Smart energy controlled water heater

• US 9,151,516 B2
• Filed: 01/24/2012
• Issued: 10/06/2015
• Est. Priority Date: 01/27/2006
• Status: Active Grant

• Current Assignee: Copeland Comfort Control LP (Emerson Electric Company)
• Original Assignee: Emerson Electric Company
• Inventors: Buescher, Thomas P., Fredricks, Thomas J., Siravuri, Rishi, Brazis, Lawrence J., Welch, Richard E., Miu, Richard
• Primary Examiner(s): CAMPBELL, THOR S
• Application Number:
  US13/356,779
• Publication Number:
  US 20120118989A1
• Time in Patent Office: 1,351 Days
• Field of Search: 219/483, 219/485, 219/486, 219/497, 219/492, 219/505, 219/508, 219/510, 219/519, 392/451, 392/463, 700/295, 700/291, 705/412
• US Class Current: 1/1
• CPC Class Codes: F24H 1/202 with resistances
• CPC Class Codes: F24H 15/12 Preventing or detecting fluid leakage
• CPC Class Codes: F24H 15/174 Supplying heated water with desired temperature or desired range of temperature
• CPC Class Codes: F24H 15/225 at different heights of the tank
• CPC Class Codes: F24H 15/238 Flow rate
• 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 9/2021 Storage heaters
• CPC Class Codes: G05D 23/1917 using digital means
• CPC Class Codes: H05B 1/0269 For heating of fluids

Abstract

A control module for a water heater includes a switching module that receives a voltage supply and outputs the voltage supply to the water heater. The water heater includes an electrical junction box that receives the voltage supply. A communication module communicates with at least one of an energy meter and an energy network external to the water heater and the control module, and receives information from the at least one of the energy meter and the energy network. The control module is mounted on the water heater and the voltage supply passes through or adjacent to the control module. The control module determines an operating characteristic of the water heater based on the voltage supply and selectively actuates the switching module to turn on and turn off the voltage supply to the water heater in response to the operating characteristic and the information.

Claims

1. A smart energy control module for a water heater, the water heater including an electrical junction box that receives a voltage supply, via voltage supply wiring, for providing power to the water heater, the control module comprising:

a switching module that receives the voltage supply wiring and outputs the voltage supply to the water heater, wherein the switching module receives the voltage supply wiring prior to the voltage supply wiring entering the electrical junction box; and

a communication module that i) communicates with at least one of an energy meter and an energy network, the at least one of the energy meter and the energy network being external to the water heater and the control module, and ii) receives information from the at least one of the energy meter and the energy network,

wherein the control module is mounted on the water heater,

wherein the voltage supply wiring passes at least one of through and adjacent to the control module, and

wherein the control module monitors current flowing through a portion of the voltage supply wiring that is external to the water heater, detects transitions between a lower heating element and an upper heating element of the water heater based on the monitored current flowing through the portion of the voltage supply wiring, and selectively actuates the switching module to turn on and turn off the voltage supply to the water heater based on the detected transitions between the lower heating element and the upper heating element and the information received from the at least one of the energy meter and the energy network.

2. The control module of claim 1 wherein the communication module wirelessly receives the information from the energy meter.

3. The control module of claim 1 wherein the information includes at least one of peak usage, load shedding, and tiered pricing information.

4. The control module of claim 3 wherein the control module turns off the voltage supply to the water heater in response to a determination that a current time or a future time corresponds to at least one of a peak usage time and a first pricing tier.

5. The control module of claim 3 wherein the control module turns off the voltage supply to the water heater further in response to a determination of an amount of hot water available in the water heater.

6. The control module of claim 3 further comprising a user interface that displays at least one of the peak usage information, the load shedding information, and the tiered pricing information.

7. The control module of claim 6 wherein the user interface allows a user to selectively turn on and turn off the voltage supply to the water heater, and displays at least one of cost savings and energy savings associated with turning on and turning off the voltage supply to the water heater at predetermined times.

8. The control module of claim 1 wherein the control module adjusts a setpoint of the water heater based on predicted usage of hot water.

9. The control module of claim 8 further comprising a user interface, wherein the control module provides a recommendation that a user adjust the setpoint via the user interface.

10. The control module of claim 8 wherein the control module operates in a first mode and at least one second mode, wherein the setpoint is adjusted at different rates in each of the first mode and the at least one second mode.

11. The control module of claim 1 wherein the control module includes a current sensor arranged to sense the current flowing through the portion of the voltage supply wiring.

12. The control module of claim 1 wherein the control module is mounted adjacent to the junction box.

13. The control module of claim 1, wherein detecting transitions between the lower heating element and the upper heating element based on the monitored current includes detecting a transient surge in the monitored current.

14. A control module for a water heater, the water heater including an electrical junction box that receives a voltage supply, via voltage supply wiring, for providing power to the water heater, the control module comprising:

a switching module that receives the voltage supply wiring and outputs the voltage supply to the water heater, wherein the switching module receives the voltage supply wiring prior to the voltage supply wiring entering the electrical iunction box; and

a usage monitoring module that monitors current flowing through a portion of the voltage supply wiring that is external to the water heater, detects transitions between a lower heating element and an upper heating element of the water heater based on the monitored current flowing through the portion of the voltage supply wiring, and that determines usage information of the water heater based on the detected transitions between the lower heating element and the upper heating element,

wherein the control module is mounted on the water heater,

wherein the voltage supply wiring passes at least one of through and adjacent to the control module, and

wherein the control module selectively actuates the switching module to turn on and turn off the voltage supply to the water heater based on the usage information.

15. The control module of claim 14 wherein the control module turns off the voltage supply to the water heater in response to a determination that a current time or a future time corresponds to at least one of a peak usage time and a first pricing tier.

16. The control module of claim 15 wherein the control module turns off the voltage supply to the water heater further in response to a determination of an amount of hot water available in the water heater.

17. The control module of claim 15 further comprising a user interface that displays at least one of peak usage information, load shedding information, and tiered pricing information.

18. The control module of claim 17 wherein the user interface allows a user to selectively turn on and turn off the voltage supply to the water heater, and displays at least one of cost savings and energy savings associated with turning on and turning off the voltage supply to the water heater at predetermined times.

19. The control module of claim 14 wherein the control module adjusts a setpoint of the water heater based on predicted usage of hot water.

20. The control module of claim 14 wherein the control module includes a current sensor arranged to sense the current flowing through the portion of the voltage supply wiring.

21. The control module of claim 14 wherein the control module is mounted adjacent to the junction box.

22. The control module of claim 14, wherein detecting transitions between the lower heating element and the upper heating element based on the monitored current includes detecting a transient surge in the monitored current.