Patent Abstract:
A water heater may be configured to temporarily increase its hot water capacity by heating water to a higher boost temperature. In some instances, the water heater may include a main controller that can accept a boost request from a remote controller, and thus may temporarily provide additional hot water capacity without, for example, requiring a homeowner to go down to the basement, out to the garage, or wherever the water heater happens to be to make manual adjustments to the water heater settings.

Full Description:
TECHNICAL FIELD 
     This disclosure relates generally to water heaters and more particularly to water heaters that are configured to provide a temporary capacity increase. 
     BACKGROUND 
     Water heaters are commonly used in homes, businesses and just about any establishment having the need for heated water. In many cases, a water heater is configured to heat water in a water heater tank using a gas-fired burner, an electric heater or some other heater element. When demand for hot water arises (e.g., someone turns on a faucet to run a shower), fresh, cold or ambient temperature water typically enters the water heater tank and “pushes out” or supplies the hotter water. When the temperature of the water in the water heater falls below a temperature set point, either though the mere passage of time or as a result of a hot water draw, the water heater typically activates a heater element to restore the temperature of the water in the tank back to the temperature set point. 
     To help reduce cycling of the water heater, a temperature differential is often employed, where the water heater does not activate the heater element until the temperature of the water in the water heater falls below the temperature set point by at least a temperature differential amount. The desired temperature set point can be referred to as the first temperature set point and the temperature at which the heater element is actually activated can be referred to as the second temperature set point, where the difference between the first temperature set point and the second temperature set point corresponds to the temperature differential. 
     A conventional water heater typically has at least one heating element or “heater,” such as a gas-fired and/or electric burner. To take advantage of the “heat-rises” principle, the heater is often located at or near the bottom of the water heater tank. Each water heater typically also has at least one thermostat or controller for controlling the heater. To facilitate the heating of water, the controller often receives signals related to the temperature of the water, oftentimes from a temperature sensor that is thermally engaged with the water within the water heater. When temperature signals from the temperature sensor indicate that the water temperature is below the second temperature set point, for example when the water temperature is below about 120° F., the controller may turn on the heater element and the water within the water heater begins to heat. After some time, the water temperature within the water heater tank may increase back to the first temperature set point, which, for example, may be about 140° F. At this point, the controller may cause the heater element to reduce its heat output or, alternatively, causes the heater element to turn off. This heating cycle may begin again when the water temperature within the water heater tank drops below the second temperature set point. 
     Water heaters are typically available in a variety of different sizes so that a particular home or building may be equipped with a water heater having a thermal capacity, or quantity of sufficiently heated water, that is sufficient for normal conditions expected for the particular home or building. However, special circumstances, such as having overnight visitors, may mean that there may be a temporary, larger than normal demand for hot water. Typically, the increased demand is accompanied by a need to have increased hot water available within a relatively short time frame. For example, several extra house guests may wish to shower in the morning, causing a temporary increased demand for hot water in a relatively short time period. One way to accommodate this situation is to initially install an oversized water heater. However, it may not be very efficient to run an oversized water heater all the time to accommodate occasional and short-term demands for increased hot water. 
     SUMMARY 
     The present disclosure relates generally to water heaters and more particularly to water heaters that are configured to provide a temporary hot water capacity increase. In one illustrative embodiment, this may be accomplished by temporarily increasing the temperature of the water in the water heater tank. In some instances, the water heater may include a main controller that can accept a boost request from a remote controller or the like, and in response, may temporarily increase the temperature of the water in the water heater tank to provide additional hot water without requiring a user to, for example, go down to the basement, out to the garage, or wherever the water heater happens to be to manually and temporarily change the set point of the water heater. 
     In an illustrative but non-limiting example, a water heater is provided that includes a water tank and a heat source that is disposed proximate the water tank. A main controller may be provided that is configured to control the heat source. The main controller may include a maximum temperature set point and an operating temperature set point, and may operate in accordance with a particular temperature differential as described above. In some cases, a remote controller may be configured to accept a request, such as from a homeowner or other user, for additional hot water capacity and may communicate a resultant boost request to the main controller. In some instances, the boost request may include instructions to increase to a boost temperature set point that is higher than the normal operating temperature set point. In some cases, the temperature differential temperature may be reduced while in the boost mode. 
