Design and Test of a Heat Pump Water Heater A proposal submitted to the Integrated Science and Technology Department

At James Madison University In partial fulfillment of the Requirements for the Degree of Bachelor of Science In Integrated Science and Technology James Madison University May 2007

By Lam Vu !evin "ost

Under The #uidance of$ %r& Tony 'hen

()ternal S*onsors$ +o,ert J& Landes of Landes -eating and 'ooling

.cce*ted ,y$ %r& Tony 'hen /Signature0

ABSTRACT
In this *ro1ect2 an air3to3air heat *um* 4as converted into a heat *um* 4ater heater /-56-07 the *erformance of such a system 4as tested in the la, using the La,Vie4TM soft4are and thermocou*les to e)amine the tem*erature change and difference throughout the system& 8ive thermocou*les are *laced in the eighty3gallon 4ater tan9 to investigate the 4ater tem*erature stratification2 and t4o thermocou*les are *laced on the suction and discharge side of the com*ressor& .m,ient tem*erature2 4ater flo4 rate2 and total energy consum*tion 4ere also monitored throughout the test& Single3cycle data 4ere collected for calculating the coefficient of *erformance /':50 of the system& The *reliminary result sho4s that the ':5 is 0&;<0&02 for .dd3on and =&=>0&0= for %ro*3in configuration 4ith no *ro*er insulation around the vessel and co**er tu,ing& . feasi,ility model of the current heat *um* 4ater heater 4as develo*ed to e)amine the *ros and cons of running this 9ind of -56system in a residential or commercial setting&

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ACKNOWLEDGE ENTS
6e 4ould li9e to ac9no4ledge %r& Tony 'hen for his outstanding 9no4ledge on the -eat 5um* 6ater -eating 8ield2 his constant guidance in anything and everything to do 4ith our *ro1ect2 and his *ersistence in hel*ing us 4henever 4e needed hel* and he 4as al4ays there to guide us& Mr& +o,ert Landes for his e)*ertise in the creation of the -56- system2 4ithout him 4e 4ould have never gotten any4here in this *ro1ect& -e 4as also there ans4ering our ?uestions and guiding us through the system& 6ithout him2 4e ,asically 4ouldn@t have a *ro1ect at all& Than9s to Mr& Joe +udmin2 for his hel* on soldering the thermocou*les together2 4ith the Amost dangerous machine in IS.T&B 8inally2 4e 4ould also li9e to than9 Mr& -enry +o,ertson for the use of his camera for the fantastic *hotos of our system&

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Ta!"e of Contents
.BST+.'T&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2 .'!C:6L(%#(M(CTS&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D Ta,le of 'ontents&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&E Ta,le of 8igures&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&F Ta,le of Ta,les&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&; Ta,le of (?uations&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&7 =&0 ICT+:%U'TI:C&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&< 2&0 +(.S:CS 8:+ STU%"&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&> D&0 LIT(+.TU+( B.'!#+:UC%&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=D E&0 S"ST(M ':M5:C(CTS&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=; E&= Mani*ulation of 'oolant&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=; E&2 The 'ycle&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=7 E&D AThe BeastB&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=< F&0 (G5(+IM(CT.L %(SI#C&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&20 F&= Tools and Materials&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2= ;&0 M(T-:%:L:#"&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2E ;&= .dd3on System&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2F ;&2 Integral /%ro*3in0 System&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&27 7&0 %.T. .C.L"SISH'.L'UL.TI:CS&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2< 7&= +unning the System&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2< 7&2 (fficiency 'alculations&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D0 <&0 (V.LU.TI:CSH:BS(+V.TI:CS&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&DD <&= .dd3on System&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&DD <&2 %ro*3in System&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&DE <&D Both Systems&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&DF >&0 ':C'LUSI:CS .C% +(':M(CT%.TI:CS&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D; >&= :+CL versus Us&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D; >&2 8inal .nalysis&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D;

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=0&0 +eferences&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D7 ==&0 .55(C%(C%I'I(S&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D>

Ta!"e of #igures
8igure =& 5rice of natural gas in .merica data over the last F years /Source$ (nergy Information .dministration2 (I. 4e,site0&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=0 8igure 2& The changing *rices of electricity *er 9ilo4att3hour over the last =2 years /Source$ (I. 6e,site0&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&== 8igure D& (nergy sources are used to generate electricity in .merica& /Source$ I(. 4e,site0&&&&&&&&&&&&&&&&&&=2 8igure E& :+CL -56- testing facility&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=F 8igure F& Ty*ical results for ,oth an .dd3on unit and integral /%ro*3in0 unit Stage = start day =2 Stage 2 day <>2 Stage D day =7=2 Stage E day 2D>2 and Stage F day 27D&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=; 8igure ;& The a,ove image is an eva*oratorHcondenser& The visi,le coils are 4hat allo4 for energy e)change&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=7 8igure 7& . ty*ical va*or com*ression cycle on a T3s diagram2 refrigerant changes state and energy content as it cycles through our heat *um* 4ater heater&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=< 8igure <& The vessel on the ,ottom contained the indoor coil sho4n on the right and the unit on to* 4or9ed as the eva*orator of the system&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=> 8igure >& This *icture sho4s the suction line accumulator& This is the ,lac9 cylinder to the left of the *icture& The *um* used to circulate the 4ater through the system is sho4n on the right& &&&&&&&&&&&&&&&&&&&&&&&&&20 8igure =0& Both the 4att3hour meter and the digital clam* ammeter in use2 the 4att3hour meter 4asn@t used ,ecause the eva*orator@s rece*tacle 4asn@t the correct one& &&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2= 8igure ==& Ty*e3( thermocou*le 4ith the violet and red 4ires2 and the cement on thermocou*le 4ith its *erfect connection at the end and a *ad that is ready to stic93on any surface&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2D

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8igure =2& Schematic of the modified -56- system&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2F 8igure =D& 'ali,ration curve for all eight thermocou*les2 as you can see it 4ent from cold to hot ,ac9 do4n to cold again&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2; 8igure =E& 'ali,ration curve for an individual thermocou*le&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2; 8igure =F& 5V' *i*e through the to* of the 4ater tan9 /left02 and the *lacement of the five thermocou*les on the 5V' *i*e /right0&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&27 8igure =;& . schematic of the %ro*3in system&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&27 8igure =7& .ttached thermocou*les and through the *urge 4hole of the vessel&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2< 8igure =<& La,Vie4TM 8ront *anel for the .dd3on unit&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&2> 8igure =>& La,Vie4TM 8ront *anel of the %ro*3in unit&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D0 8igure 20& ((S out*ut and e?uation 4indo4 for the .dd3on -56- system&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D= 8igure 2=& ':5 calculation for the %ro*3in system&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D2 8igure 22& Tem*erature *rofiles and the system ':5s ,oth as a function of time&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D2 8igure 2D& The ,all valve at the ,ottom of the tan9&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&DD 8igure 2E& Lea9 from the to* of the tan92 and a lea9 from the vessel&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&DE 8igure 2F& +esults of ,oth :+CL and the *ro1ect@s system&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D;

Ta!"e of Ta!"es
Ta,le =& :*erating conditions for each stage of dura,ility test *rotocol&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&=F Ta,le 2& Sho4s the distinct characteristics of Ty*e3( thermocou*les&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&22

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Ta!"e of E$uations
/=0&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D0 /20&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D= /D0&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&&D=

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%&' (NTROD)CT(ON
-eat *um* 4ater heating technology com,ines heat *um* and 4ater heating methods to *rovide a more efficient yet e?ually *o4erful 4ater heating solution for the ty*ical household& %e*ending on the am,ient and 4ater tem*eratures2 -56- systems can sometimes *erform u* to 2 to D times more efficiently then

