Field of the invention

[001] This invention relates to a dual function wafer heater and air-condifioning uni†.

Background to the invention

[002] The dual function uni† of the invention is essentially a “hea† harvesting” system †ha† “harvests” hea† from either or both the ambient environment, the warm air output of an air-conditioner and a water heater (typically a domestic-type water heater used for purposes of heating water for bathing, showering or dishwashing, in South Africa commonly referred †o as a “geyser”.

Summary of the invention

[003] According †o the invention a dual function water heater and air- conditioning uni† comprises an air-conditioner subassembly and a water heater subassembly interconnected for circulation of a refrigerant within a fluidic circuit configured as a vapour compression refrigeration circuit: the air-conditioner subassembly comprising an interior air-conditioning uni† configured for installation within a building and an exterior air-conditioning uni† configured for installation outside the building; the interior air-conditioning uni† including a firs† hea† exchanger interconnected in-circuit in the refrigeration circuit; the exterior air-conditioning uni† including a second hea† exchanger interconnected in-circui† in the refrigeration circuit; the water heater subassembly including a water tank and a third hea† exchanger interconnected in-circui† in the refrigeration circuit and configured for location within the water tank; the firs† and second hea† exchangers each including outlet tubes and firs† and second inlet tubes in-circui† in the refrigeration circuit; the third hea† exchanger including inlet and outlet tubes in-circui† in the refrigeration circuit; the firs† refrigerant inlet tube of each of the firs† and second hea† exchangers having an expansion valve installed in the refrigeration circuit upstream of the hea† exchanger; the second refrigerant inlet tube of each hea† exchanger having no expansion valve; the refrigeration circuit including a plurality of control valves settable †o direct the refrigerant within the refrigeration circuit; the control valves being settable such †ha†: a† leas† one of the firs† or second hea† exchangers is configured †o operate as an evaporator, in which setting of the control valves, refrigerant is introduced into the hea† exchanger through the expansion valve installed in the firs† inlet tube of †ha† hea† exchanger; a† leas† one of the firs† or second hea† exchangers may be configured †o operate as a condenser, in which setting of the control valves, refrigerant is introduced into the hea† exchanger through the second inlet tube of †ha† hea† exchanger; and the third hea† exchanger may be configured †o operate as a water heater within the water tank, in which setting of the control valves, the third heat exchanger is configured †o operate as a condenser.

[004] The control valves are preferably settable such that the dual function wafer heater and air-condifioning uni† is configured †o operate in one of a plurality of modes of operation selected from: a firs† mode of operation — water heating only; a second mode of operation — water heating and air conditioner cooling; a third mode of operation — air-conditioning cooling only; and a fourth mode of operation — air-conditioning heating only.

[005] In this form of the invention, in the firs† mode of operation — water heating only — the control valves are se† such †ha†; the firs† hea† exchanger is switched ou† of the refrigeration circuit and no refrigerant is supplied †o the firs† hea† exchanger; the third hea† exchanger is configured †o operate as a condenser, in which setting of the control valves, refrigerant is introduced from the compressor into the third hea† exchanger byway of the third hea† exchanger inlet tube; and the second hea† exchanger is configured †o operate as an evaporator, in which setting of the control valves, refrigerant is supplied †o the second hea† exchanger from the third hea† exchanger outlet tube through the firs† inlet tube of the second hea† exchanger, by way of the expansion valve of the second hea† exchanger.

[006] In this form of the invention, in the second mode of operation — water heating and air conditioner cooling — the control valves are se† such †ha†; the second hea† exchanger is switched ou† of the refrigeration circuit and no refrigerant is supplied †o the second hea† exchanger; the third heat exchanger is configured †o operate as a condenser, in which setting of the control valves, refrigerant is introduced from the compressor info the third heat exchanger byway of the third heat exchanger inlet tube; and the firs† hea† exchanger is configured †o operate as an evaporator, in which setting of the control valves, refrigerant is supplied †o the firs† hea† exchanger from the third hea† exchanger outlet tube through the firs† inlet tube of the firs† hea† exchanger, by way of the expansion valve of the firs† hea† exchanger.

[007] In this form of the invention, in the third mode of operation — air- conditioning cooling only — the control valves are se† such †ha†; the third hea† exchanger is switched ou† of the refrigeration circuit and no refrigerant is supplied †o the third hea† exchanger; the second hea† exchanger is configured †o operate as a condenser, in which setting of the control valves, refrigerant is introduced from the compressor into the second hea† exchanger by way of the second inlet tube of the second hea† exchanger; and the firs† hea† exchanger is configured †o operate as an evaporator, in which setting of the control valves, refrigerant is supplied †o the firs† hea† exchanger from the second hea† exchanger outlet tube through the firs† inlet tube of the firs† hea† exchanger, by way of the expansion valve of the firs† hea† exchanger.

[008] In this form of the invention, in the fourth mode of operation — air- conditioning heating only — the control valves are se† such †ha†; the third hea† exchanger is switched ou† of the refrigeration circuit and no refrigerant is supplied †o the third hea† exchanger; the firs† hea† exchanger is configured †o operate as a condenser, in which setting of the control valves, refrigerant is introduced from the compressor info the firs† hea† exchanger byway of the second inlet tube of the firs† hea† exchanger; and the second hea† exchanger is configured †o operate as an evaporator, in which setting of the control valves, refrigerant is supplied †o the second hea† exchanger from the second hea† exchanger outlet tube through the firs† inlet tube of the second hea† exchanger, by way of the expansion valve of the second hea† exchanger.

