PROVIDING DOMESTIC HOT WATER FROM CONVENTIONAL RESIDENTIAL SPLIT SYSTEM HEAT PUMPS
20240263837 ยท 2024-08-08
Assignee
Inventors
Cpc classification
F25B2700/2117
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2313/0292
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24H9/45
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24D2200/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2600/2507
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2600/2513
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24H4/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2600/11
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2600/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2313/0294
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B49/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24D11/0214
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B13/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24D2220/0278
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24D19/1072
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F24H4/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24D19/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24D11/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B41/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
In a split system heat pump cooling and heating system, an auxiliary hot water storage tank is provided as an energy storage bank. Two sets of coils run through this storage tank, a first set carrying hot refrigerant from the heat pump to deposit energy and a second set carrying hot potable water to remove energy. Valve and switch matrixes are operated at the heat pump to provide hot potable water from the energy storage bank during both normal space heating and cooling operations of the heat pump.
Claims
1. A set of valves with a logic device controller, in an environmental control system of the type having a split-system electrically-powered heat pump with a compressor, an outdoor coil, an outdoor fan, an indoor coil and an indoor fan associated with ducting for living space heating and cooling, a living space thermostat, a hot water tank, a tank coil in thermal communication with the hot water tank, and a tank thermostat, the set of valves and the logic device controller directing refrigerant through selected coils and interconnected piping, comprising: a valve matrix having first, second, and third reversing valves in selected energized and de-energized states that control direction of refrigerant flow through connected refrigerant piping, all three reversing valves having an input side coupled to receive compressed hot refrigerant gas from the compressor and having first and second ports, the first port of the first reversing valve coupled to the outdoor coil, the first port of the second reversing valve coupled to the indoor coil, and the first port of the third reversing valve coupled to the tank coil, all three reversing valves having respective second ports coupled in common to a suction port of the compressor, an energized state of a reversing valve coupling the input side to the first port of that reversing valve and a de-energized state of a reversing valve coupling the first port to the second port of that reversing valve; a switch matrix having first, second, and third solenoid valves in selected open and closed states together with associated check valves coupled in parallel with the solenoid valves to control ability of refrigerant flow through connected refrigerant piping, the three solenoid valves and likewise their associated check valves coupled at one end to a common section of the interconnected piping, the respective check valves only permitting refrigerant flow in a direction toward the common section, the first solenoid valve and its associated check valve coupled at a second end to the outdoor coil, the second solenoid and its associated check valve coupled at a second end to the tank coil, the third solenoid valve and its associated check valve coupled at a second end to the indoor coil; and the logic device controller operatively associated with the living space thermostat, the tank thermostat, and a periodic temperature check of the outdoor coil, to energize a selected reversing valve of the valve matrix and switch open a selected solenoid valve of the switch matrix to direct refrigerant through selected operative coils, and to selectively operate the compressor and the indoor and outdoor fans, to effect in accord with programmed modes of operation any one or more of a quiescent state, space cooling, space heating, tank water heating, and outdoor coil defrosting mode of operation in response to signals received from the thermostats.
2. The set of valves with logic device controller in the environmental control system as in claim 1, wherein the logic device controller is in a space cooling mode of operation, the first reversing valve of the valve matrix being energized and the third solenoid valve of the switch matrix being open, refrigerant from the compressor circulating successively through the energized first reversing valve, the outdoor coil, the first check valve, the open third solenoid valve, an expansion valve leading into the indoor coil, the de-energized second reversing valve, and back to the compressor, such that heat drawn from an indoor living space is sent outdoors.
3. The set of valves with logic device controller in the environmental control system as in claim 2, wherein further the second solenoid valve is closed and the third reversing valve is de-energized, such that refrigerant is fully diverted through the suction port of the compressor from the inactive tank coil.
4. The set of valves with logic device controller in the environmental control system as in claim 1, wherein the logic device controller is in a combined space cooling and water heating mode of operation, the third reversing valve of the valve matrix being energized and the third solenoid valve of the switch matrix being open, refrigerant from the compressor circulating successively through the energized third reversing valve, the tank coil, the second check valve, the open third solenoid valve, an expansion valve leading into the indoor coil, the de-energized second reversing valve, and back to the compressor, such that heat drawn from an indoor living space is supplied to the hot water tank.
5. The set of valves with logic device controller in the environmental control system as in claim 4, wherein further the first solenoid valve is closed and the first reversing valve is de-energized, such that refrigerant is fully diverted through the suction port of the compressor from the inactive outdoor coil.
6. The set of valves with logic device controller in the environmental control system as in claim 1, wherein the logic device controller is in a space heating mode of operation, the second reversing valve of the valve matrix being energized and the first solenoid valve of the switch matrix being open, refrigerant from the compressor circulating successively through the energized second reversing valve, the indoor coil, the third check valve, the open first solenoid valve, an expansion valve leading into the outdoor coil, the de-energized first reversing valve, and back to the compressor, such that heat drawn from outdoors is supplied to an indoor living space.
