U.S. patent application number 10/527608 was filed with the patent office on 2005-10-27 for water heating apparatus.
Invention is credited to McNair, Dohn Duncan, Trihey, Albert Massey, Trihey, John Massey.
Application Number | 20050235984 10/527608 |
Document ID | / |
Family ID | 31994783 |
Filed Date | 2005-10-27 |
United States Patent
Application |
20050235984 |
Kind Code |
A1 |
Trihey, John Massey ; et
al. |
October 27, 2005 |
Water heating apparatus
Abstract
Water heating apparatus including: a storage tank for storing
heated water, a gas burner assembly for heating water in the tank;
the gas burner assembly including: a housing; a gas burner in the
housing; at least one passage through the housing; and mounting
means for mounting the housing in the tank such that, in use, it is
immersed in water within the tank and wherein, when the gas burner
is operated, the temperature of the housing rises and heat transfer
to the water in the tank occurs and a convection current in the
water flows through the at least one passage to thereby increase
heat transfer to the water.
Inventors: |
Trihey, John Massey; (South
Caulfield, AU) ; Trihey, Albert Massey; (Elwood,
AU) ; McNair, Dohn Duncan; (Olinda, AU) |
Correspondence
Address: |
JENKENS & GILCHRIST, PC
1445 ROSS AVENUE
SUITE 3200
DALLAS
TX
75202
US
|
Family ID: |
31994783 |
Appl. No.: |
10/527608 |
Filed: |
March 11, 2005 |
PCT Filed: |
September 16, 2003 |
PCT NO: |
PCT/AU03/01211 |
Current U.S.
Class: |
126/615 |
Current CPC
Class: |
F24D 2200/04 20130101;
F24D 17/0068 20130101; F24H 1/206 20130101; Y02B 10/70 20130101;
Y02B 10/20 20130101 |
Class at
Publication: |
126/615 |
International
Class: |
F24J 002/42 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 16, 2002 |
AU |
2002951413 |
Apr 29, 2003 |
AU |
2003902024 |
Claims
1. Water heating apparatus including: a storage tank for storing
heated water; a gas burner assembly for heating water in the tank;
the gas burner assembly including: a housing; a gas burner in the
housing; at least one passage through the housing; and mounting
means for mounting the housing in the tank such that, in use, it is
immersed in water within the tank and wherein, when the gas burner
is operated, the temperature of the housing rises and heat transfer
to the water in the tank occurs and a convection current in said
water flows through said at least one passage to thereby increase
heat transfer to the water.
2. Water heating apparatus as claimed in claim 1 wherein there are
a plurality of said passages extending through said housing.
3. Water heating apparatus as claimed in claim 2 wherein the
housing includes a cylindrical housing sidewall and top and bottom
housing end walls, and wherein said passages are defined by tubular
elements which extend between said housing top and bottom
walls.
4. Water heating apparatus as claimed in claim 3 wherein the
housing bottom wall is inclined at a predetermined angle to the
horizontal.
5. Water heating apparatus as claimed in claim 4 wherein the
predetermined angle is in the range 1.degree. to 5.degree..
6. Water heating apparatus as claimed in claim 5 wherein the
predetermined angle is 2.5.degree..
7. Water heating apparatus as claimed in claim 4 wherein the tank
includes a cylindrical tank sidewall and top and bottom tank end
walls and wherein the axis of the cylindrical housing sidewall is
inclined at said predetermined angle relative to the axis of the
cylindrical tank sidewall.
8. Water heating apparatus as claimed in claims 1 to 7 wherein the
tank includes a heat exchanger located above the burner assembly
and coupling means for connecting a mains water supply to the heat
exchanger so that water from said supply passes through the heat
exchanger and is heated by extraction of heat from the water stored
in the tank.
9. Water heating apparatus as claimed in claim 8 wherein the heat
exchanger includes a coil.
10. Water heating apparatus as claimed in claim 8 wherein the heat
exchanger includes two coils connected in parallel.
11. Water heating apparatus as claimed in claim 9 or 10 wherein
said coil or coils are helically wound about an axis which passes
through or near to the centre of said housing.
12. Water heating apparatus as claimed in claim 8, 9 or 10 wherein
convection currents passing through said passage or passages
impinge upon said heat exchanger and wherein, as heat is absorbed
into the heat exchanger, cool convection currents are established,
said cool convection currents flow downwardly at a location between
the heat exchanger and the tank.
13. Water heating apparatus as claimed in claim 12 including a gas
control valve for controlling flow of gas to the gas burner, a
temperature sensor having an output coupled to said gas control
valve, the arrangement being such that gas is supplied to the gas
burner when the temperature sensor senses that the temperature of
the water is below an operating temperature.
14. Water heating apparatus as claimed in claim 13 wherein the
temperature sensor is located below said housing.
15. Water heating apparatus as claimed in claim 13 or 14 wherein
the sensor is located adjacent to a sidewall of the tank.
16. Water heating apparatus as claimed in claim 13, 14 or 15
wherein the sensor is located in a position such that in use said
cool convection currents impinge upon said sensor.
17. Water heating apparatus as claimed in claims 13 to 16 including
an over temperature sensor which is operable in use to stop supply
of gas to the gas burner wherein a predetermined over temperature
is reached in the tank.
18. Water heating apparatus as claimed in claim 17 wherein the gas
burner assembly includes a flue which extends upwardly from said
housing.
19. Water heating apparatus as claimed in claim 17 wherein the over
temperature sensor is mounted so that it is in the tank and in
thermal contact with said flue, the arrangement being such that the
over temperature sensor is operable to stop supply of gas to the
gas burner when the water in the tank exceeds said predetermined
over temperature or the tank includes air in the top thereof
whereby the flue will cause the over temperature sensor to sense a
temperature greater than said predetermined over temperature.
20. Water heating apparatus as claimed in claim 3 wherein a
plurality of reinforcing rods extend between housing top and bottom
walls.
21. Water heating apparatus as claimed in claim 20 wherein said
rods pass through said tubular elements.
22. Water heating apparatus as claimed in claims 1 to 21 including
a header tank located above said storage tank, a first water
conduit extending from the top of the storage tank to an upper part
of the header tank and a second conduit extending from a lower part
of the header tank to a lower part of the storage tank.