[009] The water tank heater may conveniently be the water tank of a water heater or geyser, which could be a horizontal or a vertical geyser.

[0010] In this embodiment of the invention, the third hea† exchanger (the water heater hea† exchanger) may be configured as a direc†-hea†ing immersion heating element comprising a finned tube hea† exchanger †ha† may be installed within the interior of the geyser for direct hea† transfer from the hea† exchanger †o the water within the geyser.

[0011] In this embodiment of the invention, further, the third hea† exchanger (the water heater hea† exchanger) may be configured †o conform in shape, size, general form factor and physical connection equipment †o current standardised electric water heater elements, such †ha† the water heater hea† exchanger may be retrofitted into a conventional electric geyser in place of the conventional electrical element.

Brief Description of the drawings

[0012] The invention will be further described with reference †o the accompanying drawings in which:

Figure 1 †o 4 are simplified circuit diagrams (in block diagram form) of the components of the dual function unit of the invention illustrating the unit switched, in each case, †o one of four modes of operation - each Figure illustrates only the refrigeration circuit circuitry relevant †o that mode of operation;

Figure 1 illustrates the unit switched to a first mode or cycle of operation: CYCLE 1 — WATER HEATING ONLY;

Figure 2 illustrates the uni† switched †o a second mode or cycle of operation: CYCLE 2 — WATER HEATING AND AIR CONDITIONER COOLING;

Figure 3 illustrates the uni† switched †o a third mode or cycle of operation: CYCLE 3 — AIR-CONDITIONING COOLING ONLY; and

Figure 4 illustrates the uni† switched †o a fourth mode or cycle of operation: CYCLE 4 — AIR-CONDITIONING HEATING ONLY; and

Figure 5 is a diagrammatic illustration of a conventional horizontal domestic water heater or geyser illustrating fitment of the water heating hea† exchanger of the invention †o such a conventional horizontal geyser;

Figure 6 is a diagrammatic illustration of a conventional vertical domestic water heater or geyser illustrating fitment of a pair of water heating hea† exchangers according †o the invention †o such a conventional vertical geyser;

Figure 7 is a diagrammatic isometric view of one embodiment of a finned tube water heating hea† exchanger according †o the invention;

Figure 8 is a diagrammatic side elevation of the finned tube water heating hea† exchanger of Figure 7;

Figure 9 is a diagrammatic side elevation of a further embodiment of a finned tube water heating hea† exchanger according †o the invention;

Figure 10 is a diagrammatic end elevation of the geyser mounting plate of the hea† exchanger of Figure 9;

Figure 11 is a diagrammatic sectional elevation on a line 11-11 in Figure 9;

Figure 12 is a diagrammatic side elevation of a punched fin for the hea† exchangers of Figures 7 and 9; and Figure 13 is a diagrammatic part-section side elevation on the heat exchanger tube arrangement (Figures 7 and 9), illustrating the arrangement of the heat exchanger tubes and punched fins.

Description of embodiments of the invention

[0013] Vapour-compression refrigeration, in which a refrigerant is circulated through a refrigeration circuit, is widely used in air-conditioning and refrigeration as well as in heat pumps. The refrigerant used depends on the application, but in each case, the refrigerant is a working fluid that undergoes successive first-order phase transitions during the refrigeration cycle. First-order phase transitions are substantially constant temperature processes in which large amounts of energy are absorbed or released as latent heat while the temperature remains substantially constant. These systems exploit the enthalpy of vaporisation to add heat to a medium to be conditioned, such as air in an air-conditioning system or water in a water heater heat pump and, in the reverse, the enthalpy of condensation to extract heat from the medium.

[0014] It is appreciated that heat transfer is an additive process — heat always transfers additively to a cooler medium from a warmer medium, even during cooling processes. This notwithstanding, cooling processes will sometimes be referred to in this specification using terminology such as heat “extraction” or “absorption”. This is done for ease of reference.

[0015] Vapour-compression refrigeration requires four basic components: a compressor, a condenser, a thermal expansion valve and an evaporator.

[0016] Circulating refrigerant exiting the evaporator enters the compressor in gaseous state where the refrigerant is compressed and simultaneously heated adiabatically by compression.

[0017] The superheated gas then passes through the condenser in which the gaseous refrigerant phase transitions from a gas through vapour to a liquid phase. The process of condensation expedites the release of large quantities of latent heat, which is transferred †o an external, heat extracting medium. In some systems, a wafer heater heat pump for example, the heat extracting medium is the wafer †o be heated and the latent heat is transferred, by the heat exchanger †o heat up the wafer in the wafer heater. However, in some systems, such as in most air- condifioning systems, the hea†-ex†rac†ing medium is a vented airflow that is simply discharged †o atmosphere. If will be appreciated that this constitutes an egregious waste of energy.

[0018] The condensed liquid refrigerant is next routed through an expansion valve where the liquid undergoes an abrupt reduction in pressure, resulting in adiabatic flash evaporation of the refrigerant and adiabatic cooling that creates an aufo- refrigerafion effect.

[0019] The cold (refrigerated) refrigerant liquid and vapor mixture are then routed through the evaporator in which heat must be extracted from (or rather contributed by) the surrounding medium †o replace the latent heat of condensation lost in the process of evaporation. Heat is transferred †o the refrigerant which causes continuing evaporation of the liquid refrigerant, returning if †o a gaseous state. In air- condifioning systems, the surrounding medium is air that is †o be cooled prior †o the cooled air being vented info a space or room †o be cooled. However, in some systems, such as a wafer heater heat pump for example, the hea†-con†ribu†ing surrounding medium is a vented airflow that is simply discharged †o waste (typically †o atmosphere) as wasted cooled air, once again constituting a waste of energy.

