Patent Application
20180163991
The present subject matter relates generally to heat pump water heater appliances.
Heat pump water heaters are gaining broader acceptance as a more economic and ecologically-friendly alternative to electric water heaters. These systems utilize a condenser configured in a heat exchange relationship with a water storage tank, for example wrapped around the tank in a series of coils. During operation of the vapor compression heat pump cycle, air flows across an evaporator and transfers energy to a refrigerant flowing through the evaporator. As such, the refrigerant exits the evaporator as a superheated vapor and/or high quality vapor mixture. Upon exiting the evaporator, the refrigerant enters a compressor where the pressure and temperature increase and the refrigerant becomes a superheated vapor. The superheated vapor from the compressor then enters the condenser, wherein the superheated vapor transfers energy to the water within a storage tank and returns to a saturated liquid and/or high quality liquid vapor mixture.
As heat is absorbed from the air flowing over the evaporator, condensation forms which must be collected and discharged. Thus, certain heat pump water heaters include a condensate pump for discharging collected condensate to an external drain. Notably, the exposure of a heat pump water heater to consistently wet conditions or to excessive wet/dry cycles can lead to performance issues for the heat pump water heater, such as component corrosion, refrigerant loss, decreased efficiency, and potential failure of the sealed system. However, predicting such failures and scheduling preventative or corrective maintenance can require frequent monitoring or result in unnecessary service visits.
Accordingly, a heat pump water heater appliance with features for recommending maintenance or service visits would be useful. More specifically, a heat pump water heater having an integral means for monitoring the amount of wet operation and recommending corrective action would be particularly beneficial.
The present disclosure provides a heat pump water heater and a method for servicing the heat pump water heater. The heat pump water heater includes an evaporator, a condensate collection tray, and a condensate pump for discharging collected condensate. Notably, the operating time of the condensate pump correlates to the amount of wet operation of heat pump water heater, and increased wet operation may correlate to corrosion and wear on the heat pump water heater. Therefore, an exemplary method contemplates determining an operating time of the condensate pump and, based on the operating time, determining and communicating a recommended service schedule. In addition, an operating parameter of the heat pump water heater may be adjusted, such as switching to electric heating when the operating time exceeds a predetermined threshold. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
In a first exemplary embodiment, a method for servicing a heat pump water heater is provided. The heat pump water heater includes a compressor, a condenser, and an evaporator. The method includes determining an operating time of a condensate pump of the heat pump water heater, the condensate pump being in fluid communication with a condensate collection tray for discharging condensate collected from the evaporator of the heat pump water heater and determining, based on the operating time of the condensate pump, a recommended service schedule for the heat pump water heater. The method further includes communicating the recommended service schedule.
In a second exemplary embodiment, a water heater appliance defining a vertical direction if provided. The water heater appliance includes an evaporator being configured to absorb heat and produce condensate and a condensate collection tray disposed under the evaporator along the vertical direction and being configured for collecting the condensate from the evaporator. A condensate pump is in fluid communication with the condensate collection tray, the condensate pump being configured for discharging the condensate from the condensate collection tray through a condensate discharge line. A controller is configured for determining an operating time of the condensate pump and determining, based on the operating time, a recommended service schedule for the heat pump water heater. The controller is further configured for communicating the recommended service schedule.
