Modular Electric Boiler and Heat Exchanger

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 63/676,969, filed on Jul. 30, 2024 and entitled “Modular Electric Boiler and Heat Exchanger,” the entirety of which us hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

Aspects of the disclosure generally relate to electric boilers and heat exchangers.

BACKGROUND OF THE INVENTION

Many boilers today rely on fossil fuels, such as natural gas. As many municipalities create policies and strategies to reduce and/or move away from fossil fuels, there is a need to replace existing boilers with energy efficient solutions that can operate in the same footprint as existing boilers, with better efficiency.

SUMMARY OF THE INVENTION

The following presents a simplified summary of various features described herein. This summary is not an extensive overview, and is not intended to identify key or critical elements or to delineate the scope of the claims. The following summary merely presents some concepts in a simplified form as an introductory prelude to the more detailed description provided below. Corresponding apparatus, systems, and computer-readable media are also within the scope of the disclosure.

Aspects of the disclosure generally relate to electric boilers and heat exchangers. In particular, the present disclosure describes modular electric boilers and heat exchangers that can be expanded to suit residential, commercial, and/or industrial customers' needs. Moreover, the modular electric boilers and heat exchangers described herein may be “smart” products that can easily integrate into building automation systems.

Certain aspects of the disclosure describe a modular electric boiler that is configured to add, or remove, pressure vessels to expand, or reduce, the capabilities of the modular electric boiler. The modular electronic boiler described herein may include a control panel and one or more modular pressure vessels. Each of the one or more modular pressure vessels may comprise an inlet to receive water, an outlet to output hot water, and a cavity configured to receive one or more heating elements. The one or more heating elements may attach to each of the one or more modular pressure vessels such that the heating element is located within a cavity of the chamber. The one or more heating elements may be communicatively coupled to the control panel. In operation, the control panel may activate the one or more heating elements associated with each pressure chamber. Water may enter the pressure chamber via the inlet, pass over the one or more heating elements, and exit the pressure chamber as heated water via the outlet. Modular pressure vessels may be added to expand the capabilities of the modular electric boiler. The modular pressure vessels may be stacked upon one another or placed alongside one another for expansion purposes. Moreover, the control panel may be configured to activate (e.g., turn on) each of the one or more heating elements individually. This may allow the control panel to cycle (e.g., rotate) through the one or more heating elements to ensure even heating of the water and/or prolong the life of each of the one or more heating elements by ensuring equal, or near equal, run-time for each of the one or more heating elements. The control panel may also track the cycles on each contactor, thereby prolonging the life of each contactor and preventing a single contactor from failing before the others. Accordingly, the modular electric boiler described herein can replace existing boilers with an energy efficient solution that can operate in the same, or smaller, footprint as existing boilers.

These features, along with many others, are discussed in greater detail below.

BRIEF DESCRIPTION OF DRAWINGS

The present disclosure is described by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which:

FIGS. 1A and 1B show examples of modular electric boilers in accordance with one or more aspects of the disclosure;

FIG. 1C shows an example of a plurality of pressure vessels connected to return and supply lines in accordance with one or more aspects of the disclosure;

FIG. 1D shows another example of a plurality of pressure vessels connected to return and supply lines in accordance with additional aspects of the disclosure;

FIGS. 1E-1H shows an example of a plurality of pressure vessels in a vertical arrangement in accordance with one or more aspects of the disclosure;

FIGS. 1I-M show an example of vertically arranged pressure vessels connected to supply/return lines in accordance with one or more aspects of the disclosure;

FIG. 1N shows an example of a wall-mounted boiler in accordance with one or more aspects of the disclosure;

FIG. 1O shows an example of various configurations of pressure vessels in accordance with one or more aspects of the disclosure;

FIG. 2 shows an example of a modular electric boiler in accordance with one or more aspects of the disclosure;

FIGS. 3A-3C show various perspectives of a casted pressure vessel in accordance with one or more aspects of the disclosure;

FIG. 3D shows an example of a casted pressure vessel with a single chamber in accordance with one or more aspects of the disclosure;

FIGS. 4A-4B show examples of water flow through the casted pressure vessel at different pressures;

FIGS. 5A-5B show various perspectives of a fabricated pressure vessel in accordance with one or more aspects of the disclosure;

FIGS. 6A-6N show various user interfaces of the modular electric boiler in accordance with one or more aspects of the disclosure;

FIGS. 7A-7D show an example of a process for operating a modular electric boiler with a constant/remote set point in accordance with one or more aspects of the disclosure;

FIGS. 8A-8D show an example of a process for operating a modular electric boiler with an outdoor reset set point in accordance with one or more aspects of the disclosure;

