Microprocessor control for a heat pump water heater

• US 6,212,894 B1
• Filed: 03/28/1997
• Issued: 04/10/2001
• Est. Priority Date: 03/29/1996
• Status: Expired due to Fees

• Current Assignee: WaterFurnace International, Inc. (NIBE Industrier AB)
• Original Assignee: WaterFurnace International, Inc. (NIBE Industrier AB)
• Inventors: Brown, Robert R., Mann, Christopher C., Zeplin, R. Todd
• Primary Examiner(s): Tanner, Harry B.
• Application Number:
  US08/827,301
• Time in Patent Office: 1,474 Days
• Field of Search: 622/387, 622/386, 622/30, 621/26, 621/27, 621/80, 621/77, 237/2.B, 236/20.R, 236/21.R, 236/21.B, 236/25.R
• US Class Current: 62/180
• CPC Class Codes: F24D 19/1054 the system uses a heat pump
• CPC Class Codes: F24H 15/104 Inspection; Diagnosis; Trial operation
• CPC Class Codes: F24H 15/136 Defrosting or de-icing; Preventing freezing
• CPC Class Codes: F24H 15/174 Supplying heated water with desired temperature or desired range of temperature
• CPC Class Codes: F24H 15/215 before heating
• CPC Class Codes: F24H 15/219 after heating
• CPC Class Codes: F24H 15/231 at the evaporator
• CPC Class Codes: F24H 15/242 Pressure
• CPC Class Codes: F24H 15/37 of electric heaters
• CPC Class Codes: F24H 15/38 Control of compressors of heat pumps
• CPC Class Codes: F24H 15/395 Information to users, e.g. alarms
• CPC Class Codes: F24H 15/421 using pre-stored data
• CPC Class Codes: F25B 49/02 for compression type machines, plants or systems

Abstract

A microprocessor based control system monitors and controls a heat pump water heater system and interfaces the water heating system with an external centralized control system. The microprocessor control system includes sensors, safety switches, device interface relays, user interface devices and precanned software to provide versatile monitoring and control over a heat pump type water heating system. The system generally involves a typical heat pump coupled with a domestic water heater, hot water retention tank or other body of water. The control system provides operational control over the heat pump to maintain the hot water stored in the domestic water heater in a predetermined setpoint and controls the use of electric resistance heating elements in the domestic water heater for added heating capacity for quick heat recovery type operation. The control system receives a centralized signal typically from a utility company to disable heat pump water heating operation during peak demand time periods. Control logic is provided to carry out effective liming parameter control, high evaporator temperature control, and defrost/anti-freeze protection control.

Claims

1. An electronic control system for controlling a heat pump water heater including a compressor which includes a suction side, an evaporator, refrigerant for circulating through said evaporator, and a condenser coupled with a hot water retention tank to form a hot water circuit, the hot water retention tank including means for receiving water from a supply source and means for discharging heated water, said control system comprising:

first means for sensing the temperature of water in the hot water circuit and generating a first output signal representative of such temperature;

second means for sensing the temperature of the hot water at the discharge means of the hot water retention tank and generating a second output signal representative of such temperature;

means for circulating water from the hot water retention tank, through the condenser and back to the hot water retention tank; and

a controller for receiving said first and second output signals, whereby upon detecting a rise in the temperature of hot water at said discharge means said controller energizes said circulating means, samples said first output signal and cycles the heat pump water heater to maintain a predefined hot water setpoint.

2. The electronic control system of claim 1, further comprising third means for sensing the temperature of water at said receiving means and generating a third output signal representative of such temperature, whereby upon detecting a drop in the temperature of the water receiving means, and a rise in temperature of the heated water at said discharge means, said controller energizes said circulating means, samples said first output signal and cycles the heat pump water heater to maintain a predefined hot water setpoint.

3. The electronic control system of claim 1, wherein said circulating means is a dedicated hot water circulating pump.

4. The electronic control system of claim 1, wherein the hot water retention tank is a domestic water heater having electric resistance heating elements.

5. The electronic control system of claim 1, wherein the hot water retention tank includes electric resistance heating elements, said controller energizes the electric resistance heating elements for added water heating capacity in the event the temperature of the heated water at the discharge means of the hot water retention tank or the temperature of the hot water circuit falls below a predetermined low limit temperature setpoint.

6. The electronic control system of claim 5, wherein a central control signal is capable of enabling/disabling electric resistance heating element operation.

7. The electronic control system of claim 6, wherein said central control signal is initiated by a central energy provider via a radio controlled grounded signal for the purpose of disabling electric resistance heating element operation during peak energy demand periods.

8. The electronic control system of claim 1, wherein a central control signal disables heat pump water heater operation.

9. The electronic control system of claim 8, wherein said central control signal is initiated by a central energy provider during periods of peak energy demand.

