Manufacturing method for hot water supply heater and hot water supply heater

Abstract

To more largely secure a common structure in a casing in a hot water supply heater.SOLUTION: A hot water supply heater 1 includes a heating circuit 3, a casing 100 configured to accommodate the heating circuit 3 and double plates 140. A manufacturing method for the hot water supply heater 1 comprises: a determination process of determining the number and arrangement of heating medium supply passages 38F provided at a predetermined position in a heating medium circulation passage 48; a selection process of selecting, from the plurality of types of double plates 140 in which combinations of the number and arrangement of second hole parts 146 differ, the double plate 140 in which presence / absence of the second hole parts 146 is determined in the determination process and that corresponds to the number and arrangement of the heating medium supply passages 38F; and an attachment process of attaching the double plate 140 selected in the selection process to the predetermined position of a bottom surface plate 110 in an overlapped manner.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a manufacturing method of a water heater and a water heater.

Background Art

[0002] Patent Document 1 discloses an example of an assembly method of a water heater. In this assembly method, each device is assembled to a substantially rectangular parallelepiped-shaped back cover with an open front surface and bottom surface during installation, and a bottom plate fixed to the bottom surface of the back cover. A water volume adjuster, a gas switch for hot water supply, a gas switch for heating, and a water volume adjuster are assembled to the bottom plate, and a burner for hot water supply, a burner for heating, a heat exchanger for hot water supply, a heat exchanger for heating, a fan for hot water supply, and a fan for heating are assembled to the back cover. Next, the bottom plate with each device assembled is mounted and fixed to the open bottom surface side of the back cover with each device assembled, and a front cover is fixed to the open front surface side of the back cover to assemble the water heater.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Generally, a water heater including the water heater disclosed in Patent Document 1 includes an outlet flow path (the outlet of the heat medium supply path) for supplying a heat medium to a heat dissipation terminal (heating terminal) provided outside, and the number and arrangement of this outlet flow path vary depending on the specifications of the water heater. And the outlet flow path is often provided protruding from the bottom surface portion of the water heater from the viewpoints of ease of connection and aesthetics.

[0005] Due to such circumstances, when manufacturing a water heater with a heating function, it is necessary to prepare a bottom plate corresponding to the number and arrangement of the outlet channels. If the number and arrangement of the outlet channels vary for each specification, different casings must be prepared for each specification. However, the technology of preparing different casings for each specification tends to lead to an increase in manufacturing costs and complexity in parts management.

[0006] One of the objectives of the present disclosure is to provide a technology related to a water heater with a heating function, which can ensure a larger common structure in the casing.

Means for Solving the Problems

[0007] A manufacturing method of a water heater with a heating function according to the present disclosure is a manufacturing method for manufacturing a water heater with a heating function, comprising a heat medium supply path having an outlet for the heat medium, and a terminal flow path provided at a heat dissipation terminal being connectable to the heat medium supply path, wherein the water heater with a heating function has a heat medium circulation path which is a path for circulating the heat medium together with the terminal flow path, a gas burner for burning gas, and a heat exchanger for heating the heat medium flowing through the heat medium circulation path by combustion exhaust generated by the combustion in the gas burner. The heat medium supply path constitutes a part of the heat medium circulation path, and a heating circuit for supplying the heat medium heated by the heat exchanger to the terminal flow path through the heat medium supply path; comprises a bottom plate provided with a plurality of first hole portions, and a casing configured to accommodate the heating circuit; has a configuration with or without one or more second hole portions communicating with the first hole portions, and a superimposed plate to be superimposed on a predetermined position of the bottom plate; and a determination step of determining the number and arrangement of the heat medium supply paths provided at the predetermined position in the heat medium circulation path; a selection step of selecting the superimposed plate from a plurality of types of superimposed plates with different combinations of the number and arrangement of the second hole portions, the presence or absence of the second hole portions corresponding to the number and arrangement of the heat medium supply paths determined by the determination step; An assembling step of stacking and assembling the overlapping plate selected by the selection step at the predetermined position of the bottom plate is included.

[0008] One of the water heaters of the present disclosure is a water heater provided with a heat medium supply path having an outlet of the heat medium, and a terminal flow path provided at a heat dissipation terminal can be connected to the heat medium supply path. A heat medium circulation path which is a path for circulating the heat medium together with the terminal flow path, a gas burner for burning gas, and a heat exchanger for heating the heat medium flowing through the heat medium circulation path by combustion exhaust generated by the combustion of the gas burner. The heat medium supply path constitutes a part of the heat medium circulation path, and a heating circuit for supplying the heat medium heated by the heat exchanger through the heat medium supply path to the terminal flow path. A bottom plate provided with a plurality of first hole portions, and a housing configured to accommodate the heating circuit. It has a configuration with or without one or more second hole portions communicating with the first hole portions, and an overlapping plate that overlaps at a predetermined position of the bottom plate. has The overlapping plate is selected from a plurality of types of overlapping plates having different combinations of the number and arrangement of the second hole portions, and is the overlapping plate corresponding to the number and arrangement of the heat medium supply paths.

Advantages of the Invention

[0009] The technology according to the present disclosure relates to a water heater, and a common structure can be more greatly secured in the housing.

Brief Description of the Drawings

[0010]

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Mode for Carrying Out the Invention

[0011] Each of the following is an example of the technology included in the present disclosure.

[0012] 〔1〕 A manufacturing method for manufacturing a hot water heater including a heat medium supply path having a heat medium outlet, and a terminal flow path provided at a heat dissipation terminal being connectable to the heat medium supply path, The hot water heater includes a heat medium circulation path that is a path for circulating the heat medium together with the terminal flow path, a gas burner for burning gas, and a heat exchanger for heating the heat medium flowing through the heat medium circulation path by combustion exhaust generated by combustion in the gas burner, the heat medium supply path constituting a part of the heat medium circulation path, and a heating circuit for supplying the heat medium heated by the heat exchanger to the terminal flow path through the heat medium supply path, a bottom plate provided with a plurality of first hole portions, and a housing configured to accommodate the heating circuit, a configuration having one or more second hole portions communicating with the first hole portions or a configuration not having them, and an overlapping plate that overlaps a predetermined position of the bottom plate, and having a determination step of determining the number and arrangement of the heat medium supply paths provided at the predetermined position in the heat medium circulation path, a selection step of selecting, from a plurality of types of the overlapping plates having different combinations of the number and arrangement of the second hole portions, the overlapping plate in which the presence or absence of the second hole portion corresponds to the number and arrangement of the heat medium supply paths determined by the determination step An assembling step of overlapping and assembling the overlapping plate selected by the selection step at the predetermined position on the bottom plate, A method for manufacturing a hot water heater including the above.

[0013] The method for manufacturing a hot water heater according to [1] above can achieve commonality in the bottom plate of the housing even when manufacturing hot water heaters with different numbers and arrangements of the heat medium supply paths, and it is easy to reduce the manufacturing cost. On the other hand, even if the number and arrangement of the heat medium supply paths near the predetermined position differ for each specification, an overlapping plate corresponding to the number and arrangement of the heat medium supply paths can be used, so that optimization can be achieved according to the specification.

[0014] 〔2〕 The first hole portion and the second hole portion are hole portions for passing the heat medium supply path, In the determination step, the combination of the number and arrangement of the heat medium supply paths is selected from a plurality of pre-prepared combinations, On the bottom plate, the positions of all the heat medium supply paths in the plurality of combinations are covered, and the first hole portion is provided so that the heat medium supply path can be inserted at the positions of all the heat medium supply paths, When it is determined by the determination step to provide one or more of the heat medium supply paths at the predetermined position, a overlapping plate having the second hole portion corresponding to the number and arrangement of the heat medium supply paths determined by the determination step is selected by the selection step, and when there is a first hole portion through which the heat medium supply path is not inserted, the overlapping plate configured to block the first hole portion is selected by the selection step. In the assembling step, the heat medium supply path is inserted into the first hole portion and the second hole portion in a state where the overlapping plate is overlapped on the bottom plate at the predetermined position so as to communicate the first hole portion and the second hole portion. The method for manufacturing a hot water heater according to [1].

[0015] In the method for manufacturing the hot water heater of the above [2], when it is determined by the determination step to provide one or more heat medium supply paths at predetermined positions, a laminated plate having second holes corresponding to the number and arrangement of the heat medium supply paths is selected by the selection step, and the laminated plate can be arranged so that the heat medium supply paths are inserted into the first holes and the second holes. Further, depending on the number and arrangement determined by the determination step, there may be a first hole through which the heat medium supply path is not inserted. In such a case, in the selection step, since a laminated plate configured to block the first hole that is not inserted is selected, even if there is a first hole that becomes unnecessary depending on the specifications, it is possible to make appropriate adjustments so as to block the unnecessary first hole.

[0016] 〔3〕 The plurality of types of laminated plates to be selected in the selection step have a common outer shape The method for manufacturing a hot water heater according to any one of 〔1〕 or 〔2〕.

[0017] In the method for manufacturing the hot water heater of the above [3], since the outer shapes of the plurality of types of laminated plates are made common, the manufacturing cost can be further reduced.

