WO2015097694A1

WO2015097694A1 - Programmable controller for water heater

Info

Publication number: WO2015097694A1
Application number: PCT/IL2014/051115
Authority: WO
Inventors: Elad Cohen; Ariel Cohen
Original assignee: Elad Cohen; Ariel Cohen
Priority date: 2013-12-24
Filing date: 2014-12-21
Publication date: 2015-07-02
Also published as: IL230147A; IL230147A0

Abstract

The subject matter discloses a programmable controller for activating and deactivating a heating unit in a water heating system, comprising a setup memory for storing setup parameters inputted by a user of the water heating system defining a configuration of the hot water heating system; a schedule memory for storing a schedule of hot water usage events indicating a usage time and an amount of hot water required to be heated for the event inputted by the user of the water heating system; a processor for calculating a start time based on the setup parameters for turning on the heating unit to heat water so that the required amount of hot water will be heated to a desired temperature level at the usage time indicated for the water usage events.

Description

PROGRAMMABLE CONTROLLER FOR WATER HEATER

TECHNICAL FIELD

The present disclosure relates generally to a programmable controller for controlling heating water in a water heater tank.

BACKGROUND

It is common practice to use electrical or gas water heaters to heat water in a tank for general household consumption, for example for taking showers or washing dishes. In many systems the water is not maintained at a specific temperature but only heated before it is needed. Typically the user turns on the heating system of the water heater for a desired period of time before consumption. Generally the actual required heating time is directly related to the amount of hot water needed for consumption, for example if hot water is needed for two people to have a shower then the water in the tank should be heated longer to reach a higher temperature than if only one person is planning to have a shower.

In some systems the water may also be heated by solar panels, so that in the summer the water in the tank may not need to be heated at all or only for a short period, whereas in the winter it may require extensive heating.

In many systems the activation switch for the heater is replaced with a timer, so that the user can select an amount of time for heating the water without being required to physically turn the heater on or off. Thus the user can have the water automatically heated before waking up in the morning or before arriving home from work.

Generally users select the amount of time based on a guess or past experience. Users do not calculate a time duration for heating the water based on configuration parameters of the water heating system or on the weather or a combination thereof. However if the user selects too little time the water will not be hot enough for the desired use, and if the user selects too much time the user will waste energy heating the water more than necessary. Determining the required heating time is especially problematic if the user is unfamiliar with the configuration parameters of the system, such as tank size, heater output strength, climate (geographical region), input water temperature, use of solar panels and other related parameters. Thus it would be desirable to be able to request hot water based on an amount required and a time of use without knowledge of the ability of the water heating system and configuration details of the water heating system installation.

SUMMARY

An aspect of an embodiment of the disclosure relates to a system and method for heating water. The system includes a programmable controller that controls the provision of power to a heating unit installed in a water tank. The programmable controller is initially setup with configuration parameters defining the ability of the water heating system. The user programs the programmable controller with a schedule of hot water usage events, for example showers, washing dishes or other types of events. The schedule includes details identifying times and amount of hot water required, for example every day at five o'clock to provide hot water for two showers. The programmable controller calculates a start time to activate the heating unit so that the required amount of hot water will be available at the scheduled time. The calculation is based on the configuration parameters that identify the ability of the water heating system. At the calculated time the programmable controller activates the heating unit so that the hot water will be available as scheduled.

In an exemplary embodiment of the disclosure, the configuration parameters may include: time and date, geographical region, volume of the water tank, if there are solar panels, if the water tank is upright or lying down, heat output of the heating unit, amount of water required for each event (e.g. a shower), average water temperature in the region, heating mode, if any time extensions should be applied to the calculated heating time, location of the water tank, heat loss coefficient of the water tank and other parameters. Optionally, the calculation is based only on the configuration parameters without additional information from external sensors.

There is thus provided according to an exemplary embodiment of the disclosure, a programmable controller for activating and deactivating a heating unit in a water heating system, comprising:

a setup memory for storing setup parameters defining a configuration of the hot water heating system;

a schedule memory for storing a schedule of hot water usage events indicating a usage time and an amount of hot water required to be heated for the event;

a processor for calculating a start time based on the setup parameters for turning on the heating unit to heat water so that the required amount of hot water will be heated to a desired temperature level at the usage time indicated for the water usage events; and wherein the setup parameters include an indication if the water heating system includes solar panels and the calculated start time is adjusted based on this indication.