10. The electronic control system of claim 9, wherein upon said central control signal permitting heat pump water heater startup, said electronic control system implements a random time delay of between 1 second and 30 minutes during power up.

11. The electronic control system of claim 1 further comprising a low pressure switch disposed in a suction line of the compressor and generating a low pressure output signal representative of a low pressure fault in the event refrigerant pressure falls below a predetermined limit, said controller disabling heat pump water heater and said circulating means operation upon receiving said low pressure output signal.

12. The electronic control system of claim 1 further comprising a high pressure switch disposed in a discharge line of the compressor and generating a high pressure output signal representative of a high pressure fault in the event refrigerant pressure exceeds a predetermined limit, said controller receiving said high pressure output signal.

13. The electronic control system of claim 12, wherein said controller, upon receiving such high pressure output signal, disables heat pump water heater operation for a predetermined period of time and reduces said hot water setpoint a predetermined amount, said controller, after said predetermined period of time has run, restarts heat pump water heater operation and maintains the hot water at the reduced setpoint.

14. The electronic control system of claim 13, wherein upon subsequent high pressure fault occurrences said controller, after each such high pressure fault occurrence, disables heat pump water heater operation for said predetermined period of time and further reduces said hot water setpoint said predetermined amount, said controller, after said predetermined period of time has run, restarts heat pump water heater operation for maintaining the hot water at the further reduced setpoint.

15. The electronic control system of claim 14, wherein upon said hot water setpoint being reduced to a predetermined minimum value, said controller discontinues heat pump water heater operation.

16. The electronic control system of claim 1, wherein the hot water retention tank is incorporated in the heat pump water heater and the condenser is disposed in the hot water retention tank.

17. The electronic control system of claim 1, further comprising a means for circulating a heat source through the evaporator.

18. The electronic control system of claim 17, wherein said heat source circulating means is remotely located and said controller generates a remote output signal for energizing said remote heat source circulating means.

19. The electronic control system of claim 17, further comprising a refrigerant temperature sensing means for sensing the temperature of the refrigerant flowing from the evaporator and into the suction side of the compressor, said refrigerant temperature sensing means generating a refrigerant temperature output signal representative of such temperature, said controller receiving said refrigerant temperature output signal and upon detecting an excessive suction side refrigerant temperature disabling the heat source circulating means.

20. The electronic control system of claim 19, wherein said controller, upon the suction side refrigerant temperature falling to a predetermined low limit setpoint, enabling the heat source circulating means.

21. The electronic control system of claim 17 further comprising a freeze protection sensor for sensing the temperature of compressed refrigerant entering the evaporator and generating compressed refrigerant output signal representative of the temperature of the refrigerant entering the evaporator, said controller receiving said compressed refrigerant output signal and, upon detecting a freeze condition at the evaporator according to a preset low limit temperature setpoint, disabling heat pump water heater operation for a predetermined period of time.

22. The electronic control system of claim 21, wherein the hot water retention tank includes electric resistance heating elements and said controller energizes the electric resistance heating elements to maintain said hot water setpoint upon the occurrence of a freeze condition.

23. The electronic control system of claim 1, wherein the evaporator is thermodynamically coupled to an air heat source and the heat pump water heater includes a means for circulating the air heat source through the evaporator.

24. The electronic control system of claim 1, wherein the hot water retention tank is an external body of water and said first sensing means senses the temperature of the external body of water, said controller cycling the heat pump water heater and said circulating means to maintain the temperature of the external body of water in accordance with a predefined setpoint.

25. The electronic control system of claim 1, wherein the evaporator is thermodynamically coupled to a condenser of a direct exchange heat source, whereby heat is transferred from the direct exchange heat source to the evaporator.

26. The electronic control system of claim 1, wherein said controller includes memory having at least one of a group of operational programs, said group of operational programs comprising:

liming parameter control, high evaporator temperature control, on peak setback, quick heat recovery mode, demand sampling control, periodic sampling control, fault retry and diagnostics service routine.

27. The electronic control system of claim 26, wherein said liming parameter control consists of the following steps:

monitoring the pressure at a discharge side of the compressor;

detecting excessive discharge pressure and sending a fault signal to said controller;

discontinuing heat pump water heater operation for a predetermined delay period; and

reducing said hot water setpoint by a predetermined amount.

28. The electronic control system of claim 27 comprising the further step of repeating the above steps until said hot water setpoint reaches a predetermined minimum value at which point the heat pump water heater operation is terminated.

29. The electronic control system of claim 26, wherein the evaporator is thermodynamically coupled to a heat source and the heat pump water heater includes a means for circulating the heat source, said high evaporator temperature control comprises the following steps:

monitoring the temperature of the refrigerant entering a suction side of the compressor;

detecting an excessive heat exchange medium temperature as sensed in the preceding step according to a predetermined high limit setpoint;

disabling the heat source circulating means upon detecting an excessive suction side refrigerant temperature;

enabling the heat source circulating means upon the suction side refrigerant temperature falling to a second predetermined setpoint; and

repeating the above steps to maintain suction side heat exchange refrigerant temperature between said second setpoint and said high limit setpoint.

