Condensing water heater and condensation control system
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
F24H-009/20
F24H-001/20
F24H-008/00
F24H-009/00
F24H-009/18
출원번호
US-0429075
(2017-02-09)
등록번호
US-10184690
(2019-01-22)
발명자
/ 주소
Steinhafel, Michael B.
Gourlie, Jonathan
출원인 / 주소
Bock Water Heaters, Inc.
대리인 / 주소
Stiennon & Stiennon
인용정보
피인용 횟수 :
0인용 특허 :
4
초록▼
A water heater with two non-condensing flues and a condensing flue(s) having a system to prevent condensation in the non-condensing flue(s). The downwardly extending first flue is connected by a 180 degree connector to an upwardly extending second flue. Between the non-condensing and the condensing
A water heater with two non-condensing flues and a condensing flue(s) having a system to prevent condensation in the non-condensing flue(s). The downwardly extending first flue is connected by a 180 degree connector to an upwardly extending second flue. Between the non-condensing and the condensing flues is positioned a temperature sensor. A controller receives input from the temperature sensor and is connected to the burner to control the minimum power setting and duration so as to prevent the combustion gases from falling below a temperature at which water will condense at the temperature sensor so no condensation occurs in the first two flues. Burner power settings are minimized near a water tank setpoint to improve efficiency by increasing condensation.
대표청구항▼
1. A method in a water heater, of controlling a water heater burner which has an adjustable power setting and, wherein the burner fires into a non-condensing part of a flue, the flue also having a condensing part, preventing condensation of water in the non-condensing part with the controller, compr
1. A method in a water heater, of controlling a water heater burner which has an adjustable power setting and, wherein the burner fires into a non-condensing part of a flue, the flue also having a condensing part, preventing condensation of water in the non-condensing part with the controller, comprising the steps of: locating a flue temperature sensor in the flue at a location between the non-condensing part and the condensing part of the flue;detecting a signal from a flame sensor that the burner that fires into the non-condensing part of the flue is on, so that the burner produces flue gases that travel through the water heater flue, and while the burner is on performing the steps of:monitoring the output of the flue temperature sensor and determining if the flue temperature sensor output exceeds a selected temperature above a dew point of water vapor in the combustion gases at the location of the flue temperature sensor;increasing the burner power setting if the flue temperature sensor output is below the selected temperature above the dew point and the water heater burner is at a setting less than a minimum power upper limit. 2. A method in a water heater, of controlling a water heater burner which has an adjustable power setting, wherein the burner fires into a non-condensing part of a flue, the flue also having a condensing part, preventing condensation of water in the non-condensing part, comprising the steps of: locating a flue temperature sensor in the flue at a location between the non-condensing part and the condensing part of the flue;detecting a signal from a flame sensor that the burner that fires into the non-condensing part of the flue is on, so that the burner produces flue gases that travel through the water heater flue, and while the burner is on performing the steps of:monitoring the output of the flue temperature sensor and determining if the flue temperature sensor output exceeds a selected temperature above a dew point of water vapor in the combustion gases at the location of the flue temperature sensor;wherein the burner has a minimum power range extending from a minimum power lower limit to a minimum power upper limit,wherein if the output of the flue temperature sensor is less than the selected temperature above the dew point, and the water heater burner is at a setting less than the minimum power upper limit, increasing the burner power by a first incremental step and waiting a first selected interval of time;if the output of the flue temperature sensor is greater than or equal to the selected temperature above the dew point and less than or equal to the selected temperature above the dew point plus an overshoot value, taking no action;if the output of the flue temperature sensor is greater than the selected temperature above the dew point plus the overshoot value, and if the water heater power is equal to the minimum power lower limit taking no action; andif the output of the flue temperature sensor is greater than the selected temperature above the dew point plus the overshoot value, and the power setting is greater than the minimum power lower limit decreasing the burner power by a second incremental step and waiting a second selected interval of time. 3. The method of claim 2 wherein the first incremental step and the second incremental step are the same, and wherein the first selected interval of time and the second selected interval of time are of the same length. 4. The method of claim 3 where the first incremental step and the second incremental step are 1% of a maximum power setting and the first selected interval of time and the second selected interval of time are 1 second. 5. The method of claim 2 wherein the step of locating the flue temperature sensor in the water heater flue at the location between the non-condensing part and the condensing part of the flue, further comprises placing the flue temperature sensor to measure an inside surface of a portion of a wall of the non-condensing part of the flue which is closest to the condensing part of the flue and said portion has an outside surface still in contact with water in a water tank. 6. The method of claim 2 wherein the selected temperature above the dew point is 1-10° F. above the dew point of the partial pressure of water vapor in the combustion gases at the flue temperature sensor. 7. The method of claim 2 wherein the selected temperature above the dew point is 10-100° F. above the dew point of the partial pressure of water vapor in the combustion gases at the flue temperature sensor. 8. The method of claim 2 wherein the selected minimum power upper limit of the burner is such that there is no condensation in the non-condensing flue within one minute of turning the burner on. 9. The method of claim 2 wherein the step of detecting the signal that the burner is on and the steps performing while the burner is on, are performed by a controller. 