7. The set of valves with logic device controller in the environmental control system as in claim 6, wherein further the second solenoid valve is closed and the third reversing valve is de-energized, such that refrigerant is fully diverted through the suction port of the compressor from the inactive tank coil.
8. The set of valves with logic device controller in the environmental control system as in claim 1, wherein the logic device controller is in a water heating mode of operation with an indoor living space not to be cooled, the third reversing valve of the valve matrix being energized and the second solenoid valve of the switch matrix being open, refrigerant from the compressor circulating successively through the energized third reversing valve, the tank coil, the second check valve, the open first solenoid valve, an expansion valve leading into the outdoor coil, the de-energized first reversing valve, and back to the compressor, such that heat drawn from outdoors is supplied to the hot water tank.
9. The set of valves with logic device controller in the environmental control system as in claim 8, wherein further the third solenoid valve is closed and the second reversing valve is de-energized, such that refrigerant is fully diverted through the suction port of the compressor from the inactive indoor coil.
10. The set of valves with logic device controller in the environmental control system as in claim 8, wherein whenever the logic device controller receives competing calls for both water heating and space heating, the logic device controller has programmed mode arbitration that prioritizes water heating for a specified time duration and then switches to a space heating mode of operation for a minimum specified time duration before allowing a return to another water heating mode of operation.
11. The set of valves with logic device controller in the environmental control system as in claim 1, wherein the logic device controller is in a defrost mode with an indoor living space not to be cooled, the first reversing valve of the valve matrix being energized and the second solenoid valve of the switch matrix being open, refrigerant from the compressor circulating successively through the energized first reversing valve, the outdoor coil, the first check valve, the open second solenoid valve, the de-energized third reversing valve, and back to the compressor, such that heat drawn from the hot water tank is supplied to de-ice the outdoor coil.
12. The set of valves with logic device controller in the environmental control system as in claim 11, wherein further the third solenoid valve is closed and the second reversing valve is de-energized, such that refrigerant is fully diverted through the suction port of the compressor from the inactive indoor coil.
13. The set of valves with logic device controller in the environmental control system as in claim 1, wherein the tank coil for carrying refrigerant is intertwined with a potable water coil carrying water to be heated, both the tank coil and the potable water coil passing through the hot water tank, the hot water tank containing hot water therein serving as a thermal store, the hot water contained in the hot water tank being maintained by the tank coil within a temperature range determined by the tank thermostat, water passing through the potable water coil being heated mainly by the thermal store of hot water contained within the hot water tank.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0019]
[0020]
[0021]
[0022]
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[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
DESCRIPTION OF THE INVENTION
[0030] In
[0031] A Hot Tank 221, described more fully below, is situated in a closet or garage or other space. The hot tank has two spaced apart intertwined coils 320 and 321 that extend from the top of the Hot Tank 221 to near the bottom thereof. A first of the two coils 320 is used for potable water while the second of the two coils 321 is a refrigerant coil. The two coils terminate in four coil input and output lines 323, two for each coil at the top of Hot Tank 221. The refrigerant lines 323 are interconnected to a valve matrix 231 and a switch matrix 233 that are also connected to compressor 209 and the indoor coil 206 through expansion valve 215 and the outdoor coil 210.
[0032] With reference to
[0033] Both coils 320 and 321 exit the HotTank 221 through a portion of a plastic removable lid 324 via 4 upright tubing sections 323, for final connection to the residence potable water system and refrigerant tubing system. Mounted within the plastic lid assembly 324 is a polyethylene expandable bladder 325, which expands and contracts within the HotTank 221 as the water in the tank expands and contracts due to the heating or cooling of the water during operation of the system. An adjustable thermostat 327 is mounted to the exterior of the HotTank 221, with a temperature sensor 329 located within the water being heated with a low voltage connection 329 between thermostat 327 to a controller described below.
[0034] In
[0035] In
[0036] During system operation hot refrigerant gas circulating through coil 321 heats the stored water within the HotTank 221, and as the water heats it expands. The expandable bag 325 will collapse upwards towards cap 324, preventing the HotTank from pressurizing, while also preventing air and water vapors from escaping the HotTank. This expansion and contraction control function protects the tank from excessive pressurization, while maintaining the HotTank water level due to the prevention of evaporation.
[0037] The stored water within the HotTank will be heated from the Hot refrigerant gas until it reaches the thermostat 327 setpoint (typically 125 degrees F.), at which point the Thermostat 327 sends a signal to the system controller to shut off the hot gas flow from the heat pump. Potable water within the water coil 320 receives heat from the 125 degree water solution within the HotTank 221, so when the home occupant turns on a hot water faucet, she will receive water that has been heated in the HotTank. As the hot water faucet continues to flow, cold water enters the bottom of the water coil 320, and is heated as it spirals up through the coils towards the top of the HotTank. The large reservoir of water, 64 gallons in the example herein, maintains sufficient thermal energy such that the residential occupant can receive an ample supply of hot water.
