US20100170452A1 - Water heating apparatus, especially for pools - Google Patents
Water heating apparatus, especially for pools Download PDFInfo
- Publication number
- US20100170452A1 US20100170452A1 US12/666,585 US66658508A US2010170452A1 US 20100170452 A1 US20100170452 A1 US 20100170452A1 US 66658508 A US66658508 A US 66658508A US 2010170452 A1 US2010170452 A1 US 2010170452A1
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- Prior art keywords
- water
- tubes
- condensate
- heat exchanger
- water heater
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Links
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 133
- 238000010438 heat treatment Methods 0.000 title description 4
- 239000012530 fluid Substances 0.000 claims abstract description 13
- 238000009833 condensation Methods 0.000 claims abstract description 12
- 230000005494 condensation Effects 0.000 claims abstract description 12
- 239000008236 heating water Substances 0.000 claims abstract description 5
- 238000012544 monitoring process Methods 0.000 claims abstract description 5
- 239000000463 material Substances 0.000 claims description 12
- 229910000570 Cupronickel Inorganic materials 0.000 claims description 7
- 239000010935 stainless steel Substances 0.000 claims description 7
- 229910001220 stainless steel Inorganic materials 0.000 claims description 7
- 239000004411 aluminium Substances 0.000 claims description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 6
- 238000007789 sealing Methods 0.000 claims description 5
- 238000011144 upstream manufacturing Methods 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- 238000000034 method Methods 0.000 claims description 3
- 238000013459 approach Methods 0.000 description 6
- 238000004064 recycling Methods 0.000 description 6
- 239000006227 byproduct Substances 0.000 description 5
- 238000010276 construction Methods 0.000 description 4
- 230000007797 corrosion Effects 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 4
- 230000002378 acidificating effect Effects 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 2
- 238000005536 corrosion prevention Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 230000009182 swimming Effects 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000007726 management method Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000002991 molded plastic Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000010979 pH adjustment Methods 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D7/16—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation
- F28D7/1607—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation with particular pattern of flow of the heat exchange media, e.g. change of flow direction
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
- F24H1/22—Water heaters other than continuous-flow or water-storage heaters, e.g. water heaters for central heating
- F24H1/40—Water heaters other than continuous-flow or water-storage heaters, e.g. water heaters for central heating with water tube or tubes
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/10—Control of fluid heaters characterised by the purpose of the control
- F24H15/174—Supplying heated water with desired temperature or desired range of temperature
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/212—Temperature of the water
- F24H15/215—Temperature of the water before heating
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/25—Temperature of the heat-generating means in the heater
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/30—Control of fluid heaters characterised by control outputs; characterised by the components to be controlled
- F24H15/345—Control of fans, e.g. on-off control
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/30—Control of fluid heaters characterised by control outputs; characterised by the components to be controlled
- F24H15/355—Control of heat-generating means in heaters
- F24H15/36—Control of heat-generating means in heaters of burners
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/40—Control of fluid heaters characterised by the type of controllers
- F24H15/414—Control of fluid heaters characterised by the type of controllers using electronic processing, e.g. computer-based
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H9/00—Details
- F24H9/0005—Details for water heaters
- F24H9/0036—Dispositions against condensation of combustion products
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H9/00—Details
- F24H9/16—Arrangements for water drainage
- F24H9/17—Means for retaining water leaked from heaters
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H9/00—Details
- F24H9/20—Arrangement or mounting of control or safety devices
- F24H9/2007—Arrangement or mounting of control or safety devices for water heaters
- F24H9/2035—Arrangement or mounting of control or safety devices for water heaters using fluid fuel
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
- F24H1/22—Water heaters other than continuous-flow or water-storage heaters, e.g. water heaters for central heating
- F24H1/44—Water heaters other than continuous-flow or water-storage heaters, e.g. water heaters for central heating with combinations of two or more of the types covered by groups F24H1/24 - F24H1/40 , e.g. boilers having a combination of features covered by F24H1/24 - F24H1/40
- F24H1/445—Water heaters other than continuous-flow or water-storage heaters, e.g. water heaters for central heating with combinations of two or more of the types covered by groups F24H1/24 - F24H1/40 , e.g. boilers having a combination of features covered by F24H1/24 - F24H1/40 with integrated flue gas condenser
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/281—Input from user
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H8/00—Fluid heaters characterised by means for extracting latent heat from flue gases by means of condensation
- F24H8/006—Means for removing condensate from the heater
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
Definitions
- FIG. 14 is a rear view of an alternative embodiment of the condensate recycling concept
- Tray 80 is a unitary casting and, as will be further explained below, serves as a condensate collection tray. Tray 80 sealingly communicates with a flue 82 that extends upwardly behind the heat exchanger assembly 20 , firebox 50 and fan unit 60 to a flue outlet 83 .