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that of a conventional electric resistance 4ater heater& #iven that efficiencies are that high2 this 4ould mean that -56- systems could *roduce 4aters at the same tem*eratures of a conventional system at one3third the cost& This *ro1ect 4as designed to test the dura,ility of ,oth an .dd3on heat *um* 4ater heater and an integral heat *um* 4ater heater2 4hich 4e 4ill call a A%ro*3inB system throughout this re*ort& The design modified conventional air3to3air heat *um* indoor and outdoor units to create the final heat *um* 4ater heater used for testing& The methodology and ,asic *ro1ect schema 4ere ,ased on t4o studies conducted ,y the :a9 +idge Cational La,oratory& Similar to that of the :a9 +idge studies2 ,oth a modified .dd3on and modified %ro*3in 4ater heaters 4ere used for this *ro1ect@s dura,ility testing2 and although not as e)tensive2 many of the instruments and materials used in this *ro1ect 4ere very similar to those used at :a9 +idge& Some of the instrumentation used in this *ro1ect included eight Ty*e3( thermocou*les2 a data ac?uisition unit to *rovide a connection to a La,Vie4TM interface2 4att3hour meters2 and the s*ecific -56- com*onents&

*&' REASONS #OR ST)D+

6hy is it im*ortant to study and develo* heat *um* 4ater heater technologiesI This ?uestion 4as a**roached from ,oth a glo,al stand*oint as 4ell as a local stand*oint& 8irst of all2 there have ,een studies done that sho4 that a heat *um* 4ater heater could *rove to ,e more efficient than the 4ater heaters that are currently *revalent in .merica& This means that 4hile consuming the same amount of

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in*ut energy they are ca*a,le of out*utting more heat& (fficiency is an e)tremely im*ortant as*ect to energy ,ecause every accom*lishment made 4ill allo4 for less consum*tion of energy ,y the average user of a *roduct2 and ho*efully ,y everyone together as 4ell& The lessening of overall consum*tion can mean many things to many *eo*le& 6e 4ill ,e discussing an individual@s reasons for consuming less as 4ell as reasons to consume less as a society& .merican homes currently use natural gas 4ater heaters or electrically driven 4ater heaters& Both of these 9inds of 4ater heaters de*end on an energy mar9et that can ,e ?uite s*oradic& .s you can see in igure !2 natural gas *rices over the last fe4 years have ,een going u* steadily since 200D&

#igure %& 5rice of natural gas in .merica data over the last F years /Source" (nergy Information .dministration2 (I. 4e,site0

'osts vary seasonally ,ut have ,een trending u* for ?uite some time& The red line is of *rinci*le concern in this situation& It sho4s the *rice that the average consumer in .merica *ays for natural gas& Catural gas is commonly used for home heating2 coo9ing2 and 4ater heating& If a family is de*endent u*on a mar9et that can change every fe4 months they are *utting themselves at ris9& Many factors can contri,ute to a ra*id change in natural gas *rices& A. commodity@s *rice can reflect the influence of random events2 such as oil em,argos2 *i*eline ru*tures2 hurricanes2 and a,normally cold or hot tem*eratures& Catural gas *rices certainly have ,een influenced ,y such random events& 8or e)am*le2 during a 234ee9 *eriod in 8e,ruary =>>;2 -enry -u, s*ot *rices 4ent a,ove JF&00 *er thousand cu,ic feet ,ecause of unseasona,ly cold tem*eratures&=B The truth is that there are 1ust too many things that can go 4rong in the natural gas mar9et& 6e have seen some 4ild s4ings in *rices over time due to things li9e Aunusual coldB2 ,ut it has not ,een so long since the *etroleum mar9et 4as su,1ect to huge changes& The *oint is that modern consumers are de*endent u*on unsta,le energy mar9ets and that that de*endence could cause economic *ro,lems in many different scenarios&

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6ater heaters that are currently on the mar9et are heavily de*endent on volatile energy sources 4hich can cost the average lo4 income home o4ner& It 4as 4ith these users in mind that 4e *ursued the develo*ment of heat *um* 4ater heater technologies& :ur system needs only electricity to run2 and electricity is a ,etter alternative than a direct fossil fuel mar9et& The electricity mar9et is made u* of many different fuel sources& It has sho4n the a,ility to fluctuate2 ,ut overall is has remained fairly sta,le over the last decade or so& igure # sho4s the electricity mar9et over the last decade& . heat *um* 4ater heater 4ould ,e de*endent u*on electricity2 ,ut could *rove to ,e ?uite valua,le ,ecause of its higher efficiency&

#igure *& The changing *rices of electricity *er 9ilo4att3hour over the last =2 years / Source" (I.

6e,site0 The availa,ility of domestic sources2 sta,le infrastructure and government regulation are 1ust some reasons 4hy the electricity mar9et has ,een far more sta,le than other energy mar9ets& Many *eo*le ,oth nationally and 4orld4ide 4ould ,enefit from having a 4ater heater that is consistently chea* and relia,le& In fact it is these three factors along 4ith safety that encom*ass all that *eo*le 4ant from their energy com*anies& If the develo*ment of our system can hel* to achieve that situation2 then 4e are hel*ing to im*rove *eo*le@s lives& There are even cleaner forms of energy *roduction out there& There are solar 4ater heaters that may ,e com*ara,le to our system2 ,ut solar technologies are not fully ca*a,le of meeting the demands of a modern household yet& Solar technologies are still e)*ensive and im*lementation of these systems in the average home is still many years a4ay& Many *eo*le cannot

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afford to 9ee* u* 4ith the ra*id changes associated 4ith solar energy2 along 4ith other energy sources& :ur system is a small change to a currently im*lemented system that if a**lica,le could ,e added to homes very soon& The average *erson could ,enefit greatly in ,oth the short run and long run if heat *um* 4ater heaters are researched and found to ,e as useful as 4e foresee them to ,e& . sim*le2 chea* installation 4ould allo4 lo4 income consumers to use heating and cooling e?ui*ment they already o4n to su**lement their 4ater heating or re*lace it entirely& This 4ould ,e a great o*tion for individuals2 and mass im*lementation could ,e even more ,eneficial& 6e also chose to study heat *um* 4ater heaters from a more glo,al *ers*ective& 6hen 4e tal9 a,out residential energy use 4e are usually tal9ing a,out consum*tion of fossil fuels& 6henever 4e tal9 a,out the negative effects of fossil fuel use 4e are tal9ing a,out glo,al climate change& .s seen in igure $% most of the energy economy in .merica is ,uilt on fossil fuels&

#igure ,& (nergy sources are used to generate electricity in .merica& / Source" I(. 4e,site0

The ,urning of natural gas2 coal2 *etroleum or other car,on3,ased fuels has documented negative effects& AThese include human health *ro,lems caused ,y air *ollution from the ,urning of coal and oil7 damage to land from coal mining and to miners from ,lac9 lung disease7 environmental degradation caused ,y glo,al 4arming2 acid rain2 and 4ater *ollution7 and national security costs2 such as *rotecting foreign sources of oil&2B -o4 4ould a heat *um* 4ater heater that runs off of electricity hel* in the fight against glo,al climate changeI The ans4er is any energy that is saved through efficiency lessens the emissions necessary for heating 4ater& The goal of this *ro1ect is to study and develo* a ne4 technology& This technology could *rove to ,e significantly more efficient than *revious 4ater heaters& If these -56-s are more efficient than currently *o*ular 4ater heaters then energy units are ,eing saved that 4ould

