Patent Description:
Furthermore, there is a need for improved integration between connected heating systems and valves that control flow of water into and out of the heater. For example, in some pool and spa heating systems, a manually controlled valve is used in relation to a heater bypass to control a flow rate of water entering into the heater. Normally, the user needs to manually adjust this valve based on various environmental and/or seasonal factors to ensure efficient operation of the heater. This manual adjustment is particularly important in systems where the heater comprises a heat pump and maintaining a maximum coefficient of performance (COP) for the heat pump can result in significant energy cost savings. However, the effort associated with monitoring and changing the valve manually has led users to disregard the adjustment process, which has led to inefficient use of the heat pumps.

Document <CIT> describes a swimming pool heating system which utilizes a heat pump that is used for heating heat transfer fluid which is circulated through the primary coil of a heat exchanger. The pool water is circulated through the secondary coil of the heat exchanger by means of a standard pool pump. Rather than heating all of the water which is handled by the pump, a system bypass line is connected to the pool outlet line and a diverter valve, which is located in the pool return line, is used to divert a portion of the circulated pool water to the heating system. Document <CIT> describes techniques for reducing head loss in certain water-recirculation or other systems. A motorized diverter valve may be used to divert water away from a heat exchanger when the exchanger is not in use, and the diverted water may flow through a lower-loss system to the next downstream component of the system.

In light of these and other defects there is continuing need for improved pool and spa heater systems.

Embodiments described herein include a connected heating system comprising a heater having a first inflow port and a first outflow port, a controller that monitors one or more conditions relating to the heater, a heater bypass coupled between the first inflow port and the first outflow port, and a valve that controls flow of water received from a pool into the first inflow port and the heater bypass based on operating state identified by the controller. Responsive to the controller identifying the operating state, the controller is configured to transmit control signals that direct actuation of the valve to achieve the operating state. The heater is configured to heat portions of the water from the pool that flow between the first inflow port and the first outflow port when a heating mode is active.

In some embodiments, the heater bypass includes a second inflow port coupled to the first inflow port of the heater and a second outflow port coupled to the first outflow port of the heater. The valve is coupled between the second inflow port and the second outflow port. The operating state includes a timed sequence of actuations of the valve between a closed state and an opened state. In the closed state, the valve blocks flow of the water from the pool between the second inflow port and the second outflow port, and, in the open state, the valve attenuates flow of the water from the pool into the first inflow port by directing the water received from the pool to flow into both and the first inflow port of the heater and the second inflow port of the heater bypass.

In some embodiments, the operating state includes one of a plurality of actuation states of the valve. The plurality of actuation states of the value include a fully closed state, a fully open state, and one or more intermediate states. In the fully closed state, the valve directs the water received from the pool to flow into the heater bypass by blocking flow into the first inflow port. In the fully open state, the valve enables water to flow freely into the first inflow port by blocking flow into the heater bypass. In the one or more intermediate states, the valve attenuates flow of the water from the pool into the first inflow port by directing the water received from the pool to flow into both the heater bypass and the first inflow port.

In some embodiments, the heater includes a gas heater comprising a heater control board, an ignition control module electrically connected to the heater control board, a burner, and a blower motor. The heater control board is configured to activate the blower motor and direct the ignition control module to ignite the burner to engage the heating mode.

In some embodiments, the heating system further comprises a water temperature sensor electrically coupled to the controller. In these embodiments, the one or more conditions relating to the heater include a temperature of the water flowing between the first inflow port and the first outflow port as relayed to the controller by the temperature sensor. When the controller determines that the temperature of the water is below a first preconfigured threshold, the heater control board engages the heating mode, and the controller identifies the operating state as a fully open state where the valve enables the water from the pool to flow freely into the first inflow port by blocking flow into the heater bypass. When the controller determines that the temperature of the water is above a second preconfigured threshold, the heater control board disengages the heating mode, and the controller identifies the operating state as an intermediate state where the valve attenuates flow of the water from the pool into the first inflow port by directing the water received from the pool to flow into both the heater bypass and the first inflow port.

In some embodiments, the heater control board comprises the controller. In some embodiments, the controller is electrically connected to the heater control board via a wireless medium. In some embodiments, the controller is electrically connected to the heater control board via an RS485 connection that includes a half-duplex <NUM> link that operates in a listen only mode such that the heater control board is configured to transmit only when sending of data to the controller is required.

In some embodiments, the heater system further comprises an actuator connected to the valve and electrically coupled to the controller. The actuator is configured to actuate the valve into the operating state in response to receiving the control signals from the controller.

In some embodiments, the valve includes a T configuration where one opening of the valve is coupled to the first inflow port by a pipe or conduit that is substantially parallel to the ground and another opening of the valve is coupled to the heater bypass. In these embodiments, the heater bypass is substantially perpendicular to the ground. In some embodiments, a check valve is positioned between the first outflow port and a second outflow port of the heater bypass to prevent heated water from flowing back into the heater.

In some embodiments, the heater includes a heat pump comprising a heater control board, an expansion valve, a compressor, a condenser coupled between the expansion valve and the compressor, an evaporator coupled between the expansion valve and the compressor, a fan that removes cool air from the heater and directs outside air onto the evaporator, and a thermal fluid configured to circulate through the expansion valve, the compressor, the condenser, and the evaporator. The condenser is in contact with the water flowing between the first inflow port and the first outflow port and the heater control board is configured to activate the fan, the expansion valve, and the compressor to circulate the thermal fluid to engage the heating mode. During circulation, the thermal fluid is initially heated by the outside air that collects on the evaporator, is further heated via compression by the compressor, and sheds heat to the water flowing between the first inflow port and the first outflow port at the condenser.