     Another illustrative but non-limiting example of the disclosure may be found in a water heater that includes a water tank and a gas burner that is disposed proximate the water tank. A communicating gas valve may be configured to control gas flow to the gas burner. The communicating gas valve may include a maximum temperature set point and an operating temperature set point and may operate in accordance with a particular temperature differential as described above. In some cases, a remote controller may be configured to accept a request for additional hot water capacity from a user, and to communicate a resultant boost request to the communicating gas valve. In some instances, the boost request may include instructions to increase to a boost temperature set point that is higher than the normal operating temperature set point. In some cases, the temperature differential temperature may be reduced while in the boost mode. 
     Another illustrative but non-limiting example of the disclosure may be found in a method of operating a water heater that has a communicating gas valve having a main controller and a remote controller. A maximum temperature set point may be provided, as well as operating temperature set point. The main controller may operate the water heater in accordance with the operating temperature set point. If a boost request is accepted from the remote controller, the main controller may temporarily operate the water heater in accordance with a boost temperature set point. In some cases, the temperature differential temperature may be reduced while in the boost mode. 
     The above summary is not intended to describe each and every disclosed embodiment or every implementation of the disclosure. The Description that follows more particularly exemplifies various illustrative embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       The following description should be read with reference to the drawings. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the disclosure. The disclosure may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying drawings, in which: 
         FIG. 1  is a schematic view of an illustrative but non-limiting water heater in accordance with the present disclosure; 
         FIG. 2  is a schematic block view of an illustrative control system that may be used with the water heater of  FIG. 1 ; 
         FIG. 3  is a schematic view of an illustrative main controller that may be used in the control system of  FIG. 2 ; 
         FIG. 4  is a schematic view of an illustrative remote controller that may be used in the control system of  FIG. 2 ; 
         FIG. 5  is a flow diagram showing an illustrative but non-limiting example of a method that may be carried out via the control system of  FIG. 2 ; and 
         FIG. 6  is a flow diagram showing an illustrative but non-limiting example of a method that may be carried out via the control system of  FIG. 2 . 
     
    
    
     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular illustrative embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention. 
     DESCRIPTION 
     The following description should be read with reference to the drawings, in which like elements in different drawings are numbered in like fashion. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. Although examples of construction, dimensions, and materials are illustrated for the various elements, those skilled in the art will recognize that many of the examples provided have suitable alternatives that may be utilized. 
     The disclosure relates to heating water, and as such may include fossil fuel-fired water heaters, electrically heated water heaters, boilers and the like. Merely for illustrative purposes, the drawings show a fossil fuel-fired water heater. However, it is contemplated that the any type of water heater may be used. 
       FIG. 1  shows a schematic view of an illustrative but non-limiting water heater  10 . Water heater  10  includes a water tank  12 . Cold water enters water tank  12  through a cold water line  14  and is heated by a gas burner  24 . The resulting heated water exits through a hot water line  16 . A gas control unit  18  regulates gas flow from a gas source  20  through a combustion gas line  22  and into gas burner  24 . A flue  26  permits combustion byproducts to safely exit. Water heater  10  may include a temperature sensor  28 . In some cases, temperature sensor  28  may enter water tank  12  at a location exterior to gas control unit  18 . In some instances, however, temperature sensor  28  may instead be located behind gas control unit  18 . To accommodate this, water tank  12  may include an aperture or recess (not illustrated) that is sized and configured to accept temperature sensor  28 . 
     In some cases, gas control unit  18  may be in communication with a main controller (not seen in  FIG. 1 ) that provides gas control unit  18  with appropriate command instructions. In some cases, gas control unit  18  may itself incorporate the main controller.  FIG. 2  is a schematic diagram showing how a remote controller may provide instructions to gas control unit  18 .  FIG. 2  shows a main controller  30  and a remote controller  32  that is in communication with main controller  30 . In some cases, remote controller  32  may communicate wirelessly with main controller  30 . In some instances, remote controller  32  may be electrically connected to main controller  30  via wires such as low voltage wiring, similar to the 24 volt wiring used to connect HVAC thermostats to furnaces and other HVAC equipment. These are only example connections that may facilitate communication between the main controller  30  and the remote controller  32 . 