FIGS. 9A-9C show an example of a process for operating a plurality of modular electric boilers with a constant/remote set point in accordance with one or more aspects of the disclosure;

FIGS. 10A-10C show an example of a process for operating a plurality of modular electric boilers with an outdoor reset set point in accordance with one or more aspects of the disclosure;

FIGS. 11A and 11B show an example of an element staging process in accordance with one or more aspects of the disclosure;

FIGS. 12A and 12B show another example of an element staging process using a solid-state switching device in accordance with one or more aspects of the disclosure; and

FIG. 13 shows an example computing device in accordance with one or more aspects of the disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, reference is made to the accompanying drawings, which form a part hereof, and in which are shown various examples of features of the disclosure and/or of how the disclosure may be practiced. It is to be understood that other features may be utilized and structural and functional modifications may be made without departing from the scope of the present disclosure. The disclosure may be practiced or carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. Rather, the phrases and terms used herein are to be given their broadest interpretation and meaning.

By way of introduction, features discussed herein may relate to a modular electric boiler and/or heat exchange. The modular electric boiler and/or heat exchange described herein may include a control panel and one or more pressure vessels. The number of pressure vessels included in the modular electric boiler and/or heat exchange may be based on a customer's needs. That is, pressure vessels may be added, or removed, to suit a customer's needs.

Each pressure vessel may comprise an inlet to receive water, an outlet to output hot water, and one or more cavities configured to receive one or more heating elements. The inlet and outlet may be configured to connect to existing plumbing to avoid extensive connections. Moreover, the inlet and outlet may be located so that the pressure vessel may be installed to accommodate plumbing connections on either side of the location of the modular electric boiler and/or heat exchange, thereby making the modular electric boiler and/or heat exchange easier to install in existing spaces. The one or more heating elements may attach to an exterior surface of a modular pressure vessel such that a heating element is located within a cavity of the chamber. The one or more heating elements may be communicatively coupled to the control panel.

In operation, the control panel may activate one or more heating elements. The one or more heating elements may be associated with one or more pressure chambers of a pressure vessel. Additionally or alternatively, the one or more heating elements may be associated with a plurality of pressure vessels that water may cycle through. In this regard, water may enter a pressure chamber of one or more pressure vessels, pass over the one or more heating elements contained therein, and exit each respective pressure chamber as heated water. Using the control panel to cycle (e.g., rotate) through one or more heating elements may ensure even heating of the water and/or prolong the life of each of the one or more heating elements. Accordingly, the modular electric boiler described herein can replace existing boilers with an energy efficient solution that can operate in the same, or smaller, footprint as existing fossil fuel boilers.

FIGS. 1A-1B shows an example of a modular electric boiler 100 in accordance with one or more aspects of the disclosure. The modular electric boiler 100 shown in FIG. 1A may be a 30 kilowatt (kW) to 600 kW electric water boiler. Modular electric boiler 100 may be rack-mounted. As shown in FIG. 1A, electrical components, such as a control panel 145 (shown in FIG. 1B), one or more fuse holders 135, one or more contactors 140, and a display 150 (shown in FIG. 1B) may be mounted to door 110. Each of the one or more fuse holder 135 may comprise a fuse associated with each of the one or more contactors. Door 110 may be a rack-mounted door that allows for installation of one or more components or modules in the rack. Door 110 may be configured to open to the left or to the right, thereby allowing for convenient installation in existing utility rooms and/or allocated space.

The control panel 145 may comprise any suitable computing device configured to control the operation of modular electric boiler 100. In particular, control panel 145 may comprise a computing device as shown, for example, in FIG. 13, discussed below. Control panel 145 may comprise one or more communication interfaces configured to allow communications and/or signal exchanges with one or more computing devices, such as those associated with home or building automation systems. Preferably, the one or more communication interfaces may be configured for Modbus and BACnet IP and MSTP communications. One or more fuse holders 135 may be any suitable interface for receiving a fuse. As used herein, a fuse may comprise an electrical safety device configured to provide overcurrent protection of an electrical circuit. One or more contactors 140 may be any suitable electrically controlled switch configured for switching an electrical power circuit. One or more contactors 140 may be configured to activate/disable (e.g., turn on/off) one or more heating elements (e.g., first heating element 116, second heating element 117, third heating element 118, and fourth heating element 119). Display 150 may be any suitable display capable of displaying data and/or information associated with modular electrical boiler 100. Display 150 may comprise a liquid crystal display (LCD) display technology, a light emitting diode (LED) display technology, vacuum florescent display technology, and/or the like.