In some embodiments, the connected heating system further comprises a water temperature sensor electrically coupled to the controller and configured to measure and relay to the controller a temperature of the water flowing between the first inflow port and the first outflow port. When the controller determines that the temperature of the water is below a first preconfigured threshold, the heater control board engages the heating mode, and, when the controller determines that the temperature of the water is above a second preconfigured threshold, the heater control board disengages the heating mode.

In some embodiments, the controller parses the one or more conditions relating to the heater to determine a current coefficient of performance (COP) of the heat pump, and wherein, when the current COP is less than a maximum COP, the controller identifies the operating state for the valve as one where the valve controls the flow of the water received from the pool into the first inflow port and the heater bypass to change the current COP to the maximum COP.

In some embodiments, the connected heating system further comprises a housing that contains the heater control board, the expansion valve, the compressor, the condenser the evaporator, the fan, the valve, and the heater bypass. The heater bypass includes a second inflow port coupled to the first inflow port of the heater and a second outflow port coupled to the first outflow port of the heater and the valve is coupled between the second inflow port and the second outflow port. The operating state includes a timed sequence of actuations of the valve between a closed state and an opened state. In the closed state, the valve blocks flow of the water from the pool between the second inflow port and the second outflow port. In the open state, the valve attenuates flow of the water from the pool into the first inflow port by directing the water received from the pool to flow into both and the first inflow port of the heater and the second inflow port of the heater bypass. The controller identifying the operating state so as adjust the current COP to the maximum COP includes the controller identifying a new timed sequence of actuations of the valve between the closed state and the opened state.

In some embodiments, the one or more conditions include at least one or more of a respective temperature of the water at the first inflow port and the first outflow port, a condensing temperature, and pressure at an outlet of the compressor.

In some embodiments the connected heating system further comprises a plurality of sensors that each correspond to one or more of the one or more conditions monitored by the controller, wherein the plurality of sensor include at least one of a temperature sensor, a pressure sensor, and/or a flow rate monitor.

In some embodiments, the controller is electrically connected to the heater control board via at least one of a wired medium and wireless medium.

Embodiments described herein also include a connected heating system comprising a heater having a housing, a first inflow port in fluid communication with the housing, a first outflow port, a heater control board disposed inside the housing, an ignition control module electrically connected to the heater control board and disposed inside the housing, a burner disposed inside the housing, and a blower motor disposed inside the housing. The connected heating system also comprises a controller that monitors a temperature of water flowing between the inflow port and the outflow port of the heater, a heater bypass coupled between the first inflow port and the first outflow port, and a valve that controls flow of water received from a pool into the first inflow port and the heater bypass based on operating state identified by the controller. Responsive to the controller identifying the operating state, the controller is configured to transmit control signals that direct actuation of the valve to achieve the operating state. The heater is configured to engage a heating mode to heat portions of the water from the pool that flow between the first inflow port and the first outflow port by activating the blower motor and directing the ignition control module to ignite the burner.

In some embodiments, the operating state includes one of a plurality of actuation states of the valve, the plurality of actuation states of the value including a fully closed state, a fully open state, and one or more intermediate states, wherein, in the fully closed state, the valve directs the water received from the pool to flow into the heater bypass by blocking flow into the first inflow port, wherein, in the fully open state, the valve enables water to flow freely into the first inflow port by blocking flow into the heater bypass, and wherein, in the one or more intermediate states, the valve attenuates flow of the water from the pool into the first inflow port by directing the water received from the pool to flow into both the heater bypass and the first inflow port.

In some embodiments, the connected heating system further comprises a water temperature sensor electrically coupled to the controller. The water temperature sensor measures and relays to the controller the temperature of the water flowing between the inflow port and the outflow. When the controller determines that the temperature of the water is below a first preconfigured threshold, the heater control board engages the heating mode, and the controller identifies the operating state as a fully open state where the valve enables the water from the pool to flow freely into the first inflow port by blocking flow into the heater bypass. When the controller determines that the temperature of the water is above a second preconfigured threshold, the heater control board disengages the heating mode, and the controller identifies the operating state as an intermediate state where the valve attenuates flow of the water from the pool into the first inflow port by directing the water received from the pool to flow into both the heater bypass and the first inflow port.

Embodiments described herein are also directed to a method comprising monitoring a temperature of water flowing between an inflow port and an outflow port of the heater via a controller and a sensor in communication with the controller, engaging a heating mode of the heater to heat the water flowing between the inflow port and the outflow port via a heater control board of the heater when the controller determines that the temperature of the water is below a first preconfigured temperature threshold, sending a first control signal to actuate a valve into a fully open state where the valve enables the water to flow freely into the first inflow port by blocking flow into a heater bypass when the heating mode is engaged, disengaging the heating mode of the heater when the controller determines that the temperature of the water is above a second preconfigured temperature threshold, and sending a second control signal to actuate the valve into an intermediate state where the valve attenuates flow of the water into the inflow port by directing the water to flow into both the heater bypass and the first inflow port when the heating mode is disengaged. In some embodiments of the method, the first preconfigured temperature is the same as the second preconfigured temperature. In some embodiments of the method the controller is electrically connected to the heater control board via an RS485 connection that includes a half-duplex <NUM> link that operates in a listen only mode such that the heater control board is configured to transmit only when sending of data to the controller is required.

Embodiments described herein are also directed to a method comprising monitoring one or more conditions relating to a heat pump via a controller, parsing, via the controller, the one or more conditions relating to the heat pump to determine a current coefficient of performance (COP) of the heat pump, identifying, with the controller, an operating state for a valve that adjusts the current COP to the maximum COP when the current COP is less than a maximum COP, transmitting control signals that direct actuation of the valve to achieve the operating state from the controller to an actuator for the valve, actuating the valve into the operating state via the actuator in response to receiving the actuator the control signals from the controller, and controlling flow of water received from a pool into a first inflow port of the heat pump and a second inflow port of heater bypass with the valve to adjust the current COP to the maximum COP when the valve is actuated into the operating state.