[0018] 〔4〕 The housing has a housing main body that forms an open configuration on the front end side and houses the heating circuit, and a front cover that opens and closes the housing main body from the front side. The front cover has a main body portion that has an opening and is detachable from the housing main body, and a closing portion that is attached so as to close the opening of the main body portion. The opening is provided at least at a position near the lower end of the main body portion. In a state where the closing portion is removed from the main body portion, an external space on the front side of the front cover and an internal space inside the housing main body communicate with each other through the opening. On the front end side of the laminated plate, a first rising portion that rises above the bottom plate is provided. The method for manufacturing a hot water heater according to any one of 〔1〕 to 〔3〕.

[0019] In the manufacturing method of the water heater and heater described in [4] above, regardless of the type of laminated plate selected, it is possible to connect a grounding wire to the first rising part provided on the front end side. Further, since the first rising part is provided on the front end side of the laminated plate and an opening is provided at a position near the lower end of the front cover, during construction or the like, when the closing part is not attached, it is easy to perform operations such as attaching a grounding wire to the first rising part through the opening.

[0020] 〔5〕 On the laminated plate side, a second rising part that rises above the bottom plate is provided. The bottom plate includes a bottom plate body that constitutes the bottom surface part of the water heater and heater, and a third rising part that rises upward from the bottom plate body. In the assembling step, in a state where the second rising part and the third rising part are overlapped, they are connected by inserting a second connecting member having conductivity through the second rising part and the third rising part, and the laminated plate and the bottom plate are electrically connected. The manufacturing method of the water heater and heater according to any one of [1] to [4] above.

[0021] In the manufacturing method of the water heater and heater described in [5] above, electrical connection can be achieved by a simple connection structure in which the second connecting member is inserted and connected in a state where the second rising part and the third rising part are overlapped. Even if electrical connection is not ensured or is difficult to ensure on the plate surfaces of the laminated plate or the bottom plate, if electrical connection with the second connecting member is ensured at the second rising part and the third rising part, the laminated plate and the bottom plate can be surely electrically connected and kept at the same potential.

[0022] 〔6〕 A water heater and heater provided with a heat medium supply path having a heat medium outlet, and a terminal flow path provided at a heat dissipation terminal can be connected to the heat medium supply path. A heat medium circulation path, which is a path for circulating the heat medium together with the terminal flow path, a gas burner for burning gas, and a heat exchanger for heating the heat medium flowing through the heat medium circulation path by the combustion exhaust generated by the combustion in the gas burner, and the heat medium supply path constitutes a part of the heat medium circulation path, and a heating circuit for supplying the heat medium heated by the heat exchanger to the terminal flow path through the heat medium supply path. A housing including a bottom plate provided with a plurality of first hole portions and configured to accommodate the heating circuit. A structure having one or more second hole portions communicating with the first hole portions or not having the second hole portions, and a superimposed plate superimposed on a predetermined position of the bottom plate. Having The superimposed plate is selected from a plurality of types of superimposed plates having different combinations of the number and arrangement of the second hole portions, and is a superimposed plate corresponding to the number and arrangement of the heat medium supply paths. A water heater.

[0023] The water heater according to [6] above can achieve the same effects as the manufacturing method according to [1] above.

[0024] <First Embodiment> The following description relates to the water heater 1 according to the first embodiment. The water heater 1 corresponds to an example of a water heater.

[0025] 1. Overall Configuration of the Water Heater 1 FIG. 1 is a schematic circuit diagram of the water heater 1. The water heater 1 mainly includes a hot water supply circuit 2, a heating circuit 3, a bath circuit 4, etc., and is a device capable of performing hot water supply operations, automatic water filling operations, supplementary heating operations, heating operations, etc.

[0026] The hot water supply and heating unit 1 has a housing (not shown in the figure), and inside this housing, there is a container 1A configured as a metal casing. Inside this container 1A, a first combustion system unit 5 and a second combustion system unit 6 are configured. The container 1A is configured, for example, as a metal can body or as a metal box body, and is configured to accommodate a hot water supply burner 8A (first burner), a heating burner 33A (second burner), a hot water supply side heat exchanger 7 (first heat exchanger), a heating side heat exchanger 32 (second heat exchanger), etc., which will be described later. The first combustion system unit 5 is a combustion system that performs gas combustion and water heating when the hot water supply circuit 2 performs a hot water supply operation. The second combustion system unit 6 is a combustion system that performs gas combustion and water heating during a heating operation or a supplementary heating operation.

[0027] The hot water supply circuit 2 is a circuit that performs a hot water supply operation by burning gas. Specifically, it is a circuit that heats water supplied from outside the hot water supply and heating unit 1 by the hot water supply side heat exchanger 7 and supplies hot water. The hot water supply circuit 2 includes the first combustion system unit 5. Specifically, it includes a plurality of hot water supply burners 8A and a hot water supply side heat exchanger 7. In the first combustion system unit 5, a hot water supply combustion chamber 5A is provided, and a hot water supply side burner unit 8 and a hot water supply side heat exchanger 7 are provided in the hot water supply combustion chamber 5A.

[0028] The hot water supply side burner unit 8 includes burner blocks 9A, 9B, 9C, and each of the burner blocks 9A, 9B, 9C includes a plurality of hot water supply burners 8A. Each of the plurality of hot water supply burners 8A corresponds to an example of the first burner and is configured as a gas burner that burns gas. In the hot water supply combustion chamber 5A, the entire area where the hot water supply burner 8A (first burner) is arranged is divided into a plurality of burner blocks 9A, 9B, 9C.

[0029] The hot water supply side heat exchanger 7 corresponds to an example of the first heat exchanger and is a heat exchanger heated by the exhaust gas generated by the hot water supply burner 8A (first burner). The hot water supply side heat exchanger 7 includes a hot water supply side first heat exchanger 7A and a hot water supply side second heat exchanger 7B. In the first combustion system section 5, the hot water supply side first heat exchanger 7A is provided above a plurality of hot water supply burners 8A, and the hot water supply side second heat exchanger 7B is provided above the hot water supply side first heat exchanger 7A. A pipe line 7C is connected between the downstream end of the hot water supply side second heat exchanger 7B and the upstream end of the hot water supply side first heat exchanger 7A, and the hot water flowing through the hot water supply side second heat exchanger 7B flows through the pipe line 7C to the hot water supply side first heat exchanger 7A. The hot water supply side heat exchanger 7 heats the water passing through its interior by the exhaust gas (combustion exhaust gas) generated by burning gas with a plurality of hot water supply burners 8A. The hot water supply side first heat exchanger 7A recovers sensible heat from the combustion exhaust gas discharged from the hot water supply side burner unit 8, and the hot water supply side second heat exchanger 7B recovers latent heat from the combustion exhaust gas discharged from the hot water supply side burner unit 8.

[0030] The hot water supply circuit 2 further includes a water supply pipe 11, a control valve 13A, a water flow sensor 14, a hot water outlet pipe 10, a bypass pipe 12, a control valve 13B, a thermistor 15A (hot water supply inner cylinder thermistor), a thermistor 15B (hot water supply outlet thermistor), and the like. The water supply pipe 11 is connected to the inlet of the hot water supply side heat exchanger 7. The water supply pipe 11 is connected to an external pipe and is configured as a pipe line that introduces tap water from, for example, a water supply and flows this tap water toward the upstream end (inlet) of the hot water supply side heat exchanger 7. The water flow sensor 14 is a sensor that detects the flow rate of the water flowing through the water supply pipe 11. The control valve 13A is a valve for controlling the flow rate of the water flowing through the water supply pipe 11 and is a valve that changes the opening degree of the water supply pipe 11 under external control (specifically, control by the control device 70). The hot water outlet pipe 10 is connected to the downstream end (outlet) of the hot water supply side heat exchanger 7. The hot water outlet pipe 10 is a pipe line through which the hot water heated by the hot water supply side heat exchanger 7 flows. The hot water outlet pipe 10 forms a path for discharging the hot water heated by the hot water supply side heat exchanger 7 outside the appliance.

[0031] A bypass pipe 12 is connected between the water supply pipe 11 and the hot water outlet pipe 10 so as to bypass the hot water supply side heat exchanger 7. A control valve 13B (bypass control valve) is provided in the bypass pipe 12. The control valve 13B is a valve for controlling the flow rate of the water flowing through the bypass pipe 12. Specifically, it is configured as a valve that changes the opening degree of the bypass pipe 12 in response to external control (specifically, control by the control device 70).

[0032] A thermistor 15A is provided upstream of the connection portion of the bypass pipe 12 in the hot water outlet pipe 10. The thermistor 15A detects the temperature of the hot water discharged from the hot water supply side heat exchanger 7. Specifically, it detects the hot water temperature near the outlet of the first heat exchanger 7A on the hot water supply side. A thermistor 15B is provided downstream of the connection portion of the bypass pipe 12 in the hot water outlet pipe 10. The thermistor 15B detects the hot water temperature after the water from the bypass pipe 12 is mixed. Specifically, it detects the temperature of the hot water supplied downstream of the confluence point of the bypass pipe 12 in the hot water outlet pipe 10. The temperatures of the hot water detected by these thermistors 15A and 15B are input to the control device 70 described later.