In a third exemplary embodiment of the present subject matter, a method for servicing a heat pump water heater including a compressor, a condenser, and an evaporator is provided. The method includes determining a pump operating value of a condensate pump of the heat pump water heater, the condensate pump being in fluid communication with a condensate collection tray for discharging condensate collected from the evaporator of the heat pump water heater and determining, based on the pump operating value of the condensate pump, a recommended service schedule for the heat pump water heater. The method further includes communicating the recommended service schedule.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
The casing 106 may be formed from a variety of components. As illustrated, the casing 106 may include a wrapper 116, one or more covers, such as a top cover 118 and a bottom cover 120, and a shroud 122 as illustrated. The shroud 122 may be positioned at the top portion 110 of the tank 108 along the vertical direction V such that the shroud 122 defines a chamber 124 (
Upper and lower heating elements 130, 132 (
The water heater appliance 100 also includes an inlet or cold water conduit 136 and an outlet or hot water conduit 138 that are both in fluid communication with a chamber or interior volume 114 (
As mentioned above, the water heater appliance 100 extends longitudinally between the top portion 102 and the bottom portion 104 along the vertical direction V. Thus, the water heater appliance 100 is generally vertically oriented. The water heater appliance 100 can be leveled, e.g., such that the casing 106 is plumb in the vertical direction V, in order to facilitate proper operation of the water heater appliance 100. It should be understood that the water heater appliance 100 is provided by way of example only and that the present subject matter may be used with any suitable water heater appliance, including for example any heat pump water heater appliance.
The sealed system 134 may include a compressor 140, a condenser 142 and an evaporator 144. The compressor 140 and/or evaporator 144 of the sealed system 134 may be disposed within the casing 106 at the top portion 102 of the water heater appliance 100, e.g., within the machinery compartment or shroud 122. As is generally understood, various conduits may be utilized to flow refrigerant between the various components of the sealed system 134. Thus, e.g., the evaporator 144 may be between and in fluid communication with the condenser 142 and the compressor 140. During operation of the sealed system 134, refrigerant may flow from the evaporator 144 through the compressor 140. For example, refrigerant may exit the evaporator 144 as a fluid in the form of a superheated vapor and/or high quality vapor mixture. Upon exiting the evaporator 144, the refrigerant may enter the compressor 140. The compressor 140 may be operable to compress the refrigerant. Accordingly, the pressure and temperature of the refrigerant may be increased in the compressor 140 such that the refrigerant becomes a superheated vapor.
The condenser 142 may be assembled in a heat exchange relationship with the tank 108 in order to heat water within the interior volume 114 of the tank 108 during operation of the sealed system 134. In particular, the condenser 142 may be positioned downstream of and in fluid communication with the compressor 140, and may be operable to heat the water within the interior volume 114 using energy from the refrigerant. For example, the superheated vapor from the compressor 140 may enter the condenser 142 wherein it transfers energy to the water within the tank 108 and condenses into a saturated liquid and/or liquid vapor mixture.
The sealed system 134 may also include a throttling device 146 between the condenser 142 and the evaporator 144. Refrigerant, which may be in the form of high quality/saturated liquid vapor mixture, may exit the condenser 142 and travel through the throttling device 146 before flowing through the evaporator 144. The throttling device 146 may generally expand the refrigerant, lowering the pressure and temperature thereof. The refrigerant may then be flowed through the evaporator 144.
The throttling device 146 may be any suitable components for generally expanding the refrigerant. For example, in some exemplary embodiments, the throttling device 146 may be a Joule-Thomson expansion valve, also known as a “J-T valve.” In other exemplary embodiments, throttling device 146 may be an ejector. In still other exemplary embodiments, an electronic expansion valve, a capillary tube, a fixed orifice, or any other suitable apparatus may be utilized as throttling device 146.
The water heater appliance 100 may additionally include a tank temperature sensor 148. The tank temperature sensor 148 may be configured for measuring a temperature of water within the interior volume 114 of the tank 108. The tank temperature sensor 148 can be positioned at any suitable location within the water heater appliance 100. For example, the tank temperature sensor 148 may be positioned within the interior volume 114 of the tank 108 or may be mounted to the tank 108 outside of the interior volume 114 of the tank 108. The tank temperature sensor 148 may further be positioned within an upper portion of the tank 108. Alternatively, the tank temperature sensor 148 may be positioned within a lower portion of the tank 108. When mounted to the tank 108 outside of the interior volume 114 of the tank 108, the tank temperature sensor 148 can be configured for indirectly measuring the temperature of water within the interior volume 114 of the tank 108. For example, the tank temperature sensor 148 can measure the temperature of the tank 108 and correlate the temperature of the tank 108 to the temperature of water within the interior volume 114 of the tank 108. The tank temperature sensor 148 may be any suitable temperature sensor. For example, the tank temperature sensor 148 may be a thermocouple, a thermistor, or a resistance temperature detector.