- the lower bank 26 constitutes a lower temperature zone 100 of the heat exchanger assembly and the upper bank 28 constitutes a higher temperature zone 110 .
- the respective banks of tubes are formed of differing materials: the lower tubes 27 are aluminium-sheathed stainless steel tubes, while the upper tubes 29 are of cupronickel alloy. It will be seen that the descending flow of hot gas will pass through and about tubes 29 first and then, in a cooler state, through and about tubes 27 .
- the illustrated configuration of water heater including the two-stage heat exchanger configuration and the control of burner heat output in response to monitoring of the temperature in the heat exchanger, together result in a pool heater system of significantly higher efficiency than the earlier described conventional arrangements.
- Full volume water flow say up to 400 L/min is maintained without periodic bypassing and burner output is matched with the desired set point gas temperature range in the heat exchanger.
- Condensation is accepted and properly managed by employing a two-stage heat exchanger in which the materials of the heat exchange elements are selected to suit the respective higher and lower temperature zones.
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Computer Hardware Design (AREA)
- Instantaneous Water Boilers, Portable Hot-Water Supply Apparatuses, And Control Of Portable Hot-Water Supply Apparatuses (AREA)
- Details Of Fluid Heaters (AREA)
- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
Abstract
A water heater for heating water includes a burner assembly (54) for generating a flow of hot gas. The burner assembly (54) includes a gas burner (52) and means (64) adjustable to determine a heat output of the burner assembly (54). The water heater further includes a heat exchanger assembly (20) for transferring heat from gas to water flowing therein. The heat exchanger assembly (20) has a higher temperature zone (110) and a lower temperature zone (100). The water heater is arranged to convey the flow of hot gas to the higher temperature zone (110) and in turn to the lower temperature zone (100). The water heater further includes ducting (22, 23) to conduct said flowing water to and from said heat exchanger assembly (20), means (40) to monitor the temperature of the hot gas intermediate the higher temperature zone (110) and the lower temperature zone (100), and control means (70) responsive to the temperature monitoring means (40) to modulate the heat output of the burner assembly (54) whereby to maintain the monitored temperature within a predetermined range so as to substantially prevent or minimise condensation of vapour from the hot gas in the higher temperature zone (110). There is also disclosed a modular heat exchanger apparatus (20) including like headers (34) for redirecting fluid within respective modules (24) and for interconnecting modules (24). There is also disclosed a water heater having a condensate duct (84) to direct condensate into the water for chemically treating the water.
Description
- This invention relates generally to water heating equipment, but has particularly useful application to pool and spa heaters. Respective aspects of the invention are concerned with a novel configuration of water heater, with a heat exchanger arrangement useful in pool and spa heaters, and with a practical use for the condensate that is a by-product of certain types of water heaters.
- Throughout this specification, the term “pool” includes in its ambit any kind of confined water body in which humans can be immersed, including spas, swim spas and Japanese-style immersion tubs.
- Pool heating is conventionally effected either by circulating the pool water through solar panels, typically roof-mounted, or by means of gas-fired water heaters. Water heaters for this purpose are designed to heat a continuous flow of water circulated from the pool to a target temperature in a range comfortable for swimming, and so the requirements differ considerably from, for example, hot water services, where a static body of water is heated in a tank to a relatively high temperature, and hydronic central heating systems, where a flow of water is heated but the total volume of water is much less and the target temperature significantly higher.
- Conventional pool heaters typically have a gas burner assembly that generates a hot gas flow employed to heat the water as it traverses multiple tubes in a heat exchanger. Because of the relatively high water volume and relatively low water temperature, these systems must address the problem of condensation in the gas stream as it passes among the heat exchanger tubes: the condensate is slightly acidic because of the uptake of combustion products, and is therefore a corrosive by-product. A popular material for the heat exchanger tubes is cupronickel, which is especially susceptible to corrosion by the condensate.
- Modern pool heater controllers advantageously receive a measurement of the pool water temperature, and thermostatically control the operation of the heater, and as the pool water temperature approaches a desired temperature, modulate the heater down to a very low power level to maintain the pool water temperature without noticeable stopping and starting of the heater. It has been discovered that operation at this very low power level results in low flue temperatures such that condensation and corrosion is particularly problematic.