[0033] The hot water supply circuit 2 further includes a gas pipe 16, a main gas solenoid valve 17, a gas proportional valve 18, and a switching valve 19. The gas pipe 16 is a pipe through which gas supplied from outside the hot water supply and heating unit 1 via the gas inlet passes, and forms a path for supplying gas to the hot water supply burner 8A. The main gas solenoid valve 17 is provided on the upstream side of the gas pipe 16, and the gas proportional valve 18 is provided on the downstream side of the main gas solenoid valve 17. On the gas pipe 16, the downstream side of the gas proportional valve 18 (hot water supply gas proportional valve) branches, and branch pipes 16A to each of the burner blocks 9A, 9B, 9C and branch pipes 16B to each of the burner blocks 34A, 34B are provided. Each branch pipe 16A is provided with a switching valve 19 configured as a solenoid valve. The switching valve 19 (hot water supply switching solenoid valve) switches the branch pipe 16A between an open state (supply possible state) and a closed state (shut-off state), and the supply and shut-off of fuel gas to each of the burner blocks 9A, 9B, 9C are individually switched by each switching valve 19. By switching the switching valve 19, the combustion range of the hot water supply side burner unit 8 is switched, and each combustion range is associated as a stage number.

[0034] The hot water supply circuit 2 further includes a fan 20. The fan 20 is provided below the hot water supply combustion chamber 5A. By the operation of the fan 20, combustion air is supplied to each of the hot water supply burners 8A and the heating burner 33A, and combustion exhaust discharged from the hot water supply side burner unit 8 and the heating side burner unit 33 is discharged from the exhaust port. The hot water supply circuit 2 is also provided with an igniter for ignition, an ignition electrode, a hot water supply flame rod, and the like.

[0035] The bath circuit 4 includes a bath circulation path 63 and a bath heat exchanger 50. The bath circulation path 63 forms a flow path configured to circulate the hot water derived from the external bathtub 52 and introduce it into the bathtub 52. The bath heat exchanger 50 is configured as a liquid-liquid heat exchanger that performs heat exchange between the heat medium flowing through the bath heating pipe 51 and the hot water flowing through the bath circulation path 63.

[0036] The bathtub heat exchanger 50 is provided with a pipe 50A that forms part of the bathtub circulation path 63, and the bathtub heating pipe 51 is arranged inside the pipe 50A. The bathtub circulation path 63 is configured to include the pipe 50A, the bathtub supply pipe 53, and the bathtub return pipe 54. When the bathtub circulation pump 55 operates, the bathtub circulation path 63 functions as a flow path for drawing out hot water from the bathtub 52 provided outside the water heater 1, and functions as a flow path for circulating the drawn-out hot water and introducing it into the bathtub 52. The bathtub return pipe 54 is provided with a bathtub circulation pump 55 for flowing the hot water in the bathtub return pipe 54 in a predetermined direction, and a water flow switch 57 for detecting that hot water with a predetermined flow rate or more is flowing in the bathtub return pipe 54. The bathtub return pipe 54 is provided between the bathtub 52 outside the appliance and the pipe 50A, and forms a flow path for flowing hot water from the bathtub 52 to the pipe 50A when the bathtub circulation pump 55 operates. The bathtub supply pipe 53 is provided between the pipe 50A and the bathtub 52, and forms a flow path for flowing hot water from the pipe 50A to the bathtub 52 when the bathtub circulation pump 55 operates. The bathtub supply pipe 53 is provided with a bathtub supply thermistor 64 for detecting the temperature of the hot water flowing out from the bathtub heat exchanger 50 to the bathtub 52. The bathtub return pipe 54 is provided with a bathtub return thermistor 65 for detecting the temperature of the hot water flowing into the bathtub return pipe 54 from the bathtub 52.

[0037] The drop pipe 59 is connected to the bathtub return pipe 54 in a configuration branched from the hot water outlet pipe 10. The drop pipe 59 communicates with the bathtub return pipe 54. The drop pipe 59 is provided with a hot water supply solenoid valve 60, a drop water volume sensor 61, a plurality of check valves 62, etc. When the hot water supply solenoid valve 60 provided in the drop pipe 59 is opened during the operation of the hot water supply circuit 2, the hot water heated by the hot water supply circuit 2 is supplied to the bathtub 52 through the drop pipe 59.

[0038] The heating circuit 3 is a circuit that can heat the heat medium by means of the heating-side heat exchanger 32 and supply the heat medium to the heating terminal via the heat medium circulation path 48. In the present embodiment, the heat medium is, for example, hot water. The heating circuit 3 includes a second combustion system unit 6 and a heat medium circulation path 48. The second combustion system unit 6 is provided with a heating combustion chamber 6A, and a heating-side burner unit 33 and a heating-side heat exchanger 32 are provided in the heating combustion chamber 6A.

[0039] The heating-side burner unit 33 includes burner blocks 34A and 34B, and each of the burner blocks 34A and 34B includes a plurality of heating burners 33A. Each of the plurality of heating burners 33A corresponds to an example of a second burner and is configured as a gas burner that burns gas. The entire area where the heating burner 33A (second burner) is arranged in the heating combustion chamber 6A is divided into a plurality of burner blocks 34A and 34B.

[0040] The heating-side heat exchanger 32 corresponds to an example of a second heat exchanger and is a heat exchanger heated by the exhaust gas generated by the heating burner 33A (second burner which is a gas burner). Specifically, it is a device that acts to heat the heat medium passing through its interior by the combustion exhaust gas of the heating burner 33A. The heating-side heat exchanger 32 includes a heating-side first heat exchanger 32A and a heating-side second heat exchanger 32B. In the second combustion system unit 6, the heating-side first heat exchanger 32A is provided above the plurality of heating burners 33A, and the heating-side second heat exchanger 32B is provided above the heating-side first heat exchanger 32A. The heating-side heat exchanger 32 heats the heat medium passing through its interior by the exhaust gas (combustion exhaust gas) generated by burning gas with the plurality of heating burners 33A. The heating-side first heat exchanger 32A recovers sensible heat from the combustion exhaust gas discharged from the heating-side burner unit 33, and the heating-side second heat exchanger 32B recovers latent heat from the combustion exhaust gas discharged from the heating-side burner unit 33.

[0041] The heat medium circulation path 48 is a path for circulating the heat medium so as to pass through the heating-side heat exchanger 32, and forms the flow path of the heat medium. The heat medium circulation path 48 includes a heating high-temperature forward pipe 38A, a heating low-temperature forward pipe 38B, and a heating return pipe 38C. When the heating terminal 39A is connected as shown in FIG. 1, the flow path of the heat medium circulation path 48 is configured to circulate the heat medium through the heating high-temperature forward pipe 38A, the heating terminal 39A, and the heating return pipe 38C. When the heating terminal 39Z is connected as shown in FIG. 1, the heat medium circulation path 48, together with the terminal flow path 39X, constitutes a path for circulating the heat medium so as to circulate the heat medium through the heating low-temperature forward pipe 38B, the heat medium supply path 38F, the terminal flow path 39X of the heating terminal 39Z, and the heating return pipe 38C. The heat medium supply path 38F forms a part of the heat medium circulation path 48, and the heating circuit 3 is configured to supply the heat medium heated by the heating-side heat exchanger 32 to the terminal flow path 39X via the heat medium supply path 38F.

[0042] The heating circuit 3 further includes an expansion tank 36, a heating circulation pump 37, a heating high-temperature thermostat 40, and a heating low-temperature thermostat 41. The heating high-temperature forward pipe 38A is connected to the outlet of the heating-side heat exchanger 32 (specifically, the outlet of the first heating-side heat exchanger 32A). The heating high-temperature forward pipe 38A is a pipe for flowing the heat medium from the heating-side heat exchanger 32 toward the heating terminal 39A. The heating high-temperature forward pipe 38A is configured to communicate with the heating terminal 39A and is connected so as to be able to flow the heat medium to the heating terminal 39A.

[0043] The heating return pipe 38C is connected to the inlet of the heating-side heat exchanger 32 (specifically, the inlet of the second heating-side heat exchanger 32B). The heating return pipe 38C is a pipe for flowing the heat medium that has exited from the heating terminal 39A, the heating terminal 39Z, etc. toward the heating-side heat exchanger 32. The heating return pipe 38C is configured to communicate with the heating terminal 39A and the heating terminal 39Z and is connected so as to be able to introduce the heat medium from the heating terminal 39A and the heating terminal 39Z.

[0044] Between the outlet of the second heat exchanger 32B on the heating side and the inlet of the first heat exchanger 32A on the heating side, intermediate pipes 38D and 38E are provided, and an expansion tank 36 and a heating circulation pump 37 are provided in the paths of the intermediate pipes 38D and 38E. The intermediate pipe 38D is provided between the outlet of the second heat exchanger 32B on the heating side and the expansion tank 36, and the intermediate pipe 38E is provided between the expansion tank 36 and the inlet of the first heat exchanger 32A on the heating side. A heating circulation pump 37 is provided in the middle of the intermediate pipe 38E.

[0045] A heating low-temperature forward pipe 38B branches off from a position downstream of the heating circulation pump 37 in the intermediate pipe 38E, and a plurality of heat medium supply paths 38F are provided in a configuration branched from the heating low-temperature forward pipe 38B. A thermostatic valve 39G is provided in each heat medium supply path 38F as a valve for opening and closing each heat medium supply path 38F. In the example of FIG. 1, one heat medium supply path 38F communicates with a terminal flow path 39X provided in a heating terminal 39Z, and is connected so as to supply heat medium from this heat medium supply path 38F to the heating terminal 39Z. In the example of FIG. 1, the opening at the end (specifically, the lower end) of each heat medium supply path 38F is the outlet of the heat medium from each heat medium supply path 38F. The downstream side of the heating terminal 39Z communicates with the heating return pipe 38C on the downstream side of the heating terminal 39A. The heating terminal 39A is, for example, a high-temperature heating terminal such as a heating blower that blows warm air into a bathroom or a dressing room, and includes a terminal flow path 39C through which a heat medium is introduced and flows, and functions to dissipate the heat of the heat medium flowing through the terminal flow path 39C to warm the outside. The heating terminal 39Z is, for example, a low-temperature heating terminal such as floor heating in a dressing room, and includes a terminal flow path X through which a heat medium is introduced and flows, and functions to dissipate the heat of the heat medium flowing through the terminal flow path X to warm the outside.