30. The electronic control system of claim 26, wherein said fault retry service routine consists of the following steps:

monitoring fault indication signals input to said controller;

initiating a fault retry wait period and allowing continued heat pump water heater operations;

detecting a sustained fault indication;

initiating a second fault retry weight period and allowing continued heat pump water heater operations; and

disabling heat pump water heater operation upon detecting a sustained fault indication for a second time.

31. The electronic control system of claim 30 comprising the further step of resetting the fault retry to an initial state upon failing to detect a sustained fault indication.

32. An electronic control system for controlling a heat pump water heater including a compressor, an evaporator, and a condenser coupled with a hot water retention tank to form a hot water circuit, the hot water retention tank including means for receiving water from a supply source and means for discharging heated water, said control system comprising:

first means for sensing the temperature of water in the hot water circuit and generating a first output representative of such temperature;

means for circulating water from the hot water retention tank, through the condenser and back to the hot water retention tank; and

a controller for receiving said first output signal and providing periodic sampling control, said controller energizing said circulating means for a first predetermined period of time to sample said first output signal and, upon detecting a call for heat, cycling the heat pump water heater to maintain a predefined hot water setpoint, said controller maintaining the heat pump water heater in a de-energized state for a second predetermined period of time when no demand for hot water is detected.

33. The electronic control system of claim 32 wherein said controller is reset to wait a third predetermined period of time before initiating periodic sampling operation upon the cessation of heat pump water heater operation.

34. An apparatus for heating water comprising:

an evaporator in heat exchange relationship with a heat source;

a condenser;

a compressor operatively disposed between said evaporator and said condenser and having a suction line and a discharge line;

a hot water retention tank in heat exchange relationship with said condenser, said hot water retention tank including means for receiving water from a supply and means for discharging heated water;

means for circulating water from said hot water retention tank, through said condenser and back to said hot water retention tank; and

an electronic control apparatus comprising;

first means for sensing the temperature of water stored in said hot water retention tank and generating a first output signal representative of such temperature;

second means for sensing the temperature of the domestic hot water at said discharge means of said hot water retention tank and generating a second output signal representative of such temperature; and

a microprocessor-based controller for receiving said first and second signals output, whereby upon detecting a rise in the temperature of the heated water at said discharge means said controller samples said first output signal and cycles said compressor to maintain a predefined hot water setpoint.

35. The water heating apparatus of claim 34 further comprising third means for sensing the temperature of the water supply at said receiving means of said hot water retention tank and generating a third output signal representative of such temperature, whereby upon detecting a drop in the temperature of the water at said receiving means and a rise in temperature of the heated water at said discharge means said controller samples said first output signal and cycles said compressor to maintain a predefined hot water setpoint.

36. The water heating apparatus of claim 34, wherein the hot water retention tank is a stand alone domestic water heater having electric resistance heating elements.

37. The water heating apparatus of claim 34, wherein the hot water retention tank includes electric resistance heating elements, said controller energizes the electric resistance heating elements for added water heating capacity in the event the temperature of the heated water at said discharge means of the hot water retention tank falls below a predetermined low limit temperature setpoint.

38. The water heating apparatus of claim 37, wherein a central control signal enables/disables electric resistance heating element operation.

39. The water heating apparatus of claim 38, wherein said central control signal is initiated by an energy provider via a radio controlled grounded signal.

40. The water heating apparatus of claim 34, wherein a central control signal disables water heating system operation.

41. The water heating apparatus of claim 40, wherein said central control signal is initiated by a central energy provider during periods of peak energy demand.

42. The water heating apparatus of claim 41, wherein upon said central control signal changing state so as to allow water heating system startup, said water heating system implements a random time delay of divergent length during power up.

43. The water heating apparatus of claim 34 further comprising a low pressure switch and a high pressure switch, said low pressure switch disposed in said suction line of said compressor and generating a low pressure output signal representative of a low pressure fault condition in the event refrigerant pressure falls below a preset limit, said high pressure switch disposed in said discharge line of said compressor and generating a high pressure output signal representative of a high pressure fault condition in the event refrigerant pressure exceeds a preset limit, said controller receiving said low pressure and high pressure output signals and disabling water heating system operation in the event of a low pressure fault condition or a high pressure fault condition.

44. The water heating apparatus of claim 34, wherein said heat source is a loop hydronic heat source and said water heating apparatus includes a means for circulating the loop hydronic heat source through said evaporator.

45. The water heating apparatus of claim 34, wherein said heat source is an air heat source and said water heating apparatus includes a means for circulating said air heat source through said evaporator.

