PROVIDING DOMESTIC HOT WATER FROM CONVENTIONAL RESIDENTIAL SPLIT SYSTEM HEAT PUMPS
20220341628 · 2022-10-27
Assignee
Inventors
- Rick Wylie (Roseville, CA, US)
- Robert Radcliff (Folsom, CA, US)
- Richard Bourne (Davis, CA, US)
- Mark Beutler (Carmichael, CA, US)
- James H. Phillips (Sacramento, CA, US)
- Jim Ramge (Fairfield, CA, US)
- Felix Ortiz (Sacramento, CA, US)
- Marc Disalvo (Sacramento, CA, US)
- Esteban Lopez (Citrus Heights, CA, US)
- Mike Bettencourt (Walnut Grove, CA, US)
- Robert Campbell, SR. (Orangevale, CA, US)
- Marcello Vaca (Sacramento, CA, US)
- Dujon O. Currington (Sacramento, CA, US)
Cpc classification
F25B2700/2117
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24D2200/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24H9/45
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F25B2313/0292
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
F24D11/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24D19/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24H9/00
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. An improved environmental control system of the type having a split system electrically powered heat pump having an outdoor compressor, an outdoor coil, an outdoor fan, an indoor coil, an indoor fan associated with ducting, an expansion valve, a living space thermostat and interconnecting piping, comprising: a hot water tank storing hot water therein having a tank thermostat therein and two intertwined coils therein including a first coil carrying potable water to be heated and a second coil carrying hot refrigerant from the compressor thereby maintaining heat in hot water of the hot water tank; a valve matrix having an array of reversing valves capable of communicating refrigerant fluid and vapor and further having an array of solenoid operated valves and check valves associated with the reversing valves capable of communicating refrigerant fluid and vapor with the compressor, the outdoor coil, the indoor coil, and the compressor; at least one thermostat in a living space having a desired temperature set point; a logic device controller operatively associated with the thermostat, the expansion valve and the valve matrix programmed to direct refrigerant and potable water through the coils, operate the indoor fan, the indoor coil, the outdoor fan and the outdoor coil in response to signals from the living space thermostat and the tank thermostat calling for residential heating and cooling in at least four programmed modes of valve matrix operation including a call for hot potable water, a call for space heating, a call for space cooling, and a call for a quiescent state.
2. The apparatus of claim 1 wherein the hot water tank has an upper portion and a lower portion with the upper portion having an air-filled bladder that expands and contracts in response to water temperature in the tank.
3. The apparatus of claim 2 wherein ends of the intertwined coils emerge from the hot water tank from the upper portion thereof.
4. The apparatus of claim 1 wherein the intertwined coils are separated from each other by spacers.
5. The apparatus of claim 1 wherein one of the intertwined coils is wound more tightly at a first end and less tightly at an opposite end and the second of the intertwined coils is wound in a reverse manner being less tightly wound where the first coil is more tightly wound and more tightly wound where the first coil is less tightly wound.
6. The apparatus of claim 1 wherein water stored in the hot water tank is chemically treated for metal preservation.
7. The apparatus of claim 1 wherein the hot water tank has an outer spiral wound sheet metal skin.
8. The apparatus of claim 7 wherein the hot water tank has an inner plastic shell in contact with the stored hot water.
9. The apparatus of claim 9 wherein the hot water tank has foam insulation between the sheet metal skin and the plastic shell.
10. The apparatus of claim 1 wherein the hot water tank has a lid communicating atmospheric pressure to water in the tank.
11. A hot water tank associated with a heat pump for storing hot water therein comprising: a polymer water storage tank having two intertwined coils therein including a first coil carrying potable water to be heated and a second coil carrying hot refrigerant from a heat pump thereby maintaining heat in hot water of the hot water tank whereby heated hot water in the tank from the second coil maintains heat in the first coil.
12. The apparatus of claim 11 wherein the hot water tank has an upper portion and a lower portion with the upper portion having an air-filled bladder that expands and contracts in response to water temperature in the tank.
13. The apparatus of claim 12 wherein ends of the intertwined coils emerge from the hot water tank from the upper portion thereof.
14. The apparatus of claim 11 wherein the intertwined coils are separated from each other by spacers.
15. The apparatus of claim 11 wherein one of the intertwined coils is wound more tightly at a first end and less tightly at an opposite end and the second of the intertwined coils is wound in a reverse manner being less tightly wound where the first coil is more tightly wound and more tightly wound where the first coil is less tightly wound.
16. The apparatus of claim 11 wherein water stored in the hot water tank is chemically treated for metal preservation.
17. The apparatus of claim 11 wherein the hot water tank has an outer spiral wound sheet metal skin.
18. A method of providing heated potable water comprising: providing a tank full of water to be heated; providing a first coil with potable water in the water tank; and providing a second coil in the water tank having heated fluid and vapor from a heat pump where the second coil transfers sufficient heat to water in the tank for transferring heat to the first coil with potable water.
19. The method of claim 18 further defined by intertwining the first and second coils in close proximity.
20. The method of claim 18 further defined by operating the heat pump in modes that provide space heating and space cooling while always providing heat to the first coil by heat transfer from said water tank.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
DESCRIPTION OF THE INVENTION
[0029] In
[0030] 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.
[0031] With reference to
[0032] 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.
[0033] In
[0034] In
[0035] 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.
[0036] 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.
[0037] 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.
[0038] 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.
[0039] 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.
System Operation
[0041]
[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 FIG. 9, then if the thermostat 214s send a stage-2 heat call to the system controller 430, then the controller will initiate a call that energizes resistance heating elements in fancoil 202 for as long as a) heat mode is still the operating mode, and b) there is at least one thermostat 214 calling for stage 2 heat.
[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.