[0020] To complete the refrigeration cycle, the refrigerant gas from the evaporator is routed back in the compressor †o repeat the cycle.

[0021] The dual function wafer heater and air-condifioning uni† 10 of the invention is illustrated in the drawings. The uni† 10 comprises a water heater subassembly 12 interconnected with an air-conditioner subassembly 14.

[0022] The air-conditioner subassembly 14 is similar in many respects †o a split system air conditioner system in †ha† it comprises an interior air-conditioner uni† 14.1 configured for installation within a building (no† shown) and an exterior air- conditioner uni† 14.2 configured for installation externally of the building. [0023] Firs† and second interconnected finned coil tube heat exchangers 16, 18 are installed within the inferior (14.1) and exterior (14.2) air-conditioning units, respectively. The firs† hea† exchanger 16 (this is the firs† hea† exchanger mentioned in the Claims and the Summary of the Invention) is located in the interior air- conditioner uni† 14.1 and the second hea† exchanger 18 (this is the second hea† exchanger mentioned in the Claims and the Summary of the invention) is located in the exterior air-condifioner uni† 14.2.

[0024] The wafer heater subassembly 12 includes a conventional horizontal tank wafer heater or geyser 20.

[0025] Figures 1 †o 4 illustrate (diagrammatically) a water heater subassembly 12 incorporating a horizontal geyser 20.

[0026] The dual function water heater and air-conditioning uni† 10 can be used in conjunction with vertical geysers. A vertical geyser 120 configured for integration with the dual function uni† 10 is illustrated in and described with reference †o Figure

6.

[0027] In both cases, the water heatersubassembly 12 makes use of a water heater hea† exchanger 22 (this is the third hea† exchanger mentioned in the Claims and the Summary of the invention) †ha†, in the preferred form of the invention is a finned tube hea† exchanger.

[0028] The finned tube hea† exchanger 22 is a direc†-hea†ing immersion hea†er†ha† is installed within the interior of the geyser 20, for immersion within the water in the geyser 20 and for direct hea† transfer from the hea† exchanger 22 †o the water in the geyser 20.

[0029] The water heater hea† exchanger 22 is preferably standardised †o conform, in shape, size, general form factor and physical connection equipment, †o current, standardised electric water heater elements. In this regard, the replaceable components, particularly electric water heater elements, of existing electric water heaters have been largely standardised. In the case of electric heater elements, the elements have been standardised †o conform †o small range of standard sizes, form factors and physical and electrical connections. This is to facilitate easy replacement of the elements as replaceable components. Standardisation of the water heater heat exchanger 22 to conform to the shape, size and form factor of electric water heater elements, enables retrofitting of the water heater heat exchanger 22 into conventional electric geysers in the place of the electrical element of such a conventional electric geyser.

[0030] The interior air-conditioner unit 14.1 can be configured similarly to the shape and configuration of the interior unit of a currently available split system air conditioner. Users of the interior air-conditioner unit 14.1 should be immediately familiar with the operation of the unit 14.1, which includes an exterior housing, a manually variable speed fan located within air-conditioner ducting within the housing (not shown). The fan is configured to direct ambient air (typically from a source outside of the building space served by the interior air-conditioner unit 14.1 ) over the finned tube heat exchanger coil of the interior unit heat exchanger 16 and, through a variable direction grille into the building space served by the interior air- conditioner unit 14.1. The operating controls of the interior unit 14.1 are relatively conventional and similar to existing split system air-conditioner interior units and, as will be seen below, the interior unit 14.1 can operate as an air-conditioner in heating or cooling mode.

[0031] The exterior air-conditioner unit 14.2, like a conventional split system air- conditioner, is configured for installation externally of the building served by the interior air-conditioner unit 14.1 and, like the interior air-conditioner unit 14.1, can be configured similarly to the shape and configuration of the exterior unit of a currently available split system air conditioner. The exterior air-conditioner unit 14.2 includes an exterior housing, and an automatically variable stepped speed fan located within air-conditioner ducting within the housing (not shown). The fan draws ambient air from the outside of the building, over the finned tube heat exchanger coil of the exterior unit heat exchanger 18, from where the air is simply vented to atmosphere.

[0032] The dual function water heater and air conditioning unit 10 includes an integrated refrigerant fluid flow circuit within which at least the 4 variations of the refrigeration cycle described below can be operated. The various components of the refrigeration circuit will be described with reference to the drawings in what follows.

[0033] As indicated above, Figures 1 †o 4 are simplified circuit diagrams (in block diagram form) of the components of the dual function wafer heater and air conditioner unit 10.

[0034] Figures 1 †o 4 are simplified circuif-and block diagrams illustrating the components and operation of the dual function unit 10. Each of Figures 1 to 4 illustrate one of four modes of operation and in each case, each Figure illustrates only the refrigeration circuit circuitry relevant to that mode of operation. Flaving regard to Figures 1 to 4, the refrigeration circuit circuitry includes, in addition to the componentry already described: housed within the exterior air-conditioner unit 14.2 housing: a compressor 30; control valves that are settable to direct the refrigerant within the refrigeration circuit, including a plurality of check valves 32, a first diverting manifold 34 and a second diverting manifold 36; an exterior unit expansion valve 38; and a suction diverting manifold 40; housed within the interior air-conditioner unit 14.1 housing: an interior unit expansion valve 42; and extending between the various components described above, interconnecting fluid lines that interconnect the components described above hydraulically/pneumatically to complete the refrigeration circuit — the various fluid lines are described in more detail with reference to each mode of operation of the dual function water heater and air conditioner unit 10.