In some embodiments of the method, the operating state includes a timed sequence of actuations of the valve between a closed state and an opened state. In the closed state, the valve blocks flow of the water from the pool between the second inflow port of the heater bypass and a second outflow port of the heater bypass. In the open state, the valve attenuates flow of the water from the pool into the first inflow port by directing the water received from the pool to flow into both and the first inflow port of the heater and the second inflow port of the heater bypass. The controller identifying the operating state so as adjust the current COP to the maximum COP includes the controller identifying a new timed sequence of actuations of the valve between the closed state and the opened state.

In some embodiments of the method, the one or more conditions include at least one or more of a respective temperature of the water at the first inflow port of the heat pump and a first outflow port of the heat pump, a condensing temperature, and/or a pressure at an outlet of a compressor of the heat pump.

The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.

<FIG> illustrates an exemplary connected aquatic application, such as a pool or spa system <NUM>, according to disclosed embodiments. As seen in <FIG>, the connected pool or spa system <NUM> can include a heating system <NUM> configured to heat water for the pool and/or a spa to a set temperature. One or more additional components may be optionally included in the pool or spa system <NUM>, including, for example, a filter, a booster pump, a variable speed pump, one or more sensors and/or valves, a pH and/or water chemistry regulation mechanism, a water quality monitor, a sanitizer, and various communication enabling devices, described in more detail below. One or more of the components are provided in communication with each other and the pool to form a fluid circuit. The fluid circuit facilitates water movement from the pool or spa through one or more of the pool components and the fluid circuit to accomplish various tasks including, for example, pumping, cleaning, heating, sanitizing, and the like. Additional arrangements of the one or more additional components besides those shown in <FIG> that are known in the art are also contemplated.

Still referring to <FIG>, the pool or spa system <NUM> further includes a central controller <NUM>, and a portable user device <NUM> that can interface with the central controller <NUM>, either directly over a local area network, or via a cloud network <NUM>. Although <FIG> depicts the central controller <NUM>, the portable user device <NUM>, and the cloud network <NUM>, it should be noted that various communication methodologies and connections may be implemented to work in conjunction with, or independent from, one or more local controllers associated with each individual components associated with the pool or spa system <NUM> (e.g., controller of the pump, controller of the heater, etc.).

As best seen in <FIG> and <FIG>, the heating system <NUM> is provided in the form of a heater <NUM>, a heater control board <NUM>, and a valve <NUM> that is configured to control flow of water into and out of the heater <NUM>.

The heater <NUM> includes a housing <NUM> in fluid communication with a first inflow port <NUM> and a first outflow port <NUM> designed to accommodate incoming and outgoing water, respectively, through the heater <NUM>. Plumbing is provided to facilitate fluid communication between the various components of the heating system <NUM>. The heater bypass <NUM> can be coupled between the first inflow port <NUM> and the first outflow port <NUM> and can include a second inflow port <NUM> and a second outflow port <NUM>. In some embodiments, the heating system <NUM> can include a check valve <NUM> provided in the plumbing of the first outflow port <NUM> of the heater <NUM> that is designed to prevent heated water from flowing back into the heater <NUM>.

In operation, a controller such as the heater control board <NUM>, the central controller <NUM>, and/or the portable user device <NUM>, can monitor one or more conditions relating to the heater <NUM>. The valve <NUM> can be configured to control flow of water received from a pool into the first inflow port <NUM> and the heater bypass <NUM> based on operating state identified by the controller, and the heater <NUM> can be configured to heat portions of the water from the pool that flow between the first inflow port <NUM> and the first outflow port <NUM> when a heating mode is active. Furthermore, in response to identifying the operating state, the controller can be configured to transmit control signals that direct actuation of the valve <NUM> to achieve the operating state. In some embodiments, the controller can be electrically coupled to a plurality of sensors <NUM> that relay the one or more conditions relating to the heater <NUM> to the controller.

Referring to <FIG>, in some embodiments, the valve <NUM>, can be provided as a three way valve with various open and closed positions, as described hereinbelow. The valve <NUM> can be coupled to the first inflow port <NUM> of the heater <NUM> and, in embodiments where the controller comprises the heater control board <NUM>, can be electrically connected to the heater control board <NUM> to receive control commands therefrom to change a position of the valve <NUM>. In some embodiments, the valve <NUM> may be the Intellivalve™ provided by Pentair Water Pool & Spa (Cary, NC). Furthermore, as seen in <FIG>, in some embodiments, the valve <NUM> can be placed outside of the housing <NUM> and have a T configuration where one opening of the valve <NUM> is coupled to the first inflow port <NUM> by a pipe or conduit that is substantially parallel to the ground, and another opening of the valve <NUM> is coupled to the heater bypass <NUM> that is substantially perpendicular to the ground. Further still, as seen in <FIG> the check valve <NUM> can be positioned between the first outflow port <NUM> and the second outflow port <NUM>. In some embodiments, another pipe or conduit between an exit port of the check valve <NUM> and the second outflow port <NUM> can have an s-shape configuration where one end is higher of the ground than another end. It should be noted that other additional positions and configurations for the pipes or conduits as known in the art are also contemplated.

In some embodiments, the operating state for the valve <NUM> can include one of a plurality of actuation states of the valve <NUM>. These plurality of actuation states can include a fully closed state, a fully open state, and one or more intermediate states. In the fully closed state, the valve <NUM> directs the water received from the pool to flow into the heater bypass <NUM> by blocking flow into the first inflow port <NUM>. In the fully open state, the valve <NUM> enables water to flow freely into the first inflow port <NUM> by blocking flow into the heater bypass <NUM>. In the one or more intermediate states, the valve <NUM> can attenuate flow of the water from the pool into the first inflow port <NUM> by directing the water received from the pool to flow into both the heater bypass <NUM> and the first inflow port <NUM>.