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normally ,e used ,y a less efficient system& (very unit of energy that is dis*laced ,y these ne4 technologies means less energy needs to ,e made& If that energy does not have to ,e *roduced then that means that less fossil fuel need to ,e ,urned to *roduce that energy& The reasons 4hy 4e decided to study -56-s 4as to see if they could fit into the real 4orld economy and hel* lo4 income homes as 4ell as drive do4n energy needs 4ith efficiency to limit fossil fuel ,urning&

,&' L(TERAT)RE BACKGRO)ND

This *ro1ect 4as ,ased on2 &Durability Testing of a Drop'in (eat )ump *ater (eaterD%+ and &(eat )ump *ater (eater Durability Testing' )hase IIE%+ t4o studies *erformed ,y :a9 +idge Cational La,oratory on -eat 5um* 6ater -eaters com*leted in May 20022 and May 200E res*ectively& In the studies :+CL states that since -56- systems 4ere ,asically a novel technology and haven@t made there mar9 in industry2 there 4as no real measurements of the dura,ility and efficiencies on these ty*es of systems& So the overall goal of their *ro1ect 4as to Aidentify design and com*onent 4ea9nesses that could im*act the relia,ility and *erformance of the -56- over =0 years of simulated residential use&B

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To test for efficiency and dura,ility ten -56-s 4ere *laced in an environmentally controlled test facility& 8ive systems 4ere u*graded %ro*3in 4ater heater systems2 and five units 4ere .dd3on ty*e of units2 4hich connected to a conventional -56- system& :a9 +idge then simulated the ty*ical lifes*an of a conventional 4ater heater 4hich 4as a**ro)imately 73=0 years of normal o*eration to meet the hot 4ater needs of a residence& The average lifetime of an electric 4ater heater is around == years2 and that of a gas 4ater heater is around > years& To a**ro)imate this num,er they calculated the average daily duty cycles of conventional 4ater heaters and multi*lied this ,y their average o*eration times in days and years& This num,er came out to ,e roughly 7D00 cycles& They 4ere a,le to conduct these tests in a**ro)imately a total of 200 days of testing& igure , sho4s the ,asic setu* of .dd3on and %ro*3in 4ater heaters used to conduct their tests& The facility used 4as designed and ,uilt ,y :a9 +idge in their res*onse to *rovide a controlled environment so that they could ,e tested in a Areal 4orld environment&B 8ive stage tests 4ere simulated2 and each stage 4as used to re*roduce the different conditions a -56- might have to go through 4hen in o*eration& Table ! sho4s the different *arameters used to simulate these tests& The different locations used to simulate these stages ranged from Jac9sonville 8L2 Los .ngeles '. to Boston M.& These tem*eratures and humidity@s of these areas re*resented different moisture content in the am,ient air and different areas in 4here the -56- may ,e *laced2 for instance2 in a garage or ,asement&

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#igure -& :+CL -56- testing facility

Ta!"e %& :*erating conditions for each stage of dura,ility test *rotocol

5rimary and secondary loo*s 4ere used for the *ur*ose of *roviding cold and hot 4ater to each test unit according to their individual demand& Instrumentation for the different -56-s used in the study included flo4 controls2 monitoring valves2 thermocou*les2 data ac?uisition devices2 and much more to follo4 through 4ith their overall *lan& The t4o efficiency measurements :+CL 4anted to find from their e)*eriment 4ere the (nergy 8actor /(80 and 'oefficient of 5erformance /':50 4hich 4ill ,e e)*lained later& :+CL found that the tests and results 4ere similar to those found in the first dura,ility test& igure - sho4s e)am*le results of ,oth an .dd3on unit and a ty*ical %ro*3in unit& 8rom igure - one can see that the tem*erature variations for an .dd3on unit 4ere *retty drastic& There 4as a lot more fluctuation in tem*erature in the .dd3on unit as o**osed to the integral unit& .fter all the *re3tests and *ost3tests 4ere e)amined :+CL concluded that on an overall ,asis2 -56-s 4ere a,le to *erform more efficient than that of the conventional electric and gas 4ater heaters& (nergy factors and coefficient of *erformances for the tested -56-s in :+CL 4ere considera,ly ,etter than that of conventional electric and gas 4ater heaters& 8rom their study2 :+CL 4as a,le to conclude that the -56-s 4ere a,le to *erform ,etter than the (6/(lectric 6ater -eater0 2 and they did not degrade very much over time& 8rom some *ost test o,servations ?uality issues 4ere addressed2 and only s*ecific *arts did degrade ,ut 4ere easy to re*lace& (fficiency standards for the -56-s also did not degrade over their lifecycles either&

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Figure 5. Ty*ical results for ,oth an .dd3on unit and integral /%ro*3in0 unit Stage = start day =2 Stage 2

day <>2 Stage D day =7=2 Stage E day 2D>2 and Stage F day 27D&

-&' S+STE

CO PONENTS

In this section 4e 4ill discuss the ho4 our system 4or9s and ,asic com*onents that ma9e u* the 4ater heater& :ur 4ater heater is a converted air3to3air heat *um* unit2 so it has all of the same *ieces 1ust organiKed a little differently&

-&%

anipu"ation of Coo"ant

:ur system transfers energy from 4arm air to cold 4ater through the medium of a refrigerant /-'8'3220& . refrigerant is a heat transfer fluid that has a high thermal ca*acity& This means that 4hen e)*osed to am,ient air tem*eratures it can still 4ithdra4 energy from its surrounding environment 4hen it is at a lo4 *ressure and lo4 tem*erature& The same refrigerant at high *ressure can ,e far richer in energy& This system allo4s for the refrigerant to ,e 4armed and *ressuriKed to a very high energy state ,efore it enters the condenser and at a very lo4 energy state ,efore it enters the eva*orator& 5ro*er mani*ulation of refrigerant allo4s for ?uic9 and easy transfer of energy through a heat *um* 4ater heater&

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(va*orators and condensers are very similar in structure and o**osite in function& They are ,oth a series of coils that allo4 the refrigerant to *ass through a system 4ith a large amount of surface area& It is this surface area that *romotes ma)imum heat e)change ,et4een the refrigerant fluid and the outside environment& . condenser is a system of coils 4here high energy refrigerant dissi*ates energy to the outside environment and an eva*orator is 4hen lo4 energy refrigerant is allo4ed to a,sor, energy from the outside environment& .n eva*oratorHcondenser can ,e seen in igure .&

Figure 6. The a,ove image is an eva*oratorHcondenser& The visi,le coils are 4hat allo4 for energy

e)change& There 4ere other com*onents of our system that *layed a 9ey role in refrigerant mani*ulation& It 4as this mani*ulation that allo4ed for the energy to e)change from the outside air to the 4ater& There 4ere other *ieces of our system that cycled the refrigerant and moved energy from the outside environment into the 4ater&

-&* T.e C/0"e

(ach *iece of the system hel*s to *re*are the refrigerant for high and lo4 energy environments& Before the refrigerant enters the cold 4ater 4ith lo4 energy2 4e 4ant it to ,e of a very high energy2 so that it can dum* the ma)imum amount of heat energy into the 4ater& It is the o**osite 4hen the refrigerant is going to interact 4ith the am,ient tem*erature& The com*ressor2 condenser2 e)*ansion valve2 eva*orator and accumulator all 4or9 in a cycle to move the most energy *ossi,le through the system& The com*ressor changes the refrigerant from a lo4 *ressure and lo4 tem*erature va*or into a high *ressure and high tem*erature va*or& This change *re*ares the refrigerant to dum* energy into a less energy intensive environment& The condenser is used to *ass that high energy into the 4ater& 6hen the refrigerant leaves the condenser it has lost a significant amount of its energy& The e)*ansion valve allo4s the refrigerant to significantly lo4er in *ressure and tem*erature& 6hen the refrigerant leaves the e)*ansion valve it is a mi)ture of li?uid and gas& This state is *erfect for a,sor,ing energy2 4hich it is a,out to do in the eva*orator& 6hen in the eva*orator2 the refrigerant is e)*osed to the am,ient tem*erature of the outside

