STEAM GENERATOR

Abstract

A steam generator includes a water tank configured to store water, a heat element coupled to the water tank and configured to heat the water in the water tank to produce steam, at least one sensor configured to detect a water level associated with the water tank, a valve configured to supply water to the water tank, and a controller configured to operate the valve to manage the water level in response to the detected water level and at least one variable time period.

Claims

1. A steam generator comprising: a water tank configured to store water; a heat element coupled to the water tank and configured to heat the water in the water tank to produce steam; at least one sensor configured to detect a water level associated with the water tank; a valve configured to supply water to the water tank; and a controller configured to operate the valve to manage the water level in response to the detected water level and at least one variable time period.

2. The steam generator of claim 1, wherein the at least one variable time period includes a set a duty cycle period for operation of the valve according to the detected water level, wherein the controller is configured to update the set a duty cycle period and store the updated set a duty cycle period to a memory.

3. The steam generator of claim 2, wherein the duty cycle period comprises an opening duration for the valve and a closing duration or the valve, wherein the controller adjusts at least one of the opening duration and the closing duration for at least one subsequent duty cycle period.

4. The steam generator of claim 1, wherein the at least one variable time period includes a set open time period for the valve, wherein the controller is configured to update the set open time period and store the updated set open time period to a memory.

5. The steam generator of claim 1, wherein the at least one variable time period includes an initial valve opening time, wherein the controller is configured to update the initial valve loading time and store the updated initial valve loading time to a memory.

6. The steam generator of claim 1, where the controller operates the valve to manage the water level by a variable amount of water per a certain time duration.

7. The steam generator of claim 1, wherein the at least one sensor comprises: a first probe having a first length into the water tank; and a second probe having a second length into the water tank.

8. The steam generator of claim 7, wherein the first length is shorter than the second length and corresponds to a high water level.

9. The steam generator of claim 7, wherein the second length is longer than the second length and corresponds to a low water level.

10. The steam generator of claim 7, further comprising: a probe housing including the first probe and the second probe.

11. The steam generator of claim 7, wherein the probe housing is detachable from the water tank.

12. The steam generator of claim 7, further comprising: a secondary heater element coupled to the water tank and configured to heat the water in the water tank to a standby temperature.

13. The steam generator of claim 1, wherein the controller is configured to generate a warning in response to the at least one sensor indicating a low water level.

14. A method of managing a water level in a steam generator, the method comprising: receiving sensor data for a water tank of a steam generator; monitoring water level at a first probe in the water tank; monitoring water level at a second probe of the water tank; and generating a valve command for a fill valve for the water tank in response to the detected water level and at least one variable time period.

15. The method of claim 14, wherein the at least one variable time period includes a set a duty cycle period for operation of the valve according to the detected water level, and the method comprises: updating the set a duty cycle period and store the updated set a duty cycle period to a memory.

16. The method of claim 14, wherein the at least one variable time period includes an opening duration for the valve and a closing duration or the valve, and the method comprises: adjusting at least one of the opening duration and the closing duration for at least one subsequent duty cycle period.

17. The method of claim 14, wherein the at least one variable time period includes a set open time period for the valve, and the method comprises: updating the set open time period and store the updated set open time period to a memory.

18. The method of claim 14, wherein the at least one variable time period includes an initial valve opening time, and the method comprises: updating the initial valve loading time and store the updated initial valve loading time to a memory.

19. A steam bathing system comprising: at least one steam outlet; a water tank configured to store water; a heat element coupled to the water tank and configured to heat the water in the water tank to produce steam or the at least one steam outlet; at least one sensor configured to detect a water level associated with the water tank; a valve configured to supply water to the water tank; and a controller configured to operate the valve to manage the water level in response to the detected water level and at least one variable time period that is iteratively update over a plurality of duty cycles.

20. The steam bathing system of claim 19, wherein the at least one sensor comprises: a first probe having a first length into the water tank; and a second probe having a second length into the water tank.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0016] In order to illustrate the technical solutions in the embodiments of the present disclosure more clearly, the drawings used in the description of the embodiments are briefly described below. Apparently, the drawings in the following description are merely some embodiments of the present disclosure. For those of ordinary skills in the art, other drawings may also be obtained based on these drawings without any creative work and should fall within the scope of protection of the present disclosure.