- The common approach to corrosion prevention is to design the heater so that at the maximum water flow condition, minimum water temperature and a predetermined gas flow rate the temperature in the heat exchanger remains above the dew point temperature at which condensation begins to occur. Water flow is typically reduced through the heat exchanger by diverting a proportion of the flow via a bypass. This approach places limits on the efficiency achievable with the overall heater configuration.
- Two publications that illustrate known approaches to corrosion prevention are European patent publication 0226534 and Japanese published (Kokai) application 11351559.
- It is an object of the invention, at least in one or more aspects or applications, to improve the efficiency of pool heater systems.
- The invention involves, in a first aspect, a different approach to temperature management in the heat exchanger, and, in a second aspect, the adoption of a two-part heat exchanger whereby condensate is an acceptable by-product. In a third aspect, the invention proposes recycling of the condensate for usefully treating the pool water.
- The invention accordingly provides, in its first aspect, a water heater for heating water, including:
-
- a burner assembly for generating a flow of hot gas, which burner assembly includes a gas burner and means adjustable to determine a heat output of the burner assembly;
- a heat exchanger assembly for transferring heat from gas to water flowing therein, wherein the heat exchanger assembly has a higher temperature zone and a lower temperature zone, the water heater being arranged to convey the flow of hot gas to the higher temperature zone and in turn to the lower temperature zone;
- ducting to conduct said flowing water to and from said heat exchanger assembly;
- means to monitor the temperature of the hot gas intermediate the higher temperature zone and the lower temperature zone; and
- control means responsive to said temperature monitoring means to modulate the heat output of the burner assembly whereby to maintain the monitored temperature within a predetermined range so as to substantially prevent or minimise condensation of vapour from the hot gas in the higher temperature zone.
- By modulating the heat output of the burner the monitored temperature can be maintained within a pre-determined range without reducing the volume of water flowing through the heat exchanger thereby improving efficiency. It is desirable to minimise said monitored temperature in order to maximise efficiency.
- Preferably said means to monitor the temperature of the hot gas is mounted closer to the lower temperature zone than to the higher temperature zone.
- The configuration is preferably such that the hot gas is directed downwardly from the burner assembly through the heat exchanger assembly to traverse the higher temperature zone and then the lower temperature zone. Means is advantageously provided under the heat exchanger assembly for collecting condensate that forms in said lower temperature zone.
- In a second aspect, the invention provides a heat exchanger apparatus, including:
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- a heat exchange module having a plurality of heat exchange elements, extending across a passage, the passage being arranged to convey a first fluid past and about the heat exchanger elements; and
- one or more return headers adapted to be selectively mounted to said module either for directing a second fluid in turn through any adjacent pair of heat exchange elements, or for directing a second fluid from one heat exchange element of said module to a heat exchange element of a similar module when said module is coupled to said similar module.
- The return header can have a separate sealing engagement with each bank of tubes. Most preferably, the return header has a separate sealing engagement with each tube.
- The banks of tubes are preferably relatively displaced along said passage. Advantageously, first and second banks of tubes have their tubes formed in materials that respectively suit a lower temperature operation and higher temperature operation. A suitable material for the tubes of the lower temperature bank is aluminium sheathed stainless steel while a suitable material for the tubes of the higher temperature bank is cupronickel. Copper is another material suitable for the tubes of the higher temperature bank(s).
- Preferably there are a plurality of modules in coupled relation and a plurality of like return headers for interconnecting banks of tubes within the modules and interconnecting modules. Advantageously each module has only two banks of tubes.
- In an embodiment, there are two of said modules and three return headers, two mounted for directing the second fluid from one of the banks of tubes to the other in the respective pair, and a third for directing the second fluid from a second bank of one module to a first bank of the other module. Preferably, in this embodiment, the successive spacings of the four banks of tubes along said passage are substantially equal, and the tubes of the respective pairs of banks are formed in materials that respectively suit a lower temperature operation and higher temperature operation.
- In a particularly useful application, a heat exchanger apparatus according to the second aspect of the invention is employed as the heat exchanger assembly of the first aspect of the invention.
- A third aspect of the invention relates to the condensate which is a by-product from some types of pool heater and indeed from one or more embodiments of the first and second aspects of the present invention. More particularly, in its third aspect, the invention provides a water heater for heating water, including:
-
- a burner assembly for generating a flow of hot gas;
- a heat exchanger assembly arranged to receive said flow of hot gas for transferring heat from the gas to water flowing therein;
- ducting to conduct said water to and from said heat exchanger assembly;
- means to collect condensate produced from condensation of said gas in said heat exchanger assembly; and
- a condensate duct to direct said condensate into said water for chemically treating said water.