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environment& -ere it suc9s heat energy through diffusion from the outside air& .fter the eva*orator2 the refrigerant should ,e com*letely a gas2 ,ut sometimes it is still *artially li?uid& The natural ne)t stem in the cycle 4ould move the refrigerant ,ac9 into the com*ressor2 ,ut li?uid could damage the com*ressor& 8or this reason 4e have an accumulator in *lace to ensure no li?uid enters the condenser and damages the system& This cycle is sho4n in igure / ,elo4& The energy in the system moves counter3cloc94ise& 6hen the red line is moving u*2 that sho4s the elevation in energy content caused ,y the com*ressor& 'onversely 4hen the red line is moving do4n2 that is also the energy level changing due to the e)*ansion valve& The t4o horiKontal lines re*resent the condenser and eva*orator2 and that is 4hen the energy in the system moves&

Figure 7. . ty*ical va*or com*ression cycle on a T3s diagram2 refrigerant changes state and energy

content as it cycles through our heat *um* 4ater heater& It is through these ste*s that the outside air is used to *um* heat into 4ater& The refrigerant and the *ro*er 4or9ing of the system causes ma)imum energy efficiency as the heat from the environment is *assed into the energy sin92 in this case the 4ater tan9&

-&, 1T.e Beast2

The system itself 4as ,uilt ,y +o,ert Landes2 a so*homore IS.T student2 a certified refrigeration mechanic& -e distinguished the name AThe BeastB for its large siKe and *o4erful demeanor& It contained com*onents of the ,asic -56-2 and 4as a,le to *erform in that manner& System com*onents consisted of indoor and outdoor units2 a 4ater *um*2 an <0 gallon 4ater tan92 and a suction line accumulator&

-&,&% T.e Outdoor and (ndoor )nits

The heat *um* unit 4as a Lenno) (liteL Series -SE2 2> air3to3air heat *um*& 6ithin this unit there is a com*ressor& The refrigerant used ,y this system 4as -'8'322& This air3to3air heat *um* unit has a cooling ca*acity of u* to E22000 Btus /British Thermal Units0 every hour& This is the e?uivalent of a,out =2&D 9ilo4atts of cooling ca*acity /energy rate0& The com*ressor has a 2;&F .m* Min '!T .m*acity2 and one fan motor re?uires an average voltage ,et4een 20< and 2DF and runs using a,out =H; th of a horse

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*o4er& +o, Landes modified this system so that the refrigerant circulated in the o**osite direction2 *ulling heat out of the air and dum*ing it into the 4ater tan9& If there 4as no modification made to the system2 the vessel 4ould have had to house the outdoor unit inside of it& 6e 4eren@t *lanning to house the unit2 so o*ted out on a much ,igger eva*orator rather than condenser& igure 0 sho4s ,oth the modified heat *um* and the tan9 4ith a su,merged indoor unit and the outdoor unit on to* of it& The indoor unit 4as 9e*t inside of a vessel2 4hich 4as calculated to hold a ca*acity of E0 gallons /&=F2= mD0& 6ith the E ro4 unit inside of the vessel the ca*acity dro**ed to a**ro)imately D< gallons of 4ater& This vessel 4ould later act as the tan9 for the integral unit&

Figure 8. The vessel on the ,ottom contained the indoor coil sho4n on the right and the unit on to*

4or9ed as the eva*orator of the system

-&,&* Rest of S/stem

Besides the air conditioning unit2 a suction line accumulator2 4ater *um*2 and 4ater tan9 had to ,e im*lemented for the system to 4or9& .s mentioned ,efore the suction line accumulator is in *lace to ensure that the refrigerant that enters the com*ressor is entirely va*or2 thus it acts li9e a ,uffer& The com*ressor is ,uilt to handle va*or only and if li?uid entered the com*ressor it could ,e damaged&

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Figure 9. This *icture sho4s the suction line accumulator& This is the ,lac9 cylinder to the left of the

*icture& The *um* used to circulate the 4ater through the system is sho4n on the right& The *um* 4as res*onsi,le for moving the 4ater through the vessel and into the storage tan9& 'irculation 4as im*ortant to the system as a 4hole ,ecause the vessel itself could not hold enough 4ater necessary for an average sho4er& .n <0 gallon 4ater tan9 4as used to store the 4ater and to o,serve the stratification that occurred as the 4ater cycled through the system& To o,serve stratification the hottest 4ater 4as to come through the to*2 and at the coldest *arts of the 4ater ran through the ,ottom of the tan9& 8or a normal sho4er to ,e ta9en the hottest 4ater 4ould ,e ta9en off the to* 4hile the cooler 4ater 4as 9e*t at the ,ottom&

3&' E4PER( ENTAL DES(GN

The system configuration used for this *ro1ect 4as ,ased on the system configuration from that of the :a9 +idge Study and methodology& In the study :+CL 4as a,le to test ,oth the .dd3on and %ro*3in systems& Their configuration included attaching thermocou*les throughout the system2 s*ecifically the am,ient air tem*erature2 4ater tem*eratures2 and into and out of the condenser& :nce the ,asics com*onents 4ere attached2 the system 4as run until a desired out*ut of roughly =20M8 4as o,tained2

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4hich is a**ro)imately Ahot sho4erB tem*erature& Li9e that of the :+CL study the coefficient of *erformance 4as to ,e measured and o,tained to calculate the efficiency of the system& -o4ever2 :+CL also calculated the energy factor of the systems and this *ro1ect didn@t ta9e that into account&

3&% Too"s and

ateria"s

The tools of the system 4ere *ro,a,ly one of the most integral *arts of the overall analysis and readings& 6ithout them 4e 4ouldn@t ,e a,le to ma9e an overall analysis or coefficient of *erformance calculation& The materials and tools used for the system 4ere *retty ,asic com*ared to those used ,y :+CL& -o4ever2 they gave us a *retty ,asic measurement similar to that of :+CL2 and allo4ed us to see 4hat goes into *erforming an analytical calculation similar to that of :+CL& %ifferent tools used in this *ro1ect ranged from2 4att3hour meters2 thermocou*les2 La,Vie4 TM2 and data ac?uisition devices 4ere all used in this *ro1ect&

3&%&% Watt5.our

eter

Li9e an electricity meter a 4att3hour meter is a device that measures the amount of electricity energy su**lied to a house2 device2 or ,usiness& :riginally2 the 6atts U*I 5ro (S *o4er meter 4as *urchased to read the *o4er out*utted ,y the *um* and eva*orator& -o4ever2 through am*erage constraints and 4rong rece*tacle and *lug ty*es a ne4 *o4er meter 4as used& . digital clam* ammeter for .' currents2 manufactured ,y T(CM.2 4as used to read the rising am*erage of the system& 8or correct use there had to ,e a s*lit ,et4een the ground and the active lines of the cord2 4hich 4as *retty dangerous2 ho4ever2 4ith some electrical ta*e and safety *recautions2 ris9 of electrocution 4as 9e*t at a minimum& igure !1 sho4s ,oth the 6atts U5I 5ro (S and the digital clam* in use&