In an exemplary embodiment of the disclosure, the calculated start time is based only on the setup parameters and schedule of hot water usage events. Optionally, the setup parameters include an indication of the time of year and the calculated start time is adjusted based on this indication. In an exemplary embodiment of the disclosure, the setup parameters include an indication of the volume of a water tank in the water heating system and the calculated start time is adjusted based on this indication. Optionally, the setup parameters include an indication of the geographical location of the installation of the water heating system and the calculated start time is adjusted based on this indication.

In an exemplary embodiment of the disclosure, the programmable controller does not receive measurements from sensors. Optionally, the programmable controller is connected over a network to a server that provides information for updating the setup parameters. In an exemplary embodiment of the disclosure, the programmable controller is connected over a network to a server that provides information for updating hot water usage events. In an exemplary embodiment of the disclosure, the network is the Internet and the server includes a web site that allows a user to update setup parameters or hot water usage events remotely. Optionally, the programmable controller further comprises a sensor receiver to receive temperature measurements from a thermostat providing an indication of the temperature of the water while the water is being heated. In an exemplary embodiment of the disclosure, responsive to readings of the thermostat the processor instructs the heating unit to continue heating if the water did not reach the desired temperature level based on the calculations of the processor. Optionally, responsive to readings of the thermostat the processor instructs the heating unit to start heating at an earlier time than calculated based on the setup parameters.

In an exemplary embodiment of the disclosure, the programmable controller further comprises a sensor receiver to receive temperature measurements from outdoors or in the vicinity of the solar panels. Optionally, the processor adjusts the start time responsive to the measurements received from the sensor receiver . In an exemplary embodiment of the disclosure, the programmable controller further comprises a user interface that provides audible sounds to notify that the water is heated and ready for use. In an exemplary embodiment of the disclosure, the setup parameters include an indication if a water heating tank in the water heating system is installed upright or lying down on its side and the calculated start time is adjusted based on this indication. Optionally, the setup parameters include an indication of the age of the heating unit in the water heating system and the calculated start time is adjusted based on this indication.

There is further provided according to an exemplary embodiment of the disclosure, a method of heating water using a programmable controller that activates and deactivates a heater unit in a water heating system, comprising:

entering into a memory of the programmable controller a schedule of hot water usage events indicating a usage time and a required amount of water;

calculating by a processor in the programmable controller a start time for heating water; wherein the start time is calculated based on setup parameters that were initially programmed in the programmable controller to define a configuration of the water heating system; and so that the required amount of water will be heated to a desired temperature level at the scheduled usage time; and

wherein the setup parameters include an indication if the water heating system includes solar panels and the calculated start time is adjusted based on this indication.

In an exemplary embodiment of the disclosure, the setup parameters include an indication of the time of year and the calculated start time is adjusted based on this indication. Optionally, the calculated start time is based only on the setup parameters and schedule of hot water usage events

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will be understood and better appreciated from the following detailed description taken in conjunction with the drawings. Identical structures, elements or parts, which appear in more than one figure, are generally labeled with the same or similar number in all the figures in which they appear, wherein:

Fig. 1 is a schematic illustration of a water heating system, according to an exemplary embodiment of the disclosure;

Fig. 2 is a schematic illustration of a programmable controller for controlling a heating unit of a hot water heater system, according to an exemplary embodiment of the disclosure;

Fig. 3 is a block diagram of the elements of a programmable controller for controlling a heating unit of a hot water heater system, according to an exemplary embodiment of the disclosure; and

Fig. 4 is a flow diagram of a method of controlling heating water with a hot water heating system, according to an exemplary embodiment of the disclosure.

DETAILED DESCRIPTION

Fig. 1 is a schematic illustration of a water heating system 100, according to an exemplary embodiment of the disclosure. Heating system 100 includes a water tank 110 for holding water, a heating unit 120 for heating the water in water tank 110 and a programmable controller 140 that controls turning the heating unit 120 on and off. In an exemplary embodiment of the disclosure, programmable controller 140 controls the provision of electrical power from a power source 160 to heating unit 120 over a power line 145. In some embodiments of the disclosure, the heating unit may function on gas or other energy sources wherein programmable controller 140 controls activation and deactivation of the heating unit.

Programmable controller 140 is initially programmed with setup parameters related to heating system 100 or related to configuration details of the current installation or related to both of the modules above. A user can then program programmable controller 140 with a schedule of times and hot water usage events for the controller to prepare for. Programmable controller 140 calculates a start time for activating heating unit 120 before the time of the usage event based on the setup parameters, so that the water will be heated correctly for the usage event.

