Smart energy controlled water heater

• US 9,188,363 B2
• Filed: 03/13/2013
• Issued: 11/17/2015
• 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
• Primary Examiner(s): CAMPBELL, THOR S
• Application Number:
  US13/800,411
• Publication Number:
  US 20130200168A1
• Time in Patent Office: 979 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B23P 19/00 Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation connecting metal parts or objects by metal-working procedures B21J, B23K; Tools or devices therefor so far as not provided for in other classes hand tools in general B25
• CPC Class Codes: F24D 2220/042 Temperature sensors
• CPC Class Codes: F24D 2240/26 Vertically distributed at fixed positions, e.g. multiple sensors distributed over the height of a tank, or a vertical inlet distribution pipe having a plurality of orifices
• CPC Class Codes: F24H 1/202 with resistances
• CPC Class Codes: F24H 15/12 Preventing or detecting fluid leakage
• CPC Class Codes: F24H 15/144 Measuring or calculating energy consumption
• CPC Class Codes: F24H 15/156 Reducing the quantity of energy consumed; Increasing efficiency
• CPC Class Codes: F24H 15/164 where the price of the electric supply changes with time
• CPC Class Codes: F24H 15/174 Supplying heated water with desired temperature or desired range of temperature
• CPC Class Codes: F24H 15/20 characterised by control inputs
• 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 15/315 of mixing valves
• 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 15/421 using pre-stored data
• CPC Class Codes: F24H 15/45 remotely accessible
• CPC Class Codes: F24H 9/2021 Storage heaters
• CPC Class Codes: F24H 9/25 of remote control devices or control-panels
• CPC Class Codes: G05D 23/1923 : using thermal energy, the cost of which varies in function of time
• CPC Class Codes: H02J 2310/14 : The load or loads being home appliances
• CPC Class Codes: H02J 3/14 : by switching loads on to, or off from, network, e.g. progressively balanced loading
• CPC Class Codes: H05B 1/0283 : For heating of fluids, e.g. water heaters
• CPC Class Codes: Y02B 30/70 : Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating
• CPC Class Codes: Y02B 70/30 : Systems integrating technologies related to power network operation and communication or information technologies for improving the carbon footprint of the management of residential or tertiary loads, i.e. smart grids as climate change mitigation technology in the buildings sector, including also the last stages of power distribution and the control, monitoring or operating management systems at local level
• CPC Class Codes: Y02B 70/3225 : Demand response systems, e.g. load shedding, peak shaving
• CPC Class Codes: Y04S 20/222 : Demand response systems, e.g. load shedding, peak shaving
• CPC Class Codes: Y04S 20/244 : the home appliances being or involving heating ventilating and air conditioning [HVAC] units
• CPC Class Codes: Y10T 29/49826 : Assembling or joining

Abstract

A smart energy control module for a water heater includes a switching module that receives a voltage supply and outputs the voltage supply to the water heater. 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. The control module is mounted on the water heater. The voltage supply passes at least one of through and adjacent to the control module. The control module determines at least one 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 information received from the at least one of the energy meter and the energy network.

Claims

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

a switching module that receives the voltage supply and outputs the voltage supply to the water heater;

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 passes through the control module, and

wherein the control module determines at least one operating characteristic of the water heater based on the voltage supply, 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 received from the at least one of the energy meter and the energy network;

a control circuitry portion that includes the switching module;

an electrical connection portion, wherein service wiring for providing the voltage supply to the water heater is routed through the electrical connection portion, and wherein the service wiring is electrically connected to, within the electrical connection portion, each of the switching module and internal wiring of the water heater; and

a partition that separates the control circuitry portion and the electrical connection portion.

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 operating characteristic includes a current provided to the water heater.

12. The control module of claim 11 wherein the control module includes a current sensor arranged to sense the current provided to the water heater.

13. The control module of claim 11 wherein the operating characteristic is indicative of transitioning between a lower heating element and an upper heating element of the water heater.

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

15. The control module of claim 1, wherein the electrical connection portion is adjacent to the electrical junction box.

16. The control module of claim 1, wherein the control circuitry portion includes a current sensor arranged to sense the current provided to the water heater.

17. The control module of claim 1, wherein the service wiring is electrically connected to the switching module and the internal wiring of the water heater using wire connection terminals within the electrical connection portion.

18. The control module of claim 1, wherein the partition is electrically insulative and electrically isolates the control circuitry portion from the service wiring and the internal wiring within the electrical connection portion.

19. A control module for a water heater, the water heater including an electrical junction box that receives a voltage supply, the control module comprising:

a switching module that receives the voltage supply and outputs the voltage supply to the water heater;

a usage monitoring module that determines at least one operating characteristic of the water heater based on the voltage supply and that determines usage information of the water heater based on the at least one operating characteristic,

wherein the control module is mounted on the water heater,

wherein the voltage supply passes through 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 in response to the operating characteristic and the usage information;

a control circuitry portion that includes the switching module;

an electrical connection portion, wherein service wiring for providing the voltage supply to the water heater is routed through the electrical connection portion, and wherein the service wiring is electrically connected to, within the electrical connection portion, each of the switching module and internal wiring of the water heater; and

a partition that separates the control circuitry portion and the electrical connection portion.

20. The control module of claim 19 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.

21. The control module of claim 20 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.

22. The control module of claim 20 further comprising a user interface that displays at least one of peak usage information, load shedding information, and tiered pricing information.

23. The control module of claim 22 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.

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

25. The control module of claim 19 wherein the operating characteristic includes a current provided to the water heater.

26. The control module of claim 25 wherein the control module includes a current sensor arranged to sense the current provided to the water heater.

27. The control module of claim 25 wherein the operating characteristic is indicative of transitioning between a lower heating element and an upper heating element of the water heater.

28. The control module of claim 19 wherein the control module is mounted adjacent to the junction box.

29. The control module of claim 19, wherein the control circuitry portion includes a current sensor arranged to sense the current provided to the water heater.

30. The control module of claim 19, wherein the service wiring is electrically connected to the switching module and the internal wiring of the water heater using wire connection terminals within the electrical connection portion.

31. The control module of claim 19, wherein the partition is electrically insulative and electrically isolates the control circuitry portion from the service wiring and the internal wiring within the electrical connection portion.