 145 as described in detail below.
The electronic processor 205 is communicatively coupled to the memory 210 and to the input/output device 215. The electronic processor 205 receives information regarding the operation of the water heater system 100 through the input/output devices 215. The electronic processor 205 may receive command signals received from the user interface 230 or a network and determine control signals based on the command signals received. The electronic processor 205 may then output the control signals to the input/output devices 215.
The memory 210 is configured to store algorithms and/or programs used to control the circulation pump 145, the external heater 140, and other components of the water heater system 100. The memory 210 may also store historical data, usage patterns, and the like to help control the water heater system 100. The memory 210 also stores the control method 300 described in
The input/output devices 215 output information to the user regarding the operation of the water heater system 100 and may also receive inputs. The controller 150 communicates (via wireless or wired connection) with the upper temperature sensor 130, the lower temperature sensor 135, the external heater 140, and the circulation pump 145 via the input/output devices 215. In some embodiments, the input/output devices 215 may include the user interface 230 for the water heater system 100. The input/output devices 215 may include a combination of digital and analog input or output devices required to achieve level of control and monitoring for the water heater system 100. For example, the input/output devices 215 may include a touch screen, a speaker, buttons, and the like to receive user input regarding the operation of the water heater system 100 (for example, a temperature set point at which water is to be delivered from the water tank 105). The electronic processor 205 also outputs information to the user in the form of, for example, graphics, alarm sounds, and/or other known output devices. The input/output devices 215 may be used to control and/or monitor the water heater system 100. For example, the input/output devices 215 may be operably coupled to the controller 150 to control temperature settings of the water heater system 100. For example, using the input/output devices 215, a user may set one or more temperature set points for the water heater system 100.
The input/output devices 215 are configured to display conditions, or data, associated with the water heater system 100 in real-time or substantially real-time. For example, but not limited to, the input/output devices 215 may be configured to display the temperature sensed by temperature sensors 130, 135. The input/output devices 215 may be mounted on the shell 110 of the water heater system 100, remotely from the water heater system 100 in the same room (e.g., on a wall), in another room in the building, or even outside of the building. In some embodiments, the input/output devices 215 may also generate alarms regarding the operation of the water heater system 100. The input/output devices 215 allow the controller 150 to communicate with the upper temperature sensor 130, the lower temperature sensor 135, the circulation pump 145 and the external heater 140.
In some embodiments, T_setpoint is a measured temperature from a sensor, for example the upper sensor 130, received by the controller 150. In some embodiments, where the controller 150 is communicatively coupled to the external heater 140, T_setpoint may be a set desired temperature of water at the outlet of the external heater 140 selected by an operator of the water heater system 100 (for example, via the user interface 230).
After the circulation pump 145 is activated at block 308, hot water is supplied to the water tank 105 and the method 300 returns to block 302. When the system starts from a cold tank, T_upper is less than T_setpoint-T_diff. As the external heater 140 continues to run and the circulation pump 145 supplies hot water to the water tank 105, the hot water within the water tank 105 rises to the upper portion of the tank. The water within the lower portion of the water tank 105 will remain at a constant, lower temperature as a result of the hot water entering the water tank 105 stratifying to the top of the water tank. The hot water stratification continues until the temperature of water in the upper portion of the water tank 105 reaches an approximately constant temperature. At this point, the water in the lower portion of the water tank 105 will increase in temperature, causing T_lower to increase.
Once it is determined that T_lower is greater than or equal to T_HL (block 306), and it is determined that the pump is active (block 310), a determination is made whether a rate of temperature of T_lower is increasing and a difference between T_upper and T_lower ( T_delta) is decreasing (block 311). At block 311, the controller 150 may determine if T_lower is increasing and if T_delta is decreasing by collecting multiple readings of T_upper and T_lower for a predetermined time from the upper temperature sensor 130 and the lower temperature sensor 135 respectively. When the controller 150 determines T_lower is increasing and T_delta is decreasing, the circulation pump 145 and external heater 140 are deactivated and the water heater 100 is placed into a standby mode (block 312). When the controller 150 determines T_lower is not increasing and/or T_delta is not decreasing, the controller 150 returns to block 302. When the controller 150 determines that the circulation pump 145 is not active (block 310), the controller 150 returns to block 302. At block 312, when the water heater 100 is placed into the standby mode, the controller 150 returns to block 302.