[0035] The dual function wafer heater and air-condifioning unit 10 further includes a liquid accumulator 24 and a sigh† glass 26, the liquid accumulator being installed †o receive the liquid feed from any one of the three hea† exchangers 16, 18, 22 †o ensure storage of sufficient liquid †o feed the expansion valves 38, 42 in the exterior air-conditioner uni† 14.2 and interior air-conditioner uni† 14.1.

CYCLE 1 — WATER HEATING ONLY

[0036] In Figure 1 the dual function wafer heater and air conditioning uni† 10 is switched †o a firs† mode or cycle: CYCLE 1 — WATER HEATING ONLY.

[0037] The refrigeration circuit required for CYCLE 1 — WATER HEATING ONLY operation, as illustrated in Figure 1, includes a number of components already described, including the water heater subassembly 12 and the components thereof as well as the exterior air-conditioner uni† 14.2 and the components thereof.

[0038] In CYCLE 1 mode, circulating refrigerant enters the compressor 30 by means of a suction line 44 and exits the compressor 30 as a superheated refrigerant gas by means of a ho† gas line 46 that directs the refrigerant †o the firs† and second diverting manifolds 34, 36, which switches the fluid flow †o a ho† gas line 48 that directs the superheated refrigerant gas to on inlet 50 of the water heater hea† exchanger 22.

[0039] Switched †o this configuration, the water heater hea† exchanger 22 acts as a condenser in which the gaseous refrigerant phase transitions from a gaseous phase †o a liquid phase. Besides being superheated by compression, the condensation process expedites the release of large quantities of latent hea†, which the finned tube water heater hea† exchanger 22 transfers directly †o the water in the geyser 20.

[0040] The refrigerant, now condensed †o its liquid phase, exits the hea† exchanger 22 by means of a hea† exchanger outlet 52. A fluid line 54 conveys the refrigerant †o a check valve 32.1 which directs the refrigerant †o a liquid accumulator 24 and sigh† glass 26. The liquid refrigerant is conveyed by a liquid line 56 to the exterior uni† expansion valve 38 where the liquid refrigerant is flash evaporated and conveyed †o the exterior uni† hea† exchanger 18. [0041] Switched †o this configuration, the exterior uni† hea† exchanger 18 functions as an evaporator in which adiabatic cooling is used †o effectively absorb hea† from exterior atmosphere.

[0042] Having been through the evaporator constituted by the exterior uni† hea† exchanger 18, the refrigerant exits the external uni† hea† exchanger 18 as a cool, gas phase refrigerant by way of a suction line 58 that is directed by a second diverting manifold 36 and check valve 32.2 †o the suction diverting manifold 40, from where the refrigerant is recirculated †o the compressor 30 for repetition of the refrigerant cycle.

CYCLE 2 — WATER HEATING AND AIR CONDITIONER COOLING

[0043] In CYCLE 2 mode, as illustrated in Figure 2, the dual function wafer heater and air-condifioner uni† 10 is switched †o a second mode or cycle in which the uni† 10 is used †o hea† the water in the geyser 20 and †o operate the interior air- conditioner uni† 14.1 as an air-condifioner uni† in cooling mode.

[0044] In CYCLE 2 mode, the refrigerant enters the compressor 30 by means of the suction line 44 and exits the compressor by means of the ho† gas line 46 that directs the superheated refrigerant gas †o the firs† and second diverting manifolds 34, 36.

[0045] Similarly †o CYCLE 1, the water heater hea† exchanger 22 acts as a condenser in which the gaseous refrigerant phase transitions from a vapour phase †o a liquid phase. In the transition, the latent hea† of condensation is transferred, by the finned tube water heater hea† exchanger 22 directly †o the water in the geyser 20.

[0046] The condensed liquid refrigerant exits the hea† exchanger 22 by means of the hea† exchanger outlet 52, from where the liquid line 54 conveys the liquid refrigerant †o the check valve 32.1 which directs the refrigerant †o the liquid accumulator 24 and sigh† glass 26. The liquid refrigerant is conveyed by a liquid line 60 to the interior uni† expansion valve 42 where the liquid refrigerant is flash evaporated and conveyed, by means of a line 62, †o the interior uni† hea† exchanger 16.

[0047] The interior uni† hea† exchanger 16 operates as an evaporator within which adiabatic flash evaporation of the refrigerant and adiabatic cooling of the vaporising refrigerant creates an au†o-refrigera†ion effect.

[0048] In the evaporator constituted by the interior uni† hea† exchanger 16, the cold (refrigerated) refrigerant liquid and vapor mixture are routed through the evaporator in which hea† is extracted from (or rather contributed by) the surrounding medium (the ambient air flowing over the hea† exchanger tubes) †o replace the latent hea† of condensation lost in the process of evaporation. Hea† is transferred †o the refrigerant which causes continuing evaporation of the liquid refrigerant, returning it †o a gaseous state.

[0049] Having been through the evaporator constituted by the interior exterior uni† hea† exchanger 16, the refrigerant exits the internal uni† hea† exchanger 16 as a cool, gas phase refrigerant by way of a suction line 64 †ha† is directed by the firs† diverting manifold 34 and check valve 32.3 to the suction diverting manifold 40, from where the refrigerant is recirculated †o the compressor 30 byway of the suction line 44 for repetition of the refrigerant cycle.

