IE20200011A2 - Improved hot water storage cylinder pre-plumb for a heating system and hot water system - Google Patents

Abstract

A pre-plumb hot water cylinder for a heating and hot water system configured to provide heated water to at least one heating zone and at least one hot water zone. The pre-plumb hot water cylinder comprises a hydronic fluid circulation block arranged for circulate the fluid exiting the at least one outlet pipe to the at least one heating zone and at least one hot water zone of the heating system via respective openings, each opening comprising a valve configured to control the flow of the fluid at the respective heating and/or hot water zones; the hot water cylinder comprising a control unit configured to at least control the operation of the valves provided at each opening, so as to regulate the flow of the heated fluid to each of the heating and/or hot water zones based on instructions received by a user from a display panel provided on the control unit and/or via a communication network from a software application operating on a user device. <Figure 1>

Description

IMPROVED HOT WATER STORAGE CYLINDER PRE-PLUMB FOR A HEATING SYSTEM AND HOT WATER SYSTEM The present invention relates an improved hot water storage cylinder pre-plumb for a heating and hot water system. More specifically, the present invention relates to a hot water storage tank provided with an electronically controllable hydronic fluid circulation unit.

Background to the Invention A pre-plumb hot water cylinder may be provided to store hot water along with a distribution network heating system fixed to the hot water cylinder casing which can distribute heat to a household's heat emitter circuit. In general, a pre plumb hot water cylinder is provided with a cold water inlet pipe, providing cold water in the cylinder, a heating element such as coil for heating the cold water in the cylinder to the desired temperature, and at least one hot water outlet pipe for distributing hot running water to the household, and at least one heating system distribution outlet pipe for circulating heating system water to radiators or other types of heat emitters to heat a space. In most cases, the heating element (coil) of the hot water cylinder may be operated by a controller, e.g. a thermostat, so once the water is heated to the desired temperature, the heating element may be switched off to save energy.

Existing pre-plumb hot water cylinders rely on an extended network of pipes for the distribution of hot water to different heating and hot water zones, e.g. space heating zones, and/or hot running water zone. A valve may be placed at each outlet pipe, to regulate the flow of water in each heating and/or hot water zone. However, there are several issues with existing hot water cylinders. However, due to at least the extended network of pipes, existing hot water cylinders tend to be bulky, leading to higher space requirements and complicated installation. Another issue with existing cylinders is that they lack the ability to communicate information and receive instructions from a remote user.

Therefore, there is a need to provide an improved hot water cylinder that addresses those issues.

Summary of the Invention It is an object of the present invention to provide a pre-plumped hot water cylinder for a heating system that overcomes the problems with existing solutions. More specifically, the object is to provide a compact hot water cylinder with smaller space requirements, which can be controlled remotely by a user.

According to the present invention, a pre-plumbed hot water cylinder refers to a hot water cylinder with a preinstalled plumbed heating distribution and zoning pipe kit, to help reduce installation time and standardise plumbing configuration across multiple dwelling sites The object of the present invention is achieved by providing a hot water cylinder for a heating system having the characteristics of the invention According to an aspect of the present invention, a hot water cylinder for a heating system which is configured to provide hot water to at least one heating zone and at least one hot water zone, the hot water cylinder comprising: at least one inlet pipe to input fluid in the hot water cylinder; and at least one outlet pipe from which the heated fluid exits the hot water cylinder, the heated fluid being circulated to at least one heating zone and at least one hot water zone of the heating system, the fluid exiting the outlet pipe being returned to the hot water cylinder via the at least one inlet pipe; wherein the hot water cylinder comprises a hydronic fluid circulation unit arranged for at least circulate the fluid exiting the at least one outlet pipe to the at least one heating zone and at least one hot water zone of the heating system via respective fluid openings, each fluid opening comprising a valve configured to control the flow of the fluid at the respective heating and/or hot water zones; wherein the hot water cylinder comprises a control unit configured to at least control the operation of the valves provided at each fluid opening, so as to regulate the flow of the heated fluid to each of the heating and/or hot water zones based on instructions received by a user from a display panel provided on the control unit and/or via a communication network from a software application operating on a user device Optionally, a heating element is provided in the cylinder for heating fluid in the cylinder.