In an exemplary embodiment of the disclosure, water tank 110 is connected to a running water source through a cold water input line 102 and hot water is provided to the user from a hot water output line 104. Optionally, water may be provided from water tank 110 to solar heating panels 150 on an output line 106. Solar heating panels 150 provide heated water over a line 108 back to water tank 110. The water in solar panels 150 are exposed to solar energy and are heated to a varying extent depending on the climate of the geographical region of the installation, time of day and season.

In an exemplary embodiment of the disclosure, heating system 100 may include a thermostat 130 that deactivates heating unit 120 if the temperature of the water exceeds a pre-determined temperature to prevent damage or waste of energy or a combination thereof. In some embodiments of the disclosure thermostat 130 is connected to programmable controller 140 with a communication line 135 to report regarding the temperature level of the water in water tank 110. Optionally, programmable controller 140 will deactivate heating unit 120 or extend the duration of the heating process responsive to the measurements of thermostat 130. In some embodiments of the disclosure, programmable controller 140 may begin heating earlier if for example the temperature of the water is less than expected based on the setup parameters, for example if the water is expected to be warm due to solar heating at this time of the year and it is not, programmable controller 140 may start heating earlier.

In some embodiments of the disclosure, programmable controller 140 only replaces the electrical switch for activating and deactivating heating unit 120 to simplify installation, and is not connected to any sensors. In such an embodiment, calculation of the heating start time is only based on the setup parameters and the amount of hot water required (e.g. no. of showers) and not on the readings of sensors.

Fig. 2 is a schematic illustration of programmable controller 140 for controlling heating unit 120 of hot water heater system 100, according to an exemplary embodiment of the disclosure. In an exemplary embodiment of the disclosure, programmable controller 140 includes an electronic circuit 270 enclosed by an encasement 200. Optionally, a display 250, for example an LCD or LED display is provided to display information to the user, for example the time and date, the time at which programmable controller 140 will activate heating unit 120, a countdown until finishing a heating session and deactivating heating unit 120, and/or setup parameters that the user needs to select. In an exemplary embodiment of the disclosure programmable controller 140 includes input keys such as:

1. A setup key 210 to select a setup mode for entering setup parameters or water usage events;

2. A boost key to manually activate heater unit 120 when it is not activated or to extend the activation time of an active program, for example by adding 10% to the heating time;

3. Navigation keys 230 to move about on display 250;

4. A selection key 240 to select options and turn programmable controller

140 on/off;

5. A reset button for resetting the programmable controller back to the factory defaults.

Optionally, the reset button is hidden for example implemented as a pin hole that can be activated by pushing a pin down the pinhole, and not pushed accidentally.

In an exemplary embodiment of the disclosure, one of the keys or an additional key may be used to place the programmable controller 140 into a deferred state in which programmable controller 140 is functional but does not activate heating unit 120.

Fig. 3 is a block diagram 300 of elements of programmable controller 140 for controlling heating unit 120 of hot water heater system 100, according to an exemplary embodiment of the disclosure. Optionally, electronic circuit 270 of programmable controller 140 includes the following elements:

1. A processing unit 310 for processing a control program implemented by programmable controller 140 and calculating activation duration based on initial factory preset parameters, parameters entered by the user or information from other sources such as thermostat 130;

2. A program memory 320 for storing the program implemented by programmable controller 140. Optionally, the memory is a non-volatile memory such as a ROM so that the program is not erased in case of power loss;

3. A setup memory 330 for saving parameter values input or selected by the user related to the configuration of hot water system 100;

4. A schedule memory 335 for saving a schedule of hot water usage events including a time and an indication of an amount of hot water required;

5. A user interface 340, for example including display 250 for displaying information and a keypad for entering information. Optionally, the display may be a touch screen to allow input and output;

6. A sensor receiver 350 to receive measurements from thermostat 130 or any other sensor implemented in water heating system 100, for example a temperature sensor to sense outdoor temperature or the temperature at the solar panels 150;

7. A backup battery 360 to provide a minimal amount of power to programmable controller 140 even during a power failure, for example to keep an internal clock running so that programmable controller 140 will accurately activate and deactivate heating unit 120 even if there was a power outage during the day before a water usage event. Additionally, battery backup 360 can prevent loss of the parameter values selected by the user if power is required to maintain them;

8. A power control unit 370 for controlling the input of power to heater unit 120 by activating or deactivating heater unit 120 responsive to instructions from the processor; 9. A work memory 380 such as a RAM for use by the processor to perform calculations and process the control program; and

10. A communication interface 390 for wired or wireless communication with the internet or other communication means.

In some embodiments of the disclosure, programmable controller 140 may include additional elements such as a dedicated on/off button for turning programmable controller 140 on/off or an audible alarm to alert the user at the beginning or end of a heating program or both or upon occurrence of special events, for example a power failure.

