Error recovery system for an energy controller for an electric water heater

• US 5,708,589 A
• Filed: 04/08/1996
• Issued: 01/13/1998
• Est. Priority Date: 04/08/1996
• Status: Expired due to Fees

• Current Assignee: Vaughn Manufacturing Corporation
• Original Assignee: Vaughn Manufacturing Corporation
• Inventors: Beauvais, David L.
• Primary Examiner(s): Voeltz, Emanuel T.
• Assistant Examiner(s): SMITH-STEWART, DEMETRA R
• Application Number:
  US08/629,232
• Time in Patent Office: 645 Days
• Field of Search: 364/492, 364/464, 364/464.04, 364/483, 395/750, 395/800, 395/182.13, 395/182.16, 395/182.2, 395/182.22, 395/183.18, 395/185.01, 307/35, 307/40, 307/41, 307/39, 307/29, 307/52, 307/66, 307/64, 307/38, 307/125, 307/130
• US Class Current: 700/293
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence
• CPC Class Codes: G05B 2219/23215 Check data validity in ram, keep correct validity, compare rom ram
• CPC Class Codes: G05B 2219/23308 Transfer program from ram to eprom, flash, card
• CPC Class Codes: G06F 11/1441 Resetting or repowering

Abstract

A data protection and recovery system for an energy controller for a water heater is disclosed. The energy controller is a microprocessor based system which includes a central processing unit, volatile and non-volatile memories, and a clock. It functions to energize the water heater only during a certain period of the day. During normal operation of the system, the system uses the volatile memory as a workspace, and normally copies data in the volatile memory to the non-volatile memory. The system senses electrical disturbances, such as power surges, and prevents the writing of any data to the non-volatile memory components during the electrical disturbance. After the electrical disturbance subsides, the system checks the integrity of the data written to the volatile memory, and if it was not corrupted by the electrical disturbance, the data is then written to the non-volatile memory. If the data in the volatile memory was corrupted by the electrical disturbance, the system copies the data from the non-volatile memory to the volatile memory, and the system is restarted.

Claims

1. A method for protecting the data of and recovering from data errors in an energy controller for an electric water heater, said energy controller comprising a central processing unit (CPU) logically connected to a random access memory (RAM), an electronically erasable programmable read only memory (EEPROM), and a clock with a small amount of memory, comprising the steps of:

initiating a blocking phase upon the start up of said energy controller;

monitoring the power supply to said energy controller for electrical disturbance;

initiating said blocking phase upon the detection of a disturbance in said power supply;

preventing said CPU from writing to said EEPROM and said clock during said blocking phase;

copying the contents of said EEPROM to said RAM after initiating said blocking phase;

performing an error check on the contents of said RAM;

performing a validity check on the contents of said clock;

copying the contents of said RAM to said EEPROM after said blocking phase in the event that no error occurred; and

restoring said clock from said clock memory if an error is detected in said clock.

2. The method according to claim 1, wherein said EEPROM contains information including an algorithm, the dates of holidays, and counters to track the day, date, year, and the number of occurrences of each day per month, said information being used by said energy controller in determining whether to energize said water heater.

3. The method according to claim 1, wherein said validity check of the contents of said clock comprises the steps of:

verifying that the hour in said clock is between 1 and 12 inclusive;

verifying that the minutes in said clock is between 0 and 59 inclusive;

verifying that the date in said clock is between 1 and 31 inclusive; and

verifying that the month in said clock is between 1 and 12 inclusive.

4. The method according to claim 1, wherein said electrical disturbance comprises a power surge.

5. The method according to claim 1, wherein said electrical disturbance comprises a power flicker.

6. The method according to claim 1, wherein said electrical disturbance comprises electrical noise.

7. The method according to claim 1, further comprising setting a recovery time period when said error check detects an error in contents of said RAM or said validity check detects an error in said clock and initiating said blocking phase after said recovery time period.

8. The method according to claim 7, further comprising the steps of:

copying the contents of the memory of said clock to said clock at the end of said recovery time period if the error was in said clock; and

entering said blocking phase at the end of said recovery time and then copying the contents of said EEPROM to said RAM after said blocking phase.

9. A system for protecting the data of and recovering from data errors in an energy controller for an electric water heater comprising:

a central processing unit;

an electronically erasable programmable read only memory logically connected to said central processing unit, said electronically erasable programmable read only memory containing information used for the operation of said system;

a random access memory logically connected to said central processing unit, said random access memory containing a copy of said information from said electronically erasable programmable read only memory;

a clock with a small amount of memory logically connected to said central processing unit;

a power switch logically connected to said central processing unit;

a power failure detector logically connected to said central processing unit;

a power supply to supply power to said central processing unit, said electronically erasable programmable read only memory, said random access memory, said clock, said power failure detector, and said electric switch;

external inputs logically connected to said central processing unit; and

an electric water heater connected to said power supply through said switch;

said central processing unit utilizing said information in said random access memory to close said electric switch thereby allowing the thermostatic supply of energy to said water heater, and said central processing unit utilizing said information in said random access memory to open said electric switch thereby cutting off power to said water heater;

said central processing unit updating said electronically erasable programmable read only memory with data from said RAM when not in a blocking phase; and

said central processing unit entering said blocking phase in response to a disturbance in said power supply.

10. The system according to claim 9, wherein said information of said random access memory includes an algorithm, the dates of holidays, and counters to track the day, date, year, and the number of occurrences of each day per month.

11. The system according to claim 9, wherein said central processing unit closes said electric switch during non-peak hours thereby allowing the thermostatic energization of said water heater, and further wherein said central processing unit opens said electric switch during peak hours thereby preventing the energization of said water heater.

12. A method of protecting data in an energy controller for an electric water heater, said energy controller comprising a central processing unit (CPU) logically connected to a random access memory (RAM), an electronically erasable programmable read only memory (EEPROM) and a clock, said energy controller controlling the application of electric power to said water heater in accordance with calendar information stored in said EEPROM and said RAM, comprising the steps of monitoring the power supply to said energy controller for electrical disturbance, initiating a blocking phase upon detection of a disturbance in said power supply, preventing said CPU from writing to said EEPROM during said blocking phase, copying the contents of said EEPROM to said RAM after initiating said blocking phase, and copying the contents of said RAM to said EEPROM after said blocking phase.

13. A method of recovering from data errors in an energy controller for an electric water heater, said energy controller comprising a central processing unit (CPU) logically connected to a random access memory (RAM), and electronically erasable programmable read only memory (EEPROM), said energy controller controlling the application of electric power to said water heater in accordance with calendar information stored in said EEPROM and said RAM, comprising performing the steps of performing an error check on the contents of said RAM, entering a recovery phase upon detection of an error in the contents of said RAM, copying the contents of said RAM to said EEPROM except during said recovery phase, and copying the contents of said EEPROM to said RAM after said recovery phase.

14. A method as recited in claim 13, wherein said energy controller further comprises a clock having a memory, said method further comprising performing a validity study on the contents of said clock, initiating said recovery phase upon detection of an error in said clock, and restoring said clock with data from said memory after the end of said recovery time.