It has been found that by providing a hydronic fluid circulation unit with integrated valves for regulating the flow of heated fluid to each of the heating and/or hot water zones of the heating system has the advantage of reducing the overall footprint of the hot water cylinder making installation of the hot water cylinder faster and less complicated. As a result, the hot water cylinder of the present invention is more compact when compared to existing systems, and thus occupies less space in the household. The hydronic fluid circulation unit is provided in fluid communication with at least the outlet pipe, and via a series of openings circulates the heated fluid exiting the at least one outlet pipe to the desired heating and/or hot water zone of the heating system. The openings are provided with a fluid regulating valve configured to control the flow of the fluid in the respective heating and/or hot water zones. The operation of each valve may be individually controlled via a control unit, based on instructions received by a user. The control unit may be configured to communicate information to and receive instructions from at least one remote user through a display panel, which is provided on the control unit, e.g. temperature control of the different heating and hot water zones, detection of faults, temperature and pressure information, and the like. Furthermore, the control unit is configured to connect to a communication network, e.g. a wireless communication network, allowing the exchange of information with a software application operating on a user device. In this way, a user may remotely control the operation of heating system elements, e.g. hot water cylinder: radiators, boiler, valves, and the like. The control unit may communicate to the user, via the display panel and/or the software application, a range of information about the operation of the heating system e.g. the ambient temperature, operation of each heating zone and hot water zone, temperature of the heated fluid, power consumption, fluid pressure, any detected faults, and the like.

According to embodiments of the present invention, the control unit is configured for collecting information from a plurality of sensors distributed across the heating system, and accordingly provide information to the user on the operating conditions of the heating system.

It has been found that by providing a range of sensors across the entire heating system has the advantage of allowing the user to optimise the operation of the heating system, so that so that the optimum volume of hot water is provided at any particular time. The sensors may include temperature sensors, flow sensors, pressure sensors, water level sensors, and the like.

According to embodiments of the present invention, the structure of the hydronic fluid circulation unit is formed as a single piece from a material such as brass, plastics, or another durable material.

It this way, the base structure of the hydronic fluid circulation block may be formed as a single piece, and the necessary components, such as the valves, may be integrated, and/or pre-installed. As a result, the hydronic fluid circulation unit provides a more compact structure for circulating the fluid in the heating system, thus reducing the space requirements for the hot water cylinder in the household. Furthermore, integrating and/or pre-installing the necessary components, reduces the installation time. The base structure of the hydronic fluid circulation unit may be manufactured using any known techniques, e.g. additive manufacturing.

According to an aspect of the present invention, the hydronic fluid circulation unit may comprise at least one of a circulating pump, filling loop, automatic air vent, heating and hot water valves and by-pass valve. In this way, it is possible to integrate a range of components that are necessary for the correct operation of the heating system in a single unit thus easing the installation and reducing the size of the pipe network.

According to embodiments of the present invention, the control unit and the hydronic fluid circulation unit may be covered by at least one removable cover, the cover comprising at least a first opening, via which the user can access the display of the control unit.

The use of at least one removable cover may be used to protect the hydronic fluid circulation unit and control unit from accidental damage. Furthermore, the use of the at least one removable cover may be used to restrict access to the hydronic fluid circulation unit and the control panel, thus increasing safety by making sure that only authorised users may gain access. The removable cover may be secured on the outside of the hot water cylinder with fastening means, e.g. screws, interconnecting elements, and the like. Moreover, by covering the hydronic fluid circulation unit and the control panel increase the aesthetic design of the hot water cylinder.

According to embodiments of the present invention, the valves provided on at least the openings connected to each heating zone and hot water zone may be in the form of compact valve actuators with a linear action for opening and closing flow rate to the heating or hot water zones.

According to embodiments of the present invention, the control unit and the hydronic fluid circulation unit may be secured on a surface of the hot water cylinder. For example, the control unit and the hydronic fluid circulation block may be secured on the insulation layer of the hot water cylinder. The insulation layer may be made from Expanded Polypropylene (EPP) or other suitable materials.

Alternatively, the hydronic fluid circulation unit is of modular construction comprising a plurality of bypass valves connected in series.

Brief Description ofthe drawings Figure 1 shows an example of a hydronic fluid circulation block according to embodiments of the present invention; Figure 2 shows an example of a hot water cylinder with a removable cover according to embodiments of the present invention; Figure 3 shows an example of a control unit according to embodiments of the present invention; Figure 4 is an exploded perspective view of three components of the hydronic fluid circulation block, namely a flow manifold, a bypass valve and a return manifold.

