Typical water heaters attempt to maintain the temperature of water within a tank within a desired range. To control the water temperature, a controller selectively activates and deactivates one or more heating elements submerged in the water based on one or more temperature sensors located in close proximity of the heating elements. When a heating element is activated, electricity is passed through the heating element to generate heat, which warms the water surrounding the heating element.
One potential problem associated with water heaters having electrical heating elements is the destruction of an element resulting from a dry fire condition. A dry fire condition exists when a heating element is not submerged in water. Such a condition may exist due to improper installation, repair, or operation of the water heater. For example, not realizing that the tank of a water heater is empty, a technician may activate a controller of the water heater before filling the tank with water. If power is applied to a heating element when it is not submerged in water, the heating element can quickly heat to an extremely high temperature resulting in damage to the heating element and/or other components of the water heater.
U.S. Pat. No. 6,649,881 describes exemplary techniques for detecting dry fire conditions and preventing such conditions from damaging components of a water heater. In an embodiment described by U.S. Pat. No. 6,649,881, a heating element is activated for only a short period of time, and temperatures sensed by a temperature sensor in close proximity to the heating element are measured to detect whether a dry fire condition exists. In this regard, a first temperature sensed before or just after activation of the heating element is measured and recorded. Then, a second temperature is measured after a predetermined time interval, such as one minute. If the difference of the two temperatures exceeds a predetermined threshold, then a dry fire condition is detected. In response to such a detection, operation of the heating element is disabled in an effort to prevent damage to the heating element.
The disclosure can be better understood with reference to the following drawings. The elements of the drawings are not necessarily to scale relative to each other, emphasis instead being placed upon clearly illustrating the principles of the disclosure. Furthermore, like reference numerals designate corresponding parts throughout the several views.
The present disclosure generally pertains to water heating systems capable of detecting for dry fire conditions. A water heating system in accordance with one exemplary embodiment of the present disclosure comprises a controller that determines at least one ambient condition, such as ambient temperature, and that then checks for a dry fire condition based on the ambient condition. For example, the controller may dynamically determine a sampling interval for a dry fire test based on the ambient condition. In another example, the controller may dynamically determine a threshold used for sensing a dry fire condition based on the ambient condition. Various other parameters used for testing for a dry fire condition may be based on the ambient condition in other examples.
In the embodiment shown by
In the exemplary embodiment of
In the exemplary embodiment shown by
As shown by
The controller 25 further has a relay 62 that is coupled to the power source 55, as well as the lower heating element 23. In one exemplary embodiment, the heating element 23 is a resistive device that generates heat when electrical current is passed through it. When the heating element 23 is to be activated, the control logic 50 closes the relay 62 such that electrical current from the power source 55 is passed through the heating element 23. When the heating element 23 is to be deactivated, the control logic 50 opens the relay 62 such that no current flows through it thereby preventing electrical current from passing through the heating element 23.
The controller 25 comprises a temperature sensor 57 that is in close proximity to and/or contacts the tank 15. Further, the controller 25 and, therefore, the temperature sensor 57 are located close to the heating element 21. In other embodiments, the controller 25 and/or sensor 57 may be located in other areas. The control logic 50 is coupled to the sensor 57 and controls the activation state of the upper heating element 21 based on this sensor 57. For example, if the temperature sensed by the sensor 57 falls below a first temperature threshold, referred to as a “lower set point,” for the element 21, the control logic 50 activates the heating element 21 by closing the relay 52 such that the element 21 heats water within the tank 15. The heating element 21 remains activated until the temperature sensed by the sensor 57 exceeds a second temperature, referred to as an “upper set point,” for the heating element 21. Once the control logic 50 detects that the upper set point has been exceeded, the control logic 50 deactivates the heating element 21 by opening the relay 52.
Using the relay 62, the control logic 50 may control the activation state of the lower heating element 23 based on readings from the temperature sensor 57 in the same or similar way that the control logic 50 controls the activation state of the upper heating element 21 using the relay 52. Alternatively, the system 10 may comprise another temperature sensor (not shown) in close proximity to the lower heating element 23 and in communication with the controller 25. In such an embodiment, control logic 50 may control the activation state of the lower heating element 23 based on such other temperature sensor. The upper and lower set points used to control the lower heating element 23 may the be either the same as or different than the set points used to control the upper heating element 21.
Moreover, based on readings from one or more temperature sensors, the upper and lower heating elements 21 and 23 are repetitively activated and deactivated in an attempt to maintain the temperatures of the water within a desired range. Various other techniques may be used to control the operation of the water heating system 10 and, in particular, the heating elements 21 and 23. Exemplary techniques for controlling components of the water heating system 10 are described in U.S. patent application Ser. No. 11/409,229, entitled “System and Method for Controlling Temperature of a Liquid Residing within a Tank,” and filed on Apr. 21, 2006, which is incorporated herein by reference.