[0017] FIG. 1 is an example steam generator;

[0018] FIG. 2 is another example steam generator;

[0019] FIG. 3 illustrates an example temperature probe for the steam generator;

[0020] FIGS. 4A and 4B illustrates another example steam generator;

[0021] FIG. 5 is an example external housing and display for a steam generator;

[0022] FIG. 6 illustrates example charts for the operation of a steam generator;

[0023] FIG. 7 illustrates example charts for the operation of a steam generator;

[0024] FIG. 8 illustrates an example controller for a steam generator;

[0025] FIG. 9 illustrates an example flowchart for the control system;

[0026] FIG. 10 illustrates water feed control based on a two-pole probe; and

[0027] FIG. 11 illustrates water feed control based on a one-pole probe.

DETAILED DESCRIPTION

[0028] To make those skilled in the art to better understand the solutions in the present disclosure, the technical solutions in the embodiments of the present disclosure are clearly and completely described hereinafter with reference to the drawings in the embodiments of the present disclosure. It should be apparent that the described embodiments are merely some rather than all embodiments of the present disclosure. Based on the embodiments of the present disclosure, all other embodiments obtained by those having ordinary skills in the art without going through any creative work should fall within the scope of protection of the present disclosure.

[0029] The terms first, second, third and the like in the specification, claims and drawings of the present disclosure are used to distinguish different objects, and are not used to describe a specific sequence. Furthermore, those terms including and provided with and any variations thereof are intended to cover non-exclusive inclusion. For example, processes, methods, apparatuses, products, or devices including a series of steps or units are not limited to the listed steps or units, but optionally include steps or units not listed, or optionally include other steps or units inherent to these processes, methods, products, or devices.

[0030] FIG. 1 is an example steam generator 10 including a water probe 30 and a water tank 20. The water tank 20 includes one or more heating elements that are operated by a controller, which may be implemented by a circuit board including a microprocessor 40. The water probe 3 is inserted into the water tank 20 and a portion of the water probe 3 are submerged when the water tank 20 includes enough water for the production of steam. In general, the water is heated within the water tank 20 to or beyond a boiling point of the water and the resulting steam or vapor is expelled through outlet 50 to a bathing system. A drain valve and outlet 60 may be used to empty the water tank 20 manually. The bathing system may be a showerhead, a shower enclosure, a wall-mounted dispenser, a bath, or other appliance having a steam outlet. In some examples, the steam is supplied to a sauna having a steam outline. The bathing system may include steam outlets that receive steam from a steam generator in fluid communication with steam outlets. The steam generator 10 may be disposed between, and coupled via conduit (e.g., piping or tubing), to steam outlets and a water supply. The steam generator 10 heats the water, turning it into steam that is then communicated into a shower enclosure through steam outlets. Additional, different or fewer components may be included.

[0031] FIG. 2 illustrates an example steam subsystem disposed within or in communication with the water tank 20 of the steam generator 10. The steam subsystem may include a supply line 11 (e.g., pipe or conduit), a two-way valve 12, a tank inlet 13, a main heating element 1, a sub heating element 2, a water probe 3, a relief valve 4, a water fill valve 5, a power clean valve 6, and a drain valve 7. Additional, different or fewer components may be included.

[0032] The steam generator 10 is connected to a water supply (e.g., utility) under pressure via a supply line 11. The water may pass through one or more valves, such as the water fill valve 5 and/or the two-way valve 12, which is discussed in more detail below, to the tank inlet 13. The tank inlet 13 may also include a tube or conduit that extends further into the tank 20.