23. Water heating apparatus as claimed in claim 22 including air
bubble directing means for directing air bubbles in the water in
the storage tank to said first conduit so that air bubbles are
removed from the storage tank.
24. Water heating apparatus as claimed in claim 22 as appended
indirectly to claim 7 wherein the tank top wall is inclined to the
horizontal and the first conduit is connected to an uppermost part
of said tank top wall to thereby constitute said means for
directing air bubbles.
25. Water heating apparatus as claimed in claim 22, 23 or 24 as
appended directly or indirectly to claim 8 including a heat
exchanger pressure relief valve which is coupled to discharge into
said header tank.
26. Water heating apparatus as claimed in claim 25 including a
header tank pressure relief valve which is operable to discharge if
the pressure within the header tank, and therefore the storage
tank, exceeds a predetermined operating pressure.
27. Water heating apparatus as claimed in claim 26 wherein the
operating pressure is about 50 psi.
28. A gas/solar water heating apparatus including: water heating
apparatus as claimed in any one of claims 8 to 21; a solar
collector panel; a solar storage tank; circulating means for
circulating water from the solar storage tank to the panel; a heat
exchanger in the solar storage tank; and said coupling means being
operable to pass water from said water supply through the heat
exchanger in said solar storage tank prior to passing through the
heat exchanger in said storage tank.
29. A gas/solar water heating apparatus as claimed in claim 28
wherein the solar storage tank is located beneath said storage tank
and within a single housing.
30. A gas/solar water heating apparatus as claimed in claim 29
including flue gas circulating means for directing flue gases from
the burner assembly to said solar storage tank, whereby heat in
said flue gases is absorbed into the water in the solar storage
tank.
31. A gas/solar water heating system including: a gas fired water
heater having a flue; a solar collector panel; a solar storage
tank; circulating means for circulating water from the solar
storage tank to the panel; a heat exchanger in the solar storage
tank; and said solar collector panel including a flue gas chamber
therein and flue gas ducting means for coupling said flue to the
flue gas chamber, the arrangement being such that water circulated
through the panel absorbs solar energy and heat energy from flue
gases entering the chamber.
32. A gas/solar water heating system as claimed in claim 31
including control means operable to control ignition of said gas
fired water heater and said circulating means, the control means
being operable to operate the circulating means prior to ignition
of said gas fired water heater so that the flue gases do not
overheat the panel.
33. Electrical power and hot water heating apparatus including: a
gas/solar water heating system as claimed in claim 31; an internal
combustion engine having an exhaust; an electric generator coupled
to be driven by said internal combustion engine; and exhaust gas
duct means for directing exhaust gases into said flue gas chamber
whereby the water circulated through the panel absorbs heat from
said exhaust gases.
34. Apparatus as claimed in claim 33 wherein said exhaust gas duct
means includes a venturi and wherein the end of said flue gas
ducting means is located in said venturi.
35. Hot water heating apparatus including: a gas/solar water
heating system as claimed in claim 31; an internal combustion
engine having an exhaust; and exhaust gas duct means for directing
exhaust gases into said flue gas chamber whereby the water
circulated through the panel absorbs heat from said exhaust
gases.
36. Apparatus as claimed in claim 35 wherein said exhaust gas duct
means includes a venturi and wherein the end of said flue gas
ducting means is located in said venturi.
Description
[0001] This invention relates to water heating apparatus.
[0002] More particularly, the invention relates to water heating
apparatus which can be used to provide a hot water supply such as a
domestic hot water service. The apparatus also has provision for
hydronic heating, although this need not be used in some
circumstances.
[0003] The general object of the invention is to provide a highly
efficient hot water heating apparatus.
[0004] According to the present invention there is provided water
heating apparatus including:
[0005] a storage tank for storing heated water;
[0006] a gas burner assembly for heating water in the tank;
[0007] the gas burner assembly including:
[0008] a housing;
[0009] a gas burner in the housing;
[0010] at least one passage through the housing; and
[0011] mounting means for mounting the housing in the tank such
that, in use, it is immersed in water within the tank and wherein,
when the gas burner is operated, the temperature of the housing
rises and heat transfer to the water in the tank occurs and a
convection current in said water flows through said at least one
passage to thereby increase heat transfer to the water.
[0012] Preferably, there are a plurality of said passages extending
through the housing.
[0013] Preferably, the housing includes a cylindrical housing
sidewall and top and bottom housing end walls and wherein the
passages are defined by tubular elements which extend between the
housing top and bottom walls.
[0014] Preferably the bottom wall is inclined at an angle to the
horizontal so that gas bubbles tend not to be trapped thereunder.
Trapped air and/or steam bubbles could cause localised heating
and/or corrosion.
[0015] Preferably further the storage tank includes one or more
coils located within the storage tank and above the gas burner
assembly. In use cold water from a mains supply is coupled to the
lower end of the coils so that the water circulated therethrough
absorbs heat from the water in the tank. This causes cooling of the
water adjacent to the coils and if sufficient heat is extracted
cool convection currents will be established. A temperature sensing
element can be located in a position where it is impinged on by the
cool convection currents in order to cause activation of the gas
burner. The gas burner is made sufficiently large that it is able
to provide sufficient heating capacity to the water within the tank
so that the apparatus functions as a continuous water heater should
substantial amounts of hot water be required. It will be
appreciated that the apparatus of the invention functions partly as
a storage type hot water system and a continuous hot water
system.
[0016] The apparatus used above can be used in conjunction with a
solar energy collection system. Basically, the solar energy system
can be used as a preheater for water entering the coil of the
apparatus defined above.
[0017] According to this aspect of the invention there is provided
a gas/solar hot water heating apparatus including:
[0018] water heating apparatus as defined above;
[0019] a solar collector panel;
[0020] a solar storage tank;
[0021] circulating means for circulating water from the solar
storage tank to the panel;
[0022] a heat exchanger in the solar storage tank; and
[0023] said coupling means being operable to pass water from the
mains water supply through the heat exchanger in said solar storage
tank prior to passing through the heat exchanger in said storage
tank.
[0024] Preferably, the solar storage tank is located beneath the
storage tank and within a single housing.