     As noted above, and in some instances, main controller  30  may be integrated into gas control unit  18 , while in other cases main controller  30  may be external to gas control unit  18  but in communication with gas control unit  18 . It is contemplated that main controller  30  may have several components. In some cases, main controller  30  may have an I/O block  34  that accepts signals from a temperature sensor  28  ( FIG. 1 ), remote controller  32  and/or any other suitable device or component. I/O block  34  may accommodate control signals from remote controller  32 . Main controller  30  may include a microprocessor  36  that may be configured to accept appropriate signals from I/O block  34  and determine appropriate output signals that can be outputted via I/O block  34  to other components within gas control unit  18  ( FIG. 1 ), remote controller  32  and/or any other suitable device or component. While not illustrated, microprocessor  36  may also include memory. 
     In some cases, main controller  30  may also include a Gas Control block  38 . Gas Control block  38  may receive command instructions from microprocessor  36  and may in turn provide appropriate instructions to an electrically controlled gas valve disposed within or controlled by the gas control unit  18 . 
     The illustrative remote controller  32  may also have several components. In some instances, remote controller  32  may include an I/O block  40  and a user interface  42 . I/O block  40  may, for example, receive information from the user interface  42  and provide corresponding information to main controller  30 . When provided, user interface  42  may take any desired form, and may include a display and/or one or more buttons that a user may use to enter information. 
     In some instances, user interface  42  may be configured to permit a user to request additional hot water. For example, a homeowner may anticipate that due to a larger number of occupants, hot water may run low at a particular time of day. In some cases, the homeowner may preemptively instruct water heater  10  ( FIG. 1 ) to provide additional hot water capacity to remedy the expected shortcoming via user interface  42 . It is contemplated that remote controller  32  may be configured to permit a homeowner or other user to make a request for additional hot water capacity for a particular period of time. In other cases, it is contemplated that remote controller  32  may be programmed to provide additional hot water capacity on a regular or programmed basis, perhaps at a particular time of day and/or only on certain day(s). 
     Turning now to  FIG. 3 , an illustrative but non-limiting example of gas control unit  18  is shown. Gas control unit  18  may include a temperature set point setting device  44 . In some instances, temperature set point setting device  44  may include a rotatable knob  46  having an indicator line or arrow  48 . The rotatable knob  46  may rotate relative to a temperature scale  50  that is printed or otherwise disposed on an outer surface of gas control unit  18 . In some cases, temperature set point setting device  44  may provide gas control unit  18  with an operating temperature set point. In some instances, particularly if gas control unit  18  is in communication with a remote controller such as remote controller  32  ( FIG. 2 ), temperature set point setting device  44  may provide gas control unit  18  with a maximum temperature set point, while the remote controller may provide the operating temperature set point. In some instances, both an operating temperature set point and a maximum temperature set point may be set using one or more dials or the like at the gas control unit  18 . While a rotating knob  46  is shown, it is contemplated that any suitable user interface may be provided for setting an operating temperature set point and/or a maximum temperature set point, as desired. 
       FIG. 4  shows an illustrative but non-limiting example of a remote controller  52  that may be considered as being an illustrative embodiment of remote controller  32  ( FIG. 2 ). Remote controller  52  may be mounted or otherwise disposed within a home or building, at a location that is remote from water heater  10  ( FIG. 1 ). In some cases, for example, remote controller  52  may be wall-mounted within a living space, proximate or incorporated into a HVAC controller such as a thermostat. In some instances, it is contemplated that remote controller  52  may be disposed in or near a bathroom, as a bath or shower is often a large consumer of hot water. 
     Regardless of where remote controller  52  is disposed, illustrative remote controller  52  may include one or more of a display  54 , an UP arrow  56 , a DOWN arrow  58 , and/or selection buttons  60  and  62 . In some cases, it is contemplated that display  54  may be a touch screen display such as a touch screen LCD display, and as such, remote controller  52  may not include any physical buttons. In some instances, for example, display  54  may provide a graphical representation of an operating temperature set point, the current status of water heater  10  ( FIG. 1 ), i.e., whether water heater  10  is in a draw period, recovery period or standby, or any other desired information. In some cases, display  54  may provide an indication of whether or not water heater  10  is in a boost mode period. A boost mode period is a time period during which a user has requested, sometimes via remote controller  52 , an elevated water temperature within water heater  10  in order to obtain more thermal energy from water heater  10  than may otherwise be available when operating at the operating temperature set point. 