As shown in <FIG>, in some embodiments the heater <NUM> can include a gas heater that further includes an ignition control board or module <NUM>, a blower motor <NUM>, an exhaust <NUM>, an air/fuel mixing chamber <NUM>, a burner <NUM>, heating coils <NUM> through which the water fed into the heater <NUM> flows, and one or more other components associated with a gas heater. The ignition control module <NUM> is coupled to and controlled by the heater control board <NUM>. For example, the heater control board <NUM> is configured to activate the blower motor <NUM> and direct the ignition control module <NUM> to ignite the burner <NUM> to engage the heating mode.

Furthermore, as seen in <FIG>, various embodiments for the size and shape of the heater <NUM> are contemplated so as to accommodate different water heating requirements as would be understood by those having ordinary skill in the art. For example, as seen in <FIG>, the heater <NUM> can have a large internal volume section for accommodating a larger volume of water flow. However, as seen in <FIG>, a compact lower internal volume heater is also contemplated. Further still, as seen in <FIG>, a version of the heater <NUM> where the housing <NUM> has a rounded profile is contemplated. Furthermore, as seen in <FIG> various orientations for the first inflow port <NUM> and the first outflow port <NUM> are contemplated. For example, as seen in <FIG>, <FIG>, the first inflow port <NUM> and the first outflow port <NUM> can be arranged in a vertical configuration with the first inflow port <NUM> on top of the first outflow port <NUM>. Additionally or alternatively, as seen in <FIG>, the first inflow port <NUM> and the first outflow port <NUM> can be arranged in a horizontal configuration where the first inflow port <NUM> is on a left side of the housing <NUM> and the first outflow port is on a right side of the housing <NUM>. Additional and alternative arrangements known in the art are also contemplated including arrangements where the positions of the first inflow port <NUM> and the first outflow port <NUM> are swapped.

In some embodiments, the controller, including but not limited to the heater control board <NUM>, can engage the heating mode and control actuation of the valve <NUM> based on a temperature of the water flowing between the first inflow port <NUM> and the first outflow port <NUM>. In these embodiments, one of the plurality of sensors <NUM> can include a water temperature sensor (e.g. a thermistor) and the one or more conditions relating to the heater <NUM> can include the temperature of the water flowing between the first inflow port <NUM> and the first outflow port <NUM> as relayed to the controller by the temperature sensor. In these embodiments, when the controller determines that the temperature of the water is below a first preconfigured threshold, the heater control board <NUM> can engage the heating mode and the controller can identify the operating state for the valve <NUM> as a fully open state where the valve <NUM> enables the water from the pool to flow freely into the first inflow port <NUM> by blocking flow into the heater bypass <NUM>. Furthermore, when the controller determines that the temperature of the water is above a second preconfigured threshold the heater control board <NUM> can disengage the heating mode and the controller can identify the operating state as an intermediate state where the valve <NUM> attenuates flow of the water from the pool into the first inflow by directing the water received from the pool to flow into both the heater bypass <NUM> and the first inflow port <NUM>. In some embodiments, the first preconfigured threshold can be the same as the second preconfigured threshold. However, in some embodiments the first preconfigured threshold can be lower than the second preconfigured threshold.

The heater control board <NUM> is also designed to undertake various other control operations of the heater <NUM>. For example, a user may manually turn the heater <NUM> on by pushing a button (not shown) on the heater <NUM>, or via an interface provided on the portable user device <NUM>. Alternatively, a user may enter the first or second preconfigured thresholds or other desired water temperature setpoints, or water temperature setpoint ranges (e.g., upper and lower limit) in which the heater <NUM> should maintain the water temperature at. In other embodiments, the user may set a schedule in which the heater <NUM> should operate.

In one example of the operation process described herein, the heater control board <NUM> may use inputs from one or more of the plurality of sensors <NUM>, internally stored settings, and/or control signals received from other devices (e.g., local on-board controllers, the central controller <NUM>, and/or the portable user device <NUM>) to commence various operations. Based on the inputs, the heater control board <NUM> is designed to direct (<NUM>) the ignition control module <NUM> to activate the blower motor <NUM> so as to begin mixing air and fuel together in the mixing chamber <NUM>, and feed the mix of air and fuel to the burner <NUM>, (<NUM>) the ignition control module <NUM> to ignite the burner <NUM> to combust the mix of air and fuel so that water flowing through the heating coils <NUM> is heated to the desired temperature, and (<NUM>) control operation of the valve <NUM> to one of the plurality of actuation states where approximately <NUM>% of the water flowing into the valve <NUM> flows into the heater <NUM> and through the heating coils <NUM>. In some embodiments, during a normal heating operation, the one of the plurality of operating states for the valve <NUM> may be an opened state where a small amount of water (e.g., less than <NUM>%) is bypassed around the heater <NUM> through the heater bypass <NUM>.

In some embodiments, once the heater control board <NUM> determines that the water has been sufficiently heated and has reached a pre-determined temperature setpoint, the heater control board <NUM> is designed to direct (<NUM>) the ignition control module <NUM> to deactivate the burner <NUM> and the blower motor <NUM>, and (<NUM>) the valve <NUM> to transition to a second one of the plurality of operating states where the valve <NUM> is operated between about <NUM>% to about <NUM>% to allow less than <NUM>% of the water flowing into the valve <NUM> to flow into the heater <NUM>. In some embodiments, when in the second one of the plurality of operating, the valve <NUM> can allow between about <NUM>% to about <NUM>% of the water flowing into the valve <NUM> to flow into the heater <NUM>.