[0025] In the preferred form of solar collector panel, a flue gas
chamber is provided so that flue gases can be circulated through
the panel for recovery of heat therefrom.
[0026] The invention also provides a gas/solar water heating system
including:
[0027] a gas fired water heater having a flue;
[0028] a solar collector panel;
[0029] a solar storage tank;
[0030] circulating means for circulating water from the solar
storage tank to the panel;
[0031] a heat exchanger in the solar storage tank; and
[0032] said solar collector panel including a flue gas chamber
therein and flue gas ducting means for coupling said flue to the
flue gas chamber, the arrangement being such that water circulated
through the panel absorbs solar energy and heat energy from flue
gases entering the chamber.
[0033] The gas/solar water heating system defined above may be used
in conjunction with a motor generator set. In this case the exhaust
gases from the motor can be circulated through the solar panel in
order to extract heat therefrom.
[0034] The invention also provides a hot water heating apparatus
including:
[0035] a gas/solar water heating system as defined above;
[0036] an internal combustion engine having an exhaust; and
[0037] exhaust gas duct means for directing exhaust gases into said
flue gas chamber whereby the water circulated through the panel
absorbs heat from said exhaust gases.
[0038] The invention also provides a solar collector panel which
includes a first chamber for circulating water to be heated
therethrough and a second chamber for circulating flue or exhaust
gas therethrough, the two chambers being in thermal contact with
one another so that heat from the flue gas or exhaust gas can be
absorbed into the water in the first chamber.
[0039] The invention will now be further described with reference
to the accompanying drawings, in which:
[0040] FIG. 1 is a schematic view of water heating apparatus
constructed in accordance with the invention;
[0041] FIG. 2 is a more detailed schematic view showing the
internal structure of the apparatus;
[0042] FIG. 3 is a more detailed sectional view through the lower
part of the apparatus showing the burner assembly,
[0043] FIG. 4 is an underside view of the burner assembly;
[0044] FIG. 5 is a schematic sectional view taken along the line
5-5;
[0045] FIG. 6 is a side view of the fan;
[0046] FIG. 7 is a plan view of the fan;
[0047] FIG. 8 is a control circuit for control of the
apparatus;
[0048] FIG. 9 is a schematic view of a solar/gas water heating
system;
[0049] FIG. 10 is a control circuit suitable for controlling the
solar heating apparatus of FIG. 9;
[0050] FIG. 11 shows a modified gas/solar system;
[0051] FIG. 12 shows a further modified gas/solar water heating
system;
[0052] FIG. 13 is a schematic sectional view through a combination
unit having a water heater and solar storage tank;
[0053] FIG. 14 is a schematic view of an electric water heating
apparatus;
[0054] FIG. 15 is a schematic view of a modified form of water
heating apparatus; and
[0055] FIGS. 16, 17 and 18 show details of a preferred form of
solar absorbing panel.
[0056] FIG. 1 is a schematic view of a water heating apparatus 2
constructed in accordance with the invention. The water heating
apparatus includes a main tank 4 located within a sheet metal
housing 6. Located within the tank 4 is a gas burner assembly (not
shown in FIG. 1) which is supplied with a combustible mixture of
gas and air. Located within the tank 4 is a coil assembly 8 which
in the preferred form of the invention is in the form of two
helical coils of copper tubing which are connected in parallel so
as to reduce resistance to water flow therethrough. The coil
assembly 8 includes inlet couplings 10 and 12 which are connected
to a cold water inlet line 14. The inlet line 14 is connected to a
cold water inlet coupling 16 which is accessible from the exterior
of the housing 6. In use a mains supply is connected to the
coupling 16. The coil assembly 8 includes outlet couplings 18 and
20 which are connected to a high temperature outlet line 22. The
line 22 includes a T-coupling 24 which is connected to a high
temperature outlet line 26 which terminates at a high temperature
outlet coupling 28. The outlet coupling 28 is provided so as to
utilise high temperature water which might be required in some
circumstances. As will be described in more detail below, the water
within the main tank 4 is under pressure and can be heated to above
100.degree. C., typically the operating temperature being in the
range 80.degree. C. to 90.degree. C. but temperatures of
110.degree. C. could be selected in some circumstances. High
temperature water at about this temperature is thus available from
the coil at the high temperature outlet coupling 28, assuming that
water flowing in the coil assembly has sufficient time to reach or
substantially reach the same temperature as the water within the
main tank 4. The water in the tank 4 does not boil because it is
under pressure, say 50 psi, and therefore 110.degree. C. is well
below the boiling point for water at this pressure.
[0057] The apparatus includes a mixing valve 34 which receives high
temperature water on the line 22. It also receives cold water via
line 36 which is connected into the cold water inlet line 14 via
T-coupling 38. The mixing valve includes an outlet line 40 which
extends to the housing 6 and terminates in a hot water outlet
coupling 42. The mixing valve 34 is arranged to mix cold water from
the mains supply with the high temperature water from the coil
assembly 8 so as to produce water at a temperature which is
suitable for use in bathrooms and kitchens. Typically this water is
in the range 40.degree. C. to 60.degree. C. and preferably
45.degree. C.
[0058] The apparatus 2 includes a header tank 44 which is located
within the housing and above the main tank 4. The main purpose of
the header tank 44 is to enable any air bubbles in the main tank 4
to move into the header tank 44 and to control the operating
pressure of the main tank 4, as will be described in more detail
below.
[0059] As the main tank 4 can be operated at above atmospheric
pressure, say at 50 psi, it needs to be of relatively robust
construction. Normally, it would be of welded steel construction
having a cylindrical sidewall 46, a top wall 48 and a bottom wall
50. Because the main tank 4 is made of steel, it would be
susceptible of rusting or corrosion if oxygen or air were dissolved
in the water within the main tank or otherwise admitted to the main
tank. Normally, however, the water within the main tank 4 is a
fixed body of water and any oxygen therein would cause very limited
corrosion before it were exhausted. This applies even where the
water within the main tank 4 is circulated in an hydronic heating
system because essentially the same volume of water is maintained
in the system. Nevertheless, fresh water may be occasionally
introduced into the main tank 4 to compensate for any water which
may be lost due to leakage or the like. Accordingly, the header
tank 44 is provided in order to collect any gases which may be
present in the main tank 4. The header tank 44 can be made from
non-corrosive material such as copper. The header tank 44 may have
a capacity of say five litres in circumstances where the nominal
capacity of the tank 4 is 130 litres. The top wall 48 of the main
tank 4 includes a coupling 52 to which is connected a transfer line
54, the other end of which is connected into the top of the header
tank 44. It will be seen that the top wall 48 is inclined to the
horizontal so that any gas bubbles in the main tank 4 will migrate
towards the coupling 52 and be transported to the header tank 44.