[0038] As cold water removes heat from the stored water within the HotTank, the temperature sensor reports along line 329 the dropping temperature to the thermostat 327, and when the temperature drops to the minimum temperature point, for example 110 degrees F., the thermostat 327 sends a call to the system controller to reinitiate hot-gas refrigerant flow to the refrigerant coil 321. Hot gas enters at the top of coil 321, and spirals down the coil towards the bottom of the tank, giving up heat and condensing to a sub-cooled liquid before returning to the switch matrixes of the heat pump system.
[0039] Because the hot gas refrigerant enters at the top of the tank, and the incoming cold water enters at the bottom of the tank, the tank maintains a level of heat stratification that improves the overall system performance. The very top of the HotTank 221 will be approximately 135 degrees F., while the bottom of the tank will be approximately 110 degrees F. This improves the efficiency of the refrigerant condensation process, and it improves the efficiency of the heat exchange in the water coil 320, which helps maintain a more consistent hot water temperature for the home occupants. The water coil 320 has its spiral tubes wound such that there are tighter windings leading to more length of tubing towards the top of the HotTank where temperatures are hotter, with less length towards the bottom of the tank where the temperature differential between the incoming cold water usually about 60 degrees F. and the bottom-of-tank temperature, typically about 110 degrees F. is greater, allowing for efficient heat transfer with less tubing length. This stratified heat zone design feature not only increases the efficiency of the coil heat exchange process but also increases the natural heat stratification in the HotTank.
[0040] The refrigerant coil 321 has its spiral windings spaced less tightly at the top such that there is less tubing length towards the top of the HotTank where temperatures are hotter, with greater length towards the bottom of the tank where temperature differential between the incoming refrigerant and the bottom-of-tank temperature is less. This is opposite of the water coil 320 noted above, which again helps increase the HotTank stratification and improves the overall coil efficiency of the refrigerant coil 321.
[0041] System Operation
[0042] In
[0043] The valve matrix 231 is augmented by a switch matrix 233 that uses an array of liquid-line solenoid valves 501, 502, and 503, with a corresponding check-valve arrays 511, 512, and 513 that in combination act as switches to augment valve matrix 231. The arrays of standard liquid line solenoids and check-valves, acting as switches, direct the flow of liquid refrigerant as needed to command the five different operating modes of the invention in a very cost-effective manner as compared to a custom multi-port liquid line valve. The use of these valve and switch matrixes provides the ability to support the piping that services the HotTank 221 with hot refrigerant vapor along pipe 415 and refrigerant liquid pipe 412. The outdoor unit 203 retains the original refrigerant piping that serves the air handler and fan coil 202. This piping is the refrigerant vapor line 424 and the refrigerant liquid pipe 423.
[0044] The system controller 430 is a logic device controller that can allow a single conventional split heat pump HVAC system to be operated by multiple thermostats. The controller 430 controls the valve matrix and switch matrix that drives the wiring and piping that involves all of the major components, including fancoil 202, heat pump 203, HotTank 221, air dampers and thermostats and ancillary devices including logic required to respond to the HotTank thermostat 27 and to properly sequence the operation of the custom valve matrix with reversing valves and the switch matrix with a liquid line solenoid valve array. This logic includes arbitration between the five operation modes designed to optimize the performance and reliability of the system, and to prioritize between conflicting calls among the operating modes.
[0045]
[0046] In this mode the compressor 209 has hot refrigerant gas directed through reversing valve 401 at pipe 421 to the outdoor coil 210, where the refrigerant is cooled into a liquid refrigerant by outdoor air, exiting coil 210 and flowing through check valve 511 and liquid line solenoid 503 to pipe 413 as a liquid line. Pipe 423 travels into the residence to the fancoil 202, entering refrigerant expansion valve 215 which reduces its pressure and temperature as it enters the coil 206. Blower 207 blows air across indoor coil 206, cooling the air with the cooled refrigerant in order to deliver cool air into the residence, preferably at about 52 degrees F.
[0047] Heat is absorbed by the cool refrigerant gas, converting it into a superheated gas which exits the fancoil 202 into refrigerant vapor line 424, which returns to the outdoor heat pump 203, where it passes through reversing valve 402 and enters the compressor 209.
[0048] Reversing valve 403, in its de-energized state allows pipe 415 from HotTank coil 321 of
[0049]
[0050] In
[0051] In this mode the compressor 209 hot refrigerant gas is directed through reversing valve 403 at pipe 415 to the HotTank 221 coil 321 in
[0052] The heat from the space is therefore absorbed by the refrigerant, vaporizing it into a superheated gas which exits the fancoil 202 into refrigerant vapor line pipe 424, which returns to the outdoor heat pump 203, where it passes through reversing valve 402 and enters the compressor 209 via a suction port.