A plurality of pressure vessels (e.g., first pressure vessel 115, second pressure vessel 120, third pressure vessel 125, fourth pressure vessel 130, etc.) may be mounted in the rack. As briefly discussed above, an inlet and outlet for each of the plurality of pressure vessels may be reversible to allow the pressure vessels to connect to existing plumbing, regardless of the location of existing plumbing. That is, the plurality of pressure vessels (e.g., first pressure vessel 115, second pressure vessel 120, third pressure vessel 125, fourth pressure vessel 130, etc.) may be installed such that the inlet and outlet may be either left-facing or right-facing. As shown in FIG. 1A, each of the plurality of pressure vessels (e.g., first pressure vessel 115, second pressure vessel 120, third pressure vessel 125, fourth pressure vessel 130, etc.) may have one or more heating elements installed therein. FIG. 1A shows first heating element 116, second heating element 117, third heating element 118, and fourth heating element 119 installed in first pressure vessel 115. First heating element 116, second heating element 117, third heating element 118, and fourth heating element 119 may be a resistance heating coil or an electrode. It will be appreciated that each of the plurality of pressure vessels may comprise a plurality of heating elements. The plurality of heating elements may be mounted (e.g., bolted) to each of the pressure vessels. The plurality of heating elements may be electrically coupled to contactors 140. In operation, control panel 145 may activate/deactivate the plurality of heating elements via contactors 140.

The modular electric boiler 100 shown in FIG. 1B may be a 510 kW to 1200 kW electric water boiler. FIG. 1B shows two racks. The left rack may house the electrical components, such as control panel 145, one or more fuse holders 135, one or more contactors 140, and display 150. The right rack may comprise a plurality of pressure vessels (e.g., first pressure vessel 115, second pressure vessel 120, third pressure vessel 125, fourth pressure vessel 130, etc.). While only four pressure vessels are labeled, the configuration shown in FIG. 1B may be able to accommodate up to ten (10) pressure vessels. FIG. 1B also shows return line 155 and supply line 160. Return line provide 155 may carry cooled water back to boiler 100 for reheating. Supply line 160 may deliver heated water from boiler 100 to distribution points. Modular electric boiler 100, in combination return line 155 and supply line 160, may form a closed system that provides heat in the form of hot water to various distribution points, such as radiators, plumbing fixtures, etc. In this regard, the plurality of pressure vessels may be connected to return line 155 and/or supply 160 using a variety of techniques. For example, FIG. 1C shows an example of the plurality of pressure vessels (e.g., first pressure vessel 115, second pressure vessel 120, third pressure vessel 125, fourth pressure vessel 130, etc.) being connected to supply line 160 and return line 155 via one or more flat face header gasketed connections. That is, supply line 160 and return line 155 may be bolted to the plurality of pressure vessels (e.g., first pressure vessel 115, second pressure vessel 120, third pressure vessel 125, fourth pressure vessel 130, etc.). As shown in FIG. 1C, supply line 160 and return line 155 may comprise a casted header to connect to existing plumbing through the use of bolts and gaskets. In another example, FIG. 1D shows the plurality of pressure vessels (e.g., first pressure vessel 115, second pressure vessel 120, third pressure vessel 125, fourth pressure vessel 130, etc.) being connected to supply line 160 and return line 155 via one or more National Pipe Taper (NPT) pipe connections and/or mechanical tees.

While FIGS. 1A-1D shows the pressure vessels being installed horizontally, the pressure vessels may also be installed in a vertical installation, as illustrated in FIGS. 1E-1H. FIGS. 1E and 1F show an example of the electrical components and the pressure vessels mounted in a single rack. In this regard, the electrical components may be mounted above the pressure vessels. This may protect the electrical components, for example, if the pressure vessels were to leak or have condensation form thereon. FIGS. 1G-1H show a dual-rack configuration. Again, the electrical components may be mounted above the pressure vessels. As shown in FIGS. 1E-1I, supply line 160 may comprise one or more control ports 165. One or more control ports 165 may comprise one or more sensors. The one or more sensors may be configured to measure (e.g., monitor) water temperature, flow rate, water pressure, and the like.

FIGS. 1I-1L show various configurations of vertically arranged pressure vessels connected to return line 155 and supply line 160. As shown in FIGS. 1I-1J, each of the plurality of pressure vessels may be connected to return line 155 and supply line 160 via one or more union connections. FIGS. 1L and 1M show flow restriction rings placed in the one or more connections to balance the flow of water to each of the pressure vessels. As shown in FIG. 1M, each pressure vessel may comprise a flow restriction ring with a different diameter to ensure that water flows evenly and/or equitable to each of the pressure vessels.

FIG. 1N shows an example of a wall-mounted boiler. The wall-mounted boiler shown in FIG. 1N comprises a plurality of pressure vessels connected to return line 155 and supply line 160. Wall-mounted boiler also comprises one or more fuse holders 135 and one or more contacts 140. Although not shown in FIG. 1N, wall-mounted boiler may also comprise a control panel and display, as discussed above.