Figure 5A is a plain view of the fluid circulation block with one valve fitted for illustration purposes; Figure 5B is a side view of the circulation block and illustrative valve; Figure 5C is an end view of the circulation block and valve; Figure 5D is a cross-section view along A-A of Figure 5A; and Figure 5E is a detailed cross section view of a valve housing in the circulation block as taken from Figure 5D Figure 6A is a plain view of the bypass valve; Figure 6B is a cross-section view of the bypass valve taken along the line C-C of Figure 6A; Figure 6C is a cross section view through the valve block only; Figure 6D is an end view of the bypass valve.

Figure 7A is a front view of an alternative embodiment of a hydronic fluid circulation unit mounted on a hot water cylinder, the unit being a modular unit assembled from a plurality of bypass valves connected in series; Figure 7B is a side view from one side of the modular unit attached to the hot water cylinder; Figure 7C is a perspective view of the modular unit attached to the hot water cylinder; Figure 8A is a front view of modular unit; Figure 8B is an end view of the modular unit; Figure 8C is a side view of the modular unit; and Figure 8D is a perspective view of the modular view.

Detailed Description The present invention will be illustrated using the exemplified embodiments shown in Figures 1 to 6, which will be described in more detail below. It should be noted that any references made to dimensions are only indicative and do not restrict the invention in any way. While this invention has been shown and described with reference to certain illustrated embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention as described herein. Furthermore, while the invention has been described with reference to a particular hot water cylinder, also referred to as hot water tank, for use in a heating system, it should be understood by those skilled in the art that changes in form and details may be made to facilitate other types of hot water cylinders without departing from the scope of the invention as described herein.

Figure 1 shows an example of a hydronic fluid circulation block 100 according to embodiments of the present invention. The hydronic fluid circulation block 100 is provided in fluid communication with at least an outlet pipe of the hot water cylinder 700 for circulating the heated water exiting the hot water cylinder 700 to the different heating zones and hot water zones of the heating system. The hot water cylinder 700 is provided with at least an inlet pipe for inputting water in the hot water cylinder 700, a heating element for heating the water, and an outlet pipe through which the heated water is distributed to the heating system. The heated water is returned to the hot water cylinder 700 via the inlet pipe. A hydronic fluid circulation block 100 is provided on the hot water cylinder 700. The hydronic fluid circulation block 100 comprises a base structure 101 having a plurality of at least first openings 102 each being connected to the pipe network of the heating system to circulate the heated water as required to the different heating and hot water zones. Each first opening 102 is provided with a first type valve 103, e.g. a linear action compact actuator valve, to regulate the flow of water in the different heating and/or hot water zones. The first type valves 103 are electronically operated via a control unit 710 according to instructions received by a user and/or instruction received by the control unit 710 based on information gathered from the sensors of the heating system. The hydronic fluid circulation block is linked to a circulation pump 104 connected to the inlet pipe of the hot water cylinder element (coil) 700, which is arranged for providing through an opening 106 water to the hot water cylinder 700 from a source, e.g. a hot water boiler (not shown). A bypass valve 109 is provided to release excess water from the hot water cylinder through return line openings 105. The return line openings 105 are configured to return water from the heating and hot water zones to the water boiler for heating, which is then returned for storage to the hot water cylinder 700 via the opening 106. The hydronic fluid circulation block 100 is further provided with an integrated automatic air vent 107 configured to release air from the heating systems1 distribution network. The base structure 101 of the hydronic fluid circulation block 100 may be made in one piece from a suitable material such as brass or plastics material using a moulding, casting, 3D printing or any other suitable manufacturing method. For example, the hydronic fluid circulation block 100 may be made from plastics material, a metal such as copper, or another suitable material. The different elements of the hydronic fluid circulation block 100, e.g. valves 103, 109, circulation pump 104, airvent 107, and the like are integrated into the base structure101 of the hydronic fluid circulation block, thus simplifying installation and reducing the size of the pipework connected to the plumping of the heating system.