In addition, water heater appliance 100 may additionally include an air temperature sensor 150. The air temperature sensor 150 may be configured for measuring a temperature of ambient air within the environment in which water heater appliance 100 is located. The air temperature sensor 150 can be positioned at any suitable location within or around water heater appliance 100. For example, the air temperature sensor 150 may be positioned at an inlet of evaporator 144, within chamber 124, or outside casing 106. The air temperature sensor 150 may be any suitable temperature sensor. For example, the air temperature sensor 150 may be a thermocouple, a thermistor, or a resistance temperature detector.
The water heater appliance 100 may further include a controller 154 that regulates operation of the water heater appliance 100. The controller 154 may be, for example, in operative communication with sealed system 134 (such as compressor 140, and/or other components thereof), auxiliary heating elements 130, 132, and/or tank temperature sensor 148. Thus, the controller 154 can selectively activate the sealed system 134 and/or auxiliary heating elements 130, 132 in order to heat water within interior volume 114 of tank 108.
The controller 154 includes memory and one or more processing devices such as microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of water heater appliance 100. The memory can represent random access memory such as DRAM, or read only memory such as ROM or FLASH. The processor executes programming instructions stored in the memory. The memory can be a separate component from the processor or can be included onboard within the processor. Alternatively, the controller 154 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.
Controller 154 may further include a user interface panel or control panel 156 through which a user may select various operational features and modes and monitor the operation of water heater appliance 100. In one embodiment, the user interface 156 may represent a general purpose I/O (“GPIO”) device or functional block. In one embodiment, the user interface 156 may include input components, such as one or more of a variety of electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. The user interface 156 may include a display component, such as a digital or analog display device 157 designed to provide operational feedback to a user. The user interface 156 may be in communication with the controller 154 via one or more signal lines or shared communication busses.
Water heater appliance 100 may further be communicatively coupled to a network 158 for sending and/or receiving information. Network 158 can be any type of communication network. For example, network 158 can include one or more of a wireless network, a wired network, a personal area network, a local area network, a wide area network, the internet, etc. Controller 154 may be used to establish communications with network 158. In this regard, for example, controller 154 may include a communications module to facilitate communications between controller 154 and network 158. For instance, the communications module of controller 154 may serve as an interface to permit water heater appliance 100 to transmit a service request, a notification of a condition to a user, diagnostic information, or to receive information, like a command to adjust an operating parameter of water heater appliance 100.
During operation of water heater appliance, evaporator 144 is generally configured to absorb heat, e.g., to increase the temperature of the refrigerant. As a result, condensation forms on evaporator 144. For example, condensation may form as a result of latent heat released by the water vapor in the ambient air that is passed through evaporator 144. In addition, the relative humidity of the air passed through evaporator 144 is decreased as the air is cooled by the coils of evaporator 144 and condensate is formed. As described in more detail below, the apparatus and methods discussed herein provide a useful method of using water heater appliance 100, e.g., evaporator 144, for predicting necessary maintenance procedures and/or recommending maintenance schedules.
Referring now to
Drain pump assembly 160 generally includes a condensate collection tray 162 and a drain pump 164, each of which will be described below according to an exemplary embodiment of the present subject matter. According to the illustrated embodiment, condensate collection tray 162 is positioned below evaporator 144 of water heater appliance 100 along the vertical direction V. As condensate forms on evaporator 144, it falls into condensate collection tray 162 where it is collected and prevented from falling into chamber 124 or over casing 106. By collecting the condensate, it may be discharged to a suitable drain, such as external drain 166.