[0046] The heating high-temperature thermistor 40 is provided in the heating high-temperature forward pipe 38A on the outlet side of the heating-side heat exchanger 32, and detects the temperature of the heat medium flowing out from the heating-side heat exchanger 32 (specifically, the heat medium flowing out from the heating-side first heat exchanger 32A). The temperature detected by the heating high-temperature thermistor 40 corresponds to the temperature of the heat medium flowing into the heating terminal 39A during the circulation of the heat medium passing through the heating terminal 39A. The heating low-temperature thermistor 41 is provided in the expansion tank 36. The temperature detected by the heating low-temperature thermistor 41 corresponds to the temperature of the heat medium flowing into the heating terminal 39Z during the circulation of the heat medium passing through the heating terminal 39Z.

[0047] The heating circuit 3 includes a plurality of branch pipes 16B and a plurality of heating switching solenoid valves 44. As described above, the branch pipe 16B is provided in a configuration branched from the gas pipe 16 to the heating circuit 3 side. Each heating switching solenoid valve 44 is provided in each branch pipe 16B. The heating switching solenoid valve 44 is configured to switch the branch pipe 16B where it is provided between an open state (supply possible state) and a closed state (blocked state). The supply and cutoff of the fuel gas to each of the burner blocks 34A and 34B are individually switched by each heating switching solenoid valve 44. By switching the heating switching solenoid valve 44, the combustion range of the heating-side burner unit 33 is switched, and each combustion range is associated as a stage number. Note that the heating circuit 3 is also provided with an ignition electrode, a heating frame rod, and the like.

[0048] In the example of FIG. 1, the heating terminal 39A is configured as a high-temperature heating terminal, and hot water is supplied to the heating terminal 39A by the operation of the built-in thermostatic valve. The heating terminal 39Z is configured as a low-temperature heating terminal, and hot water is supplied to the heating terminal 39Z by the operation of the thermostatic valve in the appliance. In the heating circuit 3, the hot water heated by the heating-side heat exchanger 32 circulates through the heat medium circulation path 48 due to the operation of the heating circulation pump 37. Specifically, in the heating circuit 3, when the heating circulation pump 37 operates, the hot water flowing through the heating return pipe 38C is heated by the combustion exhaust gas discharged from the heating-side burner unit 33 in the heating-side second heat exchanger 32B and the heating-side first heat exchanger 32A, and when the hot water heated by the heating-side heat exchanger 32 is in a state where it can be supplied to the heating terminal 39A (when the built-in thermostatic valve of the heating terminal 39A is in the open state), it circulates through the heating high-temperature forward pipe 38A, the heating terminal 39A, and the heating return pipe 38C, and when it is in a state where it can be supplied to the heating terminal 39Z (when the built-in thermostatic valve in the corresponding appliance is in the open state), it circulates through the heating low-temperature forward pipe 38B, the heating terminal 39Z, and the heating return pipe 38C.

[0049] As shown in FIG. 1, a bath heating pipe 51 is provided in a configuration branched from the heating high-temperature forward pipe 38A. The bath heating pipe 51 branches from a position downstream of the heating-side heat exchanger 32 in the heat medium circulation path 48 (specifically, downstream of the heating-side first heat exchanger 32A), and forms a flow path for guiding the heat medium flowing through the heat medium circulation path 48 to the bath heat exchanger 50 side. The bath heating pipe 51 is connected between the heating high-temperature forward pipe 38A and the heating return pipe 38C so as to communicate with each other.

[0050] The control valve 58 is a valve provided upstream of the bath heat exchanger 50 in the bath heating pipe 51. The control valve 58 is configured to open and close the bath heating pipe 51, and is configured to switch between a closed state that blocks the water flow passing through itself in the bath heating pipe 51 and an open state that allows the water flow passing through itself in the bath heating pipe 51. The control valve 58 has a switch. This switch is configured as a limit switch, and enters a first state in which a predetermined first signal (for example, an on signal) is output when the control valve 58 reaches the fully open state where it is most open, and enters a second state in which a second signal (for example, an off signal) different from the first signal is output when the control valve 58 is in the fully closed state where it is blocked.

[0051] The water heater 1 further includes a control device 70, a hot water supply remote controller 71, a bath remote controller 72, and a room temperature thermistor (not shown). The control device 70 is an electronic control device including an information processing device such as a CPU, a memory such as a semiconductor memory device, an interface circuit, etc., and functions as a controller that performs various controls. Various programs, data tables, set values, etc. are stored in the memory. The control device 70 is configured to be able to acquire signals from each sensor and switch (thermistor, water volume sensor, switch, etc.), and controls the hot water supply circuit 2, the heating circuit 3, the bath circuit 4, etc. The room temperature thermistor is provided as a means for detecting the air temperature that detects the temperature in the dressing room, for example, in the dressing room.

[0052] 2. Basic operations of the water heater 1 (Normal hot water supply operation) For example, when the operations of the heating circuit 3 and the bath circuit 4 are stopped, if a hot water tap provided outside the apparatus to communicate with the hot water supply pipe 10 is opened and water flows into the appliance, and when the water volume sensor 14 outputs a signal indicating water flow, the control device 70 rotates the fan 20 for a predetermined time to discharge the combustion exhaust gas stored in the hot water supply combustion chamber 5A (pre-purge). Thereafter, the control device 70 opens the main gas solenoid valve 17 and each switching valve 19 of the gas pipe 16, and opens the gas proportional valve 18 at a predetermined opening degree, and controls to supply gas to each hot water burner 8A, and operates the igniter to ignite the hot water burner 8A. When gas is burned by the hot water burner 8A by such control, the water passing through the hot water supply side heat exchanger 7 is heated by the combustion exhaust gas generated by the combustion and flows to the hot water supply pipe 10, and a hot water supply operation is performed so that the heated hot water is discharged from the above hot water tap.

[0053] During the above hot water supply operation, the control device 70 monitors the hot water supply temperature detected by the thermistor 15B provided in the hot water supply pipe 10, and performs opening / closing control of the switching valve 19 and adjustment of the opening degree of the gas proportional valve 18 so that the hot water supply temperature becomes the set temperature indicated by the hot water supply remote controller 71 or the bath remote controller 72, and continuously changes the air volume by controlling the rotation speed of the fan 20. When the above hot water tap is closed during the above hot water supply operation and the signal output by the water volume sensor 14 becomes a signal indicating a water flow stop state, and when the operations of the heating circuit 3 and the bath circuit 4 are stopped, the control device 70 closes the main gas solenoid valve 17 and the switching valve 19 to extinguish the hot water burner 8A, and rotates the fan 20 for a predetermined time to perform post-purge.

[0054] (Automatic hot water filling operation) The control device 70 can perform control to automatically fill the bathtub 52 with hot water. For example, when the hot water filling switch provided on the hot water supply remote control 71 or the bathtub remote control 72 is pressed, the control device 70 sets the hot water outlet temperature to the hot water filling temperature set by the hot water supply remote control 71 or the bathtub remote control 72 as the target temperature (e.g., 40°C) and starts hot water filling. Specifically, the control device 70 opens the hot water supply solenoid valve 60 of the drop pipe 59 to put the hot water supply circuit 2 in a water flow state, and burns the hot water supply burner 8A so that the heated hot water flows into the hot water outlet pipe 10. The hot water flowing through the hot water outlet pipe 10 in this way is supplied to the bathtub 52 through the drop pipe 59 and the bathtub return pipe 54.

[0055] After the control device 70 starts supplying hot water to the bathtub 52 in this way, it monitors whether the water volume detected by the drop water volume sensor 61 provided in the drop pipe 59 (total water volume since the start of automatic hot water filling) has reached the set water volume. When it is confirmed that it has reached, the hot water supply solenoid valve 60 is closed to stop the water flow, and the hot water supply burner 8A is extinguished to end the hot water filling. After that, the control device 70 operates the bathtub circulation pump 55 to circulate the hot water in the bathtub 52 in the bathtub circuit 4. During this circulation, the heating circuit 3 is operated and the control valve 58 is opened. After the control device 70 starts such a circulation operation after hot water filling, it monitors whether the hot water temperature detected by the bathtub return thermistor 65 has reached the target temperature. When it is confirmed that it has reached, the bathtub circulation pump 55 is stopped to end the automatic hot water filling. When the control device 70 ends the automatic hot water filling, it notifies the hot water supply remote control 71 or the bathtub remote control 72 of the end of the automatic hot water filling.