- The condensate will typically be slightly acidic, i.e. have a pH slightly less than 7, and said chemical treatment may comprise pH adjustment. In one embodiment of the third aspect of the invention, the condensate is directed into the heated stream of water immediately downstream of the heat exchanger assembly, and for this purpose said condensate duct may include a venturi at which the condensate is drawn into the heated water stream. A pump may be arranged to receive condensate from the means to collect condensate and drive the condensate through the condensate duct. In an alternative embodiment, the condensate is stored and said condensate duct forms part of dosing apparatus for selectively directing metered amounts of condensate into the pool water at any suitable location.
- In a further alternative embodiment condensate may be directed into the water with the aid of a suction tee.
- Advantageously the condensate duct may be arranged to direct the condensate into the water upstream of a pump arranged to drive said water through said water heater.
- The means to collect condensate may comprise a tray or housing base in a water heater according to the first aspect of the invention or in or below a heat exchanger apparatus according to the second aspect of the invention.
- In its third aspect, the invention further provides a method of chemically treating water in a pool comprising adding to the water condensate collected from a heat exchanger assembly of a water heater through which the pool water is circulated and heated.
- The invention will now be further described, by way of example only, with reference to the accompanying drawings, in which:
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FIG. 1 is a perspective view of a pool heater according to an embodiment of the invention, as viewed without its exterior decorative housing; -
FIG. 2 is a rear view of the pool heater depicted inFIG. 1 with some parts omitted for a better view and with the condensate venturi additionally shown in place; -
FIG. 3 is a vertical, generally central cross-section of the pool heater depicted inFIGS. 1 and 2 , with most of the heat exchanger tubes omitted for the purpose of illustration; -
FIGS. 4 and 5 are different perspective views of the heat exchanger assembly; -
FIG. 6 is a view of the heat exchanger assembly, and with many of the upper bank of tubes omitted; -
FIG. 7 is a plan view of the heat exchanger assembly; -
FIG. 8 is a cross-section on the line 8-8 inFIG. 7 ; -
FIG. 9 is a simplified schematic diagram of the burner control loop incorporating a temperature sensor in the heat exchanger assembly; -
FIGS. 10 and 11 are respectively a perspective view and an end elevation of a larger heat exchanger assembly with four banks of tubes; -
FIG. 12 is a rear view one embodiment of the third aspect of the invention entailing recycling of condensate collected from the heat exchanger assembly; -
FIG. 13 is a fragmentary axial cross-section view of the condensate venturi forming part of the embodiment ofFIG. 12 ; -
FIG. 14 is a rear view of an alternative embodiment of the condensate recycling concept; -
FIG. 15A is a perspective view of an embodiment of the return header; -
FIGS. 15B and 15C are perspective cut away views of the header ofFIG. 15A ; -
FIG. 16 is a perspective view an embodiment of the tray; -
FIG. 17 is a rear view of a further alternative embodiment of the condensate recycling concept; and -
FIG. 18 is a rear view of a further alternative embodiment of the condensate recycling concept. - The illustrated
pool heater 10 is a stacked assembly of four principal components: atray 80 over which is fitted aheat exchanger assembly 20 on which is mounted afirebox 50, which is in turn capped by afan unit 60 that includes acontroller 70 with anexternal interface 72 and alid 62 that is removable for access.Tray 80 sits inplastic base 12. -
Tray 80 is a unitary casting and, as will be further explained below, serves as a condensate collection tray.Tray 80 sealingly communicates with aflue 82 that extends upwardly behind theheat exchanger assembly 20,firebox 50 andfan unit 60 to aflue outlet 83. - In situ and in operation, pool water is circulated by a separate pump installation to a
water intake port 22 and recovered fromoutlet 23. Afan 64 withinfan unit 60 draws in a correctly proportioned combustible mixture of gas (delivered via line 65) and air, and delivers the mixture to agas burner 52 at the top offirebox 50. Thegas burner 52 and thefan unit 60 together form a burner assembly 54 (FIG. 3 ) that generates a downwardly directed flow of hot gas. This flow is received by theheat exchanger assembly 20 where heat is transferred from the hot gas to pool water flowing therein. Theburner 52 is of the premix type and includes a knitted mesh. Below theheat exchanger 20, the hot gas is guided laterally by the shapedtray 80 to the base offlue 82 and thence up the flue. -
Fan 64 constitutes a means that is adjustable to vary the volume of gas and air directed to theburner 52 and so determines the heat output of the burner. Thefan 64 andgas burner 52 together constitute a burner assembly for generating a flow of hot gas. - The construction of
heat exchanger assembly 20 is detailed inFIGS. 4 to 8 . Asimple box 24 of front, rear and side flanged plates 24 a, 24 b, 24 c provides a suitable chassis. Side plates 24 b, 24 c have two rows of apertures 25 a and 25 b that communicate with the interior ofheat exchange tubes upper banks outlet headers lower tubes 27 andupper tubes 29 towater inlet ports return header 34, a suitably profiled moulding that defines a manifold space for communicating the lower of apertures 25 a with the upper row 25 b.Vanes 31 are placed between thetubes tubes - A convenient method for assembling the module like
box 24 involves forming side plates 24 b and 24 c with apertures 25 a, 25 b being slightly oversized, e.g. 0.1 mm, to receive thetubes Tubes - Although modules having two rows defining U-shaped flow paths are illustrated, other arrangements are possible. For example, a module having three rows defining an S-shape flow path is an option.
