Modular control system and method for water heaters

• US 10,240,817 B2
• Filed: 06/09/2015
• Issued: 03/26/2019
• Est. Priority Date: 08/26/2004
• Status: Active Grant

• Current Assignee: A. O. Smith Corporation
• Original Assignee: A. O. Smith Corporation
• Inventors: Phillips, Terry G., Patterson, Wade C.
• Primary Examiner(s): Ali, Mohammad
• Assistant Examiner(s): Rao, Sheela
• Application Number:
  US14/734,873
• Publication Number:
  US 20150276267A1
• Time in Patent Office: 1,386 Days
• Field of Search: 700 86, 700275, 700299, 710 2, 710 62, 710 72, 710300, 710312, 307149, 219481, 219490, 219492, 219494, 219497, 219501, 219508, 219510
• CPC Class Codes: B23P 6/00 Restoring or reconditioning objects straightening or restoring form of sheet metal, metal rods, metal tubes, metal profiles, or specific articles made therefrom B21D1/00, B21D3/00; repairing defective or damaged objects by casting techniques B22D19/10
• CPC Class Codes: F24H 15/225 at different heights of the tank
• CPC Class Codes: F24H 15/281 Input from user
• CPC Class Codes: F24H 15/37 of electric heaters
• CPC Class Codes: F24H 15/395 Information to users, e.g. alarms
• CPC Class Codes: F24H 15/414 using electronic processing, e.g. computer-based
• CPC Class Codes: F24H 15/464 using local wireless communication
• CPC Class Codes: F24H 9/0005 for water heaters
• CPC Class Codes: F24H 9/2021 Storage heaters
• CPC Class Codes: Y10T 29/49716 Converting

Abstract

A water heating system includes a tank, one or more heating elements mounted on the water heating system, and a first controller mounted on the tank. The first controller is coupled to the one or more heating elements and includes logic to activate and deactivate the heating elements according to a first threshold value. The water heater also includes a second controller that is selectively coupled to the first controller and configured to communicate the first threshold value to the first controller, and perform an additional function related to the operation of the water heater. The first controller is configured to receive the first threshold value from the second controller and control the one or more heating elements based on the received threshold value, and to control the one or more heating elements mounted on the water heating system in a physical absence of the second controller.

Claims

1. A water heating system having a modular control system, comprising:

a tank configured to hold a fluid;

a heating element supported by the tank, the heating element configured to manipulate a temperature of the fluid;

a first controller supported by the tank, the first controller coupled to the heating element, the first controller including a communication port and a first logic to activate and deactivate the heating element according to a first threshold value;

a second controller supported by the tank, the second controller selectively connectable to the communication port of the first controller, the second controller including a second logic configured to provide additional functionality related to the same heating element, the additional functionality not enabled by the first controller when the second controller is connected to the first controller; and

a remote interface located remotely from the tank and configured to communicate wirelessly with the second controller;

wherein the first controller is configured to control the heating element mounted on the water heating system in an absence of the second controller.

2. The water heating system of claim 1, wherein second controller provides the additional functionality by being configured to receive information regarding an operation of the water heating system from a user through the remote interface, and communicate with the first controller based on the received information.

3. The water heating system of claim 2, wherein the second controller provides the additional functionality by being configured to receive information regarding the operation of the water heater from the first controller, and forward the received information to the remote interface.

4. The water heating system of claim 3, wherein the information received by the second controller includes information regarding a failure of the water heater.

5. The water heating system of claim 2, wherein the information received from the user includes the first threshold value.

6. The water heating system of claim 1, wherein the first controller includes a first base, wherein the communication port and the first logic are mounted on the first base;

and wherein the second controller includes a second base, and the second logic is mounted on the second base.

7. The water heating system of claim 1, wherein the remote interface includes a display.

8. The water heating system of claim 1, wherein the second controller includes a display.

9. The water heating system of claim 1, wherein the first controller has a first housing that covers components of the first controller, and wherein the second controller has a second housing, separate from the first housing, covering components of the second controller.

10. The water heating system of claim 1, wherein the second controller is not directly coupled to the heating element.

11. The water heating system of claim 1, wherein the first controller includes an input device that is configured to receive information regarding the first threshold value.

12. A method of upgrading the operation of a water heating system comprising a tank, a heating element mounted on the tank, and a first controller for controlling an operation of the heating element, the method comprising:

mounting an upgrade controller on the tank;

connecting the upgrade controller to a first communication port of the first controller;

providing, by the upgrade controller, additional functionality related to the heating element, the additional functionality not enabled by the first controller when the upgrade controller is connected to the first controller;

communicating wirelessly, through the upgrade controller, with a remote interface; and

controlling, by the first controller, the heating element according to a first threshold value in an absence of the upgrade controller.

13. The method of claim 12, wherein providing additional functionality includes receiving information pertaining to an operation of the water heating system from a user through the remote interface, and communicating the received information to the first controller.

14. The method of claim 13, wherein the received information includes a threshold value, wherein the first controller is configured to control the operation of the heating element based on the threshold value.

15. The method of claim 12, wherein providing additional functionality includes receiving, by the upgrade controller, information pertaining to an operation of the water heating system from the first controller.

16. The method of claim 14, wherein providing additional functionality also includes wirelessly transmitting, by the second controller, the received information pertaining to the operation of the water heating system to the remote interface.

17. The method of claim 12, further comprising displaying, on the remote interface, information regarding operation of the water heating system received from the upgrade controller.

18. An apparatus comprising:

an element configured to manipulate a temperature of a fluid;

a temperature sensor configured to sense the temperature of the fluid;

a first controller coupled to the element and the temperature sensor, the first controller including a communication port and a first logic configured to receive a sensed temperature from the temperature sensor and control the element based on the sensed temperature; and

a second controller selectively communicatively coupled to the first controller, the second controller including a second logic configured to provide additional functionality when the second controller is connected to the first controller, the additional functionality related to control of the element and not enabled by the first controller.

19. The apparatus of claim 18, further comprising a communication module configured to communicatively couple the first controller to the second controller.

20. The apparatus of claim 18, wherein the first controller is configured to control the element in an absence of the second controller.

21. The apparatus of claim 20, wherein the first controller controls the element according to a user set point.

22. A method of manufacturing a water heater, the method comprising:

providing a water heater including

an element configured to manipulate a temperature of a fluid

a temperature sensor configured to sense the temperature of the fluid, and

a first controller coupled to the element and the temperature sensor, the first controller including a communication port and a first logic configured to receive a sensed temperature from the temperature sensor and control the element based on the sensed temperature; and

providing a second controller configured to be selectively coupled to the communication port of the first controller, the second controller including a second logic configured to provide additional functionality not enabled by the first controller when the second controller is connected to the first controller.