CYCLE 3 — AIR-CONDITIONING COOLING ONLY

[0050] In CYCLE 3 mode, as illustrated in Figure 3, the dual function wafer heater and air-condifioner uni† 10 is switched simply †o operate the interior air-conditioner uni† 14.1 as an air-conditioner uni† in cooling mode.

[0051] In this mode, the circulating refrigerant enters the compressor 30 by means of the suction line 44 and exits the compressor as a superheated refrigerant gas by means of the ho† gas line 46 that directs the superheated refrigerant gas †o the firs† and second diverting manifolds 34, 36.

[0052] The diverting manifolds 34, 36 switch the fluid flow †o a ho† gas line 66 that directs the superheated refrigerant gas †o a secondary inlet 68 of the exterior uni† hea† exchanger 18, bypassing the exterior uni† expansion valve 38. The exterior uni† hea† exchanger 18 acts as a condenser in which the ho† gaseous refrigerant phase transitions from a vapour phase †o a ho† liquid phase. In the transition, the latent hea† of condensation is dumped as excess hea† †o the exterior atmosphere.

[0053] From the exterior uni† hea† exchanger 18, the ho† liquid phase refrigerant is conveyed †o a check valve 32.4 which directs the refrigerant †o the liquid accumulator 24 and sigh† glass 26 by means of a liquid line 70. The liquid refrigerant is conveyed by fluid line 60 to the interior uni† expansion valve 42 where the liquid refrigerant is flash evaporated and conveyed, by means of the fluid line 62, †o the interior uni† hea† exchanger 16.

[0054] As in CYCLE 2, the interior uni† hea† exchanger 16 and the interior uni† 14.1 operate as an air-conditioner in cooling mode.

[0055] From the interior uni† hea† exchanger 16, the refrigerant is directed, by way of the suction line 64 that is directed by the firs† diverting manifold 34 and check valve 32.3, to the suction diverting manifold 40, from where the refrigerant is recirculated †o the compressor 30 by way of the suction line 44 for repetition of the refrigerant cycle.

CYCLE 4 — AIR-CONDITIONING HEATING ONLY

[0056] In this mode of operation, circulating refrigerant enters the compressor 30 by means of the suction line 44 and exits the compressor 30 as a superheated refrigerant gas by means of the ho† gas line 46 that directs the refrigerant gas †o the diverting manifold 34.

[0057] The diverting manifold 34 switches the fluid flow †o a ho† gas line 72 †ha† directs the superheated refrigerant gas †o the inlet 76 of the interior uni† hea† exchanger 16, bypassing the interior uni† expansion valve 42.

[0058] In this mode, the interior uni† hea† exchanger 16 acts as a condenser in which the ho† gaseous refrigerant phase transitions from a vapour phase †o a ho† liquid phase in which the latent heat of condensation must be transferred †o an external medium, which is provided by inflowing cold air.

[0059] In the inferior uni† 14.1, the manually variable speed fan is operated †o direct cold air from the building space served by the interior air-conditioner uni† 14.1 over the finned tube hea† exchanger coil of the interior uni† hea† exchanger 16 and into the building space served by the interior air-conditioner uni† 14.1. The hea† exchanger tubes, heated by the latent hea† of condensation of the refrigerant transitioning from gas †o liquid, transfers refrigerant hea† †o the inflowing air †o hea† the building space served by the uni† 14.1. In this mode (CYCLE 4), therefore, the interior uni† 14.1 operates as an air-conditioner in heating mode.

[0060] From the interior uni† hea† exchanger 16, the liquid phase refrigerant is conveyed †o a check valve 32.5 which directs the refrigerant †o the liquid accumulator 24 and sigh† glass 26 by means of a liquid line 74. The refrigerant is conveyed by the liquid line 56 to the exterior uni† expansion valve 38 where the liquid refrigerant is flash evaporated and conveyed †o the exterior uni† hea† exchanger 18.

[0061] The exterior uni† hea† exchanger 18 functions as an evaporator in which adiabatic cooling is used †o effectively absorbing hea† from exterior atmosphere. The refrigerant exits the external uni† hea† exchanger 18 as a cool, gas phase refrigerant by way of the suction line 58 that is directed by the second diverting manifold 36 and check valve 32.2 †o the suction diverting manifold 40, from where the refrigerant is recirculated †o the compressor 30 for repetition of the refrigerant cycle.

Water heater heat exchanger

[0062] The invention includes a finned tube heat exchanger 22 that can be installed within the geyser tank 20.1 in the place of the electric wafer heater element conventionally used in a geyser such as this. The heat exchanger 22 is standardised †o conform, in shape, size, general form factor and physical connection equipment, †o current, standardised electric wafer heater elements. This allows replacement of the conventional electric element by the heat exchanger 22 of the invention by means of a simple retrofit. The electric element is removed and the heat exchanger 22 is simply connected in its place.

[0063] The conventional geyser 20, with the heat exchanger 22 installed therein can now be integrated with the dual function uni† 10 described with reference †o Figures 1 †o 4 by connecting the hea† exchanger 22 hydraulically/pneumatically into the refrigeration circuit described with reference †o Figures 1 †o 4 above, instead of connecting the geyser 20 into an electricity supply system.

[0064] In water heating mode (CYCLES 1 and 2), superheated refrigerant gas is supplied †o the inlet 50 of the water heater hea† exchanger 22. The water heater hea† exchanger 22 acts as a condenser in which the gaseous refrigerant phase transitions from a vapour phase †o a liquid phase, in the process releasing a large quantity of latent hea† which the finned tube water heater hea† exchanger 22 transfers directly †o the water in the geyser 20. The refrigerant, condensed †o a liquid phase, exits the hea† exchanger 22 by means of the hea† exchanger outlet 52 and recirculates †o the refrigeration circuit.

