Water heating systems and methods

Abstract

A water heating system has a controller that is electronically actuated. In this regard, the controller controls an activation state of at least one heating element by providing an electrical control signal to a relay. In one embodiment, the controller has an emergency shut-off apparatus that is mechanically actuated. Further various features can be optionally implemented to help heat related problems plaguing many conventional water heater controllers that are electronically actuated.

1 . A water heater controller, comprising: 
 a relay for controlling an activation state of a heating element;    an emergency shut-off apparatus for disabling the heating element if a temperature exceeds a threshold, the emergency shut-off apparatus having a temperature sensitive element that mechanically actuates based on the temperature, the emergency shut-off apparatus having a mechanical switch that is coupled to the relay, wherein actuation of the temperature sensitive element changes a state of the switch; and    logic configured to receive temperature data indicative of a temperature sensed by a temperature sensor, the logic further configured to control a state of the relay based on the temperature data.    
   
   
       2 . The water heater controller of  claim 1 , wherein the logic is configured to perform a comparison between the temperature data and a threshold value, wherein the logic is configured to transmit an electronic signal to the relay based on the comparison, and wherein the relay transitions from an open state to a closed state in response to the electronic signal thereby activating the heating element.  
   
   
       3 . The water heater controller of  claim 1 , wherein the logic is configured to perform a comparison between the temperature data and a threshold value, wherein the logic is configured to transmit an electrical signal to the relay based on the comparison, and wherein the relay transitions from a closed state to an open state in response to the electronic signal thereby deactivating the heating element.  
   
   
       4 . The water heater controller of  claim 1 , wherein the emergency shut-off apparatus, upon disabling the heating element, is configured to ensure that the heating element remains disabled until at least the emergency shut-off apparatus receives a user input.  
   
   
       5 . The water heater controller of  claim 1 , wherein the temperature sensitive element comprises a bimetallic disc.  
   
   
       6 . The water heater controller of  claim 1 , further comprising an electrically conductive connection coupled to the emergency shut-off apparatus, the connection composed of a metallic alloy having an International Annealed Copper Standard (IACS) of greater than 80%, a stress relaxation temperature greater than 105 degrees Celsius, and a yield stress greater than 50 kilo-pounds per square inch (ksi).  
   
   
       7 . The water heater controller of  claim 1 , further comprising: 
 a thermally conductive base;    a housing coupled to the base, the housing composed of electrically insulating material;    the temperature sensor, wherein the temperature sensor contacts the base.    
   
   
       8 . The water heater controller of  claim 7 , wherein the relay is mounted on a first side of a printed circuit board (PCB), and wherein the temperature sensor is positioned on a second side of the PCB that is opposite to the first side.  
   
   
       9 . The water heater controller of  claim 7 , wherein the temperature sensor is mounted on an element composed of thermally insulating material and is electrically coupled to the PCB.  
   
   
       10 . The water heater controller of  claim 1 , further comprising an interface for electrically connecting an electrically conductive wire to an electrically conductive connection, the interface having a hole for receiving the wire.  
   
   
       11 . The water heater controller of  claim 10 , wherein the connection is coupled to the emergency shut-off apparatus.  
   
   
       12 . The water heater controller of  claim 10 , wherein the connection is coupled to the relay.  
   
   
       13 . The water heater controller of  claim 10 , wherein the connection has at least one rib for guiding the wire as the wire is being inserted into the first hole.  
   
   
       14 . The water heater controller of  claim 10 , further comprising a housing covering the logic, the housing having a hole, wherein the wire has a coating composed of insulating material, and wherein a portion of the coating passes through the hole of the housing.  
   
   
       15 . The water heater controller of  claim 14 , wherein at least a portion of a wall of the housing contacts the coating, the portion defining the hole of the housing.  
   
   
       16 . The water heater controller of  claim 14 , wherein the interface is composed of a metallic alloy having an International Annealed Copper Standard (IACS) of greater than 80%, a stress relaxation temperature greater than 105 degrees Celsius, and a yield stress greater than 50 kilo-pounds per square inch (ksi).  
   
   
       17 . The water heater controller of  claim 10 , further comprising: 
 a thermally conductive base;    a housing coupled to the base, the housing composed of an electrically insulating material;    the temperature sensor,    wherein the temperature sensor contacts the base.    
   
   
       18 . The water heater controller of  claim 17 , wherein the relay is mounted on a first side of a printed circuit board (PCB), and wherein the temperature sensor is positioned on a second side of the PCB that is opposite to the first side.  
   
   
       19 . The water heater controller of  claim 18 , wherein the temperature sensor is mounted on an element composed of thermally insulating material and electrically coupled to the PCB.  
   
   
       20 . A water heating system, comprising: 
 a tank;    a heating element mounted on the tank; and    a controller mounted on the tank, the controller comprising: 
 an emergency shut-off apparatus that is mechanically actuated, the emergency shut-off apparatus coupled to the heating element and having a temperature sensitive element that mechanically actuates due to thermal stresses such that the heating element is disabled if the temperature exceeds a threshold;  
 a relay coupled to the heating element; and  
 logic configured to receive temperature data indicative of a temperature sensed by a temperature sensor, the logic further configured to control a state of the relay based on the temperature data.  
   
   
   
       21 . The system of  claim 20 , wherein the controller further comprises: 
 a thermally conductive base;    a housing coupled to the base, the housing composed of electrically insulating material;    the temperature sensor,    wherein the temperature sensor contacts the base.    
   
   
       22 . The system of  claim 21 , wherein the relay is mounted on a first side of a printed circuit board (PCB), and wherein the temperature sensor is positioned on a second side of the PCB that is opposite to the first side.  
   
   
       23 . The system of  claim 20 , further comprising an electrically conductive wire, wherein the controller further comprises: 
 an electrically conductive connection; and    an interface having a hole, the connection extending through the hole.    
   
   
       24 . The system of  claim 23 , further comprising a housing covering the logic, the housing having a hole, wherein the wire has a coating composed of insulating material, and wherein a portion of the coating passes through the hole of the housing.  
   
   
       25 . The system of  claim 23 , wherein the connection is composed of a metallic alloy having an International Annealed Copper Standard (IACS) of greater than 80%, a stress relaxation temperature greater than 105 degrees Celsius, and a yield stress greater than 50 kilo-pounds per square inch (ksi).  
   
   
       26 . The system of  claim 23 , wherein the connection has at least one rib for guiding the wire as the wire is being inserted into the first hole.  
   
   
       27 . A water heater controller, comprising: 
 an electromechanical switching means for controlling an activation state of the heating element;    means for disabling a heating element if a temperature exceeds a threshold, the disabling means having a mechanical switching means coupled to the relay and having a temperature sensing means that mechanically actuates based on the temperature, wherein actuation of the temperature sensing means changes a state of the mechanical switching means; and    means for receiving temperature data indicative of a temperature sensed by a temperature sensor, and for controlling a state of the relay based on the temperature data.    
   
   
       28 . A method for controlling a water heating system having a tank and a heating element mounted on the tank, comprising the steps of: 
 disabling the heating element if a temperature exceeds a threshold, the disabling step comprising the step of mechanically actuating a temperature sensitive element based on the temperature;    sensing a temperature;    transmitting temperature data indicative of the sensed temperature; and    controlling an operational state of the heating element based on the temperature data, the controlling step comprising the step of electrically actuating a relay based on the temperature data.    
   
   
       29 . The method of  claim 28 , wherein the disabling step comprises the step of ensuring that the heating element remains disabled until a user input is received.