[0056] (Automatic reheating operation) The control device 70 can perform control to automatically reheat (boil up) the water stored in the bathtub 52. For example, when the reheat switch provided on the hot water supply remote controller 71 or the bath remote controller 72 is pressed, the control device 70 sets the reheat temperature to the target temperature (e.g., 40°C) set on the hot water supply remote controller 71 or the bath remote controller 72 and starts the reheat. Specifically, the control device 70 ignites the heating burner 33A, opens the control valve 58, operates the bath circulation pump 55, and performs reheat by heating with the bath heat exchanger 50 while circulating the hot water in the bathtub 52. After starting such reheat, the control device 70 monitors whether the hot water temperature detected by the bath return thermistor 65 has reached the target temperature, and when it is confirmed that the temperature has reached, stops the bath circulation pump 55 and ends the reheat. When the control device 70 ends the reheat, it notifies the hot water supply remote controller 71 or the bath remote controller 72 of the end of the reheat.

[0057] (Heating operation) The control device 70 can perform a heating operation to supply a heat medium (e.g., hot water) to the heating terminal 39A or the heating terminal 39Z that functions as a heat dissipation terminal. For example, when the condition for supplying the heat medium to the heating terminal 39A is satisfied (e.g., when a heating instruction is received from the remote controller corresponding to the heating terminal 39A), the control device 70 ignites the heating burner 33A, operates the pump 37, and supplies the heat medium heated by the heating side heat exchanger 32 to the heating terminal 39A. Also, when the condition for supplying the heat medium to the heating terminal 39Z is satisfied (e.g., when a heating instruction is received from the remote controller corresponding to the heating terminal 39Z), the control device 70 ignites the heating burner 33A, operates the pump 37, opens the thermostatic valve 39G corresponding to the heating terminal 39Z, and supplies the heat medium heated by the heating side heat exchanger 32 to the heating terminal 39Z.

[0058] 3. Configuration of the housing 100 The hot water and heating unit 1 has an appearance as shown in Fig. 2 and includes a housing 100. The housing 100 constitutes the outer shell of the hot water and heating unit 1. Specifically, the housing 100 constitutes the front portion, upper portion, both side portions, rear portion, and bottom portion of the hot water and heating unit 1. The housing 100 is constituted of, for example, mostly or entirely a metal material. As shown in Fig. 2, the housing 100 has a housing body 102 (see Figs. 2 and 4) with an open front end side and a front cover 101 (Figs. 2 and 3) that opens and closes the housing body 102 from the front side. The housing 100 houses various components such as the hot water circuit 2, the bath circuit 4, and the heating circuit 3 shown in Fig. 1.

[0059] The housing 100 is box-shaped as a whole. As shown in Fig. 4, the housing body 102 includes an upper panel 102A, a pair of side panels 102B, 102C, a rear panel 102D, and a bottom panel 110. Each of the upper panel 102A, the pair of side panels 102B, 102C, the rear panel 102D, and the bottom panel 110 is configured in a plate shape and is constituted as a metal plate by, for example, a metal material. The front end portions of the upper panel 102A, the pair of side panels 102B, 102C, and the bottom panel 110 form a front opening 104. As shown in Figs. 2 and 4, the front cover 101 is attached to the housing body 102 so as to cover and close the front opening 104 formed in the housing body 102 from the front side. The pair of side panels 102B, 102C extend from one side in the vertical direction to the other side and are arranged with the vertical direction as their respective longitudinal directions. The upper panel 102A and the bottom panel 110 extend from one side in the horizontal direction to the other side and are arranged with the horizontal direction as their respective longitudinal directions. The rear panel 102D is arranged so as to close the rear end side of the annular body constituted by the pair of side panels 102B, 102C, the upper panel 102A, and the bottom panel 110. The front opening 104 is the opening at the front end portion of the annular body.

[0060] As shown in FIGS. 2 and 3, the front cover 101 includes a main body portion 101A and a closing portion 103, and is configured in a plate shape as a whole. The front cover 101 is mounted so as to close the front opening 104, and is configured to be detached so as to open the front opening 104, and is detachably attached to the housing main body 102. The main body portion 101A is configured in a plate shape and is a portion that is detachably attached to the housing main body 102. The main body portion 101A is a portion of the front cover 101 excluding the closing portion 103. As shown in FIG. 3, the main body portion 101A has an opening 180. The opening 180 is provided in the main body portion 101A below the center position in the vertical direction of the main body portion 101A, specifically, at a position closer to the lower end portion of the main body portion 101A.

[0061] In this specification, the direction in which the pair of side plates 102B and 102C extend is the vertical direction. Specifically, it is arranged such that the vertical direction when the water heater 1 is installed is the vertical direction. In the overlapping plate 140 described later, the plate thickness direction of the flat plate portion 142 is the vertical direction, and the direction orthogonal to the upper plate surface of the flat plate portion 142 is the vertical direction. In this specification, the predetermined direction orthogonal to the above vertical direction is the front-rear direction. In the example shown in FIG. 2 and the like, the direction orthogonal to the flat surface constituting a part of the front surface of the main body portion 101A is the front-rear direction. The direction orthogonal to the above vertical direction and orthogonal to the above front-rear direction is the left-right direction. In the example shown in FIG. 3 and the like, the direction in which the pair of side plates 102B and 102C face each other is the left-right direction, and the longitudinal direction of the bottom plate 110 (the direction in which the bottom plate 110 extends) is the left-right direction.

[0062] As shown in FIG. 2, the closing portion 103 is configured in a plate shape and is attached so as to close the opening 180 of the main body portion 101A. The closing portion 103 is made of, for example, a metal plate. A sealing material for enhancing waterproofness may be disposed between the back surface of the closing portion 103 and the front surface of the main body portion 101A (specifically, the front surface around the opening 180).

[0063] As shown in FIG. 4, a plurality (six in the example of FIG. 4) of thermostatic valves 39G are provided at predetermined positions of the housing 100. Each thermostatic valve 39G is configured to switch each heat medium supply path 38F shown in FIGS. 1 and 5 between a shut-off state (a state in which the heat medium cannot be released to the outside through the heat medium supply path 38F) and an open state (a state in which the heat medium can be released to the outside through the heat medium supply path 38F). Each heat medium supply path 38F is configured to be connectable in such a way that a terminal flow path 39X of a heating terminal 39Z provided outside the hot water heating apparatus 1 communicates therewith. In the example of FIG. 5, up to six heating terminals 39Z can be connected to each of the six heat medium supply paths 38F. In the example of FIG. 1, the heat medium supply path 38F and the terminal flow path 39X are connected in such a way that the heat medium can flow from the outlet (opening) at the end of one heat medium supply path 38F into the terminal flow path 39X. As described above, the heating circuit 3 includes a heating burner 33A that burns gas, and a heating-side heat exchanger 32 that heats the heat medium flowing through the heat medium circulation path 48 by the combustion exhaust generated by the combustion of the heating burner 33A. The heat medium supply path 38F forms a part of the heat medium circulation path 48, and the heat medium heated by the heating burner 33A is supplied to the terminal flow path 39X through the heat medium supply path 38F.

[0064] 4. Configuration regarding the bottom plate 110 and the overlapping plate 140 As shown in Fig. 6, below a plurality of thermostatic valves 39G, a plate-shaped laminated plate 140 (specifically, a first laminated plate 140A) is fixed to the upper surface of the bottom plate 110 in a configuration sandwiched between the plurality of thermostatic valves 39G and the bottom plate 110. The laminated plate 140 (first laminated plate 140A) is selected from a plurality of types of laminated plates 140 with different combinations of the number and arrangement of the second hole portions 146 by the manufacturing method described later, and is of a type corresponding to the number and arrangement of the heat medium supply paths 38F of the hot water heating machine 1 to be applied. The plurality of types of laminated plates 140 that are candidates for adoption in the manufacturing method described later have a configuration (the configurations of Figs. 7, 16, and 19) with a plurality of second hole portions 146 communicating with the first hole portion 116 described later or do not have such a configuration (the configuration of Fig. 23), and are to be overlapped at a predetermined position on the bottom plate 110. This predetermined position is a region inside the outer edge of the portion of the bottom plate 110 where the laminated plate 140 is to be overlapped (specifically, the outer edge of the portion of the bottom plate 110 where the flat plate portion 142 is to be overlapped). The laminated plates 140 in Figs. 7 and 10 are the first laminated plates 140A. The laminated plates 140 in Figs. 11 and 16 are the second laminated plates 140B. The laminated plates 140 in Figs. 12 and 19 are the third laminated plates 140C. The laminated plates 140 in Figs. 13 and 23 are the fourth laminated plates 140D. The configurations of the portions other than the flat plate portion 142 are the same for all of the first to fourth laminated plates 140A, 140B, 140C, and 140D. Further, the outer shapes of the first to fourth laminated plates 140A, 140B, 140C, and 140D are common shapes. Specifically, the shapes of the outer edges of the flat plate portions 142 of the first to fourth laminated plates 140A, 140B, 140C, and 140D are the same. The positions where the respective flat plate portions 142 of the first to fourth laminated plates 140A, 140B, 140C, and 140D are arranged on the bottom plate 110 are the same. That is, for any of the hot water heating machines 1 of specifications 1 to 4, the outer edge positions of the flat plate portions 142 on the bottom plate 110 are the same positions.

[0065] As shown in FIGS. 7 and 8, the overlapping plate 140 includes a flat plate portion 142 configured in a flat plate shape, a first rising portion 148 provided so as to bend from the flat plate portion 142 at a site where the wiring portion L is attached, and a second rising portion 149 provided so as to bend from the flat plate portion 142 while being fixed in contact with the bottom plate 110. The overlapping plate 140 is a metal plate made of, for example, a metal material, and a part of it is bent.