The header tank has an outlet near its bottom connected to a return
line 56 which serves to permit water from the header tank 44 to
return to the main tank 4.
[0060] The high temperature outlet line 22 includes a T-coupling 58
which is connected to a pressure relief valve 60. A pressure relief
line 62 extends from the valve 60 to an upper part of the header
tank 44 as shown in FIG. 1. Alternatively, the pressure relief line
62 can be diverted directly into line 64 bypassing the header tank
as shown in FIG. 2. The header tank 44 includes a pressure relief
line 64 which is coupled to a second pressure relief valve 66 which
has an outlet 68 external to the housing 6. The second pressure
relief valve 66 is arranged to relieve pressure within the header
tank 44 when the pressure therein exceeds a predetermined value,
say 50 psi. This therefore determines the operating pressure within
the main tank 4. The first pressure relief valve 60 is arranged to
relieve water pressure within the coil assembly 8 when it exceeds a
predetermined value. This can occur when cold water is admitted to
the coil assembly 8 and hot water flow is stopped. Thermal
expansion occurs in the water in the coil assembly because of heat
absorption from the water in the main tank 4. The first pressure
relief valve 60 can be set at say 200 psi so that it will relieve
excess pressure from within the coil assembly 8 when the pressure
therein reaches 250 psi (because it also needs to overcome the
internal pressure within the header tank 44).
[0061] As mentioned above, the water within the main tank 4 can be
used for hydronic heating. Accordingly, the tank 4 includes a
heating water outlet line 70 connected to a coupling 72 accessible
from the exterior of the housing 6. The apparatus also includes a
heating water return line 74 connected to a coupling 76 which is
also accessible from the exterior of the housing 6. The coupling 72
and 76 permit connection of the apparatus 2 to a space heating
system which may include radiating panels and/or fan coil units for
extracting heat from the water within the main tank 4. In hydronic
heating systems the water which is circulated is essentially a
fixed volume of water and therefore corrosion of the main tank 4
and the hydronic heating elements is not normally a significant
problem.
[0062] The apparatus 2 includes a gas inlet coupling 78 connected
to a gas supply line 80. The gas inlet line 80 supplies gas for the
burner assembly, as will be described in more detail below. Air for
combustion is admitted to the housing 6 through vents 82. The
housing 6 has a top wall 83 which includes a flue housing 84 having
vents 86 therein for discharge of flue gases from the gas
burner.
[0063] FIG. 2 schematically illustrates more details of the
internal structure of the apparatus 2. First of all, it will be
seen that a layer of insulation 90 is located between the outer
surface of the main tank 4 and the housing 6 so as to avoid heat
losses from the main tank. Located within the housing and above the
main tank 4 is a fan 92. The fan 92 draws air and gas into its
input and its outlet is connected to a gas air supply duct 94.
Admission of gas to the fan 92 is controlled by a gas control valve
96 which receives gas from the gas supply line 80.
[0064] The apparatus includes a burner assembly 100 which is
located in the lower part of the main tank 4 and in use is
completely immersed in the water within the main tank. Located
within the burner assembly 100 is a gas burner 102 which is coupled
to the duct 94. A flue pipe 104 extends from the burner assembly
through the interior of the main tank 4 and extends through the top
wall 48 to the flue housing 84. The flue pipe 104 has an inclined
opening 106 which faces away from the vents 86 so as to avoid the
possibility of rainwater or the like entering the flue pipe 104 and
the burner assembly.
[0065] As the interior of the main tank 4 is subject to above
atmospheric pressures, it is desirable that the top and bottom
walls 48 and 50 be reinforced so as to prevent buckling thereof
under the internal pressure. The illustrated arrangement shows a
convenient way in which this may be achieved. In this arrangement
there are four reinforcing rods 108, 110, 112 and 114. The lower
ends of the rods are welded to the top and bottom walls 48 and 50
so as to restrain outward deformation of these walls.
Alternatively, a single larger diameter rod could be used.
[0066] The high temperature outlet line 22 from the coil may
include a one-way or check valve 116 so as to prevent backflow of
water into the line 22.
[0067] The apparatus may also include an additional outlet for
providing sterile water which can be used for drinking or
beverages. Accordingly, the apparatus includes a sterile water
outlet line 118 connected to a sterile water outlet coupling 120.
The sterile water outlet line 118 may include a control valve 122
which operates only to permit flow therethrough when the water in
the coil assembly 8 is above a predetermined temperature, above
100.degree. C. The apparatus may also include a further high
temperature outlet line 124 connected to an outlet coupling 126 for
providing high temperature water directly from the coil assembly 8.
Where the operating temperature is at or above 100.degree. C. this
can be used as a supply of boiling water. In such a case, some cold
water should be used to reduce the temperature of the water
supplied to the high temperature outlet coupling 28 so that the
water is delivered at 60.degree. C. to 80.degree. C. The apparatus
includes a bypass line 125 including a valve 127. The valve 127 is
preferably solenoid controlled so that it is closed when the
temperature of water at the coupling 28 falls below a predetermined
value, say 60.degree. C. In the illustrated arrangement, part of
the inlet line 14 is widened and forms a water jacket 128 for the
sterile water outlet line 118 so that useful heat can be extracted
therefrom and inputted into the water flowing in the coil assembly
8. Usually cooling of the sterile water is also required.
[0068] The heating water outlet line 70 may include a valve or tap
130. When the main tank 4 is being initially filled, a mains supply
can be connected to the coupling 72 and the valve 130 opened to
fill the main tank 4 and header tank 44 to a level indicated by
line 132. After initial filling, the valve 130 can be closed and
the coupling 76 also stopped. If, however, hydronic heating is to
be utilised the valve 130 is opened after connection to the
hydronic heating components. In the illustrated arrangement, the
line 134 indicates a supply line to the hydronic components and a
circulating pump 136 may be provided in this line.