10. A water heater comprising: a water tank having a lower dome and an upper dome, and a tank wall extending therebetween;a first non-condensing flue defining a first flue wall, the first flue extending from the upper dome toward the lower dome, the first flue joining the upper dome to define an opening through the upper dome;a burner mounted to the first flue so as to fire along the first flue;wherein the first flue is connected to a second non-condensing flue by a 180 degree connector located within the water tank, the second flue defining a flue wall, the second flue extending from the connector to the upper dome, the second flue joining the upper dome to define a second flue opening through the upper dome, and the second flue defining an inner surface to which a multiplicity of radially inwardly extending metal fins are each attached by a weld, without extending through the second flue wall;at least one third condensing flue extending from the lower dome to the upper dome and connected to the second flue by a junction box on the upper dome;a setpoint temperature sensor located to sense a temperature of water contained within the water heater tank;a flue temperature sensor located in the second non-condensing flue on an inside surface of a portion of the wall of the second non-condensing flue which is closest to the third condensing flue and wherein said portion has an outside surface arranged in contact with water when the water tank is filled;a controller mounted to the water heater and connected in controlling relationship to the burner, the controller connected in temperature receiving relation to the setpoint temperature sensor and the flue temperature sensor and arranged to control a burner setting so that a temperature output of the flue temperature sensor is maintained above a dew point at which water would condense in the second flue, and to turn the burner on when the setpoint temperature sensor indicates water temperature in the water tank falls below a selected setpoint temperature;wherein the burner has a minimum power range extending from a minimum power lower limit to a minimum power upper limit; andwherein the controller is arranged to control the burner with input from the setpoint temperature sensor and the flue temperature sensor to heat and maintain water in the water tank within a selected temperature range without condensing water from operation of the burner until the third condensing flue. 11. The water heater of claim 10 wherein the 180 degree connector located within the water heater tank is formed of a lower boat shaped shell which is welded to a flat plate which forms a deck for the shell, the shell having a first hole sized to receive the first flue and a second hole sized to receive the second flue, wherein the first flue is welded to portions of the deck surrounding the first hole and the second flue is welded to portions of the deck surrounding the second hole so that the first and second flue are connected by a space defined between the shell and the deck. 12. The water heater of claim 10 wherein there are a plurality of third condensing flues extending from the lower dome to the upper dome and connected to the second flue by the junction box on the upper dome and to another junction box on the lower dome, which slopes downwardly and outwardly of the tank such that condensation water drains to a drain. 13. A method in a water heater, the water heater comprising: a water tank having a lower dome and an upper dome, and a tank wall extending therebetween; a first flue defining a first flue wall, the first flue extending from the upper dome toward the lower dome, the first flue joining the upper dome to define an opening through the upper dome; a burner mounted to the first flue so as to fire along the first flue introducing combustion gases therein; wherein the first flue is connected to a second flue by a 180 degree connector located within the water tank, the second flue defining a flue wall, the second flue extending from the connector to the upper dome, the second flue joining the upper dome to define a second flue opening through the upper dome, and the second flue defining an inner surface to which a multiplicity of radially inwardly extending metal fins are each attached by a weld, without extending through the second flue wall; at least one third condensing flue extending from the lower dome to the upper dome and connected to the second flue by a junction box on the upper dome; a setpoint temperature sensor located to sense a temperature of water contained within the water heater tank; wherein the first and second flues comprise a non-condensing flue portion, and wherein a flue temperature sensor is located at a point in the water heater between the non-condensing flue portion and the at least one third condensing flue; a controller mounted to the water heater and connected in controlling relationship to the burner, the controller connected in temperature receiving relation to the setpoint temperature sensor and the flue temperature sensor and arranged to control a power setting of the burner to turn the burner on and off; wherein the method comprises the following steps of controlling the water heater burner:detecting a signal from a flame sensor that the burner is on, so that the burner produces flue gases that travel through the water heater flue, and while the burner is on performing the steps of:monitoring the output of the flue temperature sensor and determining if the flue temperature sensor output exceeds a selected temperature above a dew point of water vapor in the combustion gases at the location of the flue temperature sensor;wherein the burner has a minimum power range extending from a minimum power lower limit to a minimum power upper limit,wherein if the output of the flue temperature sensor is less than the selected temperature above the dew point, and the burner is at a setting less than the minimum power upper limit, increasing the burner power by a first incremental step and waiting a first selected interval of time;if the output of the flue temperature sensor is greater than or equal to the selected temperature above the dew point and less than or equal to the selected temperature above the dew point plus an overshoot value, taking no action;if the output of the flue temperature sensor is greater than the selected temperature above the dew point plus the overshoot value, and if the water heater power is equal to the minimum power lower limit taking no action; andif the output of the flue temperature sensor is greater than the selected temperature above the dew point plus the overshoot value, and the power setting is greater than the minimum power setting lower limit decreasing the burner power by a second incremental step and waiting a second selected interval of time.
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이 특허에 인용된 특허 (4)
Gordon, Michael; Scott, Timothy D.; Sutherland, Jason; Stafford, Christopher; Campbell, Ross, High efficiency water heater.
Rawlings John P. (Oklahoma City OK), Subterranean heat exchange units comprising multiple secondary conduits and multi-tiered inlet and outlet manifolds.
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