     In some cases, UP arrow  56  and/or DOWN arrow  58  may be used by the user to raise or lower an operating temperature set point. In some instances, remote controller  52  may accept an operating temperature set point from a user and may communicate the operating temperature set point to main controller  30  ( FIG. 2 ). Main controller  30  may then operate water heater  10  in accordance with the operating temperature set point provided by the remote controller  52 , provided that certain safety parameters are met. For example, main controller  30  ( FIG. 2 ) may operate in accordance with the operating temperature set point as long as the operating temperature set point does not exceed a predetermined temperature safety limit such as 160° F., or perhaps 154° F. In some cases, main controller  30  may operate in accordance with the operating temperature set point as long as the operating temperature set point provided by remote controller  52  does not exceed the maximum temperature set point set by temperature set point setting device  44  ( FIG. 3 ). In some cases, the operating temperature set point is set at the main controller  30 , and not via the remote controller  32 . 
     Under normal operating conditions, main controller  30  may operate water heater  10  ( FIG. 1 ) in accordance with a particular temperature differential value. The temperature differential may be a numerical difference between a temperature at which gas burner  24  is activated and a temperature at which gas burner  24  is terminated or stopped. For example, if main controller  30  is programmed with a temperature differential value of say 10° F. and a temperature set point of 120° F., gas burner  24  may be activated when a water temperature indicated by temperature sensor  28  ( FIG. 1 ) falls to 110° F., and may run until the water temperature rises to 120° F. However, in some illustrative embodiments, if a homeowner or other user requests additional hot water via remote controller  32  ( FIG. 2 ) or otherwise, main controller  30  may operate using a lower temperature differential or even a zero differential, if desired. 
     In an illustrative embodiment, when remote controller  32  ( FIG. 2 ) instructs main controller  30  ( FIG. 2 ) that additional hot water capacity has been requested, main controller  30  may determine a boost temperature set point that may represent an increase to the operating temperature set point. For example, the boost temperature set point may be 10° F. higher than the operating temperature set point, but it will be appreciated that other temperature increases may also be employed. In some instances, the boost temperature set point may be limited by safety limits and/or by the maximum temperature set point set by, for example, the temperature set point setting device  44  ( FIG. 3 ). 
     In some embodiments, main controller  30  ( FIG. 2 ), upon receiving a boost request from remote controller  32  ( FIG. 2 ), may operate gas burner  24  ( FIG. 1 ) until the boost temperature set point has been reached. Once the boost temperature set point has been reached, the boost period may be ended and main controller  30  may in some cases revert back to the normal operating temperature set point. In some cases, main controller  30  may operate in accordance with the boost temperature set point, turning gas burner  24  on and off as appropriate to maintain the water at the boost temperature set point for a predetermined length of time. For example, main controller  30  may maintain the boost temperature set point for a period of time up to about 2 hours, although other time periods are contemplated and permissible. In some cases, main controller  30  may maintain the boost temperature set point indefinitely, until receiving a subsequent signal from remote controller  32  ( FIG. 2 ) to return to the operating temperature set point. When operating in accordance with the boost temperature set point, the water heater  10  may operate normally but with a higher temperature set point and thus attempts to heat all of the water in the water tank, and not just water around a top portion of the tank. This can significantly increase the hot water capacity of the water heater  10  during a boost period. 
       FIG. 5  is a flow diagram showing an illustrative but non-limiting example of a method that may be carried out in the operation of water heater  10  ( FIG. 1 ). Control begins at block  64 , where a maximum temperature set point is provided. In some cases, this may be done using temperature set point setting device  44  ( FIG. 3 ) or though some other user interface. Alternatively, or in addition, a maximum temperature set point may be hard coded. At block  66 , an operating temperature set point may be accepted, such as from the remote controller  32  ( FIG. 2 ) or through a dial or the like on the main controller  30 . Main controller  30  ( FIG. 2 ) may operate water heater  10  in accordance with the operating temperature set point, as shown at block  68 . 