[0066] As shown in FIGS. 6 and 7, the flat plate portion 142 is arranged so as to be overlapped on the upper side of the bottom plate 110. In the present embodiment, the bottom plate 110 is configured in a plate shape, specifically, as a longitudinally extending metal plate extending in the left - right direction. One plate surface of the bottom plate 110 is an upper surface facing upward, which is the bottom surface of the inner wall surface of the housing 100. The other plate surface of the bottom plate 110 is a lower surface facing downward, which is the lower surface of the outer wall surface of the housing 100. On the other hand, the flat plate portion 142 is configured as a metal plate. In the configuration of FIGS. 6 and 7, the flat plate portion 142 and the bottom plate 110 are overlapped in such a way that the lower plate surface of the flat plate portion 142 is in contact with the upper surface of the bottom plate 110. And, thermostatic valve related components including a plurality of thermostatic valves 39G and the components around them are arranged in contact with the upper surface of the flat plate portion 142. In the configuration of FIGS. 6 and 7, the flat plate portion 142 is provided with a plurality of second hole portions 146 for inserting the heat medium supply path 38F and a through - hole 147 for inserting the drain channel 90 for draining water. On the other hand, the bottom plate 110 is provided with a first hole portion 116 constituting an opening region overlapping the opening region of the plurality of second hole portions 146, and a through - hole 117 constituting an opening region overlapping the opening region of the through - hole 147. The lower end portion of each heat medium supply path 38F is configured in a shaft shape and is arranged so as to project downward through the first hole portion 116 while being inserted into each second hole portion 146. The drain channel 90 for draining water is arranged so as to project downward through the through - hole 117 while being inserted into the through - hole 147.

[0067] As shown in FIGS. 6 to 8, the second rising portion 149 is configured as a metal bent piece bent so as to protrude upward from the flat plate portion 142. On the other hand, as shown in FIGS. 6 and 7, the bottom plate 110 is provided with a third rising portion 119 which is configured to be cut out in the bottom plate 110. The third rising portion 119 is connected to a plate-like portion around the third rising portion 119 in the bottom plate 110 (the bottom plate main body 110A which is a portion other than the third rising portion 119 in the bottom plate 110), and is provided as a metal piece protruding upward from the bottom plate main body 110A. The second rising portion 149 is configured to be overlapped front and rear while contacting the third rising portion 119 provided on the bottom plate 110, and is fixed to the third rising portion 119 by a second connecting member 192 such as a screw. The second connecting member 192 is preferably made of a metal material having conductivity. The second rising portion 149 contacts the third rising portion 119, and the bottom plate 110 and the overlapping plate 140 are electrically connected so as to be short-circuited and kept at the same potential. Note that the overlapping plate 140 may be short-circuited by direct contact between the conductors with respect to the bottom plate 110, or the overlapping plate 140 and the bottom plate 110 may be short-circuited via a conductive second connecting member 192. Specifically, the housing 100 and the overlapping plate 140 are kept at, for example, about the same ground potential (for example, 0V).

[0068] As shown in FIG. 6, the first rising portion 148 is a portion for attaching the wiring portion L. In FIGS. 6 and 9, the wiring portion L is conceptually shown by a two-dot chain line. As shown in FIGS. 6 to 8, the first rising portion 148 is configured as a bent piece of metal bent from the flat plate portion 142, and is provided at a position in front of the hole portion 112 (specifically, the front end portion of the overlapping plate 140) in the overlapping plate 140 as shown in FIG. 6. The wiring portion L is, for example, a ground wire, and is a wiring electrically connected in a configuration short-circuited to a grounding portion (a portion maintained at a ground potential) provided outside the hot water supply and heating machine 1. The wiring portion L has, for example, a conductor exposed near the first rising portion 148, and this conductor continues from one end side to the other end side of the wiring portion L, and portions such as near the guide member 80 and the lower side thereof are covered with an insulating material (for example, a resin material). The wiring portion L is configured to pass through a guide member 80 to be described later and is attached so as to straddle the inside and outside of the housing body 102. Since the first rising portion 148 is electrically connected in a configuration short-circuited to the housing 100, when the wiring portion L is attached to the first rising portion 148 and the first rising portion 148 is grounded, the entire housing 100 is in a grounded state.

[0069] As shown in FIGS. 4 and 6, in the overlapping plate 140, a fourth rising portion 150 is provided at a position different from the above-mentioned ground wire (earthing wire). The fourth rising portion 150 is configured as a metal bent piece bent from the flat plate portion 142 and is provided at the front end portion of the overlapping plate 140 as shown in FIG. 6. The fourth rising portion 150 is arranged with one plate surface (mounting surface) facing forward. The fourth rising portion 150 is, for example, configured such that a ground wire (earthing wire) provided inside the water heater 1 can be fixed thereto, and the ground wire (earthing wire) is electrically connected in a configuration where it is short-circuited to the fourth rising portion 150, so that the ground wire (earthing wire) and the wiring portion L can be short-circuited. The structure for connecting the ground wire (earthing wire) to the fourth rising portion 150 may be the same as the structure for connecting the wiring portion L to the first rising portion 148, and may be different as long as it is a fixing structure that ensures electrical connection between the ground wire (earthing wire) and the fourth rising portion 150. If the ground wire (earthing wire) is electrically connected to the fourth rising portion 150 and the wiring portion L is electrically connected to the ground wire (earthing wire), the ground wire (earthing wire) and the wiring portion L are kept at the same potential, and are also kept at the same potential in relation to the housing 100.

[0070] As shown in FIG. 9, a through hole 112 is provided in the bottom plate 110 of the housing body 102. The hole 112 is configured to penetrate in the thickness direction of the bottom plate 110 formed in a plate shape, and communicates the space below the bottom plate 110 and the space above.

[0071] As shown in FIG. 9, the guide member 80 is a member attached to the bottom plate 110 and is a member that constitutes a path for the wiring portion L to pass through. The guide member 80 is also a member that guides the wiring portion L forward when the wiring portion L is attached. The guide member 80 is fixed to the bottom plate 110 in a configuration where it is inserted through the hole 112 from the outside (specifically, the lower side) of the housing 100. The guide member 80 includes a roof-shaped upper guide portion 87 that is a portion inserted into the hole 112 during installation, a flange-shaped opposing portion 88 that is a portion facing the lower surface of the bottom plate 110, and a cylindrical lower guide portion 89 provided below the opposing portion 88.

[0072] As shown in FIG. 9, the guide member 80 has an insertion path 82 through which the wiring portion L is inserted, and further includes an introduction port 82A for introducing the wiring portion L into the insertion path 82 and a discharge port 82B for discharging the wiring portion L from within the insertion path 82. The insertion path 82 is provided in each of the lower guide portion 89, the opposing portion 88, and the upper guide portion 87 and constitutes a continuous space passing through each of them. The introduction port 82A is an opening that forms the entrance at the lower end of the insertion path 82 and is configured as an opening at the lower end of the lower guide portion 89. The discharge port 82B is an opening that forms the exit on the upper side and the front side of the insertion path 82 and is configured as an opening on the upper side and the front side in the upper guide portion 87. Inside the insertion path 82 provided in the guide member 80, an insertion space 83 through which the wiring portion L passes extends from the introduction port 82A provided at a position lower than the bottom plate 110 to the discharge port 82B. The discharge port 82B is provided in the guide member 80 on the front side of the hole portion 112 and functions as an exit for discharging the wiring portion L from within the insertion path 82.

[0073] As shown in FIG. 3, in a state where the closing portion 103 (FIG. 2) is removed from the main body portion 101A of the front cover 101, the external space on the front side of the front cover 101 and the internal space in the housing main body 102 communicate with each other through the opening 180. And, as shown in FIG. 3, the guide member 80 is attached at a position near the front end of the bottom plate 110 on the rear side of the opening 180 (see also FIGS. 6 and 10). On the other hand, as shown in FIGS. 3 and 9, the first rising portion 148 has an attachment surface 148A for contacting the wiring portion L and attaching the first connecting member 190 (FIG. 3) disposed on the front side and the upper side at a position near the opening 180 and in front of the lead-out port 82B of the guide member 80. The attachment surface 148A is the front surface of the first rising portion 148 and is an inclined surface inclined with respect to the vertical direction. The attachment surface 148A is disposed facing the opening region side of the opening 180. As shown in FIG. 9, while the wiring portion L is in contact with the attachment surface 148A, the wiring portion L is attached to the first rising portion 148 by the first connecting member 190 (see FIG. 3, omitted in FIG. 9). The wiring portion L has, for example, a conductor exposed near the first rising portion 148, and this conductor extends from one end side to the other end side of the wiring portion L, and portions near the guide member 80 and below it are covered with an insulating material (for example, a resin material). For example, the conductor portion of the wiring portion L near the attachment surface 148A is fixed while being sandwiched between the screw head portion of the first connecting member 190 and the attachment surface 148A, and is electrically connected in a configuration that shorts to the first connecting member 190 or the attachment surface 148A. In a representative example, the screw portion (the portion where the screw groove is formed) of the first connecting member 190 and the screw hole (the portion into which the first connecting member 190 is inserted) in the first rising portion 148 are electrically connected in a configuration that shorts.