[0033] The water tank 20 includes multiple walls that form a compartment configured to store water. A rectangular prism is illustrated but any volumetric shape may be used. Within the water is one or more heat generators. The heat generators may include a resistor (e.g., resistive element) configured to convert electric energy to heat. As illustrated, the water tank 20 may include a main heating element 1 and a sub heating element 2. In order to increase the surface area that is contact with the water, the resistor may be shaped in a folded tubular shape (heating element 2) or in a coil (heating element 1). The heating element may be coupled to the water tank 20. External to the water tank 20 an electrical connection provides current to the heating element.

[0034] A power supply may provide the electrical connection to the heating elements. The power supply may include a transformer that divides power between the heating element 1 and the heating element 2. The power supply may be mounted on the circuit board 40. The microprocessor may control the switching ON and OFF of the heating elements.

[0035] As shown in FIG. 1, a thermistor 70 and a thermal fuse 71 are safety mechanisms for the steam subsystem. The switching of the heating elements may be in response to an electronic sensor (e.g., thermistor 70) that monitors the temperature of the water in the tank. When the thermistor 70 provides readings above a target temperature, the power supply is switched OFF. When the thermistor 70 provides readings below the target temperature, the power supply is switched ON.

[0036] The microprocessor may control the heating elements independently. For example, the heating element 1 is a main heater rated at a high wattage or power level that operates to bring the water to a boil to product steam in response to a control signal received from the controller. The heating element 2 is a subheater rated at a low wattage or power level that operates to bring the water into a standby temperature or warm temperature. After the heating element 2 has warmed the water, switching on the heating element 1 may bring the water to a boil in a short amount of time.

[0037] A physical switch may also cause the heating elements to be turned off in certain situations. For example, a thermal fuse 71 may be triggered when the temperature in the tank 20 reaches a high limit temperature threshold. The high limit temperature threshold may cause a mechanical break in the thermal fuse 71, cutting power to the heating elements.

[0038] The water probe 3 includes at least one sensor configured to detect a water level associated with the water tank 20. As water is provided to the water thank 20 through the water fill valve 5, the water collects in the water tank and proceeds to fill an open end 23 of the housing of the water probe 3. The probe housing is detachable from the water tank 20. As water fills the housing of the water probe 3, the water is detected, and sensor data is returned to the controller 100. The controller 100 generates a command for the water fill valve 5 to regulate the fill level in the water tank. The controller 100 is configured to set a duty cycle for operation of the water fill valve 5 according to the detected water level. As water is heated and evaporates, the resulting steam escapes through a pipe 14 (outlet 50) to the shower enclosure.

[0039] In one alternative, the relief valve 4 may be manually (e.g., via a valve handle) or electronically operated (e.g., by control signal) in order to release steam into the ambient environment. Steam may be released in the case of overheating or malfunctioning. Steam may be released in the case of maintenance, installation, or removal of the device.

[0040] In one alternative, a cleaning cycle may be implemented in order to remove or reduce deposits in the water tank 20. The cleaning cycle may be implemented electronically by the controller 100 actuating electronic valves or manually through the operation of a user actuating manual valves. For example, the cleaning cycle may be started by opening a reverse flow from the tank through the two-way valve 12 and/or the power clean valve 6 so that steam is reversed from the outlet pipe to the water inlet 13 and/or the drain 15. The drain valve 7 may be opened to flush water through the tank to carry any loosened deposits. The deposits may include calcium, irons, magnesium, or other materials.

[0041] FIG. 3 illustrates an example control system including the water probe assembly 3 for the steam generator 10 electrically connected to a controller 100 and a sensor circuit 101. Additional, different or fewer components may be included.

[0042] When the probe or pole is placed in an open area in the water tank 20, the water level may fluctuate because of boing water. In other words, the detected water level in the water tank 20 may fluctuate rapidly because the water is bowling. When the probe or pole is enclosed by the housing, water level fluctuations are reduced. Further accuracy may be obtained in the water level detect by using multiple probes or poles. For reliable water level detection, a predetermined distance D between each pole may be defined.