-
Return header 34 is shown in more detail inFIGS. 15A to 15C .Apertures 35 are connected bycavity 37 and include a recess to receive a sealing washer (not shown) to sealingly engage withindividual tubes bolt locations 36 allows the header to securely press the sealing washers with less risk of leakage due to warping of the header. This advantageously allows for a cheaper moulded plastic (instead of cast metal) construction. - It will be seen that because the cooler water traverses the lower bank of
tubes 27 and then the upper bank oftubes 29, thelower bank 26 constitutes alower temperature zone 100 of the heat exchanger assembly and theupper bank 28 constitutes ahigher temperature zone 110. Accordingly, the respective banks of tubes are formed of differing materials: thelower tubes 27 are aluminium-sheathed stainless steel tubes, while theupper tubes 29 are of cupronickel alloy. It will be seen that the descending flow of hot gas will pass through and abouttubes 29 first and then, in a cooler state, through and abouttubes 27. - The
cupronickel tubes 29 are effective heat exchange elements at higher temperatures but are highly susceptible to corrosion by any condensate that forms on them in the gas flow, while the aluminium/stainless steel tubes 27 are resistant to condensate corrosion but degrade at relatively low elevated temperatures. Accordingly, in accordance with the first aspect of the invention, the temperature profile in the gas stream across the heat exchanger is managed to accommodate these characteristics. Temperature sensor 40 (FIG. 8 ) is located on the vertically centred plane of the heat exchanger assembly inwardly from side panel 24 c between therespective banks controller 70 which adjusts thefan 64 to determine the heat output ofburner 52 in response to variousinputs including sensor 40. Other inputs may include a desired water temperature manually entered atinterface 72, and actual water temperature measured bysensor 73 oninlet header 32. A suitable controller is a Genus PCB controller. - A diagram of the main elements of the burner control loop is presented in
FIG. 9 . - In particular,
controller 70 is responsive to temperature sensor 40 (monitoring the temperature at its location in the heat exchanger assembly), to operatefan 64 so as to modulate the heat output ofburner 52, whereby to maintain the monitored temperature atsensor 40 within a predetermined set point range. This range is between a minimum selected so that the gas temperature in thehigher temperature zone 110 remains above the dew point condensation temperature, and a maximum is determined so that, inter alia, the temperature of the gas delivered into thelower temperature zone 100 is not so high as to damage aluminium/stainless steel tubes 27. In the former case, condensation of vapour from the gas is substantially prevented or minimised in thehigher temperature zone 110 of the heat exchanger assembly. -
FIGS. 10 and 11 illustrate the manner in which the heat exchanger construction is readily adaptable to provide higher capacity heat exchangers. In the heat exchanger ofFIGS. 4 to 8 , the side plates 24 b, 24 c andtubes box chassis 24 from two of these modules 105 a, 105 b fixed between front and rear plates 24 a of double height, comprising four banks 126, 128 oftubes 127, 129 can be provided. In this case, the lower and higher temperature zones are defined by the respective modules 105 a, 105 b. - This modular approach to enlarging the capacity of the heat exchanger means that three
identical return headers 34 can be utilised as illustrated to direct water between the tubes of the two lower banks and between the tubes of the two upper banks, and also, on the other side of thebox chassis 24, from the tubes of the lower, aluminium/stainless steel tubes to the upper cupronickel tubes. The inlet andoutlet headers inlet headers FIGS. 4 to 6 . - The illustrated configuration of water heater, including the two-stage heat exchanger configuration and the control of burner heat output in response to monitoring of the temperature in the heat exchanger, together result in a pool heater system of significantly higher efficiency than the earlier described conventional arrangements. Full volume water flow, say up to 400 L/min is maintained without periodic bypassing and burner output is matched with the desired set point gas temperature range in the heat exchanger. Condensation is accepted and properly managed by employing a two-stage heat exchanger in which the materials of the heat exchange elements are selected to suit the respective higher and lower temperature zones.