[0069] The apparatus may also include an electric heating element
140 located within a tube which extends laterally into the main
tank 4 a short distance above the bottom wall 50. The purpose of
the electric element 140 is to enable heating of the water within
the main tank 4 in emergency circumstances in the event that the
gas supply becomes interrupted. Typically the heating capacity of
the element 140 is 2.5 kw.
[0070] The apparatus includes a temperature sensing element 150
which is arranged to provide input signals to the gas control valve
96 which controls flow of gas to the fan 92 and the operation of
the fan 92. Basically, when the temperature sensor 150 senses a
temperature below its set operating temperature, say 80.degree. C.
to 90.degree. C., it has contacts which close and this causes the
gas control valve to supply gas to the fan 92 and to operate the
fan. This causes a flow of a combustible gas air mixture through
the duct 94 to the burner 102. The control valve 96 also causes
ignition of the gas so that heating will occur. The gas burner
assembly 100 includes a plurality of water passages 152
therethrough. When heating occurs within the burner assembly 100,
convection currents will be established causing rising heated
convection currents to flow upwardly through the coil assembly 8
where heat transfer will take place to water within the coil
assembly 8. This causes consequential cooling of the water within
the main tank 4, thereby causing cooler, downwardly flowing
convection currents to occur near the sidewalls of the main tank 4.
This cooler water will then be drawn into the lower ends of the
passages 152 through the burner assembly 100 and reheated. These
convection flow paths within the water in the main tank 4 provide
for good heat transfer. Heat transfer also takes place from flue
gases flowing in the flue pipe 104.
[0071] The temperature sensing element 150 is located at a level
just below the bottom of the burner assembly 100 and relatively
close to the sidewall of the main tank 4. This ensures that it is
in the path of downwardly flowing cooler convection currents. When
these cooler convection currents impinge on the temperature sensing
element 150 they will cause its contacts to close or remain closed
for operating the gas control valve 96. If the temperature of the
water within the main tank 4 rises to above the operating
temperature of the sensing element 150, its contacts will open and
the control valve 96 will stop operation of the fan 92 and supply
of gas to the fan. The arrangement has the advantage that once the
water within the main tank 4 has reached operating temperature,
limited amounts of water can be drawn from the outlets 28 and 42
without creating large convection currents which would reach the
sensing element 150. Thus limited amounts of water can be taken
from the apparatus without activating the gas burner 102. If,
however, large quantities of heat are extracted from the water
within the main tank 4, such as when a bathroom shower or the like
is operated, then large convection currents will flow downwardly
and will impinge upon the temperature sensor 150. This will quickly
activate the burner 102 to therefore ensure that the temperature of
the water within the main tank 4 is not significantly reduced.
[0072] FIGS. 3 and 4 schematically illustrate the burner assembly
100 in more detail. It will be seen that the burner assembly
includes a burner housing 170 having a cylindrical sidewall 172,
top wall 174 and bottom wall 176. The housing includes a mounting
tube 178 which is welded to the sidewall 172 and is also provided
with a flange 180 which permits welding to the inside face of the
cylindrical sidewall 46 of the main tank 4. The top wall 174
includes a flue port 182 into which is welded the lower end of the
flue pipe 104.
[0073] As best seen in FIGS. 4 and 5, the burner assembly includes
a plurality of convection current tubes 184 which are welded into
openings 186 and 188 formed in the top and bottom walls 174 and 176
respectively of the burner housing.
[0074] It will be noted from FIG. 3 that the central axis 189 of
the housing 170 is inclined to the vertical. Preferably the
inclination is in the range from 1.degree. to 5.degree. and
preferably 21/2.degree., the inclination being exaggerated somewhat
in FIG. 3 for clarity of illustration. The tubes 184 define the
convection flow passages 152 described previously. It will be also
seen that the reinforcing rods 108, 110, 112 and 114 pass through
the tubes. This enables them to be connected at central areas of
the top and bottom walls 48 and 50 of the main tank 4 where support
is most critical. The main purpose of the installation of the
burner housing 170 is so that its top and bottom walls 174 and 176
are inclined to the horizontal. It has been found that this avoids
retention of gas bubbles, particularly beneath the bottom surface
176 which might occur if it were horizontally disposed.
Accumulation of gas bubbles beneath the bottom wall 176 could cause
localised overheating which in turn may produce and sustain
localised boiling and excessive noise and vibration. Thus, the
inclination of the surfaces is a simple but effective way of
overcoming serious problems which may occur in practice.
[0075] As the burner housing 170 is subjected to the full internal
pressure within the main tank 4, it must be of relatively robust
construction and the provision of the tubes 184 also serve to
strengthen the housing. The bottom wall 176 may be additionally
strengthened by a reinforcing bar 190 which is welded to the
underside of the bottom wall 176, as shown.
[0076] As seen in FIG. 3, the burner 102 includes a stainless steel
tube 200 having a closed inner end 202. The inner part of the body
includes a multiplicity of perforations having a size of the order
of say 1 mm. The tube 200 is provided with a mounting flange 204
which enables it to be connected to the sidewall 46 by means of
threaded studs which project from the sidewall 46 of the main tank.
The lower end of the air gas duct 94 is connected to the flange 204
via a gasket (not shown). The arrangement is such that the air gas
mixture is admitted to the interior of the tube 200 so that it can
escape through the perforations therein. Located adjacent to the
exterior of the tube 200 are ignition electrodes 210 and 212 and a
flame detection electrode 214. The electrodes are connected by
means of conductors 216 which pass through the mounting tube 178
and are coupled to the gas control valve 96. The air gas mixture
passing through the perforations forms jets of burning flame which
heat the interior of the housing 170. The arrangement has very good
heat transfer because the burner assembly 100 is immersed in the
water in the tank and convection currents flow through the passages
152 therein to enhance heat transfer.