[0043] The water probe (water probe assembly 3) may be a probe array having multiple probes that extend through a water probe housing at different lengths into the water tank 20. The probe array may include a first probe 31 having a first length into the water tank. The probe array may include a second probe 32 having a second length into the water tank. The length of the first probe 31 is shorter than the length of the second probe 32. The first length and first probe 31 correspond to a high water level within the housing of the water probe 3. The second length at the second probe 32 correspond to a low water level within the housing of the water probe assembly 3. A grounding point may provide a reference point for the electrical signal like the ground probe 33 (pole) or a connection directly the tank surface.

[0044] In a water level feedback loop, the probe could be one-pole or two-pole except grounding. In the case of the one-pole, the controller 100 uses the pole detecting both of the proper water level and low water level. When using the two-pole probe, the controller 100 may operate the water fill valve 5 based on the first pole 31. The controller 100 may determine the abnormal water level in response to data from the secondary probe 32 indicative of whether the water level in the water tank 20 is below the low level. This following disclosure describes controlling mechanisms with the two-pole probe and explains briefly how to achieve the goal with one-pole probe.

[0045] The principle of the water level control is to supply a small amount of water at every duty cycle. The volume of water flowing into the tank during boiling may be recalculated at every duty cycle. In this way, constant steam production could be achieved while maintaining the desired water level.

[0046] Every duty cycle having a certain length of time, the fill valve 5 is open during the calculated time and is closed until the next duty cycle. The duration of duty cycle could be 1, 2, 5, 10 or 20 seconds. When determining the length of duty cycle, in particular the tank size and the fill valve durability may be considered. The following example includes a period of 4 seconds but any duration of duty cycle period may be used.

[0047] When calculating the opening time at every cycle, the pole could detect water or the absence of water. If the pole detects water, the amount of water to supply is higher than evaporation. So, the current opening time is reduced by a decrement in time value (e.g., 10 ms). If the open time is 500 ms means that valve opens for 500 ms and closes for 3.5 seconds. After detecting, the opening time is adjusted to 490 ms, and the close time is 3.51 seconds.

[0048] However, the opening time may not increase whenever the pole does not detect water at every duty cycle. Instead, if water is not detected after a certain number of duties (e.g., 35th-operation), the opening time increases by increment of one step (e.g., 10 ms).

[0049] If water is not detected after another number of duties (e.g., 70th operation), the time increases by an increased increment of multiple steps. One example of increased multiple steps may include a first increase of 20 ms, a second increase of 30 ms, a third increase of 40 ms, and so on.

[0050] The increased or decreased opening time of adjusting the volume of water may cause the water level to stay near the first pole (e.g., within a predetermined height or a predetermined deviation to the first pole).

[0051] During steam production, water does not flow into the tank if the fill valve 5 is broken or water outage happens. The controller 100 may detect those abnormal situations and stop the heating element activation.

[0052] In the two-pole configuration, if the secondary probe 32 does not detect water, the water supplying error detection process starts. The valve does not turn off until the first probe 31 detects the water. If water does not reach the first probe 31 for a time buffer (e.g., 40 seconds), the controller 100 generates the valve-related error deciding that there could be water fill valve 5 failure or water outage.

[0053] In the one-pole configuration, there is no indicator saying of abnormal situations like the secondary pole of the two-pole system. Instead, when the increment of multiple steps is calculated, the water supplying error detection process starts.

[0054] The initial valve opening time (factory-set time) may be saved to EEPROM or flash memory at the controller or processor. The value loads into RAM area when power cycles. The recalculated value of the opening time is saved to the RAM and a special memory like a flash memory and an EEPROM. The system keeps using the latest valve even after cycling power.

[0055] The probe array may include a common (ground) probe 33 for grounding. The common probe 33 may have a third length that is longer that the second length of the second probe 32.

[0056] FIGS. 4A and 4B illustrates another example steam generator. The example steam generator of FIG. 1 may be rated at 5, 7, 9, or 11 kilowatts. The larger steam generator of FIGS. 4A and 4B may be rated at 13 or 15 kilowatts. The probe 3 may be installed through an auxiliary enclosure 51. The auxiliary enclosure 51 may include an openable or removable lid 52 that provides access to the probe 3 by the user or technician.