[0074] 5. Manufacturing Method The following description relates to a manufacturing method of the hot water heater 1. The manufacturing method of the hot water heater 1 mainly includes a determination step, a selection step, and an assembly step. Other than these steps, known techniques of the manufacturing method of the hot water heater can be adopted.

[0075] The determination step is a step of determining the number and arrangement of the heat medium supply paths 38F provided at a predetermined position in the heat medium circulation path 48. As a premise of this manufacturing method, a plurality of types of specifications of the hot water and heating unit 1 are prepared. Specifically, including the hot water and heating unit 1 (specification 1) disclosed in FIGS. 1 to 9, four types of hot water and heating units 1 (specifications 1 to 4) are prepared as exemplified by the bottom surface configuration in FIGS. 10 to 13. These multiple types of hot water and heating units 1 have different combinations of the number and arrangement of the heat medium supply paths 38F.

[0076] Specifically, the hot water and heating unit 1 of specification 1 shown in FIGS. 1 to 9 and FIG. 10 is provided with a configuration in which six heat medium supply paths 38F are branched. As shown in FIG. 4, a thermostatic valve 39G for switching each of the six heat medium supply paths 38F between a blocked state and an open state is provided as a built-in thermostatic valve disposed within the housing 100 of the hot water and heating unit 1. In the hot water and heating unit 1 of specification 1, it is set as the "first combination" arranged in the first arrangement where six heat medium supply paths 38F are branched.

[0077] The hot water and heating unit 1 of specification 2 shown in FIGS. 11 and 14 to 16 is provided with a configuration in which three heat medium supply paths 38F are branched. As shown in FIG. 14, a thermostatic valve 39G for switching each of the three heat medium supply paths 38F between a blocked state and an open state is provided as a built-in thermostatic valve disposed within the housing 100 of the hot water and heating unit 1. The hot water and heating unit 1 of specification 2 has a configuration in which three heat medium supply paths 38F are omitted from the hot water supply circuit shown in FIG. 1. In the hot water and heating unit 1 of specification 2, it is set as the "second combination" arranged in the second arrangement where three heat medium supply paths 38F are branched.

[0078] The hot water and heating unit 1 of specification 3 shown in FIGS. 12 and 17 to 20 is provided with one heat medium supply path 38F. As shown in FIGS. 12 and 20, a thermostatic valve 39G for switching one heat medium supply path 38F between a blocked state and an open state is provided as an external thermostatic valve disposed outside the housing 100 of the hot water and heating unit 1. The hot water and heating unit 1 of specification 3 has a configuration in which five heat medium supply paths 38F are omitted from the hot water supply circuit shown in FIG. 1. In the hot water and heating unit 1 of specification 3, it is set as the "third combination" which is the third arrangement where one heat medium supply path 38F protrudes.

[0079] The water heater 1 of Specification 3 shown in FIGS. 13 and 21 to 23 has a configuration in which the heat medium supply path 38F is not provided. Therefore, the heat medium supply path 38F is not arranged at the position of the laminated plate 140. The water heater 1 of Specification 4 has a configuration in which six heat medium supply paths 38F are omitted from the hot water supply circuit of FIG. 1. In the water heater 1 of Specification 3, it is regarded as the "fourth combination" where the heat medium supply path 38F does not exist (the number of heat medium supply paths is 0 and there is no arrangement).

[0080] As shown in FIGS. 10 to 13, at least the bottom plate 110 of the housing 100 is made common so that the bottom plate 110 can be applied to all of Specifications 1 to 4. The bottom plate 110 covers the positions of all the heat medium supply paths 38F in a plurality of combinations assumed in Specifications 1 to 4, and the first hole 116 is provided so that the heat medium supply path 38F can be inserted at the positions of all the heat medium supply paths 38F (see FIGS. 10 to 13).

[0081] On the basis of such a premise, in the determination process, the combination of the number and arrangement of the heat medium supply paths 38F is selected from a plurality of prepared combinations. For example, when manufacturing the water heater 1 of Specification 1, the combination of six heat medium supply paths 38F and their arrangement (the first combination) as shown in FIG. 10 is selected. When manufacturing the water heater 1 of Specification 2, the combination of three heat medium supply paths 38F and their arrangement (the second combination) as shown in FIG. 11 is selected. When manufacturing the water heater 1 of Specification 3, the combination of one heat medium supply path 38F and its arrangement (the third combination) as shown in FIG. 12 is selected. When manufacturing the water heater 1 of Specification 4, the combination (the fourth combination) of a configuration without a heat medium supply path 38F (a configuration where the number of heat medium supply paths 38F is 0 and there is no arrangement) as shown in FIG. 13 is selected.

[0082] In this manufacturing method, a selection step is performed after the determination step. The selection step is a step of selecting a stacked plate 140 corresponding to the number and arrangement of the heat medium supply paths 38F determined in the determination step from among a plurality of types of stacked plates 140 having different combinations of the number and arrangement of the second hole portions 146. Specifically, as shown in FIG. 7 (specification 1), FIG. 16 (specification 2), FIG. 19 (specification 3), and FIG. 23 (specification 4), stacked plates 140 corresponding to each specification are prepared. In the examples of FIGS. 7 to 9, the stacked plate 140 of the hot water heater 1 of specification 1 is the first stacked plate 140A. In the examples of FIGS. 10, 15, and 16, the stacked plate 140 of the hot water heater 1 of specification 2 is the second stacked plate 140B. In the examples of FIGS. 11, 17 to 20, the stacked plate 140 of the hot water heater 1 of specification 3 is the third stacked plate 140C. In the examples of FIGS. 12, 21 to 23, the stacked plate 140 of the hot water heater 1 of specification 4 is the fourth stacked plate 140D. And the plurality of types (here, four types) of stacked plates 140 to be selected in the selection step have a common outer shape (see also the broken lines in FIGS. 10 to 13).

[0083] When it is determined by the determination step to provide one or more heat medium supply passages 38F at a predetermined position (when any one of Specifications 1 to 3 is determined), a laminated plate 140 having second hole portions 146 corresponding to the number and arrangement of the heat medium supply passages 38F determined by the determination step is selected. When there are first hole portions 116 through which the heat medium supply passages 38F are not inserted (when any one of Specifications 2 to 4 is determined), a laminated plate 140 configured to block the first hole portions 116 is selected by the selection step. For example, when it is determined by the determination step to adopt "Specification 1" in which six heat medium supply passages 38F are provided at the above-mentioned predetermined position, a first laminated plate 140A having second hole portions 146 corresponding to the number and arrangement of the heat medium supply passages 38F of Specification 1 determined by the determination step is selected. Alternatively, when it is determined by the determination step to adopt "Specification 2" in which three heat medium supply passages 38F are provided at the above-mentioned predetermined position, a second laminated plate 140B having second hole portions 146 corresponding to the number and arrangement of the heat medium supply passages 38F of Specification 2 determined by the determination step is selected. The second laminated plate 140B is provided with three second hole portions 146 so as to enable the three heat medium supply passages 38F to be inserted through the positions of the three heat medium supply passages 38F, and a portion for blocking the first hole portions 116 is provided at a position where there are no heat medium supply passages 38F among the plurality of first hole portions 116.

[0084] In the manufacturing method, after the selection step, an assembling step is performed. The assembling step is a step of overlapping and assembling the laminated plate 140 selected by the selection step at a predetermined position of the bottom plate 110. When any one of Specifications 1 to 3 is selected, in the assembling step, with the laminated plate 140 overlapped at a predetermined position of the bottom plate 110 so as to communicate the first hole portions 116 and the second hole portions 146, the heat medium supply passages 38F are inserted into the first hole portions 116 and the second hole portions 146. For example, when it is determined by the determination step to adopt Specification 1 and the first laminated plate 140A is selected by the selection step, in the assembling step, as shown in FIG. 6, with the laminated plate 140 overlapped at the above-mentioned predetermined position of the bottom plate 110 so as to communicate the first hole portions 116 and the second hole portions 146, six heat medium supply passages 38F are inserted into the first hole portions 116 and the second hole portions 146 as shown in FIGS. 4 and 10 for assembling.

[0085] The assembly process may include a connection process of connecting a wiring part L (ground wire) inside the water heater 1, and the connection process may be performed during construction. As described above, the housing 100 has a housing body 102 with an open front end side and accommodating the heating circuit 3, and a front cover 101 that opens and closes the housing body 102 from the front side (see Fig. 3). As shown in Figs. 2 and 3, the front cover 101 has a main body part 101A having an opening 180 and being detachable from the housing body 102, and a closing part 103 attached so as to close the opening 180 of the main body part 101A. The opening 180 is provided at least at a position near the lower end of the main body part 101A. In such a configuration, in a state where the closing part 103 is removed from the main body part 101A, the external space in front of the front cover 101 and the internal space in the housing body 102 communicate with each other through the opening 180. On the front end side of the laminated plate 140, a first rising part 148 rising above the bottom plate 110 is provided and is arranged at a position where operation and work are easy. And in the connection process, the wiring part L (ground wire) is connected to the first rising part 148 by a first connecting member 190 (see Figs. 3 and 9).