[0077] FIGS. 6 and 7 diagrammatically illustrate the fan 92 and gas
control valve 96 in more detail. It will be seen that the fan 92
includes an outlet 220 which is coupled to an elbow 222 formed at
the upper end of the gas air duct 94. The fan is driven by a fan
motor located within a fan motor housing 224 located on the side of
the fan, as shown in FIG. 7. The inlet to the fan is in the form of
a venturi 226 which is located generally centrally of the axis of
the impeller (not shown) of the fan. Located centrally of the
venturi 226 is a gas inlet duct 228 which permits gas such as
natural gas or town gas from the valve 96 to be entrained in air
flowing into the venturi 226, when the fan motor is operated.
[0078] The apparatus includes an over temperature sensing element
230 to sense when excessive temperatures are reached within the
interior of the main tank 4. It is preferred that the over
temperature sensor 230 is located on the upper surface of the top
wall 48 of the main tank 4 and is also connected or close to the
flue pipe 104. Normally the sensor 230 will be at about the same
temperature as the water in the tank 4 and will therefore be at the
operating temperature of the water, say 110.degree. C. If, however,
the temperature rises above this point the sensor 230 will be
sensed by the control valve 96 which will then operate to stop the
fan 92 and flow of gas to the burner 102. With the over temperature
sensor 230 mounted in this position, should an air gap develop in
the top of the main tank 4 the temperature will rise because the
sensor 230 is in thermal contact with the flue pipe 104. Thus the
sensor also indirectly functions to detect the presence of an air
gap within the top of the main tank 4 and to shut off supply of gas
in that event. The sensors 150 and 230 are of known type having a
fluid filled bulb including a diaphragm coupled to operate contacts
of a switch.
[0079] The fan 92 can be of a commercially available type, such as
a Zeihl Model MVL RG130. This fan produces a flow rate of about 50
cubic feet per minute at an outlet pressure of about 2 inches water
gauge. The gas control valve 96 can also be of known type and one
suitable valve is made by SIT Model No. 577 DBG. This control valve
has all of the necessary functions built into it to control the
apparatus 2 including control of the ignition electrodes 210 and
212 and the spark detecting electrode 214.
[0080] FIG. 8 diagrammatically illustrates the wiring of the gas
control valve 96 to other control components in the system. The
temperature sensing element 150 includes contacts 231 and 232 which
are normally closed when the sensing element 150 senses a
temperature below the operating temperature. This provides mains
power into the gas control valve 96 to therefore enable operation
of the fan 92 and opening of a gas valve (not shown) inside the gas
control valve 96. The sensing element 150 has a back terminal 234
which is arranged to be closed when the sensing element 150 senses
the correct operating temperature. This deactivates the fan and
enables supply of mains electricity to the circulating pump 136 via
a manually settable room thermostat 236 or other controller. This
configuration ensures that heat from the water within the main tank
4 is only used for hydronic heating at times when the temperature
of the water within the main tank 4 is at operating level. Thus,
there is inherently a priority given to hot water extracted from
the coil assembly 8 over heat required for hydronic heating.
[0081] Details of the gas control valve 96 are well known and need
not be described in detail. Briefly, the gas control valve 96 has
the following operating sequences. When it is first activated, it
causes the fan 92 to operate so as to cause purging air to flow
through the duct 94 and into the burner housing 170. This removes
any exhaust products from previous combustion. Gas is then supplied
to the duct 94 and the ignition electrodes 210 and 212 are operated
for a predetermined period, say five seconds. If ignition is
successful, this will be sensed by the flame sensor 214 and
combustion will continue until the correct operating temperature is
sensed by the temperature sensor 150 or an over temperature is
sensed by the over temperature sensor 230. If ignition is not
successful, the ignition cycle is repeated a predetermined number
of times, say three times, and if no flame is detected a Lockout
condition is set. This requires a manual override to be applied, as
indicated by the override button 238 across the over temperature
sensor 230, as shown. The gas control valve 96 may include or have
associated therewith an indicating panel which has a Flame Prove
indicator lamp 240 which is activated when correct combustion is
sensed. The indicator panel may include a Lockout indicator lamp
242 which is illuminated when a lock-out condition is entered.
[0082] A prototype of the water heating apparatus has been
constructed and has proven to be very efficient. The prototype had
the following nominal dimensions:
1 height of main tank 4 914 mm diameter of main tank 4 560 mm
approximate volume of main tank 4 130 litres height of burner
housing 170 406 mm diameter of burner housing 170 406 mm number of
tubes 184 20 effective surface area of burner housing 170 1.85 sqm
ratio of burner surface area 0.014 sqm/l 170 to volume of main tank
4 diameter of burner 200 50 mm diameter of reinforcing rods 108,
110, 112, 114 12.7 mm volume of header tank 44 11.5 litres diameter
of flue pipe 104 76.2 mm number of coils in the coil assembly 8 2
number of convolutions of each coil 9 length of each coil 12.19 m
external diameter of each coil 12.7 mm gas input 200 MJ/hour normal
water temperature at outlet coupling 28 80-90.degree. C. normal
water temperature at outlet coupling 42 45.degree. C. normal water
temperature at outlet coupling 126 80-90.degree. C. normal water
temperature at outlet coupling 120 20.degree. C. normal water
temperature at coupling 72 80-90.degree. C. approximate time to
heat water within the main tank 10 mins to operating
temperature
[0083] The water heating apparatus 2 can be used in conjunction
with a solar heating system. FIG. 9 illustrates a water heating
system 250 which incorporates the water heating apparatus 2 and
solar energy collecting apparatus 252 which includes a solar panel
254 and a solar pre-heating tank 256. The tank 256 is connected to
an outlet line 258 including a solar circulating pump 260. The pump
260 operates to circulate water from within the tank 256 to the
solar panel 254 where it is heated by solar energy and then
returned to the tank 256 via return line 262. A cold water mains
supply 264 can be connected to the cold water inlet line 36 via a
non-return valve 266. The pre-heating tank 256 includes a heat
transfer coil 268 through which is circulated cold water from the
mains supply 264 via inlet line 270. The outlet of the coil 268 is
connected to the water inlet line 14. In this arrangement, the hot
or warm water stored in the tank 256 acts as a pre-heater for water
circulating through the coil assembly 8 of the apparatus 2. The
outlet 68 of the pressure relief valve 66 can be connected to the
top of the tank 4 so that water and energy are not lost.