Figure 10. Both the 4att3hour meter and the digital clam* ammeter in use2 the 4att3hour meter 4asn@t

used ,ecause the eva*orator@s rece*tacle 4asn@t the correct one&

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3&%&* Data A0$uisition De6i0e

%ata .c?uisition %evices are devices that ta9e real 4orld data and from that data mani*ulate them using a com*uter& 8or the thermocou*le readings to interface 4ith La,Vie4 TM a thermocou*le interface card /T'I'0 4as used to *rovide this connection& :riginally2 4e meant to use t4o devices manufactured ,y Cational Instruments& -o4ever2 4hen they 4ere in use 4e couldn@t seem to get the correct tem*eratures or signals out from them& There 4as too much noise 4ithin the cards2 4hich gave inaccurate readings& Therefore2 the :M(#. -igh S*eed < 'hannel card 4as *urchased and used for this *ro1ect& :nce im*lemented2 the :M(#. device *rovided more accurate tem*erature readings and a *erformed much ,etter than the original devices&

3&%&, T.ermo0oup"es
Thermocou*les are tem*erature sensors and their ,asic *ur*ose is to convert the thermal *otential difference into an electrical *otential difference out*utted onto a com*uter& Thermocou*les are *retty easy to im*lement and can measure 4ide ranges of tem*eratures2 ho4ever2 *recision in tem*erature readings is their main limitation& 8or this *ro1ect Ty*e3( thermocou*les 4ere used to measure the tem*eratures throughout the 4ater tan92 am,ient air tem*eratures2 and the tem*eratures into and out of the condenser& To create the thermocou*les the ti*s of the ty*e3( 4ire had to ,e soldered correctly so the ti*s touched and the *otential difference could ,e read throughout the 4ire& This involved using a soldering iron and connecting the ti*s so that there could ,e a direct connection& :ne *ro,lem 4e encountered 4as that t4o thermocou*les 4e soldered didn@t ta9e the tem*eratures from the co**er tu,ing surface in and out of the condenser and 4e had to *urchase ne4 thermocou*les that 4ould ,e a,le to read the tem*eratures& :ne solution 4e found 4as to use cement3on thermocou*les 4hich ,asically had a finer ti* than 4hat 4e soldered and stuc9 directly to the surface of the condenser co**er tu,ing& igure !! sho4s the ,asic ty*e3 ( thermocou*le 4ire and a cement3on thermocou*le used to find the tem*eratures going into and out of the condenser& Table # sho4s the accuracy range and resolution of a ty*e3( thermocou*le&
Table 2. Sho4s the distinct characteristics of Ty*e3( thermocou*les

(nput T/pe E

Range 3200 to =000N' /3D2< to =<D2N80

A00ura0/7 89C: O=&F

Reso"ution 89C: 0&0=F

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Figure 11. Ty*e3( thermocou*le 4ith the violet and red 4ires2 and the cement on thermocou*le 4ith its

*erfect connection at the end and a *ad that is ready to stic93on any surface&

3&%&- La!;ie<T
To *erform the calculations and analysis of the coefficient of *erformance the data ac?uisition device@s readings 4ouldn@t have ,een a,le to ,e ta9en 4ithout La,Vie4TM& The La,oratory Virtual Instrumentation (ngineering 6or9,ench /La,Vie4TM0 uses dataflo4 language to structure gra*hical ,loc9 diagrams to *erform data ac?uisition2 instrumentation control2 and industrial automation to *erform visual and analytical analyses of a system& 8or this *ro1ect La,Vie4 TM 4as used to ac?uire tem*erature readings throughout the system and these tem*eratures 4ere then e)*orted the data into ()cel& It *rovided a *ractical user interface 4hich 4ould hel* us e)*ort our data and let us see the data ac?uisition in real time as it 4as ha**ening& It 4as et to ta9e a**ro)imately 2 measurements every second&

3&%&3 Engineering E$uation So"6er 8EES:

(ngineering (?uation Solver also 9no4n as ((S 4as used to *erform the uncertainty analysis on the ':5 of the system& It hel*ed 4ith the ,uilt3in thermodynamic *ro*erty information2 and 4ould *erform an uncertainty analysis ,ased on the system com*onents automatically& By *rogramming in the systems e?uations2 varia,les2 and uncertainty of each measurant2 a ':5 analyses 4as calculated and a**lied 4ithout any trou,le&

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=&'

ETHODOLOG+

The methodology for this *ro1ect 4as ,ased of the same system configuration and methodology *erformed off the :a9 +idge Cational La,oratory study& The fundamental methodology consisted of attaching the thermocou*les throughout the tan92 and to the condenser in and out& :nce all the thermocou*les 4ere attached run and monitor the system until the desired out*ut 4as o,tained2 4hich 4as different from :a9 +idge 4ho ran it for the lifetime of the -56-& :nce the desired out*ut 4as o,tained *erform an analysis and calculate the 'oefficient of 5erformance2 the efficiency of the system& This same methodology 4ould first ,e a**lied to the .dd3on System and later the %ro*3in system&

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=&% Add5on S/stem

The original *lan for this *ro1ect 4as to test the efficiency and o,tain the coefficient of *erformance for a modified .dd3on heat *um* 4ater heater& igure !# sho4s a schematic of the modified .dd3on -56used in this *ro1ect& 8ive thermocou*les 4ere *laced throughout the 4ater tan92 t4o thermocou*les on the in and out of the condenser and one thermocou*le to measure the am,ient tem*erature& .s de*icted in igure !# the 4ater loo* occurred on the ,ottom of the tan9 to the to* and the refrigerant loo* occurred 4ithin the vessel and eva*orator& Through stratification hot 4ater flo4ed to the to* of the tan9 4here the coldest 4ater flo4ed out of the tan9 through the ,ottom&

Figure 12. Schematic of the modified -56- system

=&%&% Ca"i!ration of T.ermo0oup"e

To *re*are for accurate tem*erature readings 4e first had to cali,rate all the thermocou*les then install the thermocou*les ,ased on the system configuration& 'ali,ration of the thermocou*les 4as a very sim*le *rocess& 'ali,ration is ,asically the *rocess of determining the relation ,et4een an out*ut /in our case the tem*erature0 and the value of the true in*ut& 6e are fundamentally trying to get all the thermocou*les to read a standard measurement tem*erature& 'ali,ration of the < ty*e3( thermocou*les involved a ,ea9er of freeKing ice 4ater at tem*eratures near or close to 0 ' and a ,ea9er of ,oiling hot 4ater at tem*eratures roughly around =00' on a hot *late& The ne)t ste* involves using La,Vie4TM to e)*ort the data out into ()cel& Therefore2 after starting the La,Vie4TM *rogram 4e then di**ed all < thermocou*les into to the cold icy 4ater2 then after a num,er of seconds ?uic9ly moved the ,undle from the cold 4ater to the hot 4ater and 4aited around 2 to D minutes until the tem*eratures 4ere close to that of the hot 4ater tem*erature of =00'& .fter reading the out*utted data 4e 4ere a,le to o,tain cali,ration curves for each

25 |

individual thermocou*le and that 4as the cali,ration curve for each thermocou*le 4ithin La,Vie4 TM& igures !$ and !, sho4 the overall cali,ration curves of the < thermocou*les and an individual cali,ration curve of one thermocou*le&