- The third aspect of the invention is concerned with the novel usage for the condensate collected in
tray 80 which is depicted in more detail inFIG. 16 . The concept is that this condensate, which contains traces of combustion by-products and is thereby slightly acidic, is recycled to the pool water as an effective chemical treatment. There are various ways in which this can be done. In the first (illustrated inFIGS. 12 and 13 ), a suitably dimensionedconduit 84 communicates thesump 81 viaoutlet 89 of tray 80 (seeFIG. 16 ) with thefeed port 86 of aventuri suction device 87 fitted withinwater outlet port 23.Conduit 84 includessolenoid valve 85 for selectively determining when condensate can flow to the venturi. Thesolenoid valve 85 is used to closeconduit 84 when theheater 10 and pump are not in use to prevent water flowing throughconduit 84 totray 80. A suitable construction for theventuri 87 is illustrated inFIG. 13 : it will be seen that thefeed port 86 at the end ofconduit 84 communicates with achamber 87 from which anaperture 88 opens into the neck of the venturi. - A float sensor (not shown) may be associated with the
sump 81 to detect blockage of theoutlet 89 orconduit 84. - In the alternative condensate recycling arrangement depicted in
FIG. 14 , adrain hose 90 fromsump 81 conveys the condensate to astorage reservoir 92 from which the condensate is selectively drawn via atube 93 by adosing unit 94 for delivery at aninsertion point 98 in the poolwater return pipe 96 downstream ofwater heater 10. - In a further alternative embodiment illustrated in
FIG. 17 thedrain hose 90 is selectively closed by thesolenoid valve 201. Downstream along thedrain hose 90 from thesolenoid valve 201 is thecondensate pump 202. Thecondensate pump 202 may be activated and thesolenoid valve 201 opened to drive condensate collected in thetray 80 through thepump discharge line 203. Thepump discharge line 203 extends from thepump 202 to asuction tee 204 positioned along thereturn pipe 96 downstream ofwater heater 10. The use of thesolenoid valve 201 prevents water back feeding from thereturn pipe 96 to thetray 80. -
FIG. 18 illustrates a further alternative embodiment which includes acollector reservoir 210 interposed between thetray 80 and thesolenoid valve 201 along thedrain hose 90 to store condensate. Acondensate suction line 211 extends from thesolenoid valve 201 to asuction tee 212. Thesuction tee 212 is fitted to aninlet line 214 for supplying water to thewater intake port 22. Apump 213 is positioned along theinlet line 214 to draw water from the swimming pool and drive the water through the heat exchanger 20 (the water is in turn returned to the pool via the return pipe 96). Thesuction tee 212 is thereby in a low pressure region upstream of thepump 213 and in addition is configured to create some venturi effect so that condensate may be drawn into theinlet pipe 214 when thesolenoid valve 201 is open. - It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.
Claims (39)
1. A water heater for heating water, including:
a burner assembly for generating a flow of hot gas, which burner assembly includes a gas burner and means adjustable to determine a heat output of the burner assembly;
a heat exchanger assembly for transferring heat from gas to water flowing therein, wherein the heat exchanger assembly has a higher temperature zone and a lower temperature zone, the water heater being arranged to convey the flow of hot gas to the higher temperature zone and in turn to the lower temperature zone;
ducting to conduct said flowing water to and from said heat exchanger assembly;
means to monitor the temperature of the hot gas intermediate the higher temperature zone and the lower temperature zone; and
control means responsive to said temperature monitoring means to modulate the heat output of the burner assembly whereby to maintain the monitored temperature within a predetermined range so as to substantially prevent or minimise condensation of vapour from the hot gas in the higher temperature zone.
2. A water heater according to claim 1 wherein use the monitored temperature is maintained within a pre-determined range without reducing the volume of water flowing through the heat exchanger.