In some embodiments, the controller 150 is not communicatively coupled to the external heater 140. In such embodiments, when the desired outlet temperature is set at the external heater 140, the desired outlet temperature of the external heater 140 may be adjusted to a temperature greater than the current T_setpoint, stored by the controller 150, minus T_diff (block 304). A hot water draw may reduce T_lower to be less than T_HL while T_upper remains the same, which may lead to short cycling of the water heater. To prevent short cycling, the controller 150 determines if T_lower is less than T_HL (block 314). When the controller 150 determines that T_lower is less than T_HL, the controller further determines if the circulation pump 145 is activated (block 316). When the controller 150 determines the circulation pump 145 is activated, it returns to block 302; when the controller 150 determines that the circulation pump 145 is not activated, the controller 150 continues to keep the circulation pump 145 deactivated and the water heater 100 remains in the standby mode (block 312). When the controller 150 determines that T_lower is greater than or equal to T_HL (block 314), the controller 150 returns to block 312 and then block 302.
While the water heater system 100 is in the standby mode, the controller 150 updates T_setpoint and T_HL. In some embodiments, T_setpoint is updated based on a maximum temperature sensed by the upper temperature sensor 130 while in the standby mode. In some embodiments, T_setpoint is set by an operator of the water heater system 100 (for example, via the user interface 230) and is associated with the outlet temperature of the external heater 140. In some embodiments, T_HL is a predetermined default value automatically set based on a set temperature of the external heater 140. In further embodiments, the operator of the water heater system 100 is able to configure T_HL to be higher (or lower) than the predetermined default value.
The method 300 may be applied to other types, configurations, geometries, and sizes of water heaters beyond what is illustrated. Such embodiments may include more than one tank, external heater, sensors, pumps, and the like. Depending on such characteristics of the water heater, additional steps may be added to the method 300. For example,
When it is determined at block 310 that the circulation pump 145 is not activated, T_upper is compared to T_setpoint (block 502). When T_upper is greater than or equal to T_setpoint (block 502), the circulation pump 145 and the external heater 140 are deactivated and the water heater 400 is placed into the standby mode (block 506) and the controller 150 returns to block 302. When T_upper is less than T_setpoint (block 502), T_lower is compared to a second high limit temperature threshold T_HL2 at block 504. When T_lower is greater than T_HL2 (block 504), the circulation pump 145 and external heater 140 are deactivated and the water heater 400 is placed into the standby mode (block 506).
When T_lower is less than T_HL2 and circulation pump 145 is activated, T_lower is compared to T_HL at block 508. When T_lower is less than T_HL (block 508), the controller 150 returns to block 302. When T_lower is greater than or equal to T_HL (block 508), the controller 150 may determine if T_lower is increasing and if T_delta is decreasing (block 510).
At block 510, the controller 150 may determine if T_lower is increasing and if T_delta is decreasing by collecting multiple readings of T_upper and T_lower for a predetermined time from the upper temperature sensor 130 and the lower temperature sensor 135 respectively. When the controller 150 determines T_lower is increasing and T_delta is decreasing (block 510), the circulation pump 145 and external heater 140 are deactivated and the water heater 400 is placed into the standby mode (block 506). When the controller 150 determines T_lower is not increasing and/or T_delta is not decreasing (block 510), the controller 150 receives another T_upper from the upper temperature sensor 130 and another T_lower from the lower temperature sensor 135 (block 512) and returns to block 505.
Within the control method 500, when there is an external hot water draw (a hot water draw not by the recirculation loop 402) that causes T_lower to be less than T_HL, the controller 150 may execute only the blocks within the control method 500 that are in control method 300 (blocks 302, 304, 306, 308, 310, 311, and 312).
The controller 150 may include additional features to aid in the efficiency of the water heater system 100. In some embodiments, the controller 150 is further configured to drive a modulation pump. For example, when the upper temperature sensor 130 senses the temperature in the upper area of the tank approaching T_setpoint, the controller 150 modulates down the pump so to reduce the flow rate running through the external heater 140.
Various features and advantages of the application are set forth in the following claims.