Figure 13. 'ali,ration curve for all eight thermocou*les2 as you can see it 4ent from cold to hot ,ac9

do4n to cold again

Figure 14. 'ali,ration curve for an individual thermocou*le

=&%&* (nsta""ation of t.e T.ermo0oup"es

8or the .dd3on system five thermocou*les 4ere *laced throughout the 4ater tan9& .fter the cali,ration 4e had to find a *iece of material small enough to fit the diameter of the o*ening in the 4ater heater& . 5V' *i*e 4as chosen ,ecause the diameter of the o*ening 4as less the P inch& The tan9 height 4as a**ro)imately F feet so every thermocou*le 4as *laced roughly one foot a4ay from each other& 6ith this configuration stratification 4ithin the 4ater tan9 could ,e o,served2 the hottest 4ater at the to* of the 4ater tan9 and the coldest 4ater at the ,ottom of the tan9& .s de*icted ,y igure !- the diameter of the o*ening at the to* of the 4ater tan9 4as fairly small2 and the 5V' ,arely fit through that o*ening& .s

26 |

de*icted in the .dd3on schematic2 five thermocou*les 4ere *laced throughout the 4ater tan92 and three thermocou*les 4ere *laced as the am,ient tem*erature2 and the condenser inlet and outlet&

Figure 15. 5V' *i*e through the to* of the 4ater tan9 /left02 and the *lacement of the five thermocou*les

on the 5V' *i*e /right0&

=&* (ntegra" 8Drop5in: S/stem

Very similar to that of the .dd3on system2 the %ro*3in -56- had the same *ur*ose of heating u* 4ater& -o4ever2 instead of heating u* the se*arate 4ater tan92 4e measured the tem*erature of the 4ater 4ithin the vessel& igure !. sho4s a schematic of a dro* in system& T4o *arts 4ere ta9en out of the .dd3on system ,ecause they 4ere not needed& They 4ere the 4ater tan92 and the *um*& Instead of heating u* the 4ater tan92 the D< gallon vessel 4as used&

Figure 16. . schematic of the %ro*3in system

27 |

=&*&% (nsta""ation of T.ermo0oup"es

Instead of ta9ing five measurements in the vessel li9e in the .dd3on system2 three measurements sufficed& To get the thermocou*les into the 4ater vessel they 4ere attached to a very thin 4ire and *ut through a *urge hole that 4as used to *urge *ressure& igure !/ sho4s 4here the thermocou*les 4ere installed in the vessel and the 4ire that the thermocou*les 4ere attached to&

Figure 17. .ttached thermocou*les and through the *urge 4hole of the vessel

>&' DATA ANAL+S(S?CALC)LAT(ONS

The overall goal for this *ro1ect 4as to run the system to its desired out*ut of a**ro)imately =20 8& :nce this tem*erature 4as o,tained the coefficient of *erformance 4ould then ,e calculated and analyKed&

>&% Running t.e S/stem

6e ran the system for ,oth an .dd3on -56- and a %ro*3in -56-& igures !0 and !2 sho4 the La,Vie4TM front *anel that 4as used for each of the systems& 6ithout La,Vie4 TM the data 4ouldn@t have ,een a,le to ,e o,tained through ()cel& 6hile the system ran the La,Vie4TM front *anel allo4ed us to see the tem*erature fluctuations and stratification o,served in the 4ater tan9&

28 |

Figure 18. La,Vie4TM 8ront *anel for the .dd3on unit

29 |

Figure 19. La,Vie4TM 8ront *anel of the %ro*3in unit

>&* Effi0ien0/ Ca"0u"ations

The -56- industry relies on t4o inde)es of energy efficiency they are the coefficient of *erformance /':50 and the energy factor /(80& The ':5 is a measure of instantaneous energy out*ut of a system in com*arison 4ith its instantaneous energy in*ut& The (8 is a measure of a 4ater heater@s overall energy efficiency ,ased on the amount of hot 4ater *roduced *er unit of fuel consumed over a ty*ical day& Three factors that hel* calculate the (8 are the recovery efficiency2 stand,y losses2 and cycling losses throughout the -56-& .verage ':5s of a -56- range from =&03D&02 as average (8 for a -56- ranges from 0&F32&0& :+CL 4as a,le to calculate the (8 and ':5s of their systems& -o4ever2 this *ro1ect only calculated the ':5 of the system2 ,ecause of time constraints and com*lications 4hich 4ill ,e discussed in later sections it 4as not run for the full lifetime of the system& The efficiency e?uation for anything is usually out*ut over in*ut& The e?uations ,elo4 sho4 the ,asic ste*s in finding the ':5 of a heat *um* 4ater heater&
COPHP = QH %esired :ut*ut = +e?uired In*ut Wnet ,in
(1)

30 |

Q H = mc p T

6here2 m = mass [ 9g ] = T f Ti

c p = s*ecific heat 9JH9g 3 o C

8*:

Wnet ,in = 5o4er Time

6here2 5o4er = I V [ 6atts] Time = Time [ hrs ]

(3)

To o,tain the ':5 from our data out*ut 4e first had to *ic9 an instance of time 4here 4e thought all tem*eratures 4ithin the 4ater tan9 4as the highest& 6e then a**lied the a,ove e?uations into ((S 4here 4e 4ere a,le to calculate each *art of the e?uation and ':5&

>&*&% Add5on S/stem Ca"0u"ations

igure #1 sho4s the ((S out*ut and in*ut of the .dd3on -56-& .s you can see ((S 4as *retty easy to use to calculate ,oth the ':5 and any other calculations needed&

Figure 20. ((S out*ut and e?uation 4indo4 for the .dd3on -56- system

.s you can see the ':5 of the .dd3on system 4as ?uite lo4& This ha**ened ,ecause of many factors that affected the system discussed in later sections& ((S 4as also a,le to calculate an uncertainty analysis attri,ute to the system2 mainly lea9s and cutting and turning on the *um*& This 4as automatic and too9 the tedious *rocess of long calculations of *artial derivatives and num,ers a4ay&

>&*&* Drop5in S/stem Ca"0u"ation

.s you can see in igure #!2 the %ro*3in system configuration 4or9ed out much ,etter than that of the .dd3on system& It fi)ed a num,er of factors that affected that of the .dd3on&

31 |

Figure 21. ':5 calculation for the %ro*3in system

The ':5 for the %ro*3in system 4as much higher than that of the .dd3on system& This 4as ,ecause there 4as no heat loss through the 4ater loo* and room for error& Li9e the .dd3on system calculations ((S *rovided an uncertainty analysis so that tedious calculations 4ouldn@t have to ,e made& 6ith this calculation already in*utted into the *rogram made life a lot easier& .s de*icted in igure ## the stratification of the tem*eratures can ,e o,served& This 4as only for three thermocou*les *ut throughout the vessel& .lso in igure ## the ':5 *rofile of our system 4as *retty good2 and the system 4as most efficient at D0 minutes2 and 4e ran the system to a**ro)imately ;0 minutes& The ':5 started to dro* after it reached its high ,ecause the efficiency of the eva*orator started to dro*& +efrigerant inside the eva*orator got 4armer and couldn@t ,ring in any more energy from the am,ient air&

Figure 22. Tem*erature *rofiles and the system ':5s ,oth as a function of time

32 |

@&' E;AL)AT(ONS?OBSER;AT(ONS
Theoretically2 the configuration for this *ro1ect should have 4or9ed out ?uite 4ell and the efficiency of the system should have ,een ?uite high& -o4ever2 there 4ere many com*lications ,rought on 4ith the system& (ach system had its se*arate set of errors ho4ever2 this configured -56- system 4or9ed as it 4as su**osed to and ended u* 4or9ing out ?uite 4ell&