As shown by
The control logic 50 is also coupled to a temperature sensor 63, such as a thermistor, for detecting ambient temperature. For example, the sensor 63 may be mounted on a side of the controller 25 opposite of the tank 15 so that the sensor 63 is shielded from the tank 15 by other components of the controller 25 (e.g., a printed circuit board) in an effort to prevent the temperature of the tank 15 from affecting the readings by the sensor 63. Further, the sensor 63 may be exposed such that external air contacts the sensor 63. Other locations of the sensor 63 are possible in other examples. For example, the sensor 63 may be located remotely from the system 10 shown by
In one exemplary embodiment, the control logic 50 is implemented in software and executed by an instruction execution apparatus, such as the apparatus 72 depicted in
The exemplary embodiment of the instruction execution apparatus 72 depicted by
When the controller 25 is initially activated (e.g., powered-up) the control logic 50 first tests the heating elements 21 and 23 for dry fire conditions. If the dry fire tests are passed (i.e., no detection of a dry fire condition), then the control logic 50 begins controlling the heating elements 21 and 23 based on their respective set points, as described above. However, if either of the elements 21 or 23 fails a dry fire test (i.e., a dry fire condition is detected), then the control logic 50 ensures that the relays 52 and 62 remain in an open state so that the heating elements 21 and 23 remain deactivated until the dry fire condition can be resolved. For example, the control logic 50 may provide an indication via data interface 59 that a dry fire condition has been detected. A user may then investigate the state of the system 10 in an effort to remedy the problem causing the detected dry fire condition. Once the problem has been remedied, the user may provide an input for restarting operation of the controller 25. In response, the control logic 50 may again test for a dry fire condition and then commence with normal operation if no dry fire condition is now detected.
Note that it is unnecessary for each of the heating elements 21 and 23 to be tested for dry fire conditions. In fact, if the heating element 21 is located above the heating element 23, as shown by
There are various techniques that may be used to detect dry fire conditions. In one exemplary embodiment, the heating element 21 is activated for only a very short time period (e.g., about 5 to 10 seconds). In this regard, the control logic 50 closes the relay 52 for about 5 to 10 seconds and then opens relay 52. The duration of the activation time period is selected to be low enough such that the heating element 21 and/or other components of the system 10 will not be damaged by activation of the heating element 21 if it is not submerged in water (i.e., if a dry fire condition exists). After the temporary activation of the heating element 21, the temperature sensor 27 is sampled numerous times by the control logic 50 during a time interval, referred to hereafter as the “sampling period.” In one exemplary embodiment, the duration of the sampling period is selected based on an ambient condition, such as ambient temperature. For example, the control logic 50 may be configured to determine, based on a reading from the temperature sensor 63, the ambient temperature outside of the water heater tank 15. Based on this ambient temperature, the control logic 50 may be configured to determine the duration of the sampling period. In this regard, the rate of temperature change of the heating element 21 during a dry fire condition may be greater if the ambient temperature is lower. Thus, if the ambient temperature is high, the sampling period may be longer as compared to an example for which the detected ambient temperature is lower.
In addition to or in lieu of determining a sampling period based on ambient temperature, a threshold used to detect a dry fire condition can be dynamically determined based on ambient temperature. For example, if the ambient temperature is relatively high, then the control logic 50 may select a threshold that is lower as compared to an example for which the detected ambient temperature is lower.
To enable dynamic selection of the appropriate sampling period duration and/or threshold, a table 92 (
In one exemplary embodiment, rate of temperature change is sampled numerous times during the sampling period. In this regard, the control logic 50 determines a first rate of change sample by taking a first reading of the temperature sensor 27 and then taking another reading shortly thereafter. The control logic 50 subtracts the two temperature readings and divides the difference by the time interval between the two readings to yield a rate of change value, which can be stored as a first sample. The control logic 50 repeats this process to determine other rate of temperature change samples. Using such samples, the control logic 50 calculates the rate of change (referred to hereafter as “aT”) in the temperature change rate and compares aT to a threshold, such as the dynamically selected threshold described above, to determine whether a dry fire condition exists. Note that the calculated value, which is compared to the threshold in this embodiment, essentially indicates the temperature acceleration of the heating element 21. In this regard, if RT is the average rate of temperature change during the sampling period, then aT represents the rate at which RT is changing.
To better illustrate the foregoing, assume that two rate of temperature change samples are taken. The first sample is taken during a time interval, t0, and represents an average rate of temperature change during this time interval. The second sample is taken during a time interval, t1, after interval t0 and represents an average rate of temperature change during interval t1.
