Smart energy controlled water heater

• US 9,605,872 B2
• Filed: 10/27/2015
• Issued: 03/28/2017
• 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:
  US14/923,791
• Publication Number:
  US 20160047572A1
• Time in Patent Office: 518 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 water heater includes an electrical junction box that receives a voltage supply. The electrical junction box includes at least one cover plate for providing access to an internal portion of the water heater. The voltage supply passes through the at least one cover plate and connects to internal wiring of the water heater. A method for providing a control module on the water heater includes routing service wiring for providing the voltage supply to the water heater into an electrical connection portion of the control module, routing the internal wiring of the water heater into the electrical connection portion of the control module, and connecting the service wiring to the internal wiring of the water heater within the electrical connection portion of the control module.

Claims

1. A method for providing a control module on a water heater, the water heater including an electrical junction box that receives a voltage supply, the electrical junction box including at least one cover plate for providing access to an internal portion of the water heater, wherein the voltage supply passes through the at least one cover plate and connects to internal wiring of the water heater, the method comprising:

routing service wiring for providing the voltage supply to the water heater within an electrical connection portion of the control module;

routing the internal wiring of the water heater within the electrical connection portion of the control module; and

connecting the service wiring to the internal wiring of the water heater within the electrical connection portion of the control module.

2. The method of claim 1 further comprising:

removing the at least one cover plate and arranging the control module adjacent to the electrical junction box in a first opening corresponding to the at least one cover plate.

3. The method of claim 1 further comprising:

arranging the control module on the at least one cover plate; and

routing the internal wiring of the water heater through the at least one cover plate into the electrical connection portion of the control module.

4. The method of claim 1 wherein the at least one cover plate includes a first cover plate and a second cover plate, the method further comprising:

removing the first cover plate; and

arranging the control module adjacent to the electrical junction box in an opening corresponding to the first cover plate,

wherein the second cover plate is removable to provide access to the internal wiring of the water heater.

5. The method of claim 1 further comprising:

forming an opening in the at least one cover plate;

arranging the control module on the at least one cover plate; and

routing the internal wiring of the water heater through the opening in the at least one cover plate into the electrical connection portion of the control module.

6. The method of claim 1 further comprising connecting the voltage supply to a relay arranged within the control module.

7. The method of claim 6 wherein connecting the voltage supply to the relay includes connecting the service wiring to terminals arranged within the electrical connection portion of the control module.

8. The method of claim 7 further comprising arranging the relay within a control circuitry portion of the control module.

9. The method of claim 8 further comprising providing a partition between the electrical connection portion of the control module and the control circuitry portion of the control module.

10. The method of claim 9 further comprising providing a current sensor within the control circuitry portion of the control module in electrical communication with the voltage supply.

11. A control module for a water heater, the water heater including an electrical junction box that receives a voltage supply, the electrical junction box including at least one cover plate for providing access to an internal portion of the water heater, wherein the voltage supply passes through the at least one cover plate and connects to internal wiring of the water heater, the control module comprising:

an electrical connection portion, wherein service wiring for providing the voltage supply to the water heater and the internal wiring of the water heater are each routed within the electrical connection portion of the control module; and

terminals for connecting the service wiring to the internal wiring of the water heater within the electrical connection portion of the control module.

12. The control module of claim 11 wherein the control module is arranged in adjacent to the electrical junction box in an opening corresponding to the at least one cover plate.

13. The control module of claim 11 wherein:

the control module is arranged on the at least one cover plate; and

the internal wiring of the water heater is routed through the at least one cover plate into the electrical connection portion of the control module.

14. The control module of claim 11 wherein the at least one cover plate includes a first cover plate and a second cover plate, wherein the control module is arranged adjacent to the electrical junction box in an opening corresponding to the first cover plate, and wherein the second cover plate is removable to provide access to the internal wiring of the water heater.

15. The control module of claim 11 wherein:

the at least one cover plate includes an opening;

the control module is arranged on the at least one cover plate; and

the internal wiring of the water heater is routed through the opening in the at least one cover plate into the electrical connection portion of the control module.

16. The control module of claim 11 further comprising a relay arranged within the control module, wherein the relay is connected to the voltage supply.

17. The control module of claim 16 wherein the voltage supply is connected to the relay via a connection between the service wiring and the terminals.

18. The control module of claim 17 further comprising a control circuitry portion, wherein the relay is arranged within the control circuitry portion.

19. The control module of claim 18 further comprising a partition between the electrical connection portion and the control circuitry portion.

20. The control module of claim 19 further comprising a current sensor arranged within the control circuitry portion in electrical communication with the voltage supply.