Allowing water to flow into the heater <NUM> when the heater <NUM> is not actively heating permits measurement of the temperature of the water irrespective of the state of the valve <NUM>. Further, directing a small water flow through the heater <NUM> during this operation also can reduce the resistance in the system and decrease an amount of wear and tear on a heat exchanger of the heater <NUM>. For example, in some embodiments, when the heater <NUM> is bypassed, an internal heat exchanger can be exposed to a lower flow rate and a reduced overall volume of water having certain corrosive properties. This can extend the service life of the heat exchanger because the heater <NUM> can be subjected to a less-corrosive environment during the periods in which the heat exchanger is being bypassed. The bypass operation can also include other benefits. For example, in some embodiments, when the heater <NUM> is being bypassed, a speed of a variable flow pump's motor that pumps water to the heater <NUM> can be reduced because a total dynamic head of the system will be lower than it is when the heater is not being bypassed. This speed reduction can reduce the electrical usage of the variable speed pump and result in energy bill cost savings for the user.

In some embodiments, the percentages that the valve <NUM> is opened or closed in the various ones of the plurality of operating states can be set by a user either locally on the heater <NUM> or via the portable user device <NUM> through the central controller <NUM>. For example, in some embodiments, the portable user device <NUM> can receive user input setting the open/close percentages which the central controller <NUM> can relay to the heater control board <NUM> for storage in a local memory thereof.

<FIG> is a connection diagram for the heating system <NUM> according to disclosed embodiments. In some embodiments, the heater control board <NUM> can be coupled to various sensors and switches <NUM> that monitor for and/or activate at the presence of different potential error or fault conditions for the heater <NUM> and can include a data connection <NUM> for coupling the heater control board <NUM> to the valve <NUM>. In some embodiments, the heater control board <NUM> can be connected to the central controller <NUM> using an RS485 connection <NUM> and can communicate control signals, outputs from the various sensors and switches <NUM>, and other relevant data using a customized protocol.

Furthermore, in some embodiments, the RS485 connection <NUM> can include a half-duplex <NUM> link that operates in a listen only mode. In some embodiments, the listen only mode can include the heater control board <NUM> being configured to transmit only when sending of data to the central controller <NUM> is required. In some embodiments, the heater control board <NUM> can be configured only to transmit in response to a command from the central controller <NUM>. In some embodiments, the heater control board <NUM> can ensure data integrity prior to use of the data, by using one or more of a proper address, a proper opcode, a proper packet length, and a proper checksum when compiling and transmitting data to the central controller <NUM>.

In some embodiments, the central controller <NUM> can be configured as the system master and also operate in a listen only mode (e.g. transmitting only when required). In these embodiments, the central controller <NUM> can send continuous 'heartbeat' or 'keep alive' packets to the heater control board <NUM> at a preconfigured rate, such as, for example, approximately every <NUM> seconds. The continuous 'heartbeat' or 'keep alive' packets can be sent as an undependable transmission where no response from the heater control board <NUM> is expected or required. In some embodiments, the heater control board <NUM> can be configured to revert to a standalone or default operation when the continuous 'heartbeat' or 'keep alive' packets fail to be received for more than a preconfigured amount of time (e.g. <NUM> seconds). In some embodiments, the continuous 'heartbeat' or 'keep alive' packets can be assigned a global destination address when sent to enable the continuous 'heartbeat' or 'keep alive' packets to be received by the heater control board <NUM> and any other heater control boards in the connected pool or spa system <NUM>.

In some embodiments, the RS485 connection <NUM> can include color coded <NUM> wire terminals. For example, in some embodiments, the <NUM> wire terminals can be color coded with black indicating a DC/Signal Ground, green indicating RS485 'B' / '-Data', Yellow indicating RS485 'A' / '+Data', and Red indicating +15VDC.

In some embodiments, a command packet from the central controller <NUM> to the heater control board <NUM> can include a first preconfigured value associated with the central controller <NUM> as the source address, a second preconfigured value associated with the heater control board <NUM> as the destination address, and various control commands for the heater control board <NUM> in the info field. In some embodiments, the second preconfigured value can be set via user input on a front panel of the heater <NUM> and/or remotely via the portable user device <NUM>. In some embodiments, the various control commands can include one or more of (<NUM>) a System On/Off byte configured to switch the heater <NUM> between a first mode where the heater is deactivated, a second mode where the heater <NUM> is activated to heat a pool, and/or a third mode where the heater <NUM> is activated to heat a spa, (<NUM>) a Pool Water Heat Set Point byte that sets a specific water temperature (e.g. between <NUM> - <NUM> Celsius ( <NUM>-<NUM> °F) for heating in the second mode, (<NUM>) a Spa Water Heat Set Point byte that sets a specific water temperature (e.g. between <NUM> - <NUM> Celsius ( <NUM>-<NUM> °F) for heating in the third mode, and (<NUM>) a service mode byte that can switch operation of the heater controller board <NUM> between remote control, local control, or standalone mode.

In some embodiments, a response packet from the heater control board <NUM> to the central controller <NUM> can include the second preconfigured value as the source address, the first preconfigured value as the destination address, and operation data about the heater control board <NUM> in the info field. In some embodiments, the operation data can include one or more of (<NUM>) a heater model ID byte that identifies a model number of the heater <NUM>, (<NUM>) a heater mode byte that identifies whether the heater is in the first, second, or third mode, (<NUM>) a heating status byte that identifies whether the burner <NUM> is currently firing or not, and (<NUM>) an error mode byte that can include error information pertaining to the potential error or fault conditions for the heater <NUM> sent as error codes using <NUM> individual bit flags. In some embodiments, a value of <NUM> can be used to indicate NO ERROR. In some embodiments, spare bytes of the packet can be assigned to additional error codes when more than <NUM> error codes are needed.

