Water heater control using external temperature sensor

• US 9,752,798 B2
• Filed: 02/23/2016
• Issued: 09/05/2017
• 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:
  US15/050,548
• Publication Number:
  US 20160169556A1
• Time in Patent Office: 560 Days
• Field of Search: None
• 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 23/1931 to control the temperature of one space
• CPC Class Codes: H05B 1/0297 : Heating of fluids for non specified applications

Abstract

A system and method for controlling a water heater that operates according to a voltage supply includes a temperature sensor, mounted on at least one of a temperature and pressure (T&P) valve of the water heater and a hot water line of the water heater, that generates a temperature signal corresponding to a first temperature of the at least one of the T&P valve and the hot water line. A control module mounted on the water heater includes a switching module that receives the voltage supply and outputs the voltage supply to the water heater. The voltage supply passes at least one of through and adjacent to the control module. The control module determines a second temperature of water within the water heater based on the temperature signal and selectively actuates the switching module to turn on and turn off the voltage supply to the water heater based on the second temperature.

Claims

1. A method for controlling a water heater that operates according to a voltage supply, the method comprising:

mounting a temperature sensor on at least one of a temperature and pressure (T&

P) valve of the water heater and a hot water line of the water heater;

generating a temperature signal corresponding to a first temperature of the at least one of the T&

P valve and the hot water line;

mounting a control module on the water heater, the control module including a switching module that receives the voltage supply and outputs the voltage supply to the water heater, wherein the voltage supply passes at least one of through and adjacent to the control module; and

using the control module,

determining, using the first temperature indicated by the temperature signal, a second temperature, wherein the second temperature is an actual temperature of water within the water heater, and wherein the first temperature and the second temperature are different, and

selectively actuating the switching module to turn on and turn off the voltage supply to the water heater based on the second temperature.

2. The method of claim 1 further comprising determining a relationship between the first temperature and the second temperature.

3. The method of claim 2 further comprising:

monitoring the first temperature for a predetermined period; and

determining the relationship based on changes in the first temperature during the predetermined period.

4. The method of claim 2 wherein the relationship includes an offset between the first temperature and the second temperature.

5. The method of claim 2 further comprising determining the relationship based on a maximum of the first temperature during a predetermined period.

6. The method of claim 5 wherein the maximum is related to a temperature setpoint of the water heater, and wherein when the first temperature is at the maximum, the second temperature is at the temperature setpoint.

7. The method of claim 6 further comprising determining the relationship based on a difference between the temperature setpoint and the maximum.

8. The method of claim 6 further comprising programming the control module with the temperature setpoint.

9. The method of claim 6 further comprising selecting the temperature setpoint from a plurality of possible temperature setpoints.

10. The method of claim 1 further comprising:

determining usage history of the water heater based on the voltage supply; and

selectively actuating the switching module further based on the usage history.

11. The method of claim 10 further comprising selectively actuating the switching module further based on at least one of peak usage information, load shedding information, and tiered pricing information.

12. The method of claim 10 further comprising selectively actuating the switching module further based on a predetermined minimum temperature.

13. The method of claim 12 wherein the predetermined minimum temperature is a predetermined amount less than a temperature setpoint of the water heater.