Systems and methods for controlling water heaters

• US 9,829,897 B2
• Filed: 02/03/2014
• Issued: 11/28/2017
• Est. Priority Date: 02/03/2014
• Status: Active Grant

• Current Assignee: Copeland Comfort Control LP (Emerson Electric Company)
• Original Assignee: Emerson Electric Company
• Inventors: Koopman, Wayne A.
• Primary Examiner(s): Anya, Charles E
• Application Number:
  US14/171,416
• Publication Number:
  US 20150220091A1
• Time in Patent Office: 1,394 Days
• CPC Class Codes: F23N 1/082 using electronic means
• CPC Class Codes: F24D 2200/04 Gas or oil fired boiler
• CPC Class Codes: F24H 1/205 with furnace tubes
• CPC Class Codes: F24H 15/175 where the difference between the measured temperature and a set temperature is kept under a predetermined value
• CPC Class Codes: F24H 15/223 in the water storage tank
• CPC Class Codes: F24H 15/36 of burners
• CPC Class Codes: F24H 15/421 using pre-stored data
• CPC Class Codes: F24H 9/2035 using fluid fuel
• CPC Class Codes: G05D 23/1919 characterised by the type of controller

Abstract

A water heater includes a storage tank, a sensor configured to measure a temperature of water in the storage tank, a burner configured to heat the water in the storage tank, and a controller communicatively coupled to the sensor and the burner. The controller is configured to initiate a call for heat when the measured temperature reaches a trigger temperature, wherein the trigger temperature is a differential amount less than a set-point temperature, calculate a reduced activation time when the call for heat results in a predetermined number of calls for heat occurring within a predetermined time period, and control the burner based on the reduced activation time.

Claims

1. A processor for a controller of a water heater, the processor programmed with instructions such that when the instructions are executed, the processor is configured to:

receive an output from a sensor indicating a measured temperature of water in the water heater;

initiate a call for heat when the measured temperature reaches a trigger temperature, wherein the trigger temperature is a differential amount less than a set-point temperature;

calculate a reduced activation time when the call for heat results in a predetermined number of calls for heat occurring within a predetermined time period, wherein the reduced activation time is calculated based on a predetermined scaling factor and wherein the reduced activation time is less than a standard activation time required to heat the water from the trigger temperature to the set-point temperature; and

control, based on the reduced activation time, a burner that is configured to heat the water in the water heater.

2. The processor of claim 1, wherein the processor is configured to calculate the reduced activation time as the differential amount multiplied by the predetermined scaling factor.

3. The processor of claim 1, wherein the processor is configured to calculate the reduced activation time as a predetermined percentage of an activation time for a previous call for heat.

4. The processor of claim 1, wherein the processor is further configured to activate the burner until the measured temperature reaches the set-point temperature when the call for heat does not result in the predetermined number of calls for heat occurring within the predetermined time period, and wherein the predetermined number of calls for heat is two.

5. The processor of claim 1, wherein the processor is configured to control the burner such that the burner is activated for the reduced activation time.

6. The processor of claim 1, wherein the processor is configured to control the burner such that the burner remains activated for the reduced activation time once the measured temperature reaches the trigger temperature.

7. The processor of claim 1, wherein the processor is configured to control the burner such that the burner remains activated for the reduced activation time once the measured temperature reaches a predetermined buffer temperature.

8. A water heater comprising:

a storage tank;

a sensor configured to measure a temperature of water in the storage tank;

a burner configured to heat the water in the storage tank; and

a controller communicatively coupled to the sensor and the burner, the controller configured to;

initiate a call for heat when the measured temperature reaches a trigger temperature, wherein the trigger temperature is a differential amount less than a set-point temperature;

calculate a reduced activation time when the call for heat results in a predetermined number of calls for heat occurring within a predetermined time period, wherein the reduced activation time is calculated based on a predetermined scaling factor and wherein the reduced activation time is less than a standard activation time required to heat the water from the trigger temperature to the set-point temperature; and

control the burner based on the reduced activation time.

9. The water heater of claim 8, wherein the controller is configured to calculate the reduced activation time as the differential amount multiplied by the predetermined scaling factor.

10. The water heater of claim 8, wherein the controller is configured to calculate the reduced activation time as a predetermined percentage of an activation time for a previous call for heat.

11. The water heater of claim 8, wherein the controller is further configured to activate the burner until the measured temperature reaches the set-point temperature when the call for heat does not result in the predetermined number of calls for heat occurring within the predetermined time period.

12. The water heater of claim 8, wherein the controller is configured to control the burner such that the burner is activated for the reduced activation time.

13. The water heater of claim 8, wherein the controller is configured to control the burner such that the burner remains activated for the reduced activation time once the measured temperature reaches the trigger temperature.

14. The water heater of claim 8, wherein the controller is configured to control the burner such that the burner remains activated for the reduced activation time once the measured temperature reaches a predetermined buffer temperature.

15. A method for operating a water heater using a controller, the method comprising:

receiving, at the controller, an output from a sensor indicating a measured temperature of water in the water heater;

initiating, using the controller, a call for heat when the measured temperature reaches a trigger temperature, wherein the trigger temperature is a differential amount less than a set-point temperature;

calculating, using the controller, a reduced activation time when the call for heat results in a predetermined number of calls for heat occurring within a predetermined time period, wherein calculating the reduced activation time comprises calculating the reduced activation time as the differential amount multiplied by a predetermined scaling factor; and

controlling, using the controller, a burner based on the reduced activation time, the burner configured to heat the water in the water heater.

16. The method of claim 15, wherein controlling a burner comprises controlling the burner such that the burner is activated for the reduced activation time.

17. The method of claim 15, wherein controlling a burner comprises controlling the burner such that the burner remains activated for the reduced activation time once the measured temperature reaches the trigger temperature.

18. The method of claim 15, wherein controlling a burner comprises controlling the burner such that the burner remains activated for the reduced activation time once the measured temperature reaches a predetermined buffer temperature.