[0084] In the system 250, the apparatus 2 can be identical to that
shown in FIGS. 1 to 8. Alternatively, it could be modified by the
omission of the header tank 44. In this case an overflow duct 272
is provided to connect the top of the main tank 4 to the top of the
pre-heater tank 256. This would accommodate any thermal expansion
of the water within the main tank 4. The pre-heater tank 256 may
itself have an overflow outlet 274 for discharge of water in the
event that it is overfilled or over-pressurised. The solar
collecting apparatus 252 may include a temperature sensor 276
mounted in the solar panel 254 and a temperature sensor 278 mounted
at the bottom of the pre-heater tank 256. The control circuitry for
the solar system 250 is such that when the temperature sensed by
the sensor 276 is lower than the temperature sensed by the sensor
278, the solar circulating pump 260 is not operated because this
would cause loss of heat. At other times the solar circulating pump
260 can be operated.
[0085] FIG. 10 illustrates a control circuit 280 which is suitable
for controlling the solar system 250. It will be seen that the
temperature sensors 276 and 278 are connected to inputs of a
comparator 282. The arrangement is such that when a higher voltage
level is produced by the sensor 276 compared to that of the sensor
278, a positive voltage is produced at the output of the comparator
282. This is amplified in amplifying stages 284 and then coupled to
the input of a drive transistor 286 which activates the operating
coil of a relay 288 which controls supply of power to the solar
circulating pump 260.
[0086] FIG. 11 illustrates a modified form of solar system 290
which is similar to that shown in FIG. 9. The same reference
numerals have been used to denote parts which are the same as or
correspond to those of the earlier embodiment. In this arrangement,
flue gases from the water heating apparatus 2 are circulated
through the solar panel 254 so that the heat from the flue gases
can be extracted and absorbed into the water circulating in the
pre-heater tank 256. In order to accomplish this, the system 290
includes a flue gas duct 292 which is coupled into the lower end of
the panel 254 so that hot flue gases flow in a chamber 294
therethrough. The flue gases are in thermal contact with the
circulating water so that the water in the pre-heater tank 256 is
heated. The flue gases may then pass to an outlet duct 296
connected to a balanced flue assembly 298. The system may include
an air inlet duct 300 which extends from the balanced flue assembly
298 to the air inlet of the fan 92. This arrangement reduces the
possibility of unreliable operation of the burner 102 which might
be caused by fluctuations in pressure in the flue lines.
[0087] In this arrangement, the control circuit 280 for the pump
260 could be linked to the control valve 96 to ensure that optimum
performance is achieved. More particularly, the arrangement could
be such that the pump 260 is always operated before the burner 102
is activated so that the panel 254 will have water circulated
through it before any flue gases enter the chamber 294. This
ensures that the panel 254 is not overheated due to the passage of
the flue gases therethrough
[0088] FIG. 12 diagrammatically illustrates a modified system 310
in accordance with a further aspect of the invention. This
arrangement is generally similar to that shown in FIGS. 9 and 11
but the system includes an internal combustion engine 312 which is
coupled to an electric generator 314 or other device. The generator
314 is arranged to charge batteries 316. The batteries can be used
for powering various electrical appliances which are arranged to
operate on DC. Alternatively, the batteries 316 could be coupled
via an inverter so as to produce 240 volts AC whereby normal
domestic electric appliances could be operated.
[0089] The internal combustion engine 312 has an exhaust 318 which
is coupled via an exhaust line 320 to the solar absorber panel 254.
It is preferred that the exhaust line 320 is connected into the
flue gas duct 292 which is used to convey flue gases from the
burner to the solar absorber panel. The preferred way of connecting
the duct 292 to the exhaust line 320 is by forming a venturi 322 in
the exhaust line 320 and arranging for the end of the flue gas duct
292 to be located in the venturi 322. The exhaust gases flowing in
the line 320 will generally be at a higher pressure and flow rate
than the flue products in the duct 292 and by having the venturi
coupling, the exhaust gases will tend to entrain the flue products
into the larger flow and then into the panel 254. In this way heat
energy in the exhaust gases from the internal combustion engine can
also be collected by water circulating in the solar panel 254. This
arrangement provides for efficient utilisation of the fuel used for
the burner assembly 100 as well as the internal combustion engine
312. The system 310 could be advantageously used in remote
locations to provide combined electric power, hot water and heating
services. The internal combustion engine 312 can also be used to
operate on the same gas source which is used for the water heating
apparatus 2. It will be further appreciated that the system 310
avoids transmission losses which can be significant in normal
electricity distribution systems.
[0090] Pollution could be reduced by causing the flue gases from
the burner assembly 100 and exhaust gases from the engine 312 to
bubble through the water circulating in the panel 254 and at least
some of the pollutants will remain in the water. Use of the venturi
322 ensures that an undesirable high back pressure is not created
in the flue pipe 104 which could interfere with operation of the
burner 102. In this arrangement the pump 260 is operated so as to
circulate water through the panel 254 before either the engine 312
or the burner 102 is operated so as to avoid overheating of the
panel 254.
[0091] FIG. 13 shows a combined unit 350 which essentially is the
water heating apparatus 2 shown in FIGS. 1 to 8 having the
pre-heater tank 256 located within the same housing 6 and beneath
the main tank 4. This arrangement is very convenient and also
reduces heat losses which might occur in the various fluid lines
and ducts which interconnect the tanks shown in the arrangements of
FIGS. 9, 11 and 12.
[0092] A number of enhancements are included in the combined unit
350. In particular, it will be seen that the burner 102 is located
near the top wall 174 of the burner housing 170 and the flue pipe
104 is directed downwardly. The flue pipe 104 is located near the
lowest point on the bottom wall 176 of the housing so that any
condensate will be drained therefrom. The flue gases pass into a
flue gas jacket 352 which extends above the pre-heater tank 256 and
adjacent to the sidewalls and bottom wall thereof as shown. This
enables heat transfer from the flue gases into the water contained
within the pre-heater tank 256. The jacket 352 is connected to a
flue pipe 354 which extends to the flue housing 84.
[0093] It will be further seen that in the unit 350, the bottom
wall 50 of the main tank 4 is inclined somewhat to the horizontal.