3. A water heater according to claim 1 wherein said control means is operable to minimize said monitored temperature.
4. A water heater according to claim 1 wherein said means to monitor the temperature of the hot gas is mounted closer to the lower temperature zone than to the higher temperature zone.
5. A water heater according to claim 1 wherein the lower temperature zone and the higher temperature zone each have tubes for carrying water through the flow of hot gas, the tubes of the lower temperature zone and the higher temperature zone being formed of materials that respectively suit lower temperature operation and higher temperature operation.
6. A water heater according to claim 5 wherein the tubes of the lower temperature zone are formed of aluminium sheathed stainless steel and the tubes of the higher temperature zone are formed of cupronickel.
7. A water heater according to claim 5 wherein the tubes of the higher temperature zone are formed of copper.
8. A water heater according to claim 1 configured for the flow of hot gas to travel downwardly from the burner assembly through the higher temperature zone and in turn through the lower temperature zone.
9. A water heater according to claim 1 having means to collect condensate produced from condensation of gas in said lower temperature zone.
10. A water heater according to claim 9 including a condensate duct arranged to direct said condensate into the water for chemically treating the water.
11. A water heater according to claim 10 wherein the condensate duct is arranged to direct said condensate into the ducting from the heat exchanger assembly.
12. A water heater according to claim 10 wherein the condensate duct is arranged to direct condensate into the water upstream of a pump arranged to drive water through the water heater.
13. A water heater according to claim 10 including a venturi to draw said condensate into the water.
14. A water heater according to claim 10 including a suction tee to draw the condensate into the water.
15. A water heater according to claim 10 including a pump arranged to receive condensate from said means to collect condensate and drive said condensate through said condensate duct.
16. A water heater according to claim 9 including a dosing apparatus for storing and selectively directing metered amounts of condensate into the water at any suitable location.
17. A heat exchanger apparatus, including:
a heat exchange module having a plurality of heat exchange elements extending across a passage, the passage being arranged to convey a first fluid past and about the heat exchanger elements; and
one or more return headers adapted to be selectively mounted to said module either for directing a second fluid in turn through any adjacent pair of heat exchange elements, or for directing a second fluid from one heat exchange element of said module to a heat exchange element of a similar module when said module is coupled to said similar module.
18. A heat exchanger apparatus according to claim 17 wherein each heat exchange element is a bank of tubes.
19. A heat exchanger apparatus according to claim 18 wherein the return header has a separate sealing engagement with each tube.
20. A heat exchanger apparatus according to claim 18 wherein the banks of tubes are relatively displaced along said passage.
21. A heat exchanger apparatus according to claim 18 wherein the banks of tubes respectively form one or more lower temperature banks of tubes and one or more higher temperature banks of tubes having their tubes formed in differing materials that respectively suit lower temperature operation and higher temperature operation.
22. A heat exchanger apparatus according to claim 21 wherein the tubes of the one or more lower temperature banks of tubes are formed of aluminium sheathed stainless steel and the tubes of the one or more higher temperature banks of tubes are formed of cupronickel.
23. A heat exchanger apparatus according to claim 21 wherein the tubes of the one or more higher temperature banks of tubes are formed of copper.
24. A heat exchanger apparatus according to claim 18 having a plurality of the modules in coupled relation and a plurality of like return headers interconnecting banks of tubes within the modules and interconnecting modules.
25. A heat exchanger apparatus according to claim 18 to wherein each module has only two banks of tubes.
26. A heat exchanger apparatus according to claim 25 having two of said modules and three of said return headers, two of the return headers being respectively mounted for directing the second fluid between the banks of tubes within a respective module, and a third return header for directing the second fluid from a second bank of one module to a first bank of the other module.
27. A heat exchanger apparatus according to claim 26 wherein the successive spacings of the banks of tubes along said passage are substantially equal, and the tubes one of the modules and the tubes of the other of the module being formed in materials that respectively suit a lower temperature operation and higher temperature operation.
28. A heat exchanger apparatus according to claim 18 wherein the first fluid is hot gas from a burner assembly and the second fluid is water.
29. A water heater according to claim 1 wherein the heat exchanger assembly includes:
a heat exchange module having banks of tubes extending across a passage, the passage being arranged to convey the hot gas past and about the bank of tubes; and
one or more return headers adapted to be selectively mounted to said module either for directing the water in turn through any adjacent pair of tube banks, or for directing the water from one bank of tubes of said module to a bank of tubes of a similar module when said module is coupled to said similar module.