46. The water heating apparatus of claim 34 further comprising a freeze protection sensor disposed in said suction line of said compressor, said freeze protection sensor generating a freeze condition output signal representative of a freeze condition, said controller receiving said freeze condition output signal and, according to a preset low limit temperature setpoint, disabling water heating system operation upon detecting a freeze condition.

47. The water heating apparatus of claim 34, wherein said heat source is a condenser of a direct exchange heat source, whereby heat is transferred from the refrigerant of said direct exchange heat source to said evaporator by circulating the refrigerant through said evaporator.

48. A method of controlling a heat pump water heater having a compressor, an evaporator, and a condenser coupled with a hot water retention tank to form a hot water circuit, the hot water retention tank including means for receiving water from a supply and means for discharging heated water, said method comprising the following steps:

sensing the temperature of the water at the receiving means of the hot water retention tank and sensing the temperature of the heated water at the discharge means of the hot water retention tank;

utilizing a microprocessor-based controller to detect a hot water demand based upon a decrease in the temperature of the water at the receiving means of the hot water retention tank in conjunction with an increase in the temperature of the heated water at the discharge means of the hot water retention tank;

upon detecting such hot water demand, causing water to circulate between the hot water retention tank and the condenser; and

sensing the temperature of the water in the hot water circuit and cycling the heat pump water heater compressor to maintain the water in the hot water retention tank at a predetermined setpoint.

49. The method of controlling a heat pump water heater of claim 48 wherein the hot water retention tank includes electric resistance heating elements, said control method comprising the further step of energizing the electric resistance heating elements for additional water heating capacity in the event the hot water circuit water temperature or the temperature of the heated water at the discharge means of the hot water retention tank falls below a predetermined low limit.

50. The method of controlling a heat pump water heater of claim 49 comprising the additional step of disabling the electric resistance heating elements according to an external control signal.

51. The method of controlling a heat pump water heater of claim 48 comprising the additional step of disabling heat pump water heater operation during periods of peak energy demand according to a central control signal.

52. The method of controlling a heat pump water heater of claim 48 comprising the additional step of circulating the water in the hot water circuit and sensing the temperature of the water therein if no demand for hot water is sensed after a preset period of time.

53. The method of controlling a heat pump water heater having a compressor, an evaporator, a condenser coupled with a hot water retention tank to form a hot water circuit, and means for circulating the water contained in the hot water circuit, the hot water retention tank including means for receiving water from a supply and means for discharging heated water, said control method comprising the following steps:

energizing the hot water circulating device;

sensing the temperature of the water in the hot water circuit and generating a signal representative of such temperature;

utilizing a microprocessor-based controller to detect a call for water heating according to the hot water circuit temperature sensed and a predetermined setpoint;

upon detecting that no call for water heating exists, said controller de-energizing the hot water circulating device and waiting a predetermined period of time before repeating the above steps;

upon detecting a call for water heating, said controller cycling the heat pump water heater compressor to maintain the predetermined setpoint; and

waiting a predetermined period of time and energizing the hot water circulating device.

54. The method of controlling a heat pump water heater of claim 53 wherein the hot water retention tank includes electric resistance heating elements, said control method comprising the further step of energizing the electric resistance heating elements for additional water heating capacity in the event the hot water circuit water temperature or the temperature of the heated water at the discharge means of the retention tank falls below a predetermined low limit.

55. The method of controlling a heat pump water heater of claim 54 comprising the additional step of disabling the electric resistance heating elements according to an external control signal.

56. The method of controlling a heat pump water heater of claim 53 comprising the additional step of disabling heat pump water heater operation during periods of peak energy demand according to an external control signal.

57. A method of monitoring liming conditions for use in controlling a heat pump water heater comprising a compressor, an evaporator, a condenser coupled with a hot water retention tank to form a hot water circuit, and means for circulating the water contained in the hot water circuit, the hot water retention tank including means for receiving water from a supply and means for discharging hot water, a high pressure switch disposed in a discharge line of the compressor and generating a first output signal representative of a high pressure fault condition, and a controller for receiving said first output signal, said liming control method comprising the following steps:

disabling heat pump water heater operation for a first predetermined period of time and reducing a hot water setpoint a first predetermined amount upon said controller receiving said first output signal;

restarting heat pump water heater operation after said first predetermined period of time has run and maintaining the hot water temperature according to the reduced setpoint;

disabling heat pump water heater operation a second predetermined period of time and further reducing said hot water setpoint by a second predetermined amount upon subsequent high pressure fault occurrences; and

restarting heat pump water heater operation after said second predetermined period of time has run and maintaining the hot water at the further reduced setpoint.

58. The method of monitoring liming conditions of claim 57, wherein upon said hot water setpoint reaching a predetermined minimum value, said controller discontinues heat pump water heater operation.