As seen in <FIG>, in some embodiments, the various sensors can include one or more of an automatic fuel shutoff switch that stops fuel from flowing into the mixing chamber <NUM> when a temperature of the water leaving the heater <NUM> is above a preconfigured threshold (e.g. greater than <NUM> Celsius ( <NUM> <NUM>F), a high limit switch that activates when a temperature of the water entering the heater <NUM> is above a preconfigured threshold (e.g. greater than <NUM> Celsius ( <NUM> <NUM>F), a pressure switch that activates when there is no flow into the heater <NUM>, an air flow switch that activates when there is not a differential pressure across an air orifice to indicate that the blower motor <NUM> is not operating correctly, a thermistor that monitors a temperature of the water flowing in the heater <NUM>, and a stack flue sensor (SFS) that monitors a temperature of exhaust gas from the heater <NUM>. In some embodiments, the error codes for the customized protocol can represent different outputs from the various sensors and switches <NUM>. For example, in some embodiments the error codes can include (<NUM>) an indication that automatic fuel shutoff switch has activated, (<NUM>) an indication that the high limit switch has activated, (<NUM>) an indication that the pressure switch has activated, (<NUM>) an indication that the air flow switch has activated, (<NUM>) a thermistor open signal that indicates that thermistor or wiring thereof may be open circuited, (<NUM>) a thermistor short signal that indicates that thermistor or wiring thereof may be short circuited, (<NUM>) an indication that a value of the SFS has exceeded a preconfigured temperature value (e.g. <NUM> Celsius ( <NUM> <NUM>F), (<NUM>) an SFS open signal that indicates that SFS or wiring thereof may be open circuited, (<NUM>) an SFS short signal that indicates that SFS or wiring thereof may be short circuited, and (<NUM>) and RS485 Connection Loss indicator.

In some embodiments, the ignition control module <NUM> can include a flame sense mechanism that outputs a voltage across two pins that can be between <NUM> and 1VDC. In these embodiments, the closer the value is to 1VDC, the stronger the flame. As seen in <FIG>, the heater control board <NUM> can include a connection <NUM> to the flame sense output pins of the ignition control module <NUM>. The connection <NUM> can include a relay that connects the two pins to the microcontroller for reading and processing. In some embodiments, the heater control board <NUM> can, via the RS485 connection <NUM> to the central controller <NUM>, provide feedback to the user on whether or not the flame sense value is within an acceptable range or an unacceptable range indicative of a possible fuel or air supply issue. After reading, the voltage the relay can be turned off so as to disconnect the pins for a preset amount of time between readings.

<FIG> illustrates another exemplary embodiment of the pool or spa system <NUM>, according to disclosed embodiments. As seen in <FIG>, the connected pool or spa system <NUM> can include a heater <NUM> in place of the heating system <NUM> that is also configured to heat water for the pool and/or a spa to a set temperature. Furthermore, as seen in <FIG> the one or more additional components in the pool or spa system <NUM>, including, for example, the filter, the booster pump, the variable speed pump, the one or more sensors and/or valves, the pH and/or water chemistry regulation mechanism, the water quality monitor, the sanitizer, and the various communication enabling devices, described in more detail below can be arranged in a different configuration from that of <FIG>. In particular, as seen in <FIG> the booster pump is positioned after the filter and the water quality monitor is positioned after the filter, before the heater <NUM>, and before the booster pump. However, further arrangements of the one or more additional components in the pool or spa system <NUM> as would be known to those of ordinary skill in the art are also contemplated. As described above in connecting with <FIG> the one or more of the components are provided in communication with each other and the pool to form a fluid circuit and/or filtration system. The fluid circuit facilitates water movement from the pool or spa through one or more of the pool components and the fluid circuit to accomplish various tasks including, for example, pumping, cleaning, heating, sanitizing, and the like.

As seen in <FIG> and <FIG>, the heater <NUM> can include a housing <NUM> in which a heater bypass <NUM>, a condenser <NUM>, a heater control board <NUM>, and a valve <NUM> are provided. The heater <NUM> includes a first inflow port <NUM> and a first outflow port <NUM> from the condenser <NUM> that are designed to accommodate incoming and outgoing water, respectively, through the condenser <NUM>. Plumbing is provided to facilitate fluid communication between the various components of the heater <NUM> as would be understood by those having ordinary skill in the art. The heater bypass <NUM> can be coupled between the first inflow port <NUM> and the first outflow port <NUM> and can include a second inflow port <NUM> and a second outflow port <NUM>. In some embodiments, the second inflow port <NUM> can be coupled to the first inflow port <NUM> and the second outflow port <NUM> can be coupled to the first outflow port <NUM> inside the housing <NUM> as seen in <FIG>. However, in some embodiments, the valve <NUM> and/or the heater bypass <NUM> can be provided outside of the housing <NUM>.

Similar to the heating system <NUM> described herein, in operation, the controller (e.g. the heater control board <NUM>, the central controller <NUM>, and/or the portable user device <NUM>), can monitor one or more conditions relating to the heater <NUM>. The valve <NUM> can be configured to control flow of water received from a pool into the first inflow port <NUM> and the heater bypass <NUM> based on operating state identified by the controller, and the heater <NUM> can be configured to heat portions of the water from the pool that flow between the first inflow port <NUM> and the first outflow port <NUM> when a heating mode is active. Furthermore, in response to identifying the operating state, the controller can be configured to transmit control signals that direct actuation of the valve <NUM> to achieve the operating state. In some embodiments, the controller can be electrically coupled to a plurality of sensors <NUM> (see <FIG>) that relay the one or more conditions relating to the heater <NUM> to the controller.