[0057] FIG. 5 is an example external housing and a display 70 for a steam generator 10. The display 70 may include one or more segmented displays or liquid crystal displays (LCD) that display alphanumerical values for error codes. An error code may be identified by the controller 100 when an abnormal condition exists in the sensor data collected from the steam generator 10. The error codes may be sent to a central controller (e.g., shower controller) or an external device or server. FIG. 5 also illustrates an input device 71 including one or more buttons (e.g., touchscreen, numbers, selectors, alphanumeric characters) to turn the steam generator 10 on and off. The input device 71 may also receive settings as described herein.

[0058] FIGS. 6 and 7 illustrate example charts for the steam flowrate of the steam generators 10. FIG. 6 illustrates that for an ON-OFF water feed control only, steam levels 201 fluctuate at times just after water is supplied (water supply spikes 202) when the water fill valve 5 is operated in direct response to the water level.

[0059] FIG. 7 illustrates that the water feed mechanism described above outperforms the general ON-OFF water feed control in terms of steam consistency. For example, the steam flowrate is smoothed out using the water level feedback above in which the duty cycle of the water fill valve 5 is incremented and decremented based on the water level detected by the first probe 31.

[0060] Table 1 summarize the comparison between the ON-OFF water feed control and the water feed mechanism described above.

TABLE-US-00001 TABLE 1 Average gap of Steam Average gap of Steam flowrate: LB/HR flowrate: LB/HR (During stable (During stable period) - 5 kW period) - 11 kW ON/OFF 8 6 New feed 2.5 0.5

[0061] FIG. 8 is an example block diagram for a controller 100 for the steam generator 10. The controller 100 may include a processor 300, a memory 352, and a communication interface 353 for interfacing with devices or to the internet and/or other networks 346. In addition to the communication interface 353, a sensor interface may be configured to receive data from the sensors described herein or data from any source. The controller 100 may include an integrated an indicator (e.g., display, LED, speaker, or other output devices). The components of the control system may communicate using bus 348. The control system may be connected to a workstation or another external device (e.g., control panel) and/or a database for receiving user inputs, system characteristics, durations and any of the thresholds described herein.

[0062] Optionally, the control system may include an input device 355 and/or a sensing circuit 356 in communication with any of the sensors such as water probe 3. The sensing circuit receives sensor measurements from sensors as described above. The input device 355 may alternatively include one or more user inputs such as buttons, touchscreen, a keyboard, a microphone or other mechanism for calibrated any of the system characteristics, durations and any of the thresholds described herein.

[0063] Optionally, the control system may include a drive unit 340 for receiving and reading non-transitory computer media 341 having instructions 342. Additional, different, or fewer components may be included. The processor 300 is configured to perform instructions 342 stored in memory 352 for executing the algorithms described herein.

[0064] FIG. 9 illustrates an example flow chart for the operation of the controller 100 for the control system of the apparatus according to any of the embodiments described herein. Additional, different or fewer acts may be included.

[0065] At act S101, the controller 100 (e.g., processor 300) receives sensor data from the water level probe 3. The water level may include a sensor corresponding to a first height of the water tank and a sensor corresponding to a second height of the water tank. Additionally, sensor data may be received from a temperature sensor.

[0066] At act S103, the controller 100 (e.g., processor 300) monitors the sensor data for the first height of the water tank. For example, the controller 100 may sample data for the first sensor every sampling interval and compare the sample to a target threshold for the first height of the water tank. At act S104, the controller 100 (e.g., processor 300) may generate and send a control signal for a subheater based on the comparison of the water level at the first height to the target threshold. The subheater may bring the water level to a standby temperature as long as the water in the tank is above the first height.

[0067] At act S107, the controller 100 (e.g., processor 300) monitors the sensor data for the second height of the water tank. For example, the controller 100 may sample data for the second sensor every sampling interval and compare the sample to a target threshold for the second height of the water tank. At act S109, the controller 100 (e.g., processor 300) may generate and send a control signal for a fill valve based on the comparison of the water level at the second height to the target threshold in order to maintain the water level at at least the second height. When the water meets or exceeds the seconds height, the controller 100 generates a control signal to activate the main heater and bring the water in the tank to a boil producing steam.