According to an exemplary embodiment, condensate collection tray 162 may define a discharge port 170 through which condensate may be pumped by drain pump 164 to external drain 166. As illustrated, drain pump 164 is positioned outside condensate collection tray 162 and includes a pump inlet 172 in fluid communication with condensate collection tray 162. In this regard, drain pump 164 is configured for drawing out and discharging condensate from condensate collection tray 162 through a condensate discharge line 174. According to one embodiment, condensate collection tray 162 may be sloped or can define a low region for collecting condensate near pump inlet 172. In order to prevent backflow of condensate into the condensate collection tray 162, drain pump assembly 160 may further include a check valve 176 positioned on condensate discharge line 174. Any suitable type of check valve or one-way valve may be used to stop the backflow and check valve 176 may be placed at any suitable location downstream of pump inlet 172.
Although drain pump 164 is illustrated as being positioned outside condensate collection tray 162 and outside of chamber 124 and shroud 122, according to alternative embodiments, drain pump 164 could be positioned in any other suitable location where it is in fluid communication with condensate collection tray 162. For example, according to alternative embodiments, drain pump 164 may be located within shroud 122 and may be mounted directly to condensate collection tray 162. Thus, pump inlet 172 draws condensate directly from condensate collection tray 162 and discharges to external drain 166. In this regard, condensate discharge line 174 may be routed through discharge port 170, or discharge port 170 may be plugged or removed and condensate discharge line 174 may extend up out of condensate collection tray 162 and through shroud 122. Other configurations for condensate collection tray 162, drain pump 164, and condensate discharge configurations in general are possible and within the scope of the present subject matter.
According to the illustrated exemplary embodiment, drain pump 164 is a peristaltic pump mounted to the outside of water heater 100 by discharge port 170. However, it should be appreciated that drain pump 164 may be any suitable type of fluid pump having any size, configuration, or position suitable for drawing condensate from condensate collection tray 162 and discharging it through condensate discharge line 174.
According to an exemplary embodiment, drain pump assembly 160 may further include a condensate level sensor 180 that is generally configured for measuring a level of condensate within condensate collection tray 162. Condensate level sensor 180 may be operably coupled with controller 154 to provide an indication of when condensate needs to be discharged from condensate collection tray 162. Condensate level sensor 180 may be any suitable type of water level sensor, such as a float sensor, a capacitive sensor, an optical sensor, a reed switch, etc.
The present disclosure is further directed to methods 200 for operating water heater appliances. Method 200 can be used to operate any suitable water heater system or water consuming appliance, such as a heat pump water heater. For example, method 200 may be utilized to operate water heater appliance 100 (
As used herein, “wet” operations or cycles may generally refer to those operating times or cycles when a threshold amount of condensate is produced during operation of the sealed system of the heat pump water heater. For example, an operating cycle that necessitates use of the condensate pump to discharge collected condensate may be referred to as a “wet cycle.” By contrast, “dry” operations or cycles may generally refer to those operating times or cycles when little or no condensate is collected in the condensate collection tray. Notably, the thresholds of what is deemed a wet or dry cycle may vary according to various embodiments of the present subject matter.
Referring now specifically to
As used herein, “pump operating value” may refer to a measure of the frequency and magnitude of operation of the condensate pump. For example, according to one embodiment, the pump operating value is a cumulative operating time of the condensate pump over a lifetime of the condensate pump. In this manner, the pump operating value, i.e., the pump operating time, can provide an indication of the cumulative amount of exposure of the sealed system and the heat pump water heater to wet conditions. According to an alternative embodiment, the pump operating value is a cumulative cycle count of wet/dry cycles over a lifetime of the condensate pump. In this regard, a controller can count the number of times the sealed system experiences a wet cycle and is allowed to dry before the next wet cycle. Such a count of the number of wet/dry cycles can also provide an indication of the cumulative usage of the heat pump water heater and be used to predict corrosion or premature wear on the components of the heat pump water heater.
Method 200 further includes, at step 220, determining, based on the pump operating value of the condensate pump, a recommended service schedule for the heat pump water heater. Notably, the exposure of a heat pump water heater to consistently wet conditions or to an excessive number of wet/dry cycles can lead to performance issues for the heat pump water heater. In this regard, for example, constant exposure of a sealed system to an excessively humid environment or increased wet cycle operation increases the likelihood of corrosion and may lead to refrigerant loss, decreased efficiency, and potential failure of the sealed system. Similarly, large accumulative exposure to wet/dry cycling over a time period can cause similar issues.
