Water heater and method of operating a water heater

• US 9,405,304 B2
• Filed: 03/15/2013
• Issued: 08/02/2016
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: A. O. Smith Corporation
• Original Assignee: A. O. Smith Corporation
• Inventors: Branecky, Brian T.
• Primary Examiner(s): Fennema, Robert
• Assistant Examiner(s): Sivanesan, Sivalingam
• Application Number:
  US13/834,929
• Publication Number:
  US 20140277816A1
• Time in Patent Office: 1,236 Days
• Field of Search: 700/300
• US Class Current: 1/1
• CPC Class Codes: F24H 1/202 with resistances
• CPC Class Codes: F24H 15/156 Reducing the quantity of energy consumed; Increasing efficiency
• CPC Class Codes: F24H 15/184 Preventing harm to users from exposure to heated water, e.g. scalding
• CPC Class Codes: F24H 15/225 at different heights of the tank
• CPC Class Codes: F24H 15/254 Room temperature
• CPC Class Codes: F24H 15/269 Time, e.g. hour or date
• 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 2250/00 Electrical heat generating means
• CPC Class Codes: F24H 9/2021 Storage heaters
• CPC Class Codes: G05D 23/1923 using thermal energy, the cost of which varies in function of time
• CPC Class Codes: G05D 23/1928 sensing the temperature of one space

Abstract

A water heater that includes a tank for holding water, a heat source, a temperature sensor, a communication module operable to communicate with an external controller remote from the water heater, and a controller including a processor and a computer readable memory storing instructions that, when executed by the processor, cause the controller to operate the water heater. The communication module receives commands from the external controller for further operating the water heater.

Claims

1. A water heater comprising:

a tank for holding water;

a first heating element extending into the tank;

a second heating element extending into the tank;

a first temperature sensor thermally coupled to the water;

a second temperature sensor thermally coupled to the water;

a communication module operable to communicate with an external controller remote from the water heater; and

a controller including a processor and a computer readable memory storing instructions that, when executed by the processor, cause the controller to

determine a first temperature value related to a first temperature sensed by the first temperature sensor,

determine a second temperature value related to a second temperature sensed by the second temperature sensor,

receive a command and a ratio from the external controller, and

when the received command is a first command,

provide a plurality of slot time periods,

provide a random number, which is limited by the number of the plurality of slot time periods,

control current to the first heating element and the second heating element under a first strategy for a first group of slot time periods based on the random number and the ratio, and

control current to the first heating element and the second heating element under a second strategy for a second group of slot time periods based on the random number and the ratio.

2. The water heater of claim 1 wherein the first group of slot time periods and the second group of slot time periods form the plurality of slot time periods.

3. The water heater of claim 1 wherein the instructions, when executed by the processor, further cause the controller to, when the received command is a second command,

control current to the first heating element based on the first temperature value traversing a first set point, and

control current to the second heating element based on the second temperature value traversing a second set point, and

when the received command is a third command,

control current only to the first heating element and not the second heating element, the control being based on the first temperature value.

4. The water heater of claim 3 wherein the instructions, when executed by the processor, cause the controller to control current to the first heating element and the second heating element under the first strategy for the first group of slot time periods by,

entering the first group of slot time periods,

when in the first group of slot time periods,

controlling current to the first heating element based on the first temperature value traversing a first set point, and

controlling current to the second heating element based on the second temperature value traversing a second point, and

wherein the instructions, when executed by the processor, cause the controller to control current to the first heating element and the second heating element under the second strategy for the second group of slot time periods by

entering the second group of time periods,

when in the second group of time periods,

controlling current only to the first heating element and not the second heating element, the controlling being based on the first temperature value.

5. The water heater of claim 4 wherein the second command is a full-load command for allowing the water heater to provide current using the first heating element and the second heating element, wherein the third command is a reduced-load command for allowing the water heater to provide current using only the first heating element and not the second heating element, and wherein the first command is a return-load command for allowing, during the first group of time periods, the water heater to provide current using the first heating element and the second heating element, and for allowing, during the second group of time periods, the water heater to provide current using only the first heating element and not the second heating element.

6. The water heater of claim 1 wherein the instructions, when executed by the processor, cause the controller to control current to the first heating element and the second heating element under a first strategy for a first group of slot time periods by,

entering the first group of slot time periods, and

when in the first group of slot time periods,

control current to the first heating element based on the first temperature value traversing a first set point, and

control current to the second heating element based on the second temperature value traversing a second point, and

wherein the instructions, when executed by the processor, cause the controller to control current to the first heating element and the second heating element under a second strategy for a second group of slot time periods by,

enter the second group of time periods, and

when in the second group of time periods,

control current only to the first heating element and not the second heating element, the controlling being based on the first temperature value.