Referring now to <FIG>, in some embodiments, the valve <NUM>, can be provided as a <NUM> way valve with various open and closed positions, as described hereinbelow. The valve <NUM> can be coupled between the second inflow port <NUM> and the second outflow port <NUM> and, in embodiments where the controller comprises the heater control board <NUM>, can be electrically connected to the heater control board <NUM> to receive control commands therefrom to change a position of the valve <NUM>. In some embodiments, the operating state for the valve <NUM> can include a timed sequence of actuations of the valve <NUM> between a closed state and an opened state, wherein, in the closed state, the valve blocks flow of the water from the pool between the second inflow port <NUM> and the second outflow port <NUM>, and wherein, in the open state, the valve attenuates flow of the water from the pool into the first inflow port <NUM> by directing the water received from the pool to flow into both and the first inflow port <NUM> and the second inflow port <NUM>.

In some embodiments, the heater <NUM> can include a heat pump. <FIG> is a partial cross-sectional view and <FIG> is a schematic view of various internal components of a heat pump embodiment of the heater <NUM> according to disclosed embodiments. As seen in <FIG> and <FIG>, in these embodiments, the heater <NUM> can include the heater control board <NUM>, an expansion valve <NUM>, a compressor <NUM>, the condenser <NUM> coupled between the expansion valve <NUM> and the compressor <NUM>, an evaporator <NUM> coupled between the expansion valve <NUM> and the compressor <NUM>, a fan <NUM> that removes cool air from the heater and directs outside air onto the evaporator <NUM>, and a thermal fluid configured to circulate through the expansion valve <NUM>, the compressor <NUM>, the condenser <NUM>, and the evaporator <NUM> in a path indicate by arrow A.

The condenser <NUM> is in contact with the water flowing between the first inflow port <NUM> and the first outflow port <NUM> to transfer heat between the circulating thermal fluid and the water. Furthermore, the heater control board <NUM> can be configured to activate the fan <NUM>, the expansion valve <NUM>, and the compressor <NUM> to circulate the thermal fluid to engage the heating mode. During such circulation, the thermal fluid is initially heated by the outside air that collects on the evaporator <NUM>, is further heated via compression by the compressor <NUM>, and sheds heat to the water flowing between the first inflow port <NUM> and the first outflow port <NUM> at the condenser <NUM>. In some embodiments, the thermal fluid is heated from a liquid state into a gaseous state before entering the compressor <NUM> and cooled back into the liquid state when shedding heat to the water flowing between the first inflow port <NUM> and the first outflow port <NUM>. Various embodiments for the thermal fluid are contemplated such as refrigerant fluids like R22, R32, R407, R410, and other similar fluids known in the art.

In some embodiments, the controller, including but not limited to the heater control board <NUM>, can engage the heating mode based on a temperature of the water flowing between the first inflow port <NUM> and the first outflow port <NUM>. In these embodiments, one of the plurality of sensors <NUM> can include a water temperature sensor (e.g. a thermistor) configured to measure and relay to the controller a temperature of the water flowing between the first inflow port <NUM> and the first outflow port <NUM>. In these embodiments, when the controller determines that the temperature of the water is below a first preconfigured threshold, the heater control board <NUM> can engage the heating mode. Furthermore, when the controller determines that the temperature of the water is above a second preconfigured threshold, the heater control board <NUM> can disengage the heating mode. In some embodiments, the first preconfigured threshold can be the same as the second preconfigured threshold. However, in some embodiments the first preconfigured threshold can be lower than the second preconfigured threshold.

In some embodiments, the controller, including but not limited to the heater control board <NUM>, can control actuation of the valve <NUM> to mediate flow of water through the condenser <NUM> such that a COP of the heater <NUM> is maximized. In these embodiments, the controller parses the one or more conditions relating to the heater <NUM> to determine a current COP of the heater <NUM>. When the current COP is less than a maximum COP, the controller identifies the operating state for the valve <NUM> as one where the valve <NUM> controls the flow of the water received from the pool into the first inflow port <NUM> and the heater bypass <NUM> to change the current COP to the maximum COP. For example, in embodiments where the valve <NUM> is the two-way valve that controls the flow rate through the condenser <NUM> via the timed sequence of actuations between the open and the closed states, the operating state of the valve <NUM> identified by the controller can include new timed sequence of actuations (e.g. holding the valve <NUM> open or closed for a longer or shorter time) of the valve <NUM> between the closed state and the opened state so as adjust the current COP of the heater <NUM> to the maximum COP. In some embodiments the controller can dynamically adjust the timing of the opening and closing of the valve <NUM> to achieve the maximum COP for the heater <NUM>. For example, the controller can continue to adjust the timing of the opening and closing of the valve <NUM> until the controller determines that the COP for the heater <NUM> is at the maximum as indicated by the one or more conditions of the heater <NUM>. In some embodiments, the controller can be configured to wait a preconfigured time after changing the timing of the opening and closing of the valve <NUM> before continuing to monitor the one or more conditions of the heater <NUM> and adjusting the timing so as to achieve the maximum COP. Waiting the preconfigured time can enable the one or more conditions of the heater <NUM> to balance or stabilize in response to the changed timing.

Various embodiments for the monitoring and calculating the current COP of the heater <NUM> are contemplated. For example, in some embodiments, the one or more conditions monitored by the controller can include at least one of temperature of the water at the first inflow port <NUM>, temperature of the water at the first outflow port <NUM>, a condensing temperature, and pressure of the thermal fluid at an outlet of the compressor <NUM>. Additionally, in some embodiments, the one or more conditions monitored by the controller can include environmental conditions, external temperature, seasonal information, geographic information, and/or a flow rate of water through the pool or spa system <NUM> as directed by some of the one or more additional components. For example, in some embodiments, the one or more additional components can include one or more variable speed pumps that alter the flow rate of the water to enable low speed filtering and a high speed skimming period where debris is evacuated on the surface of the pool. Additionally, the flow rate of the water can change based on clogging of a filter and execution of a backwash cycle to unclog the filter. In some embodiments, a preferred flow rate in the condenser <NUM> to achieve a maximum COP for the heater <NUM> is approximately <NUM> to <NUM> m3/h when the flow rate in the connected pool or spa system <NUM> is approximately <NUM> to 18m3/h.