[0068] At act S111, one or more error codes may be generated by the controller 100 (e.g., processor 300) in certain scenarios. In one scenario, water is detected at the second height but not at the first height. The controller 100 generates a first error code indicative of errant water detection. In another example, the temperature data indicates a low temperature even when the subheater and/or main heater are in operation. The controller 100 generates a second error code indicative of errant temperature.

[0069] FIGS. 10 and 11 illustrates a water management mechanism implemented by the controller 100 described herein. The controller 100 is configured to operate the valve to manage the water level in response to the detected water level and at least one variable time period. In one example, the at least one variable time period includes a set a duty cycle period for operation of the valve according to the detected water level and the controller 100 is configured to update the set a duty cycle period and store the updated set a duty cycle period to the memory 352. In addition or in the alternative, the duty cycle period includes an opening duration for the valve and a closing duration or the valve, and the controller 100 is configured to adjust at least one of the opening duration and the closing duration for at least one subsequent duty cycle period. In addition or in the alternative, the at least one variable time period includes a set open time period for the valve, and the controller 100 is configured to update the set open time period and store the updated set open time period to the memory 352. In addition or in the alternative, the at least one variable time period includes an initial valve opening time, and the controller is configured to update the initial valve loading time and store the updated initial valve loading time to a memory.

[0070] FIG. 10 illustrates an example flow chart for water feed control based on a two-pole probe and operation of the controller 100 for the control system of the apparatus according to any of the embodiments described herein (e.g., steam generator 10). Additional, different or fewer acts may be included.

[0071] At act S201, the water feed sequence is started. The water sequence may be started in response to a user input command (e.g., from user input 71). The water sequence may be started in response to power supplied to the system.

[0072] At act S203, the controller (e.g., processor 300) loads the last valve open time from memory 352 (e.g., flash memory). The last valve open time may be referred to as a default valve value or stored valve value.

[0073] At act S205, the controller (e.g., processor 300) receives sensor data from the first pole 31. The controller analyzes the sensor data from the first pole to determine whether the first pole senses water. The sensor data may be a binary value (e.g., ON or OFF). The sensor data may be compared to threshold by the controller.

[0074] When the first pole 31 at act S205 senses water, the routine proceeds to act S223. When the first pole 31 at act S205 does not detect water, the routine proceeds to act S207.

[0075] At act S223, the controller (e.g., processor 300), when the first pole sensor data indicates that the first pole 31 sensing water, performs one or more actions associated with stopping or slowing the flow of water into the steam generator 10. The controller turns the water valve 5 OFF. The controller may decrease the valve open time and store the decreased valve open time into memory 352 (i.e., for access the next time the routine is as act S203). The controller may also initialize the open counter (i.e., set the open counter to zero). The controller may return to act S205.

[0076] At act S207, the controller (e.g., processor 300) receives sensor data from the second pole 32. The controller analyzes the sensor data from the second pole to determine whether the first pole senses water. The sensor data may be a binary value (e.g., ON or OFF). The sensor data may be compared to threshold by the controller.

[0077] When the second pole 32 at act S207 senses water, the routine proceeds to act S225. When second first pole 32 at act S207 does not detect water, the routine proceeds to act S209.

[0078] At act S225, the controller (e.g., processor 300) determines whether the full open timer is running. If yes, the controller proceeds to act S227 where it determines whether a predetermined time period (e.g., 40 seconds) has passed since the valve was open. If yes, an error is generated by the controller at act S229. The error may be shown on display 70. If the predetermined time period has not passed, the water valve 5 is opened at act S231. The routine returns to repeat act S205.

[0079] Starting at act S209, when neither the first pole 31 nor the second pole 32 has detected water, the controller (e.g., processor 300) performs the following subsequence. At act S209, the controller adjusts the valve open time. For example, the valve open time may be increased by the predetermined amount.