This ensures that any condensate will tend to run to the lowest
point on the bottom wall 50 and then enter the jacket 352 rather
than collect on the bottom wall 50. This reduces the possibility of
corrosion of the bottom wall 50. Similarly, the tank 256 has a top
wall 356 which is also inclined and generally parallel to the
bottom wall 50. The tank 256 has a bottom wall 358 which is also
inclined so that condensate will drain therefrom to a condensate
trap 360. The lower part of the jacket 352 is formed with the
condensate trap 360 which has an outlet 362. This arrangement
ensures that any condensate from the flue products will be
collected in the trap 360 and expelled from the outlet 362 when the
trap is full.
[0094] The tank 256 may include a central reinforcing rod 364 which
extends between the top wall 356 and bottom wall 358 so as to avoid
bucking of these parts due to internal pressure within the tank
256. The tank 256 may also include a pressure relief valve 366.
[0095] As in the arrangement of FIG. 9, when the sensor 276 senses
a temperature higher than that at the sensor 278, the pump 260 is
operated so that the water within the pre-heater tank 256 is heated
by solar absorption. When hot water is drawn from the main tank 4
for hot water or for heating purposes, the water supplied to the
coil assembly 8 will be pre-heated in the pre-heater tank 256
because it is circulated through the coil 268. This of course
reduces gas consumption.
[0096] In the arrangement of FIG. 13, the tank 256 may be purposely
left with an air gap which is between say 5% and 10% of the volume
of the tank 256. The air gap 370 can therefore accommodate thermal
expansion of the water within the tank 256 without the need for a
separate expansion vessel.
[0097] FIGS. 14 and 15 illustrate how the principles of the
invention can be applied to electric water heaters in order to
improve the efficiency thereof. The same reference numerals have
been used to denote parts which are the same as or correspond to
those of earlier embodiments. In this arrangement, the heater is
filled so as to leave an air gap 370 which can accommodate thermal
expansion of the water within the main tank 4. The tank includes a
filling line 382 to which a supply of cold water can be connected
for initial filling of the tank. The upper part of the tank
includes an inspection opening 384 which defines the upper level of
the water within the tank and also enables an operator to observe
the level of water within the tank. After initial filling the line
382 and opening 384 are both closed.
[0098] The heater 380 includes a second electric heating element
386 and a second temperature sensor 388. In normal operation, the
element 140 is operated so as to heat the water within the tank.
The element 140 is subject to control of the first temperature
sensor 150 which is located at a level beneath the element 140 and
generally below the coil assembly 8. When cold water circulates
through the coil assembly 8, it is heated. This causes cool
convection currents to flow downwardly. When the convection
currents impinge on the temperature sensor 150, the element 140 is
activated. If cooling continues sufficiently, the cool convection
currents will impinge on the second sensor 388 and this will cause
operation of the second element 386.
[0099] FIG. 15 is a diagrammatic cross-sectional view which shows
how the element 140 may have additional electric heating elements
390, 392 and 394 located beside it for additional energy input to
the water within the tank.
[0100] FIGS. 16 to 20 show the preferred form of solar panel 254
which can be used in the system 290 shown in FIG. 11. This
arrangement absorbs heat from the flue gases from the burner
102.
[0101] FIG. 17 shows the components which make up the panel 254 in
a schematic exploded view. The components include the glass sheet
400 beneath which are located upper, intermediate and lower
stainless steel sheets 402, 404 and 406. The upper sheet 402 is
pressed so as to have laterally extending indentations or grooves
408 thereon. Normally these are about 3 mm deep. The edges of the
upper sheet 402 are formed with edge flanges 410 to facilitate
joining of the upper sheet 402 to the intermediate sheet 404 by
means of welding or the like. When the sheets 402 and 404 are
joined, a water cavity 412 is defined therebetween, as shown in
more detail in FIG. 18. The edges of the intermediate sheet 404 are
formed with downturned flanges 414 whereas the edges of the lower
sheet 406 are formed with upwardly facing channels 416. The
underside-of the intermediate sheet 404 has a plurality of U-shaped
channel sections 418 connected thereto by spot welding or the like.
The lower sheet 406 is joined to the intermediate sheet 404 by spot
welding or the like. The flanges 414 and the channels 416 combine
to form an inlet manifold 420 and outlet manifold 422. The
manifolds 420 and 422 extend along respective sides of the panel
and the hot flue combustion products from the water heater 2 are
introduced into the manifold 420 and then flow through a gas cavity
424 defined between the intermediate and lower sheets 404 and 406,
which remain spaced apart by the channel sections 418. The flue
gases transfer heat to water within the water cavity 412 by
conduction and the cooled flue gases are expelled through the
manifold 422.
[0102] An insulation layer 426 is provided so as to be located
beneath the lower sheet 406. The insulation layer 426 is provided
with rebates 428 along its lateral edges so as to accommodate the
manifolds 420 and 422 in the completed assembly as shown in more
detail in FIG. 18.
[0103] The panel includes a base 430 which can be formed from sheet
metal such as galvanised iron. Its edges are formed upwardly so as
to define sides 432 of the panel. The sides are shaped so as to
define inwardly facing grooves 434 for receipt of the glass sheet
400.
[0104] The top surface of the upper sheet 402 is preferably treated
so that it is absorbent. This may be done by heat treatment of
stainless steel to make it selectively absorbent of solar energy,
in a known manner. Alternatively, absorbent coatings may be applied
thereto.
[0105] This arrangement provides an inexpensive solar panel which
has a water cavity 412 for heating water circulated therein and a
gas cavity 424 for transferring heat from the flue gases to the
water circulating in the water cavity 412.
[0106] Many modifications will be apparent to-those skilled in the
art without departing from the spirit and scope of the
invention.
[0107] For instance, in the arrangement of FIG. 13, the burner
assembly 100 includes a gas burner 102. In a modified arrangement
the burner 102 could be omitted and hot gas or liquid, which would
normally be wasted, could be circulated through the housing 170 so
that heat therefrom is extracted for heating of the water within
the tank 4. The waste gas or liquid could be from a boiler, engine
or other device which produces hot gases. This would be
particularly suitable in industrial applications where useful heat
can be extracted from hot gases which would otherwise be lost to
the atmosphere.
* * * * *