MODULAR CONTROL SYSTEM AND METHOD FOR WATER HEATERS

• US 20070246551A1
• Filed: 03/27/2007
• Published: 10/25/2007
• Est. Priority Date: 08/26/2004
• Status: Active Grant

• Current Assignee: A. O. Smith Corporation
• Original Assignee: A. O. Smith Corporation
• Inventors: Patterson, Wade, Phillips, Terry
• Granted Patent: US 8,660,701 B2
• Time in Patent Office: Days
• US Class Current: 236/20.R
• 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 heater has a modular control system. The water heater comprises a tank, a heating element, a first controller, and a second controller. The heating element is coupled to the tank. The first controller is mounted on the tank and has a first communication port. The second controller has a second communication port communicatively coupled to the first communication port of the first controller. The first controller is configured to control the heating element in accordance with any desired algorithm in an absence of the second controller, and the second controller is configured to perform at least one function in addition to or in lieu of the first controller.

Claims

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

a tank;

a heating element mounted on the tank;

a first controller mounted on the tank, the first controller coupled to the heating element; and

a second controller interfaced with the first controller and configured to perform at least one function in addition to or in lieu of a function capable of being performed by the first controller,

wherein the first controller is capable of controlling operation of the heating element in an absence of the second controller.

2. The water heating system of claim 1, wherein the second controller has a communication port detachably coupled to a communication port of the first controller.

3. The water heating system of claim 1, wherein the second controller has a display device.

4. The water heating system of claim 1, wherein the second controller has a wireless communication device.

5. The water heating system of claim 4, wherein the second controller has logic configured to receive, via the wireless communication device, data indicative of a user input for establishing a set point to be used for controlling the heating element.

6. The water heating system of claim 5, wherein the first controller does not have a wireless communication device.

7. The water heating system of claim 5, wherein the logic is configured transmit, via the wireless communication device, information pertaining to operation of the water heating system.

8. 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.

9. The water heating system of claim 8, wherein the tank has a compartment, wherein the first controller resides in the compartment, and wherein the second housing has a rim inserted into the compartment and contacting a wall of the tank defining the compartment.

10. The water heating system of claim 9, wherein the second housing is secured to the tank via frictional forces between the rim and the wall.

14. The water heating system of claim 5, wherein the logic is configured to transmit, via the wireless communication device, information pertaining to operation of the water heating system.

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

a tank;

a heating element mounted on the tank;

a first controller mounted on the tank and having a first communication port, the first controller having logic for controlling the heating element; and

a second controller interfaced with the first controller and configured to perform at least one function in addition to or in lieu of a function capable of being performed by the first controller, the second controller having a communication port detachably coupled to the first communication port.

12. The water heating system of claim 11, wherein the second controller has a wireless communication device.

13. The water heating system of claim 12, wherein the second controller has logic configured to receive, via the wireless communication device, data indicative of a user input for establishing a set point to be used for controlling the heating element.

15. The water heating system of claim 11, 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.

16. The water heating system of claim 15, wherein the tank has a compartment, wherein the first controller resides in the compartment, and wherein the second housing has a rim inserted into the compartment and contacting a wall of the tank defining the compartment.

17. The water heating system of claim 16, wherein the second housing is secured to the tank via frictional forces between the rim and the wall.

18. A method for controlling a water heating system comprising a tank, a heating element, and a first controller for controlling an operation of the heating element, the method comprising the steps of:

mounting a second controller on the tank;

interfacing the second controller with the first controller; and

performing at least one function in addition or lieu of a function capable of being performed by the first controller,

wherein the first controller is capable of controlling operation of the heating element in an absence of the second controller.

19. The method of claim 18, wherein the mounting step is performed after the first controller has activated the heating element at least once.

20. The method of claim 18, wherein the interfacing step comprises the step of detachably coupling a communication port of the second controller to a communication port of the first controller.

21. The method of claim 18, further comprising the step of wirelessly communicating at least one signal via a communication device of the second controller.

22. The method of claim 18, wherein the tank has a compartment, wherein the first controller resides in the compartment, wherein the second controller has a housing, and wherein the mounting step comprises the step of inserting a rim of the housing into the compartment such that the rim contacts a wall of the tank defining the compartment.