[0080] Examples for adjusting the valve open time may include the following: (1) if the open counter is less than 35 ms, the open time is the same with the last open time; (2) else if the counter is less than 70, increase the open time by 1 step (10 ms); and (3) else if the counter is more than 70, increase the open time by 2-step (20 ms). For example, when the counter is 35, the controller increases 1-step (10 ms) to the value for the valve open time that is saved in memory 352. For further example, when the counter is 70, the controller increases 2-step (20 ms) for the value for the valve open time that is saved in memory 352.

[0081] At act S213, the controller (e.g., processor 300) starts the valve open timer. The controller sets a valve period time (duration of duty cycle period) of an initial value (e.g., 4 seconds). The controller increases the open counter. At act S215, the controller (e.g., processor 300) turns the fill valve ON.

[0082] At act S217, the controller (e.g., processor 300) determines whether the valve open time is stopped. If the valve open timer is not stopped, the routine repeats act S217 to continuously monitor the valve open timer. Once the valve open timer is stopped, the controller turns off the water valve 5 OFF at act S219.

[0083] At act S221, the controller (e.g., processor 300) determines whether the valve period timer is stopped. When the fill valve period timer is not stopped, the routine repeats act S221 to continuously monitor the fill valve period timer. Once the valve period timer is stopped, the routines act S205 to check the sensor data from the first pole 31 and second pole 32 again.

[0084] FIG. 11 illustrates water feed control based on a one-pole probe operation of the controller 100 for the control system of the apparatus according to any of the embodiments described herein (e.g., steam generator 10).

[0085] At act S301, the water feed sequence is started. The water sequence may be started in response to a user input command (e.g., from user input 71). The water sequence may be started in response to power supplied to the system.

[0086] At act S303, the controller (e.g., processor 300) loads the last valve open time from memory 352 (e.g., flash memory). The last valve open time may be referred to as a default valve value or stored valve value.

[0087] At act S305, the controller (e.g., processor 300) receives sensor data from the probe (single pole operation). The controller analyzes the sensor data to determine whether the probe senses water. The sensor data may be a binary value (e.g., ON or OFF). The sensor data may be compared to threshold by the controller.

[0088] When the probe at act S305 senses water, the routine proceeds to act S323. When the probe at act S305 does not detect water, the routine proceeds to act S309.

[0089] At act S323, the controller (e.g., processor 300), performs one or more actions associated with stopping or slowing the flow of water into the steam generator 10. The controller turns the water valve 5 OFF. The controller may decrease the valve open time and store the decreased valve open time into memory 352 (i.e., for access the next time the routine is as act S203). The controller may also initialize the open counter (i.e., set the open counter to zero). The controller may return to act S305.

[0090] Starting at act S309, when no water has been detected, the controller (e.g., processor 300) performs the following subsequence. At act S309, the controller checks if the open counter has reached a maximum value (e.g., 100). When the maximum value has reached, the water valve 5 has been opened too long and an error is generated at act S325. The controller may send a signal or message to display 70 to display the error. The error may be a code that indicates a timeout error.

[0091] At act S311, the controller adjusts the valve open time. For example, the valve open time may be increased by the predetermined amount.

[0092] At act S313, the controller (e.g., processor 300) starts the valve open timer. The controller sets a valve period time (duration of duty cycle period) of an initial value (e.g., 4 seconds). The controller increases the open counter. At act S315, the controller (e.g., processor 300) turns the fill valve ON.

[0093] At act S317, the controller (e.g., processor 300) determines whether the valve open time is stopped. If the valve open timer is not stopped, the routine repeats act S317 to continuously monitor the valve open timer. Once the valve open timer is stopped, the controller turns off the water valve 5 OFF at act S319.

[0094] At act S321, the controller (e.g., processor 300) determines whether the valve period timer is stopped. When the fill valve period timer is not stopped, the routine repeats act S321 to continuously monitor the fill valve period timer. Once the valve period timer is stopped, the routines act S305 to check the sensor data from the single probe again.