Fig. 4 is a flow diagram 400 of a method of controlling heating water with a hot water heating system 100, according to an exemplary embodiment of the disclosure. In an exemplary embodiment of the disclosure, programmable controller 140 needs to be initially setup to know details of the water heating system 100 in which it is installed, so that a heating duration can be calculated. Optionally, the user presses and holds setup key 210 for an extended period (e.g. 3 seconds or more) to enter a parameter setup screen (410). In the parameter setup screen the user is requested to provide information relating to the physical parameters of the water tank 110, heating unit 120, solar panels 150, geographical location of the system, electrical ability of the heater, date and time and so forth.

Following is a list of optional parameters that are entered by the user:

1. Time and date;

2. Geographical region (including climate);

3. Volume of water tank 110, for example 50, 80, 120, 150, 200 Liters;

4. If the water tank is connected to solar panels;

5. If the water tank 110 is installed lying down or upright (since this has an effect on the effectiveness of the heating process);

6. Heat output of heating unit 120 (Watts);

7. Age of heating unit 120 (older units are less effective since they are covered with residue (e.g. stone));

8. Amount of water required for an average shower;

9. Time required for an average shower;

10. Average water temperature in the region (will be adjusted automatically for calculating heating duration according to the time of the year); 11. Heating mode (e.g. fast - with maximum heat output, slow - with low heat output);

12. Heating time extension, for example if the program should add an extra amount of time to the calculated duration of the heating process, for example 5%, 10% or a fixed amount of time;

13. Location of the water tank 110 (e.g. outside, inside, cellar, attic);

14. Heat loss coefficient of water tank 110.

Optionally, other parameters that have an effect on the heating process may be provided, for example the user may select season levels such as winter, spring, summer and fall. Programmable controller 140 may use the season levels instead of or in addition to the date or geographical region or a combination thereof. In an exemplary embodiment of the disclosure, parameters that are not updated by the user will assume factory default values.

In an exemplary embodiment of the disclosure, at least one of the above listed setup parameters are used to calculate the time to start heating the water in water tank 110.

After entering the setup parameters (410), the user can enter a hot water usage schedule (420) (usage events). Optionally, this option is selected by pressing setup key 210 for a short period (e.g. a simple click). In an exemplary embodiment of the disclosure, the user provides dates and times and a number of showers required. For example the user can define that every Sunday, Tuesday and Wednesday 3 showers will be taken starting at 17:00. Optionally, the user can provide multiple programs. In some embodiments of the disclosure, the user can select specific days of the month or provide specific dates.

Once the user has selected hot water usage events, water heating system 100 calculates (430) a time duration for activating heating unit 120 before the times selected by the user. In an exemplary embodiment of the disclosure, water heating system 100 will activate the heater (440) at the calculated time, so that the water will be heated sufficiently to provide the requested amount of hot water at the scheduled times. Optionally, the calculation is only based on the setup parameters. Alternatively, if programmable controller 140 receives measurements from sensors such as an indication of the actual temperature of the water in water tank 110 then it can take them into account in the calculation and extend or shorten the heating duration. Optionally, programmable controller 140 may stop heating the water if the actual desired temperature is reached before heating for the full duration.

In an exemplary embodiment of the disclosure, programmable controller 140 can provide an audible signal, for example a sequence of beeps or play a tune to announce that the water is ready for consumption. Optionally, programmable controller 140 may also provide a visual indication such as flashing lights, a text message or a special picture.

In an exemplary embodiment of the disclosure, the user can press boost key 220 during the duration of a heating program to increase the heating duration, for example to accommodate for another shower more than specified in the original schedule or if the weather is colder than usual at that time of year. In an exemplary embodiment of the disclosure, if the user presses boost key 220 not during a heating program then it will immediately start to heat for a pre- selected amount of time, for example 10-15 minutes or half an hour.

In an exemplary embodiment of the disclosure, the user may provide feedback by adjusting the initial setup, for example by setting the heating time extension value based on the experience of the user. Thus if there was not enough hot water for the scheduled events programmable controller 140 can be updated to increase heating in the future.

In some embodiments of the disclosure, programmable controller 140 will heat the water so that it will be ready for a first shower and if necessary will continue heating during the first shower or sequential showers so that there will be enough hot water for additional showers.