[0053] Reversing valve 401, in its de-energized state allows pipe 421 from outdoor coil 210 to be connected to the suction port of compressor 209, allowing the compressor to draw down most of the trapped refrigerant in coil 210 so that it can be fully available to coil 321, shown in
[0054] This cycle continues until either thermostat 214 is satisfied, or thermostat 227 is satisfied. If thermostat 214 satisfies first, then the system controller switches into the water heating mode described below with reference to
[0055]
[0056] In this mode the compressor 209 supplies hot refrigerant gas directed through reversing valve 402 at pipe 424 to the refrigerant coil 206 in fancoil 202, where the refrigerant is cooled into a liquid refrigerant by indoor air, as indoor fan 207 blows cooler indoor air across coil 206, thereby transferring heat from the refrigerant to the indoor airstream, allowing the air to exit the fancoil and into the home duct system at around 100 degrees F. The sub-cooled refrigerant exits coil 206 through pipe 423 and flows through check-valve 513 and liquid line solenoid 501 to the check-valve/metering device or expansion valve 515. Here it reduces its pressure and temperature as it enters outdoor coil 210. Blower 211 pulls air through the outdoor coil 210, allowing the cold liquid refrigerant to pick up heat from the outdoor air as it vaporizes. The superheated refrigerant vapor exits coil 210 and flows through reversing valve 401 to the compressor 209 suction inlet port where it continues the cycle back through compressor 209.
[0057] Reversing valve 403, in its de-energized state allows pipe 415 from HotTank coil 321 in
[0058]
[0059] In this mode the compressor 209 supplies hot refrigerant gas directed through reversing valve 403 at pipe 415 to the refrigerant coil 321, seen in
[0060] Reversing valve 402, in its de-energized state allows pipe 424 from coil 206 in fancoil 202 to be connected to the suction port of compressor 209, allowing the compressor to draw down most of the trapped refrigerant in coil 206 so that it can be fully available for coil 210 in the outdoor unit and coil 321 in the hot tank 221. This cycle continues until thermostat 227 is satisfied, at which time all components are de-energized.
[0061]
[0062] In this mode the compressor 209 hot refrigerant gas is directed through reversing valve 401 at pipe 421 to the refrigerant coil 210 in outdoor unit 203, where the hot-gas quickly de-ices outdoor coil 210. usually occurring in 3 minutes or less. As the refrigerant circulates through outdoor coil 210 it is condensed into a sub-cooled liquid, exiting through check valve 511 and liquid line solenoid 502 into pipe 412 to the check-valve/metering device 515 at the refrigerant inlet of coil 321 of
[0063] Compressor 209 compresses the low-pressure low temperature vapor into a high pressure, high temperature vapor, where it flows through reversing valve 401 to pipe 421 and coil 210, delivering the superheated refrigerant necessary to de-ice coil 210, completing this circuit. This avoids the process described above, where a typical heat pump system withdraws heat from the residence through the fancoil 202, which initiates an uncomfortable cooling effect within the home. The removal of heat from the HotTank for the defrost cycle should not be noticeable to the home occupants, greatly improving the indoor comfort. Once it is recognized that the outdoor coil 210 is de-iced, the outdoor fan 211 is energized allowing the system controller to return to its previous operation mode of space heating as described in
Mode Arbitration
[0064] A critical function of the system controller 430 is to arbitrate between the residential living space thermostat 214 and the HotTank water heater thermostat 227, as the integrated heat pump system cannot function in all modes concurrently. Below is the arbitration logic that is incorporated into the system controller 430. [0065] 1. A call for water heating is given top priority. [0066] a. When water heating thermostat 227 initiates a call for heating, system controller 430 will immediately switch into water heating of
[0077] Space thermostats 214 all incorporate stage 1 and stage 2 discrete heating contacts. If the system controller is operating in space heating mode as in
[0078] During all of these various scenarios, the system controller 430 is also properly opening and closing motorized air-duct dampers in order to align system airflow with the actual needs of a specific thermostat home zone. This feature is a standard operating function in home heating and ventilation systems. The system controller 430 also contains a feature described as Thermal Equalizer, described in the previous patent to Wylie, incorporated by reference herein, which following a call for space heating from a specifically designated space thermostat 214, with the location of this designated space thermostat will be the lowest level floor in a multi-level home, then a call for space heating will be de-energized after a few minutes, adjustable in the system controller 430 from 5-15 minutes, but the fancoil fan 207 will continue running in order to extract trapped heat from the highest-level floor in the residence and ducted back down to the registers located in the lowest-level floor in the home, for this period of time.