[0065] The hea† exchanger 22 is located in essentially the same location as the replaced electric element and the hea† exchanger 22 is mounted †o the geyser 20 using the connectors (other than electrical connectors) and the fastenings typically used for installation of the electric water heater element it replaces.

[0066] The finned tube portion 22.1 of the hea† exchanger 22 is a direct-heating immersion heater †ha† is similar in size and shape †o the electric element replaced by the hea† exchanger 22. The finned tube portion 22.1 of the hea† exchanger 22 is installed within the interior of the geyser water tank 20.1 for immersion within the water in the tank 20.1 and for direct hea† transfer from the hea† exchanger 22 †o the water in the tank 20.1 during the water heating cycles (CYCLES 1 and 2) described above.

[0067] To mount the hea† exchanger 22 †o a geyser 20, the hea† exchanger 22 is provided with a mounting plate 22.2 standardised †o conform †o the shape, size and form factor of the mounting plates of electric elements replaced by the hea† exchanger 22.

[0068] As can be seen from Figures 7 and 8, the heat exchanger 22 is a finned tube heat exchanger in which the fins are constituted by a stack of evenly-spaced metal fin plates 22.9 secured to metal refrigerant tubes 22.6. The tubes 22.6 are interconnected in a tortuous path coil arrangement secured within header blocks 22.7, 22.8 which serve to interconnect the tubes 22.6 hydraulically/pneumatically to permit refrigerant to flow through the tubes 22.6 from the heat exchanger inlet tube 50 to the heat exchanger outlet tube 52.

[0069] Figures 9 to 13 illustrate a second embodiment of the heat exchanger 22. In these drawings, similar items are numbered with numbers corresponding to those used in Figures 7 and 8, incremented by 100.

[0070] The embodiment of the heat exchanger 122 illustrated in Figures 9 to 11 is also a finned tube heat exchanger in which the fins are constituted by a stack of evenly-spaced metal fin plates 122.9 secured to metal refrigerant tubes 122.6. The tubes 122.6 are interconnected in a tortuous path coil arrangement in which the tubes 122.6, at the one end (the upper end in Figure 9) are bent into a U-shape. At their other ends, the U-shaped tubes 122.6 are interconnected by means of short U- tubes 122.10 that are soldered onto the open ends of the U-shaped tubes 122.6. This serves to interconnect the tubes 122.6 hydraulically/pneumatically to permit refrigerant to flow through the tubes 122.6 from the heat exchanger inlet tube 150 to the heat exchanger outlet tube 152.

[0071] To mount the heat exchanger 122 to a geyser 20, the heat exchanger 122 is provided with a mounting plate 122.2 standardised to conform to the shape, size and form factor of the mounting plates of electric elements replaced by the heat exchanger 122. This drawing illustrates the mounting holes 122.13 by means of which the mounting plate 122.2 is mounted to the geyser 120.

[0072] In this embodiment, the heat exchanger 122 includes an electric heater element 22.11 in addition to the heat exchanger tubes 122.6. In cold climate environments, it is possible that the external ambient air temperature becomes so cold that the unit 10 will most likely fail to heat the water in the geyser 20 sufficiently. In these environments, the electric heater element 22.1 1 can be switched in-circuit to assist in heating the water in the geyser 20 to the desired pressure under control of the geyser thermostat. In the most basic implementation of this embodiment of the invention, the electric heater element 22.1 1 could simply be wired †o the premises main electricity distribution board, where a circuit breaker or switch could be used †o switch the electric wafer heater element in or out of circuit manually. Alternatively, the uni† 10 could be supplied with an ambient air temperature sensor and the uni† programmable logic could be programmed †o switch the electric heater element 22.1 1 in-circui† †o assist with water heating when the air temperature sensor registers an ambient air temperature below a predetermined temperature, which could be anything between -15° C and -5° C and preferably -10° C.

[0073] The hea† exchanger 122 also includes a protector tube 122.12 †ha† is secured †o the hea† exchanger mounting plate 122.2 by welding or the like. The protector tube extends about the outside of the tube and fin array of the hea† exchanger 122 and serves †o protect the tubes 122.6 and fins 122.9 against damage during transport, handling and installation.

[0074] In both embodiments of the hea† exchanger 22 (Figures 7 and 8; Figures 9 to 11 ), the tubes 22.6, 122.6 and fin plates 22.9, 122.9 are preferably fabricated from copper, the thermal conductivity of which is well matched †o the working fluids used in the refrigeration circuit and the water in the geyser 20, 120.

[0075] As can be seen from Figures 12 and 13, the fin plates (numbered 22.9 for ease of reference) are made from thin copper plates 22.9.1. Tube mounting holes 22.9.2 are formed in the plate 22.9.1 to accommodate the refrigerant tubes 22.6, 122.6. The tube mounting holes 22.9.2 are formed by press-forming, cutting and flaring, †o create a flared collar extending from the surface of the plate 22.9.1, the collar including a sleeve portion 22.9.3 and a flared abutment portion 22.9.4. The sleeve 22.9.3 serves as a spacer between adjacent fin plates 22.9 and the tube mounting hole 22.9.2 and the sleeve 22.9.3 are dimensioned †o be a tight fit about the external surface of the surface of the refrigerant tube 22.6, 122.6 to facilitate conductive hea† transfer between the tube and fin plate. The flared collar abutment 22.9.4 serves as a stop formation between adjacent fin plates 22.9. Horizontal geyser (typical — South Africa)

[0076] The geyser 20 illustrated in the diagrams of Figures 1 †o 4 is essentially a conventional horizontal wafer heater or geyser, which is illustrated in more detail (but still diagrammafically) in Figure 5. The geyser 20 includes a thermally insulated wafer tank 20.1 that has a cold wafer inlet pipe 20.2 and a ho† water outlet pipe 20.3, suitably configured for connection of the geyser 20 into domestic or other plumbing.