As shown in Figures 4 to 6, the exemplary embodiment shown in these figures comprises a base structure 101 manufactured from brass or a similar material connected to a bypass valve 109 which in turn is connected to a return manifold 110. The base structure 101 includes four valve seating chambers 112 in fluid communication into which four valves 103 are located (only one of which is shown in Figure 5). As shown in Figure 5E, the valve 103 can be located centrally within a valve seating chamber 112 so as to function as a two port valve. As shown in Figure 6, the bypass valve 109 includes a block 114 into which a plunge type bypass valve 116 is located so as to conduct the flow between two chambers 117 and 118.

In the alternative embodiment shown in Figures 7A, 7B, 7C and 8A, 8B, 8C and 8D the hydronic fluid circulation unit 201 is of modular construction and comprises a plurality (in this example, four) of valves 203 connected together in series, each of the valves being two port valves. Although four valves 203 are shown in the drawings, the number of valves can be more or less depending on the circumstances and plumbed and connected to the hot water cylinder 700 as appropriate but not shown in these drawings. Also not shown are a bypass valve and a manifold which are used as required Figure 2 shows a hot water cylinder 700 with a hydronic fluid circulation block 100 and control unit 710 according to embodiments of the present invention. The control unit 710 comprises a display panel, which is configured to communicate information to the user and accordingly receive user instructions for operating the heating system. For example, the control unit 710 gathers information from a plurality of sensors in the heating system, e.g. ambient temperature, water temperature in the cylinder, pressure, water level, fault detection, and the like, and accordingly display the information on a Graphic User Interface (GUI) operating on the display panel. The display panel is provided with a touch-sensitive display. As shown in figure 2, the hydronic fluid circulation block 100 and the control unit are protected by a removable cover 740, which may be provided as a single module or may be split into several parts to protect independently different elements of the hot water cylinder. For example, the removable cover 740 of Figure 2 is provided with a top part that protects the control unit 710 and a bottom part that protects the hydronic fluid circulation block. The bottom cover part is also provided with openings 721 so that the hydronic fluid circulation block 100 can be connected to the plumping installation of the heating system. The removable cover is releasably secured on the hot water cylinder 700. As shown in figure 2, the hydronic fluid circulation block 100 may be positioned approximately at the lower end of the hot water cylinder 700.

Figure 3 shows an exemplified implementation of the control unit 710 according to embodiments of the present invention. As shown the control unit 710 is provided with a communication module 711 arranged for exchanging information with at least one remote user device 300 via a communication network 400. For example, the communication module 711 may transmit information obtained from the sensors, e.g. ambient temperature, water temperature, water level, pressure, faults detected and the like, to a remote user device running a software application. The information transmitted from the control unit 710 will be processed and analysed by the software application before being presented to the user 300 in the desired format. The user 300 using the software application may provide, on the basis on the information received, instructions to the control unit 710, to operate the heating system in the desired manner. For example, the user may set a time and temperature for switching on or off the different heating zones of the heating system, or the user may instruct the control unit only to store a specific amount of water. A local user 500 may interact with the heating system via the display panel 714 of the control unit 711, instead of using the software application. A memory 713 is provided for storing a range of data such as the information provided by the sensors, a set of executable programs, and any other desired information. The control unit 710 is provided with a processor arranged for processing the information received by the sensors and/or users 300 or 500, via respectively the communication network 400 and/or the display panel 714. For example, based on the information and/or instructions received, the processor 712 may call an executable program code from the memory 713 to perform a user-defined task, e.g. set heating zone temperature at a predetermined level, which accordingly requires the operation of at least some of the valves 103, 109 in the hydronic fluid circulation block 100. The processor 712 may display certain information on the display panel 714 of the control unit relating to the operation of the heating system, such as average power consumed, ambient temperature, and the like.

In general, the routines executed to implement the embodiments of the invention, whether implemented as part of an operating system or a specific application, component, program, object, module or sequence of instructions, or even a subset thereof, may be referred to herein as computer program code, or simply program code. Program code typically comprises computer readable instructions that are resident at various times in various memory and storage devices in a computer and that, when read and executed by one or more processors in a computer, cause that computer to perform the operations necessary to execute operations and/or elements embodying the various aspects of the embodiments of the invention. The computer readable program instructions for carrying out operations of the embodiments of the invention may be, for example, assembly language or either source code or object code is written in any combination of one or more programming languages.

The program code embodied in any of the applications/modules described herein is capable of being individually or collectively distributed as a program product in a variety of different forms. In particular, the program code may be distributed using the computer readable storage medium having the computer readable program instructions thereon for causing a processor to carry out aspects of the embodiments of the invention.

