Date: Jan 24, 2024
Rinnai is synonymous with innovative heating solutions, providing customers with advanced technology designed for efficiency and reliability. As they ventured into their new project - the HydraHeat™ Hot Water Heat Pump - Rinnai turned to our expertise to develop an electronic control system refined for performance. We worked closely with Rinnai to create a control system harnessing the efficiency of heat pump technology, with estimations of up to 75% savings on hot water costs*.
Rinnai's HydraHeat™ represents the evolution of water heating solutions, integrating heat pump technology with traditional hot water systems for enhanced energy efficiency. Recognizing the potential of this technology, Rinnai required a state-of-the-art electronic control system. The goal was not only to control the heat pump efficiently but also to ensure user safety, compliance with regulatory standards, and ease of use.
Challenges
Creating an electronic control system for a highly efficient heat pump hot water cylinder introduced several challenges, including:
Solution
Our innovative design solution addressed Rinnai's requirements and included the following key features:
Wireless Communications Board
The integrated board we developed embeds both Wi-Fi/Bluetooth for local network connectivity and a cellular modem for broader communication potential. This dual-approach ensures the HydraHeat™ is versatile, satisfying various user scenarios from remote technician access to everyday consumer control via a specialised app.
Firmware Development
HydraHeat™is controlled by firmware developed with the following features for optimal performance:
Technician App
To provide a comprehensive monitoring and maintenance tool for the HydraHeat systems, we designed a specialized Technician's Interface Application. This Windows-based program, once installed on a technician's PC, allows for a direct connection to the HydraHeat system via a USB cable. The intuitive application facilitates not only the monitoring of system performance but also provides capabilities for firmware upgrades and fault diagnostics, ensuring HydraHeat operates at peak efficiency and reliability.
Certification and Compliance
We managed the compliance testing phases, ensuring the HydraHeat™ met all required standards for electrical safety, EMC, and radio compliance. This comprehensive testing guaranteed the system's reliability and safety, clearing it for consumer use.
Production Quality through Automated Test Fixture
To ensure consistent quality during the production of the HydraHeat™ control systems, we developed an automated test fixture equipped with custom test software. This fixture is essential for methodically checking and verifying each PCB as it comes off the manufacturing line. The test software runs through a comprehensive set of functional tests and records the outcomes for quality control purposes.
The fixture's user interface is straightforward, enabling technicians to execute the test sequences quickly and effectively. In just a few minutes, the fixture can complete the full spectrum of necessary tests for these complex electronic boards. The results are logged for ongoing production quality analysis, and each board is imprinted with a unique serial number to provide trackability.
The test fixture uses a bed of nails method for making contact with designated test points on the PCBs. This setup, though sophisticated in its implementation, allows for rigorous quality assurance checks within the production environment. By integrating this testing procedure, we ensure that every HydraHeat™ control system delivered to Rinnai is reliable and meets the stringent quality standards expected by both us and the customer.
Our collaboration with Rinnai yielded the control system for their innovative HydraHeat™ product, a testament to innovative engineering and user-centric design. This venture has positioned Rinnai's new heat pump hot water cylinder as a future-proof solution for sustainable living. The HydraHeat™, which was recently launched, promises eco-friendly efficiency for everyday homes, signaling Rinnai's commitment to greener solutions and energy savings of up to 75% on hot water costs.
* All the content in this article, including imagery, has been approved by Rinnai for publication.
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