In an exemplary embodiment of the disclosure, programmable controller 140 is connected to a network 180, for example the Internet via communication interface 390. Optionally, the connection may be wired or wireless (e.g. Wi-Fi). In some embodiments of the disclosure, programmable controller 140 may receive information from a central server 190 over network 180. For example central server 190 may provide weather information for the geographical region of programmable controller 140. Optionally, the weather information may be used to override statistical assumptions about the weather based on the date and geographical region in the setup parameters. In an exemplary embodiment of the disclosure the weather information may include details such as if it is cloudy, rainy, sun strength, temperature and the like. In an exemplary embodiment of the disclosure, the network connection can enable programmable controller 140 to receive instructions remotely from a user, for example a user may activate or deactivate programmable controller 140 using a mobile telephone or a workstation connected to the Internet.

In some embodiments of the disclosure, the user can access a web site that enables the user to remotely program programmable controller 140, for example to change setup parameters or update water usage events. Optionally, the user may control programmable controller by sending an email or SMS to central server 190 or to a dedicated account.

It should be appreciated that the above described methods and apparatus may be varied in many ways, including omitting or adding steps, changing the order of steps and the type of devices used. It should be appreciated that different features may be combined in different ways. In particular, not all the features shown above in a particular embodiment are necessary in every embodiment of the disclosure. Further combinations of the above features are also considered to be within the scope of some embodiments of the disclosure. It will also be appreciated by persons skilled in the art that the present disclosure is not limited to what has been particularly shown and described hereinabove.

Claims

CLAIMS I/We claim:

1. A programmable controller for activating and deactivating a heating unit in a water heating system, comprising:

a setup memory for storing setup parameters inputted by a user of the water heating system defining a configuration of the hot water heating system;

a schedule memory for storing a schedule of hot water usage events indicating a usage time and an amount of hot water required to be heated for the event inputted by the user of the water heating system;

a processor for calculating a start time based on the setup parameters for turning on the heating unit to heat water so that the required amount of hot water will be heated to a desired temperature level at the usage time indicated for the water usage events.

2. A programmable controller according to claim 1, wherein the calculated start time is based only on the setup parameters and schedule of hot water usage events.

3. A programmable controller according to claim 1, wherein the setup parameters include an indication of the time of year according to a date inputted by the user of the heating system during installation and the calculated start time is adjusted based on this indication.

4. A programmable controller according to claim 1, wherein the setup parameters include an indication of the volume of a water tank in the water heating system and the calculated start time is adjusted based on this indication.

5. A programmable controller according to claim 1, wherein the setup parameters include an indication of the geographical location of the installation of the water heating system and the calculated start time is adjusted based on this indication.

6. A programmable controller according to claim 1, wherein the programmable controller does not receive measurements from sensors.

7. A programmable controller according to claim 1, wherein the programmable controller is connected over a network to a server that provides information for updating the setup parameters.

8. A programmable controller according to claim 1, wherein the programmable controller is connected over a network to a server that provides information for updating hot water usage events.

9. A programmable controller according to claim 8, wherein the network is the Internet and the server includes a web site that allows a user to update setup parameters or hot water usage events remotely.

10. A programmable controller according to claim 1, further comprising a sensor receiver to receive temperature measurements from a thermostat providing an indication of the temperature of the water while the water is being heated.

11. A programmable controller according to claim 10, wherein responsive to readings of the thermostat the processor instructs the heating unit to continue heating if the water did not reach the desired temperature level based on the calculations of the processor.

12. A programmable controller according to claim 10, wherein responsive to readings of the thermostat the processor instructs the heating unit to start heating at an earlier time than calculated based on the setup parameters.

13. A programmable controller according to claim 1, further comprising a sensor receiver to receive temperature measurements from outdoors or in the vicinity of the solar panels.

14. A programmable controller according to claim 13, wherein the processor adjusts the start time responsive to the measurements received from the sensor receiver.

15. A programmable controller according to claim 1, further comprising a user interface that provides audible sounds to notify that the water is heated and ready for use.

16. A programmable controller according to claim 1, wherein the setup parameters include an indication if a water heating tank in the water heating system is installed upright or lying down on its side and the calculated start time is adjusted based on this indication.

17. A programmable controller according to claim 1, wherein the setup parameters include an indication of the age of the heating unit in the water heating system and the calculated start time is adjusted based on this indication.

18. A method of heating water using a programmable controller that activates and deactivates a heater unit in a water heating system, comprising:

19. A method of heating water using a programmable controller according to claim 18, wherein the setup parameters include an indication of the time of year and the calculated start time is adjusted based on this indication.

20. A method of heating water using a programmable controller according to claim 18, wherein the calculated start time is based only on the setup parameters and schedule of hot water usage events.