7. The water heater of claim 1 wherein the ratio defines a first length of time for the first group of slot time periods relative to a second length of time for the second group of slot time periods.

8. The water heater of claim 1 wherein the random number defines a first time slot of the first group of slot time periods.

9. The water heater of claim 1 wherein the random number and the ratio defines a first time slot of the second group of slot time periods.

10. A method of operating a water heater to be placed at a consumer location and to be in communication with an external controller, the water heater including a tank for holding water, a first heating element extending into the tank, a second heating element extending into the tank, a first temperature sensor coupled to the tank, and a second temperature sensor coupled to the tank, the method comprising:

sensing a first temperature with the first temperature sensor;

determining a first temperature value related to the first temperature;

sensing a second temperature with the second temperature sensor;

determining a second temperature value related to the second temperature;

receiving a command and a ratio from the external controller; and

when the received command is a first command,

providing a plurality of slot time periods,

providing a random number, which is limited by the number of the plurality of slot time periods,

controlling current to the first heating element and the second heating element under a first strategy for a first group of slot time periods based on the random number and the ratio, and

controlling current to the first heating element and the second heating element under a second strategy for a second group of slot time periods based on the random number and the ratio.

11. The method of claim 10 wherein the first group of slot time periods and the second group of slot time periods form the plurality of slot time periods.

12. The method of claim 10 and further comprising, when the received command is a second command,

controlling current to the first heating element based on the first temperature value traversing a first set point, and

controlling current to the second heating element based on the second temperature value traversing a second set point, and

when the received command is a third command,

controlling current only to the first heating element and not the second heating element, the controlling being based on the first temperature value.

13. The method of claim 12 wherein when the received command is the first command,

entering the first group of time periods,

when in the first group of time periods, the step of controlling current to the first heating element and the second heating element under the first strategy includes

controlling current to the first heating element based on the first temperature value traversing a first set point, and

controlling current to the second heating element based on the second temperature value traversing a second point,

entering the second group of time periods, and

when in the second group of time periods, the step of controlling current to the first heating element and the second heating element under the second strategy includes

controlling current only to the first heating element and not the second heating element, the controlling being based on the first temperature value.

14. The method of claim 13 wherein the second command is a full-load command for allowing the water heater to provide current using the first heating element and the second heating element, wherein the third command is a reduced-load command for allowing the water heater to provide current using only the first heating element and not the second heating element, and wherein the first command is a return-load command for allowing, during the first group of time periods, the water heater to provide current using the first heating element and the second heating element, and for allowing, during the second group of time periods, the water heater to provide current using only the first heating element and not the second heating element.

15. The method of claim 10 wherein when the received command is the first command,

entering the first group of time periods,

when in the first group of time periods, the step of controlling current to the first heating element and the second heating element under the first strategy includes

controlling current to the first heating element based on the first temperature value traversing a first set point, and

controlling current to the second heating element based on the second temperature value traversing a second point,

entering the second group of time periods, and

when in the second group of time periods, the step of controlling current to the first heating element and the second heating element under the second strategy includes

controlling current only to the first heating element and not the second heating element, the controlling being based on the first temperature value.

16. The method of claim 10 wherein the ratio defines a first length of time for the first group of slot time periods relative to a second length of time for the second group of slot time periods.

17. The method of claim 10 wherein the random number defines a first time slot of the first group of slot time periods.

18. The method of claim 17 wherein the random number and the ratio defines a first time slot of the second group of slot time periods.

19. A method of operating a water heater to be placed at a consumer location and to be in communication with an external controller, the water heater including a tank for holding water, a heat source, and a temperature sensor coupled to the tank, the method comprising:

sensing a temperature with the temperature sensor;

determining a temperature value related to the temperature;

receiving a command and a ratio from the external controller; and

when the received command is a first command,

providing a plurality of slot time periods,

providing a random number, which is limited by the number of the plurality of slot time periods,

controlling the heat source under a first strategy for a first group of slot time periods based on the random number and the ratio, and

controlling the heat source under a second strategy for a second group of slot time periods based on the random number and the ratio.

20. The method of claim 19 wherein the heat source includes a plurality of heat sources and each of the plurality of heat sources is selected from the group consisting of a gas burner, an electric resistance heating element.