[0077] A finned tube hea† exchanger 22 according †o the invention is installed within the geyser tank 20.1 in the place of the electric water heater element conventionally used in a geyser such as this — a conventional horizontal geyser. The hea† exchanger 22 is standardised †o conform, in shape, size, general form factor and physical connection equipment, †o current, standardised electric water heater elements. This allows replacement of the conventional electric element by the hea† exchanger 22 of the invention by means of a simple retrofit. The electric element is removed and the hea† exchanger 22 is simply connected in its place. Like the replaced electric element, the hea† exchanger 22 is disposed horizontally within the geyser tank 20.1 .

[0078] The conventional geyser 20, with the hea† exchanger 22 installed therein can now be integrated with the dual function uni† 10 described with reference †o Figures 1 †o 4 by connecting the hea† exchanger 22 hydraulically/pneumatically into the refrigeration circuit described with reference †o Figures 1 †o 4 above, instead of connecting the geyser 20 into an electricity supply system.

[0079] In water heating mode (CYCLES 1 and 2), superheated refrigerant gas is supplied †o the inlet 50 of the water heater hea† exchanger 22. The water heater hea† exchanger 22 acts as a condenser in which the gaseous refrigerant phase transitions from a vapour phase †o a liquid phase, in the process releasing a large quantity of latent hea† which the finned tube water heater hea† exchanger 22 transfers directly †o the water in the geyser 20. The refrigerant, condensed †o a liquid phase, exits the hea† exchanger 22 by means of the hea† exchanger outlet 52 and recirculates †o the refrigeration circuit. [0080] The hea† exchanger 22 is located in essentially the same location as the replaced electric element and the hea† exchanger 22 is mounted †o the geyser 20 using the connectors (other than electrical connectors) and the fastenings typically used for installation of the electric water heater element it replaces.

[0081] The finned tube portion 22.1 of the hea† exchanger 22 is a direc†-hea†ing immersion heater similar †o the electric element replaced by the hea† exchanger 22. The finned tube portion 22.1 of the hea† exchanger 22 is installed within the interior of the geyser water tank 20.1 for immersion within the water in the tank 20.1 and for direct hea† transfer from the hea† exchanger 22 †o the water in the tank 20.1 during the water heating cycles (CYCLES 1 and 2) described above.

Vertical geyser (typical USA, Europe, Australia)

[0082] Conventional electric geysers of the vertical type typically use two electric heater elements located within the geyser tank, including a base element located closely adjacent the base of the geyser, where the cold wafer inlet is also located, and a demand element located relatively high up within the geyser tank, where the ho† water outlet is also located. The heater element control circuit switches between the base element and the demand element with the demand element taking precedence. The base element normally carries the major heating load, and the demand element is simply switched in when the water temperature around the demand element drops below a predetermined temperature. The geyser is typically supplied with thermostats and †hermos†a†-driven switches †o monitor and control switching in and ou† of the heating elements.

[0083] When the water temperature around the demand element drops below a predetermined temperature, the demand element provides assistance heating †o address instantaneous ho† water demands on the geyser. In the USA, Europe and Australia, during base element heating only, a typical 200L vertical geyser will produce an electrical load demand of 4.6kW, switched between the demand and base element.

[0084] Figure 6 illustrates a conventional vertical geyser 120 in which the electric heating elements have been replaced by heat exchangers 22 according to the invention. The geyser 120 includes a thermally insulated water tank 120.1 that has a cold water inlet pipe 120.2 located adjacent the base of the geyser 120 and a ho† water outlet pipe 120.3 located relatively high up within the geysertank 120.1, both inlets being suitably configured for connection of the geyser 120 into domestic or other plumbing.

[0085] The hea† exchangers 22 replacing the electric elements are located in the same locations as the electric elements †o constitute a base element (the lower hea† exchanger 22.3) and a demand element (the upper hea† exchanger 22.4).

[0086] Such a vertical geyser 120, with the hea† exchangers 22 installed therein is integrated with the dual function uni† 10 described with reference †o Figures 1 †o 4 by connecting the hea† exchangers 22 in-circui† into the refrigeration circuit described with reference †o Figures 1 †o 4 above, instead of connecting the geyser 20 into an electricity supply system.

[0087] In the refrigeration circuit, in water heating mode (CYCLES 1 and 2), superheated refrigerant gas flows through the hea† exchangers 22 as follows: superheated refrigerant gas is supplied †o the inlet 150.1 of the demand element 22.4; the refrigerant flows through the demand element 22.4, operating as a condenser; the refrigerant exits the demand element 22.4 through the demand element outlet 152.1 into a connecting ho† gas line 150/152; the ho† gas line 150/152 conveys the refrigerant from the demand element 22.4 †o the base element 22.3; the refrigerant is supplied †o the inlet 152.2 of the base element 22.3; the refrigerant flows through the base element 22.3, operating as a condenser; and the refrigerant exits the base element 22.3 through the base element outlet 150.2 back into the refrigeration circuit.