In such an example, the control logic 50 can calculate the value, aT, which is indicative of the temperature acceleration from interval t0 to t1, according to the following equation:
where Rt0 is the rate of temperature change for interval t0 (i.e., the first sample), Rt1 is the rate of temperature change for interval t1 (i.e., the second sample), and dt1-t0 is the duration from the beginning of t0 to the end of t1, assuming that t1 occurs immediately after t0. Comparing the measured temperature acceleration, instead of a temperature difference as described in U.S. Pat. No. 6,649,881 B2, to a threshold may enable quicker detection of a dry fire condition. Note that the above example that uses two rate of temperature change samples to calculate temperature acceleration is presented for illustrative purposes, and the calculated temperature acceleration may be based on any number of rate of temperature change samples in other embodiments.
Moreover, if aT does not exceed the threshold, then the control logic 50 determines that a dry fire condition does not exist. In such a case, the control logic 50 begins to control the activation states of the heating elements 21 and 23 based on whether temperatures sensed via at least sensor 57 exceed upper and lower set points for the heating elements 21 and 23. However, if aT exceeds the threshold, then the control logic 50 determines that a dry fire condition exists. In such a case, the control logic 50 deactivates the heating elements 21 and 23 by placing both of the relays 52 and 62 into an open state, and the control logic 50 provides a warning indicating that a dry fire condition exists. For example, the control logic 50 may cause the data interface 59 to display a warning message or illuminate a light source, such as a light emitting diode (LED), to indicate the existence of a dry fire condition.
An exemplary use and operation of the system 10 will be described hereafter with particular reference to
Assume that, as shown by
Upon power-up, the control logic 50 takes a reading of the temperature sensor 63 to determine ambient temperature, as shown by block 111 of
As shown by block 115 of
After the heating element 21 is activated for a short duration, the control logic 50 samples the temperature sensor 27 every x seconds, where x is predefined. For example, the control logic 50 may be configured to sample the temperature sensor 27 every 5 seconds. For each five second time period, the control logic 50 would calculate the change in temperature (ΔT) by subtracting the temperature reading taken at the beginning of the five second period from the temperature reading taken at the end of the same five second period.
The control logic 50 continues sampling the sensor 27 in block 117 for a length of time equal to the sampling period determined from the table 92 in block 114 (i.e., D3 in the current example). In this regard, the control logic 50 continues sampling in block 117 until the control logic 50 determines in block 121 that the sampling period, as measured from the beginning of block 117, has expired. Thus, from the beginning of block 117 until a “yes” determination in block 121, the control logic 50 calculates n number of ΔT values (i.e., ΔT1, ΔT2, ΔT3, . . . ΔTn). For simplicity, assume that n is an even number.
Upon a “yes” determination in block 121, the control logic 50 determines a value, aT, as shown by block 124 of
Ravg1=(ΔT1+ΔT2+ΔT3+ . . . ΔTn/2)/(0.5nx) Equation (2)
where x is the time between each sample, as described above. Further, the control logic 50 calculates Ravg2, which is the average temperature change rate for the last half of the sampling period according to Equation (3) below.
Ravg2=(ΔT(n/2)+1+ΔT(n/2)+2+ΔT(n/2)+3+ . . . ΔTn)/(0.5nx) Equation (3)
Then, the control logic 50 calculates aT according to Equation (4) below.
aT=(Ravg2−Ravg1)/D3 Equation (4)
where D3 is the duration of the sampling period being used in the current dry fire test. Note that aT essentially indicates the temperature acceleration sensed by the temperature sensor 27 during the sampling period. In other embodiments, aT may be calculated via other techniques.
After determining aT, the control logic 50 compares aT to the threshold (i.e., TH3 in the instant example) determined in block 114, as shown by block 128 of
Note that the techniques described above for sampling the sensor 27 and determining aT are exemplary and other techniques are possible in other examples. For example, in another embodiment, sensor 27 could be sampled at the beginning of the sampling period, at the mid-point of the sampling period, and at the end of the sampling period. In other words, x could be equal to the sampling period duration divided by 2. In such an example, ΔT1 could be determined by subtracting the readings taken at the beginning and the mid-point of the sampling period, and ΔTn could be determined by subtracting the readings taken at the mid-point and the end of the sampling period. In such an example, Equation (2) is reduced to the following equation, assuming that the sampling period duration is equal to D3.
Ravg1=(ΔT1)/(0.5D3) Equation (5)
In addition, Equation (3) is reduced to the following equation.
Ravg2=(ΔTn)/(0.5D3) Equation (6)
In other embodiments, yet other techniques may be used to determine aT.
Moreover, by dynamically determining parameters of a dry fire test based on an ambient condition, the dry fire test can be more efficiently performed. Accordingly, the time required for completion of the dry fire test may be reduced.
This application claims priority to U.S. Provisional Application No. 60/775,078, entitled “Water Heating System and Method for Detecting Dry Fire Conditions,” and filed on Feb. 21, 2006, which is incorporated herein by reference.
Number | Date | Country | |
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60775078 | Feb 2006 | US |