@&% Add5on S/stem

Many of the *ro,lems encountered throughout this system occurred 4hile the .dd3on system 4as ,eing used& The main *ro,lem encountered 4as flo4 rate differences& Unli9e that of :+CL2 this system had no flo4 rate controls2 4hich controls the amount of flo4 into and out of all the o*enings and throughout the *i*e& :nce the thermocou*les 4ere installed inside the 4ater tan9 4e noticed that the 4ater 4ould flo4 into the tan92 ,ut the 4ater didn@t flo4 out of the ,ottom of fast enough as the *um* 4as *um*ing in the 4ater& igure #$ sho4s the o*ening of the tan9 and ho4 the ,all valve at the ,ottom restricted the flo4 of the 4ater into the hose& This resulted in the ,uild u* of *ressure inside of the 4ater tan9 and since the thermocou*les 4eren@t closed off lea9s throughout the to* of the tan9& :ne 4ay to solve this 4as to seal off the o*ening at the to* of the thermocou*le hole&

Figure 23. The ,all valve at the ,ottom of the tan9

:nce the thermocou*le o*ening 4as sealed off 4ith caul92 4e figured the *ressure 4ould ma9e the flo4 out of the ,ottom of the valve come out faster& -o4ever2 this didn@t ha**en either and ne4 lea9s occurred throughout the system& That 4as our main *ro,lem2 lea9s2 lea9s2 and more lea9s& 6ith the *ro*er im*lementation of flo4 control2 for instance2 ,eing a,le to control the horse*o4er of the *um* and thus the 4ater flo4 rate of 4ater loo*2 or ,eing a,le to o*en u* the ,ottom valve of the tan9 more2 the lea9s could ,e reduced2 and less maintenance 4ould ,e needed& 6e found that the main *ro,lem and cause of

33 |

the lea9s 4ere the *ressure differences throughout the system mainly from the o*enings of the hose and the *um* *i*es going into the 4ater heater& :nce the lea9s in the 4ater heater 4ere fi)ed2 lea9s in the 4ater vessel 4here the condenser 4as contained started to form& The ':5 of our system 4as so lo4 ,ecause there 4as constant maintenance of the system throughout the run& 'onsidering all the lea9s 4e had a regiment of 4here 4e had to turn on the *um* and 4hen there 4as a lea9 from the 4ater tan92 4e cut the *um* off and let the lea9 su,side then 4e noticed a lea9 from the vessel and had to turn on the *um*& This really 9illed our efficiency ,ecause 4e 4eren@t getting the hottest 4ater into the tan9 at all times& This 4as a real *ro,lem for us2 so 4e decided to s4itch to the %ro*3in -56- configuration& igure #, sho4s the lea9s from ,oth the 4ater tan9 and the vessel& .s de*icted 4hen there 4as a lea9 from the 4ater tan9 4e had to cut the *um* off2 then 4hen there 4as a lea9 form the vessel 4e had to turn the *um* on to 9ee* the 4ater flo4ing&

Figure 24. Lea9 from the to* of the tan92 and a lea9 from the vessel

@&* Drop5in S/stem

6ith the %ro*3in system 4e didn@t encounter nearly as many *ro,lems as 4e did 4ith the .dd3on system& 6e 4ere a,le to run the 4hole system and actually ac?uired a tem*erature of =20 82 4hich 4e 4ere ?uite *roud of& Because the %ro*3in system 4as ,asically the vessel of the condenser 4e 4ere a,le to heat the 4ater u* *retty fast& :rdinarily an integral ty*e -56- system has a F0 gallon 4ater tan9 and there are ,ac9 u* electric resistance 4ires to heat the 4ater u* faster if needed& :ur system 4as a**ro)imately D; gallons and 4e didn@t have any electric resistance 4ires attached to it& :ur 4ater heated u* to a**ro)imately =208 in roughly one hour2 4hich is ?uite slo4 com*ared to other 4ater heaters& -o4ever2 4e 4ere ?uite ha**y 4ith the outcome ,ecause the system actually *erformed as intended&

34 |

@&, Bot. S/stems

6ith ,oth systems 4e noticed there 4ere some efficiency issues that may have affected the ':5s& The amount of refrigerant charged 4as ?uite lo4 4hen 4e ran the system2 and Mr& +o, Landes had to refill it& :nce the refrigerant 4as refilled to a ,etter su,cool level at the suction of the com*ressor2 4e noticed the condenser get a lot 4armer than it did ,efore2 and it heated the 4ater faster than it normally had& .nother *ro,lem for ,oth systems 4as the lac9 of insulation 4e had around our *i*ing for the 4ater cycle& . lot of heat 4as lost from this *i*ing and once lost it couldn@t come ,ac9& 6e also had *ro,lems 4ith the thermocou*les in the condenser inlet and outlet& :riginally2 the soldered thermocou*les 4ouldn@t conduct 4ith the co**er tu,ing and insulation *ut around the thermocou*le& 6e had to *urchase the ty*e3( cement on thermocou*les to solve this *ro,lem& They had more accurate reading and 4ere very easy to im*lement& .nother *recaution 4e had throughout this *ro1ect 4as our com*uter e?ui*ment and electronic e?ui*ment 4as no farther then 2 feet a4ay from the system& Lea9s resulted to a lot of e)*osure to the e?ui*ment and the ris9 of electrocution&

35 |

A&' CONCL)S(ONS AND RECO ENTDAT(ONS

'onsidering that ,oth the .dd3on and %ro*3in system 4ere ,oth mani*ulated and configured air conditioners to 4or9 as -56-s 4e 4ere ?uite ha**y 4ith the outcomes2 and e)cited to see a real cycle and ho4 the things a**lied in ,oo94or9 and a classroom setting 4ere actually a**lied& In all conte)ts 4e 4ere a,le to re*licate the e)*eriments conducted ,y :+CL ,ut in a very much smaller scale&

A&% ORNL 6ersus )s

Belo4 in igure #, sho4s an average of 4hat :+CL o,tained for their =0 systems2 and 4hat 4e o,tained for our system& .s you can see :a9 +idge *erformed very 4ell and 4as a,le to ta9e measurements for the lifetime of their -56- systems& . lot of this had to do 4ith many factors that :+CL had and 4e didn@t& 8irst :a9 +idge had a steady environment and 4as a,le to re*licate the different environments for their different stages& They had ,etter and more accurate e?ui*ment 4hich they 4ere a,le to measure and control flo4 rates and levels of 4ater 4ithin the tan9s& :+CL also had ,etter insulation throughout their *i*ing of the system 4hich *revented heat loss& Since :+CL 4as e)amining the lifetime of the system too2 they 4ere mainly trying to calculate the energy factor and didn@t e)amine the ':5 into de*th& To reiterate2 :+CL 4as testing real -56- to *erform in a residential and commercial environment2 4hile our system 4as a modified system to *erform li9e a -56-&

Figure 25. +esults of ,oth :+CL and the *ro1ect@s system

A&* #ina" Ana"/sis

The main goal of this *ro1ect 4as to ,e a,le to calculate and e)amine the efficiencies of a modified -56-& 6e 4ere a,le to o,tain the ':5 of our system for ,oth an .dd3on and %ro*3in ,asis& :+CL had and ':5 of 2&;= 4hile ours had a ':5 of around =&=>2 4hich 4ould ma9e it initially more efficient than some electric and gas 4ater heaters ,ut not nearly as efficient as a manufactured -56-& 6hen com*ared to electric and gas 4ater heaters our system *erformed 1ust as 4ell as they did& So *otentially2 our system could ,e im*lemented in a real 4orld conte)t ho4ever2 it@s not very li9ely that something of that sort of system2 a system 4ith no *ro*er insulation 4ould ,e installed in your house&