In some embodiments, each of the plurality of sensors <NUM> can correspond to one or more of the one or more conditions monitored by the controller. For example, the plurality of sensors <NUM> can include various temperature sensors positioned throughout the connected pool or spa system <NUM> including, for example, at the first inflow port <NUM> and the first outflow port <NUM>, various pressure sensors, various flow rate monitors, and other sensors as would be understood by those in the art.

<FIG> is an isometric view of the actuator 78A for the valve <NUM>. As seen in <FIG>, the actuator 78A can include a power and data connector 80A that electrically couples the actuator 78A to the controller and or a valve control board <NUM> (see <FIG>). The actuator 78A can be configured to receive control signals from the controller via the power and data connector 80A and responsive thereto, actuate the valve <NUM> into the operating states as described herein. In some embodiments the actuator 78A can include the valve actuator for the Intellivalve™ provided by Pentair Water Pool & Spa (Cary, NC). In some embodiments, the actuator 78A can include approximately <NUM> defined positions into which the valve <NUM> can be actuated. Furthermore, in some embodiments, the power and data connector 80A can include a RS485 Modbus.

<FIG> is an isometric view of another actuator 78B for the valve <NUM> according to disclosed embodiments. Similar to the actuator 78A, the actuator 78B can include a power and data connector 80B that electrically couples the actuator 78B to the controller and/or the valve control board <NUM> (see <FIG>). The actuator 78B can be configured to receive control signals from the controller via the power and data connector 80B and responsive thereto, actuate the valve <NUM> into the operating states as described herein. In some embodiments, control of the valve <NUM> can be accomplished by controlling a supply time of electric power to actuator 78B.

In some embodiments, the valve <NUM> or the actuator 78A or 78B can be supplied as a retrofit kit for the heater <NUM>. Further still, in some embodiments valve control board <NUM> can be embedded in the actuator 78A or 78B or housed externally and electrically coupled thereto as shown in <FIG>. In some embodiments, the valve control board <NUM>, either separately or in conjunction with the heater control board <NUM>, the central controller <NUM>, and/or the portable user device <NUM>, can comprise the controller as described herein.

Various embodiments for interfacing the actuators 78A and 78B with the valve <NUM> are contemplated. For example, as seen in <FIG>, in embodiments where the valve <NUM> includes a two-way valve <NUM>, the actuator 78A can be secured to the valve <NUM> by fasteners <NUM> such that it interfaces with a two-way spline <NUM> of the valve <NUM> that is maneuvered by the actuator 78A to position the valve <NUM> in the operating sates as described herein. Similarly, as seen in <FIG>, in embodiments where the valve <NUM> includes a three-way valve <NUM>, the actuator 78A can be secured to the valve <NUM> by fasteners <NUM> such that it interfaces with a three-way spline <NUM> of the valve <NUM> that is maneuvered by the actuator 78A to position the valve <NUM> in the operating sates as described herein. It will be appreciated, that similar interfacing operations as described and shown for the actuator 78A are contemplated with respect to the actuator 78B. Furthermore, it should also be appreciated that the actuators 78A and 78B, the two-way valve <NUM>, and the three way valve <NUM> shown in <FIG> can be used in relation to the connected heating system <NUM> and the valve <NUM> as shown in <FIG>.

In some embodiments, the heater control board <NUM> and/or the valve control board <NUM> can be coupled to various sensors and switches that monitor for and/or activate at the presence of different potential error or fault conditions for the heater <NUM> and can include a data connection for coupling the valve control board <NUM> to the valve <NUM>. In some embodiments, the valve control board <NUM> can be connected to the central controller <NUM> using an RS485 connection such as described here or the like and can communicate control signals, outputs from the various sensors and switches, and other relevant data using a customized protocol as described herein. In some embodiments, the valve control board <NUM> can be configured only to transmit in response to a command from the central controller <NUM>. In some embodiments, the valve control board <NUM> can ensure data integrity prior to use of the data, by using one or more of a proper address, a proper opcode, a proper packet length, and a proper checksum when compiling and transmitting data to the central controller <NUM>.

It is to be understood that the controller (e.g. the heater control boards <NUM> and <NUM>, the central controller <NUM>, and/or the portable user device <NUM>) and other connected devices and sensors as disclosed herein can include respective transceiver and a memory devices, each of which can be in communication with control circuitry, one or more programmable processors, and executable control software as would be understood by one of ordinary skill in the art. In some embodiments, the control software can be stored on a transitory or non-transitory computer readable medium, including, but not limited to local computer memory, RAM, optical storage media, magnetic storage media, flash memory, and the like, and some or all of the control circuitry, the programmable processors, and the control software can execute and control at least some of the methods described herein.

Claim 1:
A connected heating system (<NUM>) for aquatic applications, comprising:
a heater (<NUM>) having a first inflow port (<NUM>) and a first outflow port (<NUM>);
a controller (<NUM>) that monitors one or more conditions relating to the heater (<NUM>);
a heater bypass (<NUM>) coupled between the first inflow port (<NUM>) and the first outflow port (<NUM>); and
a valve (<NUM>) that controls flow of water received from a pool into the first inflow port (<NUM>) and the heater bypass (<NUM>) based on an operating state identified by the controller (<NUM>),
wherein, responsive to the controller (<NUM>) identifying the operating state, the controller (<NUM>) is configured to transmit control signals that direct actuation of the valve (<NUM>) to achieve the operating state, and
wherein the heater (<NUM>) is configured to heat portions of the water from the pool that flow between the first inflow port (<NUM>) and the first outflow port (<NUM>) when a heating mode is active.