[0095] Processor 300 may be a general purpose or specific purpose processor, an application specific integrated circuit (ASIC), one or more programmable logic controllers (PLCs), one or more field programmable gate arrays (FPGAs), a group of processing components, or other suitable processing components. Processor 300 is configured to execute computer code or instructions stored in memory 352 or received from other computer readable media (e.g., embedded flash memory, local hard disk storage, local ROM, network storage, a remote server, etc.). The processor 300 may be a single device or combinations of devices, such as with a network, distributed processing, or cloud computing.

[0096] Memory 352 may include one or more devices (e.g., memory units, memory devices, storage devices, etc.) for storing data and/or computer code for completing and/or facilitating the various processes described in the present disclosure. Memory 352 may include random access memory (RAM), read-only memory (ROM), hard drive storage, temporary storage, non-volatile memory, flash memory, optical memory, or any other suitable memory for storing software objects and/or computer instructions. Memory 352 may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. Memory 352 may be communicably connected to processor 300 via a processing circuit and may include computer code for executing (e.g., by processor 300) one or more processes described herein. For example, the memory 352 may include graphics, web pages, HTML files, XML files, script code, shower configuration files, or other resources for use in generating graphical user interfaces for display and/or for use in interpreting user interface inputs to make command, control, or communication decisions.

[0097] In addition to ingress ports and egress ports, the communication interface 353 may include any operable connection. An operable connection may be one in which signals, physical communications, and/or logical communications may be sent and/or received. An operable connection may include a physical interface, an electrical interface, and/or a data interface. The communication interface 353 may be connected to a network. The network may include wired networks (e.g., Ethernet), wireless networks, or combinations thereof. The wireless network may be a cellular telephone network, an 802.11, 802.16, 802.20, or WiMax network, a Bluetooth pairing of devices, or a Bluetooth mesh network. Further, the network may be a public network, such as the Internet, a private network, such as an intranet, or combinations thereof, and may utilize a variety of networking protocols now available or later developed including, but not limited to TCP/IP based networking protocols.

[0098] While the computer-readable medium (e.g., memory 352) is shown to be a single medium, the term computer-readable medium includes a single medium or multiple media, such as a centralized or distributed database, and/or associated caches and servers that store one or more sets of instructions. The term computer-readable medium shall also include any medium that is capable of storing, encoding or carrying a set of instructions for execution by a processor or that cause a computer system to perform any one or more of the methods or operations disclosed herein.

[0099] In a particular non-limiting, exemplary embodiment, the computer-readable medium can include a solid-state memory such as a memory card or other package that houses one or more non-volatile read-only memories. Further, the computer-readable medium can be a random access memory or other volatile re-writable memory. Additionally, the computer-readable medium can include a magneto-optical or optical medium, such as a disk or tapes or other storage device to capture carrier wave signals such as a signal communicated over a transmission medium. A digital file attachment to an e-mail or other self-contained information archive or set of archives may be considered a distribution medium that is a tangible storage medium. Accordingly, the disclosure is considered to include any one or more of a computer-readable medium or a distribution medium and other equivalents and successor media, in which data or instructions may be stored. The computer-readable medium may be non-transitory, which includes all tangible computer-readable media.

[0100] In an alternative embodiment, dedicated hardware implementations, such as application specific integrated circuits, programmable logic arrays and other hardware devices, can be constructed to implement one or more of the methods described herein. Applications that may include the apparatus and systems of various embodiments can broadly include a variety of electronic and computer systems. One or more embodiments described herein may implement functions using two or more specific interconnected hardware modules or devices with related control and data signals that can be communicated between and through the modules, or as portions of an application-specific integrated circuit. Accordingly, the present system encompasses software, firmware, and hardware implementations.

[0101] The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments may be apparent to those of skill in the art upon reviewing the disclosure. Other embodiments may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representational and may not be drawn to scale. Certain proportions within the illustrations may be exaggerated, while other proportions may be minimized. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.

[0102] While this specification contains many specifics, these should not be construed as limitations on the scope of the invention or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the invention. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

[0103] One or more embodiments of the disclosure may be referred to herein, individually and/or collectively, by the term invention merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.

[0104] It is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is understood that the following claims including all equivalents are intended to define the scope of the invention. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.