[0086] On the other hand, on the side of the laminated plate 140, a second rising part 149 rising above the bottom plate 110 is provided. The bottom plate 110 includes a bottom plate main body 110A constituting the bottom surface part of the water heater 1 and a third rising part 119 rising upward from the bottom plate main body 110A. In the assembly process, in a state where the second rising part 149 and the third rising part 119 are overlapped, a second connecting member 192 having conductivity is inserted through the second rising part 149 and the third rising part 119 so as to connect them, and the laminated plate 140 and the bottom plate 110 are electrically connected (see Figs. 6 and 9).

[0087] 6. Examples of effects The manufacturing method of the above-described hot water supply and heating machine 1 can achieve standardization of the bottom plate 110 of the housing 100 even when manufacturing hot water supply and heating machines 1 with different numbers and arrangements of the heat medium supply paths 38F, making it easy to reduce manufacturing costs. On the other hand, even if the number and arrangement of the heat medium supply paths 38F near a predetermined position (the position where the overlapping plate 140 is attached) vary depending on the specifications, an overlapping plate 140 corresponding to the number and arrangement of the heat medium supply paths 38F can be used, so that optimization can be achieved according to the specifications.

[0088] In the above-described manufacturing method, when it is determined by the determination step to provide one or more heat medium supply paths 38F at a predetermined position, an overlapping plate 140 having second hole portions 146 corresponding to the number and arrangement of the heat medium supply paths 38F is selected by the selection step, and the overlapping plate 140 can be arranged so that the heat medium supply paths 38F are inserted through the first hole portions 116 and the second hole portions 146. Also, depending on the number and arrangement determined by the determination step, there may be first hole portions 116 through which the heat medium supply paths 38F are not inserted. In such a case, in the selection step, an overlapping plate 140 configured to block the non-inserted first hole portions 116 is selected, so that even if there are first hole portions 116 that become unnecessary depending on the specifications, appropriate measures can be taken to block the unnecessary first hole portions 116.

[0089] In the above-described manufacturing method, since the outer shapes of the plurality of types of overlapping plates 140 to be selected in the selection step are common shapes, the manufacturing costs can be further reduced.

[0090] In the above-described manufacturing method, regardless of which combination is selected and which type of overlapping plate 140 is selected, it is possible to connect the wiring portion L (ground wire) to the first rising portion 148 provided on the front end side. Also, since the first rising portion 148 is provided on the front end side of the overlapping plate 140 and an opening 180 (see FIG. 3) is provided at a position near the lower end portion of the front cover 101, in a state where the closing portion 103 is not attached, it is easy to perform operations such as attaching the wiring portion L (ground wire) to the first rising portion 148 through the opening 180.

[0091] The above-described manufacturing method can achieve electrical connection by means of a simple connection structure in which the second connecting member 192 is inserted through the second rising portion 149 and the third rising portion 119 in a superposed state. Even if electrical connection is not ensured or is difficult to ensure on the plate surfaces of the overlapping plate 140 and the bottom plate 110, if electrical connection with the second connecting member 192 is ensured in the second rising portion 149 and the third rising portion 119, the overlapping plate 140 and the bottom plate 110 can be surely electrically connected and kept at the same potential.

[0092] <Other Embodiments> The present invention is not limited to the embodiments described above with reference to the description and drawings. For example, the features of the above-described or below-described embodiments can be combined in any combination within a non-contradictory range. Also, any feature of the above-described or below-described embodiments can be omitted if it is not explicitly specified as essential. Furthermore, the above-described embodiments may be modified as follows.

[0093] In the above-described embodiments, four types of water heaters with different combinations of the number and arrangement of the heat medium supply paths are exemplified, but other arrangements and combinations may be adopted. Also, the combination is not limited to four types, and may be three types or less, or five types or more.

[0094] In the above-described embodiments, the wiring portion L is connected to the first rising portion 148, but the wiring portion L may not be connected.

[0095] It should be considered that all aspects of the embodiments disclosed this time are illustrative and not restrictive. The scope of the present invention is not limited to the embodiments disclosed this time, and it is intended that all modifications within the scope indicated by the claims or within the scope equivalent to the claims are included.

Description of Reference Numerals

[0096] 1: Water Heater 3: Heating Circuit 32: Heating-side heat exchanger (heat exchanger) 32A: First heating-side heat exchanger (heat exchanger) 32B: Second heating-side heat exchanger (heat exchanger) 33: Heating-side burner unit (gas burner) 33A: Heating burner (gas burner) 38F: Heat medium supply path 39A: Heating terminal (heat dissipation terminal) 39C: Terminal flow path 39G: Thermostatic valve 39X: Terminal flow path 39Z: Heating terminal (heat dissipation terminal) 48: Heat medium circulation path 100: Housing 101: Front cover 101A: Main body part 102: Housing main body 103: Closing part 110: Bottom plate 110A: Bottom plate main body 116: First hole part 117: Through hole 119: Third rising part 140: Overlapping plate 142: Flat plate part 146: Second hole part 147: Through hole 148: First rising part 148A: Mounting surface 149: Second rising part 180: Opening 190: First connecting member 192: First connecting member L: Wiring part (ground wire)

Claims

1. A manufacturing method for manufacturing a hot water heater equipped with a heat medium supply path having a heat medium outlet, and a terminal flow path provided at a heat dissipation terminal is connectable to the heat medium supply path, The hot water heater is A heat medium circulation path which is a path for circulating the heat medium together with the terminal flow path, a gas burner for burning gas, and a heat exchanger for heating the heat medium flowing through the heat medium circulation path by combustion exhaust generated by the combustion in the gas burner, the heat medium supply path constitutes a part of the heat medium circulation path, and a heating circuit for supplying the heat medium heated by the heat exchanger to the terminal flow path via the heat medium supply path, A bottom plate provided with a plurality of first holes, and a housing configured to accommodate the heating circuit, A structure having one or more second holes communicating with the first holes or not having them, and a superimposed plate that is superimposed on a predetermined position of the bottom plate, It has, A determination step of determining the number and arrangement of the heat medium supply paths provided at the predetermined position in the heat medium circulation path, A selection step of selecting the superimposed plate corresponding to the number and arrangement of the heat medium supply paths determined by the determination step from a plurality of types of the superimposed plates having different combinations of the number and arrangement of the second holes, An assembly step of superimposing and assembling the superimposed plate selected by the selection step on the predetermined position of the bottom plate, A manufacturing method of a hot water heater including

2. The first hole and the second hole are holes for passing the heat medium supply path, In the determination step, the combination of the number and arrangement of the heat medium supply paths is selected from a plurality of prepared combinations, On the bottom plate, the positions of all the heat medium supply paths in the plurality of combinations are covered, and the first holes are provided so that the heat medium supply paths can be inserted at the positions of all the heat medium supply paths. When it is determined by the determination step to provide one or more of the heat medium supply paths at the predetermined position, a laminated plate having the second hole portions corresponding to the number and arrangement of the heat medium supply paths determined by the determination step is selected by the selection step, and when there are the first hole portions through which the heat medium supply paths are not inserted, the laminated plate configured to block the first hole portions is selected by the selection step. In the assembling step, with the laminated plate superposed on the predetermined position of the bottom plate so as to communicate the first hole portion and the second hole portion, the heat medium supply paths are inserted into the first hole portion and the second hole portion. The method for manufacturing a hot water heater according to claim 1.

3. The plurality of types of laminated plates to be selected in the selection step have a common outer shape. The method for manufacturing a hot water heater according to claim 1 or claim 2.

4. The housing has a housing main body that houses the heating circuit and has an open front end side, and a front cover that opens and closes the housing main body from the front side. The front cover has a main body portion that has an opening and is attached and detached to and from the housing main body, and a closing portion that is attached so as to close the opening of the main body portion. The opening is provided at least at a position near the lower end portion of the main body portion. In a state where the closing portion is removed from the main body portion, an external space on the front side of the front cover and an internal space in the housing main body communicate with each other through the opening. A first rising portion that rises above the bottom plate is provided on the front end side of the laminated plate. The method for manufacturing a hot water heater according to claim 1 or claim 2.

5. A second rising portion that rises above the bottom plate is provided on the laminated plate side. The bottom plate includes a bottom plate main body that constitutes the bottom surface portion of the hot water heater, and a third rising portion that rises upward from the bottom plate main body. In the assembling step, with the second rising portion and the third rising portion superposed, a second connecting member having conductivity is inserted through the second rising portion and the third rising portion to connect them, and the laminated plate and the bottom plate are electrically connected. The method for manufacturing a hot water heater according to claim 1 or claim 2.

6. A hot water heater including a heat medium supply path having an outlet of a heat medium, and a terminal flow path provided at a heat dissipation terminal is connectable to the heat medium supply path. A heat medium circulation path that is a path for circulating the heat medium together with the terminal flow path, a gas burner that burns gas, and a heat exchanger that heats the heat medium flowing through the heat medium circulation path by the combustion exhaust generated by the combustion in the gas burner. The heat medium supply path constitutes a part of the heat medium circulation path, and a heating circuit that supplies the heat medium heated by the heat exchanger to the terminal flow path through the heat medium supply path. A housing including a bottom plate provided with a plurality of first hole portions and configured to accommodate the heating circuit. A structure having one or more second hole portions communicating with the first hole portions or not having them, and a superimposed plate that is superimposed on a predetermined position of the bottom plate. It has. The superimposed plate is selected from a plurality of types of superimposed plates having different combinations of the number and arrangement of the second hole portions, and is a superimposed plate corresponding to the number and arrangement of the heat medium supply paths. A hot water and heating machine.

Images