Computer readable storage media, which is inherently non-transitory, may include volatile and non-volatile, and removable and non-removable tangible media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules, or other data. Computer readable storage media may further include RAM, ROM, erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid state memory technology, portable compact disc read-only memory (CD-ROM), or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and which can be read by a computer. A computer-readable storage medium should not be construed as transitory signals per se (e.g., radio waves or other propagating electromagnetic waves, electromagnetic waves propagating through a transmission media such as a waveguide, or electrical signals transmitted through a wire). Computer readable program instructions may be downloaded to a computer, another type of programmable data processing apparatus, or another device from a computer readable storage medium or an external computer or external storage device via a network.

Computer readable program instructions stored in a computer readable medium may be used to direct a computer, other types of programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions that implement the functions/acts specified in the flowcharts, sequence diagrams, and/or block diagrams. The computer program instructions may be provided to one or more processors of a general-purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the one or more processors, cause a series of computations to be performed to implement the functions and/or acts specified in the flowcharts, sequence diagrams, and/or block diagrams.

In certain alternative embodiments, the functions and/or acts specified in the flowcharts, sequence diagrams, and/or block diagrams may be re-ordered, processed serially, and/or processed concurrently without departing from the scope of the invention. Moreover, any of the flowcharts, sequence diagrams, and/or block diagrams may include more or fewer blocks than those illustrated consistent with embodiments of the invention.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the embodiments of the invention. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms comprise and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Furthermore, to the extent that the terms includes, having, has, with, comprised of, or variants thereof are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term comprising.

While all of the inventions have been illustrated by a description of various embodiments and while these embodiments have been described in considerable detail, it is not the intention of the Applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the Applicants general inventive concept It is to be understood that the invention is not limited to the specific details described herein which are given by way of example only and that various modifications and alterations are possible without departing from the scope of the invention as defined in the appended claims.

Claims (10)

CLAIMS:

1. A pre-plumb hot water cylinder for a heating system configured to provide hot water to at least one heating zone and at least one hot water zone, the hot water cylinder comprising: at least one inlet pipe to input fluid in the hot water cylinder; and at least one outlet pipe from which the heated fluid exits the hot water cylinder distribution block, the heated fluid being circulated to at least one heating zone and at least one hot water zone of the heating system, the fluid exiting the outlet pipe being returned to the hot water cylinder distribution block via the at least one inlet pipe; wherein the hot water cylinder comprises a hydronic fluid circulation unit arranged for circulate the fluid exiting the at least one outlet pipe to the at least one heating zone and at least one hot water zone of the heating system via respective openings, each opening comprising a valve configured to control the flow of the fluid at the respective heating and/or hot water zones; the hot water cylinder comprising a control unit configured to at least control the operation of the valves provided at each opening, so as to regulate the flow of the heated fluid to each of the heating and/or hot water zones based on instructions received by a user from a display panel provided on the control unit and/or via a communication network from a software application operating on a user device.

2. A hot water cylinder according to claim 1, wherein the control unit is configured for collecting information from a plurality of sensors distributed across the heating system, and accordingly provide information to the user on the operating conditions of the heating system.

3. A hot water cylinder according to claim 1 or 2, wherein the hydronic fluid circulation unit is a one piece block made from brass, plastics or other durable material.

4. A hot water cylinder according to claim 3, in which the hydronic fluid circulation block comprises a plurality of valve seating chambers in fluid communication and a corresponding number of valves located in the valve seating chamber.

5. A hot water cylinder according to Claim 1 or 2, wherein the hydronic fluid circulation unit is of modular construction comprising a plurality of bypass valves connected in series.

6. A hot water cylinder according to Claim 3, Claim 4 or Claim 5, in which a separate bypass valve is connected to and is in fluid communication with the circulation unit.

7. A hot water cylinder according to Claim 6 in which a return manifold is connected to and is in fluid communication with the bypass valve.

8. A hot water cylinder according as claimed in any one of the preceding claims in which a heating element is provided in the cylinder for heating fluid in the cylinder.

9. A hot water cylinder as claimed in any one of the preceding claims, in which the control unit and hydronic fluid circulation unit are enclosed by at least one removable cover which has at least one opening via which a user can access the display of the control unit.

10. A hot water cylinder substantially as herein described with reference to and as shown in the accompanying drawings.