Retrofit Water Heater Control With On-Demand Recirculation
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Solution Overview
Problem
Existing water heater control systems are limited in their ability to efficiently regulate both electric and fuel-fired water heaters, lack integration with hot water recirculation systems, and require professional installation, leading to energy waste and complexity.
Innovation Solution
A backward-compatible, programmable, and on-demand water heater and recirculation pump control unit that can be retrofitted to existing systems, allowing local and remote control of both electric and fuel-fired water heaters, integrating with recirculation systems, and featuring an on-demand sensor for immediate heating activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a programmable control unit is integrated with the water heater, then energy efficiency and operational control are improved, but device complexity increases
Solution Approach 1:
The patent combines the programmable control unit, recirculation pump controller, and water heater thermostat into a single integrated control system. This merging allows the system to manage both heating operations and recirculation pumping through one unified interface, reducing energy waste by coordinating operations while avoiding the complexity of multiple separate control systems.
Solution Approach 2:
The control unit is designed to perform multiple functions: it serves as a programmable thermostat for the water heater, a controller for the recirculation pump, and an on-demand sensor system. This multi-functionality eliminates the need for separate devices for each function, reducing overall system complexity while improving energy efficiency through coordinated operation.
2Reliability
If professional installation is required for control systems, then reliability is improved, but ease of operation deteriorates
Solution Approach 1:
The control unit is designed as a modular, self-contained device that can be installed as a single unit rather than requiring complex wiring and integration of multiple components. This segmentation into a ready-to-install module maintains reliability through proven design while dramatically improving ease of installation for end users.
Solution Approach 2:
The control unit incorporates built-in programming capabilities and automatic configuration features that allow end users to install and program the system themselves without requiring professional technicians. The system performs self-diagnosis and automatic setup, maintaining reliability while enabling user-friendly installation.
3Reliability
If recirculation pump is continuously operated, then hot water availability is improved, but energy consumption increases
Solution Approach 1:
The recirculation pump operates periodically rather than continuously, being activated by the programmable timer to circulate hot water before predicted periods of high demand. This periodic operation maintains hot water availability in the system while dramatically reducing the pump's energy consumption compared to continuous operation.
Solution Approach 2:
The control unit incorporates sensors that monitor water temperature and flow conditions, using this feedback to intelligently control when the recirculation pump should operate. The system activates the pump only when conditions indicate hot water is needed, maintaining reliability of hot water supply while minimizing unnecessary energy consumption.
4Speed
If on-demand sensor activation is implemented, then responsiveness is improved, but device complexity increases
Solution Approach 1:
The on-demand sensor system is merged with the existing thermostat and control unit, using the same processor and control circuitry to handle both scheduled operations and on-demand activation. This integration provides immediate response to hot water demand while avoiding the complexity of a separate dedicated sensor system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides energy-efficient, user-friendly, and cost-effective control of water heater temperatures and recirculation pump operations, reducing energy waste and eliminating the need for professional installation.
Implementation Method 1
an on-demand sensor for immediate activation of the heating source in response to a signal
Implementation Method 2
For electric water heaters, the heating source is one or more electric heating elements which protrude horizontally from the sides of the tank into the water
Implementation Method 3
The thermostat consists of an internal (inside the tank) thermometer or other heat sensing device connected by an electrical or electronic circuit to a temperature control device
Implementation Method 4
by means of an external pump (typically powered by electricity), recirculates the water from the pipe lines back into the hot water heater
Data Source
AI summary
A programmable and on-demand hot water heater unit that locally and remotely changes the set temperature for a conventional water heater and locally and remotely activates the hot water recirculation pump associated with a conventional hot water heating system.