30. A water heater for heating water, including:
a burner assembly for generating a flow of hot gas;
a heat exchanger assembly arranged to receive said flow of hot gas for transferring heat from the gas to water flowing therein;
ducting to conduct said water to and from said heat exchanger assembly;
means to collect condensate produced from condensation of said gas in said heat exchanger assembly; and
a condensate duct to direct said condensate into said water for chemically treating said water.
31. A water heater according to claim 30 wherein the condensate duct is arranged to direct said condensate into the ducting from the heat exchanger assembly.
32. A water heater according to claim 30 wherein the condensate duct is arranged to direct condensate into the flowing water upstream of a pump arranged to drive water through said water heater.
33. A water heater according to claim 30 including a venturi to draw said condensate into said water.
34. A water heater according to claim 30 including a suction tee to draw said condensate into said water.
35. A water heater according to claim 30 including a pump arranged to receive condensate from said means to collect condensate and drive said condensate through said condensate duct.
36. A water heater according to claim 30 including a dosing apparatus along said condensate duct for storing and selectively directing metered amounts of condensate into the water at any suitable location.
37. A method of chemically treating water in a pool comprising adding to the water condensate collected from a heat exchanger assembly of a water heater through which the pool water is circulated and heated.
38. A water heater according to claim 2 wherein said control means is operable to minimize said monitored temperature.
39. A water heater according to claim 38 wherein the lower temperature zone and the higher temperature zone each have tubes for carrying water through the flow of hot gas, the tubes of the lower temperature zone and the higher temperature zone being formed of materials that respectively suit lower temperature operation and higher temperature operation.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2007903605 | 2007-07-04 | ||
AU2007903605A AU2007903605A0 (en) | 2007-07-04 | Water heating apparatus, especially for pools | |
PCT/AU2008/000987 WO2009003244A1 (en) | 2007-07-04 | 2008-07-04 | Water heating apparatus, especially for pools |
Publications (1)
Publication Number | Publication Date |
---|---|
US20100170452A1 true US20100170452A1 (en) | 2010-07-08 |
Family
ID=40225658
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/666,585 Abandoned US20100170452A1 (en) | 2007-07-04 | 2008-07-04 | Water heating apparatus, especially for pools |
Country Status (4)
Country | Link |
---|---|
US (1) | US20100170452A1 (en) |
AU (1) | AU2008271930B2 (en) |
NZ (3) | NZ616544A (en) |
WO (1) | WO2009003244A1 (en) |
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US20120240869A1 (en) * | 2011-03-25 | 2012-09-27 | Laars Heating Systems Company | Condensing gas appliance and condensate trap therefor |
US20180195742A1 (en) * | 2017-01-11 | 2018-07-12 | Noritz Corporation | Hot water apparatus |
US10024572B1 (en) | 2012-12-20 | 2018-07-17 | Htp, Inc. | Heat exchanger |
JP2019113280A (en) * | 2017-12-26 | 2019-07-11 | 株式会社ノーリツ | Heat exchange device and heat source machine |
WO2020023758A1 (en) * | 2018-07-25 | 2020-01-30 | Hayward Industries, Inc. | Compact universal gas pool heater and associated methods |
US11473857B2 (en) * | 2020-01-04 | 2022-10-18 | Intellihot, Inc. | Modular exhaust |
WO2023010136A1 (en) * | 2021-07-30 | 2023-02-02 | Friction Flow, LLC | Pool heating system with baffles to generate heat |
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FR2955923B1 (en) * | 2010-02-02 | 2015-01-02 | A Theobald Sa | METHOD FOR CONTROLLING A BOILER TO LIMIT CONDENSATION IN THE EXHAUST ROOM |
AU2011213724B2 (en) | 2010-08-18 | 2016-03-24 | Zodiac Pool Systems, Inc. | Improved flow control and improved heat rise control device for water heaters |
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FR3004799B1 (en) * | 2013-04-23 | 2015-04-10 | Guillot Ind Sa | METHOD FOR PROTECTING A CONDENSER AGAINST OVERHEATING |
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WO2023010136A1 (en) * | 2021-07-30 | 2023-02-02 | Friction Flow, LLC | Pool heating system with baffles to generate heat |
Also Published As
Publication number | Publication date |
---|---|
AU2008271930A1 (en) | 2009-01-08 |
AU2008271930B2 (en) | 2012-03-22 |
WO2009003244A1 (en) | 2009-01-08 |
NZ601752A (en) | 2013-11-29 |
NZ616544A (en) | 2015-01-30 |
NZ582223A (en) | 2012-09-28 |
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