     Control passes to block  70 , where a boost request is accepted from, for example, the remote controller  32  ( FIG. 2 ). In some cases, main controller  30  ( FIG. 2 ) may calculate or otherwise determine a boost temperature set point, and may operate water heater  10  ( FIG. 1 ) in accordance with the boost temperature set point as shown at block  72 . In some instances, water heater  10  ( FIG. 1 ) may be operated in accordance with the boost temperature set point for a predetermined length of time, and sometimes set the temperature differential to zero or any other desired temperature differential. Reducing the temperature differential to zero may cause the main controller  30  to immediately activate the heater element of the water heater. In some cases, water heater  10  may be operated in accordance with a boost temperature set point only if the boost temperature set point falls below particular safety limits and/or below the maximum temperature set at block  64 . In some cases, the main controller  30  may adjust the boost temperature set point to be within particular safety limits and/or within the maximum temperature set at block  64 . 
       FIG. 6  is a flow diagram showing another illustrative but non-limiting example of a method that may be carried out in the operation of water heater  10  ( FIG. 1 ). In  FIG. 6 , it can be seen that certain steps or operations, indicated by solid lines, may be manifested within main controller  30  ( FIG. 2 ), while other steps or operations, indicated by dashed lines, may be manifested within remote controller  32 , but this is not required. At block  74 , it can be seen that a homeowner or other user has pressed a Boost button or otherwise activated a boost mode via remote controller  32  ( FIG. 2 ). A boost button may, for example, correspond to one of the selection buttons  60  or  62  shown on remote controller  52  ( FIG. 4 ), or may be a touch button on a touch screen display. At block  76 , main controller  30  receives the boost request. 
     Control passes to block  78 , where if main controller  30  ( FIG. 2 ) is operating in accordance with an operating temperature set point, main controller  30  enters a boost mode. If main controller  30  is already in boost mode when the Boost button is pushed, the main controller may cancel the boost mode, return to operating in accordance with an operating temperature set point, and return to block  74 . 
     At block  80 , main controller  30  enables the boost mode. In some cases, main controller  30  may also start a counter or timer that can be used to set a maximum time period for the boost mode. Control is then passed to decision block  82 . At decision block  82 , a determination is made whether the normal operating temperature set point is at or below 140° F. (where 140° F. is selected for illustrative purposes only). If the operating temperature set point is less than or equal to 140° F. at decision block  82 , control passes to block  86  where a boost temperature set point is set equal to the normal operating temperature set point plus 10° F. (where 10° F. is selected for illustrative purposes only) or the maximum temperature set point, whichever is less. Control then passes to block  88 , where the operating temperature set point is compared to the maximum temperature set point. If the operating temperature set point is already equal to the maximum temperature set point when the boost button is pressed, remote controller  32  ( FIG. 2 ) may provide a graphical or other indication of this condition (such as flash “MAX”), telling the user that no boost is available because the water heater  10  ( FIG. 1 ) is already operating at the maximum temperature set point. In some cases, this may cause the user to adjust the maximum temperature set point using, for example, temperature set point setting device  44  ( FIG. 3 ). It is contemplated that this determination, and a corresponding display such as that shown at block  88 , may also take place even if, at decision block  82 , the normal operating temperature set point was greater than 140°. 
     Returning back to decision block  82 , if the normal operating temperature set point is greater than 140° F., control passes to block  84  where the boost temperature set point is set equal to 150° F. That is, if the normal operating temperature set point is greater than 140° F., the boost temperature set point is not increased by 10° F., but rather is only raised to 150° F. 
     From blocks  84  and  88 , control is passed to block  90 . In block  90 , main controller  30  ( FIG. 2 ) may temporarily set the temperature differential equal to zero or some other reduced value as desired. This may trigger operation of gas burner  24  ( FIG. 1 ) sooner than it would otherwise be started, thereby initiating the heating cycle sooner. At block  92 , remote controller  32  ( FIG. 2 ) may provide a graphical or other indication that water heater  10  ( FIG. 1 ) is in a boost mode. Control is then passed to block  94 , where main controller  30  determines if the boost temperature set point has been reached, or if the timer started in block  80  has expired. In the illustrative embodiment, if either event has occurred, control passes to block  96  where the main controller  30  exits the boost mode and returns to operating at the operating temperature set point. If the boost temperature set point has not been reached and if the timer started in block  80  has not expired, control reverts to block  80 , where the timer is continued. 
     In some cases, the main controller  30  may include an anti-stacking control algorithm to help prevent stacking in the water tank, such as described in U.S. Pat. No. 6,560,409 and 6,955,301, which are incorporated herein by reference. 
     The disclosure should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the invention can be applicable will be readily apparent to those of skill in the art upon review of the instant specification.

Technology Classification (CPC): 5