36 |

By loo9ing at our system you 4ouldn@t necessarily 4ant to install it in your ,asement or garage& "ou 4ould need a 2E0 V *o4er su**ly to run the eva*orator2 and running it 4ould ,e ?uite loud& %uring the testing *hase 4e 4ere a,le to hear the system run from outside the door4ay2 even 4hen it 4as closed& This indicates that our system is not ?uite suita,le for a garage or ,asement ty*e setting& The inefficiencies in the system 4ere 4hat ,rought our ':5 so lo4& The lo4 insulation throughout the *i*es and the vessel caused massive heat loss& Lea9s throughout the system also caused constant maintenance and loss of 4ater& The lea9s ha**ened in *art ,ecause of the *um* ,eing too *o4erful2 and ,asically lead to the ,all valve at the ,ottom of the 4ater tan92 4hich restricted our flo4 rate and created *ressure differences throughout the system& .lthough 4e encountered so many *ro,lems in *articular 4ith the .dd3on system2 this system *erformed very 4ell and 4as very 4ell constructed and maintained ,y Mr& +o, Landes& 6e couldn@t have gotten any4here 4ithout his 9no4ledge of refrigeration and the system& 6ith the %ro*3in system the 4ater heated u* to hot sho4er tem*erature in 1ust under an hour2 4hich 4as very e)citing& 8or the .dd3on unit if flo4 rate and *ressure controls 4ere im*lemented the lea9s 4ould ,e 9e*t to a minimum and the ':5 of the system 4ill most li9ely increase& 8or the %ro*3in unit 4ith a fe4 changes in insulation and a larger tan9 siKe2 this system almost *erformed ,etter than a commercial 4ater heater& :verall2 this *ro1ect 4as a success and 4e 4ere a,le to o,tain our re?uired results in efficiency /the system ':502 4hile also testing the dura,ility of the -56-s&

%'&' Referen0es 37 |

=$ (nergy Information .gency& AU3S3 4atural 5as Mar6ets" Mid'Term )rospects for 4atural 5as Supply3+ (I.& :nline& htt*$HH444&eia&doe&govHoiafHservicer*tHnatgasHcha*terE&html& June 2002& 2$ Un9no4n& AThe (idden 7ost of ossil uels3+ Union of 'oncerned Scientists& :nline& htt*$HH444&ucsusa&orgHcleanQenergyHfossilQfuelsHthe3hidden3cost3of3fossil3fuels&html& .ugust 200F& D$ Mur*hy2 +&6& Tomilinson2 J&J& & ield Tests of a 8Drop'in9 Residential (eat )ump *ater (eater3+ :a9 +idge Cational La,oratory& :+CLHTM32002H207& Se*tem,er 2002& E$ Ba)ter2 Van Lin9ous2 +&L& A(eat )ump *ater (eater Durability Testing : )hase II3+ :a9 +idge Cational La,oratory& :+CLHTM3200EH===& May 200E&

38 |

%%&' APPENDEND(C(ES

AppendiB A& S*ecs for the digital clam* ammeter 39 |

AppendiB B& Manual for the 6atts U*I 5ro (S

40 |

41 |

AppendiB C& S*ecs for the Lenno) (lite Series -S 2>

S*ecifications of LennoB E"ite Series HS *A .ir 'onditioner$ /Modified ,y Ro!ert C& Landes to an .ir3to36ater -56-0 L(CC:G Industries Inc&2 %allas2 Ta)es MHC$ -S2>30E23=E SHC$ F<><8 EF=<D Compressor8s:D +efrigerant$ 8actory 'harge$ (lectrical +ating$ +L. /+unning Load .m*s0$ L+. /Loc9ed +otor .m*s0$ 'ooling 'a*acity$ Min '!T .m*acity$ #an otor8s:D %esign 5ressure$ Cominal Voltage$ = HC#C5** F l,s =0 :Ks = 5-2 ;0 -K 20&D =27 2;2000 to 2>2200 BtuHhr / >&= to @&= EWF note that DE=2 BtuHhr R = 960 .m*erage Minimum$ 2;&F = -i$ 27< *sig Lo$ =EE *sig 20<H2DF V /Min =>7H Ma) 2FD V0

42 |

5-$ 8L. /8ull Load .m*s0$ -orse*o4er$ Ma) 8use or '!T& B+!&$

= =&= =H; h* / %*3 WF note that = h* R 7E; 60 8usi,leH'ou*le 'ircuit /-.'+ 5(+ C('0$ E0

AppendiB D& S*ecs for the T'I' Series :M(#. card

43 |

AppendiB E& 'ement3on thermocou*les s*ecifications

44 |

45 |

46 |

AppendiB #& Suction line accumulator descri*tion

47 |

AppendiB G& Ty*e ( thermocou*le descri*tion

Thermocou*le 6ire S E T/pe2 %u*le) Insulated

(nput T/pe E

Range 3200 to =000N' /3D2< to =<D2N80

A00ura0/7 89C: O=&F

Reso"ution 89C: 0&0=F

ITS3>0 Ta,le for t/pe E thermocou*le 9C ' % * , 3 = > @ A %'

T.ermoe"e0tri0 ;o"tage in m; 0 =0 20 D0 E0 F0 ;0 70 <0 >0 =00 ==0 =20 =D0 =E0 0&000 0&F>= =&=>2 =&<0= 2&E20 D&0E< D&;<F E&DD0 E&><F F&;E< ;&D=> ;&>>< 7&;<F <&D7> >&0<= 0&0F> 0&;F= =&2F2 =&<;2 2&E<2 D&=== D&7E> E&D>F F&0F= F&7=E ;&D<; 7&0;; 7&7FE <&EE> >&=F= 0&==< 0&7== =&D=D =&>2E 2&FEF D&=7E D&<=D E&E;0 F&==7 F&7<= ;&EFE 7&=DF 7&<2D <&F=> >&222 0&=7; 0&770 =&D7D =&><; 2&;07 D&2D< D&<77 E&F2; F&=<D F&<E< ;&F22 7&20D 7&<>2 <&F<> >&2>2 0&2DF 0&<D0 =&EDE 2&0E7 2&;70 D&D0= D&>E2 E&F>= F&2E> F&>=F ;&F>0 7&272 7&>;2 <&;F> >&D;D 0&2>E 0&<>0 =&E>F 2&=0> 2&7DD D&D;F E&00; E&;F; F&D=F F&><2 ;&;F< 7&DE= <&0D= <&72> >&EDE 0&DFE 0&>F0 =&FF; 2&=7= 2&7>F D&E2> E&07= E&722 F&D<2 ;&0E> ;&72F 7&E0> <&=0= <&7>> >&F0F 0&E=D =&0=0 =&;=7 2&2DD 2&<F< D&E>2 E&=D; E&7<< F&EE< ;&==7 ;&7>E 7&E7< <&=70 <&<;> >&F7; 0&E72 =&07= =&;7< 2&2>F 2&>2= D&FF; E&200 E&<FD F&F=E ;&=<E ;&<;2 7&FE7 <&2E0 <&>E0 >&;E7 0&FD2 =&=D= =&7E0 2&DF7 2&><E D&;20 E&2;F E&>=> F&F<= ;&2F= ;&>D0 7&;=; <&D0> >&0=0 >&7=< 0&F>= =&=>2 =&<0= 2&E20 D&0E< D&;<F E&DD0 E&><F F&;E< ;&D=> ;&>>< 7&;<F <&D7> >&0<= >&7<>

48 |

AppendiB H& La,Vie4 8ront *anel for the .dd3on unit

49 |

AppendiB (& La,Vie4 8ront *anel for the %ro*3in unit

50 |

AppendiB C& ':5 calculation and its uncertainty analysis using ((S for the .dd3on unit

51 |

AppendiB K& ':5 calculation and its uncertainty analysis using ((S for the %ro*3in unit

52 |