[0088] Both hea† exchangers 22.3 and 22.4 ac† as condensers, bu† the phase transition of the refrigerant from gaseous †o liquid phase will adjust automatically †o the temperature of the water in the geyser 120.

State 1 I Low demand

[0089] In this state: the temperature of the wafer in the geyser 120 is relatively stable a† or near the preset ho† water temperature; the hea† demand of the water is relatively low; as a result, refrigerant hea† discharge from the demand element 22.4 is relatively low; and as a further result, there is significant pass-through of ho† gaseous refrigerant from the demand element 22.4 †o the base element 22.3.

[0090] Most of the heating in this state is provided by the base element, in which the bulk of the phase transition of the refrigerant from gaseous †o liquid phase occurs and which, as a result, generates the bulk of the latent hea† of condensation.

[0091] Typical heating load distribution: base element >60%; demand element <40%.

State 2 I High demand

[0092] In the even† of high ho† water demand, ho† water flows from the geyser outlet 120.3 and cold water flows into the geyser inlet 120.2, progressively displacing the hot water in the tank 120.1 with progressively rising cold water.

[0093] In the case of a high ho† water demand, the inflowing cold water causes the water temperature around the demand element 22.4 †o drop progressively lower.

[0094] As this happens, the phase transition of the refrigerant in the demand element 22.4 adjusts progressively and automatically in reaction †o the changing water temperature. This occurs in the following manner as the refrigerant gas flows through the hea† exchangers 22: superheated refrigerant gas is supplied †o the inlet 150.1 of the demand element 22.4; the refrigerant flows through the demand element 22.4, operating as a condenser; as the water temperature around the demand element 22.4 reduces progressively, the hea† demand of the water increases progressively; as a result, refrigerant hea† discharge from the demand element 22.4 increases progressively with the progressive temperature decrease of the water; this results in the degree of phase transition (within the demand element 22.4) from ho† gas †o liquid phase of the refrigerant becoming progressively greater; and it results, further, in the pass-through of refrigerant in ho† gaseous phase from the demand element 22.4 †o the base element 22.3 decreasing progressively.

[0095] With the progressive decrease in water temperature in the geyser 120, the heating load, in this state, is transferred progressively †o the base element. In a steady-state in which most of the water in the geyser 120 is relatively cold, the bulk of the phase transition of the refrigerant from gaseous †o liquid phase occurs in the base element 22.3. As a result, the base element 22.3 generates the bulk of the latent hea† of condensation.

[0096] Typical heating load distribution transitions progressively: from steady-state: base element >60%; demand element <40%; through interim state: base element >40%; demand element <60%;

†o steady-state: base element >60%; demand element <40%.

State 3 I Instantaneous (non-sustained) demand

[0097] In the event of a state of ho† water demand, where the ho† water demand is instantaneous bu† no† sustained, typically the inflowing cold wafer introduces insufficient quantities of cold water into the geyser tank 120.1 to change the refrigerant cycle completely from †ha† described with reference †o State 1 (low demand) †o State 2 (high demand).

[0098] In this state: the temperature of the water in the geyser 120 is initially relatively stable a† or near the preset ho† water temperature; as a result of the non-sustained, instantaneous water demand, a non- sustained water temperature differential develops between the water adjacent the demand element 22.4 and the water adjacent the base element 22.3; the hea† demand of the water adjacent the base element 22.3 is relatively low; the hea† demand of the water adjacent the demand element 22.4 is relatively high; refrigerant hea† discharge from the demand element 22.4 is relatively high; the degree of phase transition (within the demand element 22.4) from ho† gas †o liquid phase of the refrigerant increases; most of the heating in this state is provided by the demand element 22.4, in which the bulk of the phase transition of the refrigerant from gaseous †o liquid phase occurs and which, as a result, generates the bulk of the latent hea† of condensation; and as the temperature of the water in the geyser 120 returns †o the preset ho† water temperature, the geyser and refrigeration circuit revert †o State 1 (low demand).

[0099] Typical heating load distribution — instantaneous (non-sus†ained) demand: base element >40%; demand element <60%.

[00100] Because the dual function water heater and air conditioner uni† 10 relies, for heating and cooling, on a free running electric motor and a compressor †ha† imposes a relatively low load on the compressor motor, the electrical load imposed, by the uni† 10, on the electricity supply system is relatively low and has a relatively low current draw. In fact, when the uni† 10 operates in CYCLE 2 — WATER HEATING AND AIR-CONDITIONING COOLING — water heating is essentially free, since the ho† gaseous phase refrigerant exiting the interior uni† hea† exchanger 16 is applied directly †o the water heater hea† exchanger 22, in which the refrigerant is condensed and the latent hea† of condensation is transferred, by the finned tube water heater hea† exchanger 22 directly †o the water in the geyser 20.

[00101] In most of the operating modes and cycles described in this specification, the dual function water heater and air conditioner uni† 10 operates a† a Coefficient of Performance (COP) of 3 or better — the COP of a hea† pump or air-conditioning system is a ratio of useful heating or cooling compared †o energy input — COP = Q/W, where Q (hea† supplied or removed (heating or cooling)) is compared †o W (required work — the energy input required).

[00102] Besides such power and cos† saving benefits, the low power utilisation of the dual function uni† 10 makes it possible †o operate the uni† 10 on battery power, which is currently not possible with existing water heaters or geysers.

[00103] Further to enhance the battery compatibility of the dual function uni† 10, the uni† drive electronics could be configured †o include a motor sot† starter, a device commonly used with AC electrical motors temporarily †o reduce the starting torque and electric current surge of the motor during s†ar†-up.