According to an exemplary embodiment, the relationship between exposure to such “wet” conditions and corrosion or maintenance requirements may be established in a database. For example, a look-up table may be preprogrammed into the appliance controller and may be used to provide a service recommendation based on the number of hours the condensate pump has operated. It should be appreciated, however, that other means for defining such a relationship are possible and within the scope of the present subject matter. For example, the relationship may be embodied in a mathematical equation, may be retrieved from an internet database, etc.
To quantify the amount of wet operation of the sealed system and the heat pump water heater, the appliance controller can monitor the operation of the condensate pump. In this regard, the time of operation of the condensate pump corresponds to the amount of condensate collected (and the general humidity of the ambient environment). In addition, the number of wet/dry cycles can correspond to fluctuations in the humidity of the ambient environment and/or the operation of the heat pump water heater or the condensate pump. Therefore, by monitoring the operation of the condensate pump for tracking the extent of wet operation of the sealed system, the heat pump water heater can proactively diagnose potential problems and recommend a service visit, maintenance schedule, or other remedial action if needed.
Method 200 further includes, at step 230, communicating the recommended service schedule. The communication may be made from the heat pump water heater in any manner and to any person or entity. For example, according to one exemplary embodiment, the communication may be a command or indication using a display 157 on the user interface panel 156 of the heat pump water heater 100. More specifically, controller 154 may be configured for transmitting a signal to display 157 for illuminating a service indicator, providing a maintenance command, etc. Such an indication may be intended for the user of the appliance so that they may inspect or repair the appliance, or to a third party maintenance technician performing such maintenance.
According to an alternative embodiment, the recommended service schedule may be communicated to a third party, such as a maintenance service provider, via the internet. In this regard, for example, controller 154 may be used to establish communications with the internet, e.g., via network 158 as described above. The information communicated may include specific maintenance needs, diagnostic information, or other procedures. In addition, an appointment for a maintenance visit from the maintenance service provider could be scheduled and a notification of the appointment may be forwarded to the user of the appliance.
In this manner, using the relationship between wet operation and corrosion or wear on the heat pump water heater, a recommended maintenance or service schedule may be determined and communicated without requiring frequent and unnecessary service visits or maintenance checks. For example, if the magnitude of wet operation or wet/dry cycles has been abnormally high over the lifetime of the heat pump water heater, a maintenance visit may be scheduled earlier than usual to inspect and/or repair the heat pump water heater. By contrast, if the magnitude of wet operation or wet/dry cycles has been abnormally low over the lifetime of the heat pump water heater, a routine maintenance visit may be delayed until a later date or until the number of condensate pump operating hours exceeds some predetermined threshold.
According to an exemplary embodiment, method 200 further includes, at step 240 adjusting an operating parameter of the heat pump water heater when the pump operating value exceeds a predetermined threshold. For example, if the pump operating value is the operating time of the condensate pump, an operating parameter may be adjusted when the operating time exceeds some predetermined time threshold, e.g., 100 hours or 500 hours. According to an exemplary embodiment, adjusting the operating parameter of the heat pump water heater comprises switching off the compressor and operating an electric heating element. The heat pump water heater may thereafter operate using only the electric heating element until the sealed system is serviced and/or repaired. However, it should be appreciated that according to alternative embodiments, any suitable operating parameter of the heat pump water heater or the sealed system may be adjusted. For example, the compressor might be adjusted to operate only at half speed, a cycle time could be decreased, or the heat pump water heater may be shut down altogether.
The heat pump water heater and method of operation described above provide an integrated and effective means for recommending and communicating a maintenance or service schedule for a heat pump water heater. The method may ensure proper, timely maintenance of the heat pump water heater while eliminating premature or unnecessary service visits or maintenance checks. It should be appreciated that aspects of water heater appliance 100 described herein are used only for the purpose of explaining aspects of the present subject matter. Other configurations are possible and within the scope of the present subject matter.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