FIG. 1O shows an example of the various arrangements and configurations of pressure vessels and how the boilers may add additional pressure vessels to expand the capabilities of the boilers described herein. As shown on the left side of FIG. 1O, residential boilers may comprise a pressure vessel with a single chamber. Additional chambers may be added to suit customer demands and/or needs. The examples shown in FIGS. 1A-1O are merely illustrative and the modular boilers contemplated by this disclosure may be modified, expanded, or condensed in accordance with the descriptions disclosed herein. In particular, the modular boilers described herein may range from 30 kW to 1.2 Megawatts (MW) and may have a maximum operating temperature of 230° F. The modular boilers described herein may operate at a plurality of voltages (e.g., 208V, 240V, 480V) and/or phases and have a compact footprint. In this regard, the 208V and 240V boiler may operate on single-phase or three-phase power, while the 480V boiler may operate on three-phase power. For example, the modular boilers described herein may have three-foot print platforms and fit through most standard doors. All three footprint platforms allow for two sides of the modular boiler to maintain a zero side clearance installation. The three footprint platforms also all allow for one of the smallest installation and maintenance footprints, required by code, in the market. The modular boilers described herein may also provide multiple step control and SCR rectifier and an integrated multi boiler sequencer. The modular boilers described herein are also configured to operate at an ASME-approved 150 psi maximum pressure.

FIG. 2 shows an example of modular electric boiler 200 with a single pipe 262 for both the supply line and the return line. FIG. 2 does not include the electrical components (e.g., control panel 145, one or more fuse holders 135, one or more contactors 140, display 150, etc.) described above, but one of ordinary skill in the art would recognize that the electrical components to operate modular electric boiler 200 would be substantially similar, if not identical, to the electrical components (e.g., control panel 145, one or more fuse holders 135, one or more contactors 140, display 150, etc.) discussed above with respect to FIGS. 1A-1B. As shown in FIG. 2, modular electric boiler 200 comprises a plurality of pressure vessels (e.g., first pressure vessel 115, second pressure vessel 120, third pressure vessel 125, fourth pressure vessel 130, fifth pressure vessel 215, sixth pressure vessel 220, seventh pressure vessel 225, eight pressure vessel 230, ninth pressure vessel 235, tenth pressure vessel 240, etc.) connected to supply/return line 262. While FIG. 2 shows the plurality of heating elements (e.g., first heating element 116, second heating element 117, third heating element 118, and fourth heating element 119) associated with first pressure vessel 115, it will be appreciated that each of the pressure vessels shown in FIG. 2 may comprise a plurality of heating elements, similar to the description above with respect to FIGS. 1A-1B.

FIG. 2 shows a plurality of flow control mechanism (e.g., first flow control mechanism 242, second flow control mechanism 244, third flow control mechanism 246, fourth flow control mechanism 248, fifth flow control mechanism 250, sixth flow control mechanism 252, seventh flow control mechanism 254, eight flow control mechanism 256, ninth flow control mechanism 258, tenth flow control mechanism 260) between each of the plurality of pressure vessels and the supply/return line 262. The plurality of flow control mechanisms may comprise one or more of a flow control switch or a pump. Modular electric boiler 200 may use one or more flow control switches to ensure that the flow of water is above a required amount for the unit to prevent overtemperature failures in low, or no, flow conditions. Certain pressure vessels and/or heating elements may be de-activated (e.g., turned off) to conserve energy during non-peak and/or low use hours. Preferably, certain pressure vessels and/or heating elements may be de-activated (e.g., turned off) by the control panel. Additionally or alternatively, control panel may use the flow control switch to prevent water from flowing to the deactivated pressure vessels. Similarly, the control panel may activate a subset (or all) of the pressure vessels and/or heating elements during peak hours. Accordingly, control panel may use the flow control switch to allow water to flow to the subset (or all) of the pressure vessels. The use of flow control switches may enable a boiler-within-a-boiler design that consumes less energy during non-peak and/or low use periods. The boiler-within-a-boiler design achieved through the use of flow control switches may allow modular electric boiler 200 to dynamically scale to meet demands.

The pressure vessels discussed above with respect to FIGS. 1A-1G and FIG. 2 may be manufactured using a variety of techniques. FIG. 3A shows an example of a casted pressure vessel 300. Casted pressure vessel 300 may be formed by pouring a liquid material (e.g., metal) into a mold and letting the liquid material solidify until casted pressure vessel 300 is formed. The mold may comprise sand, metal, or ceramic. The mold may comprise a hollow cavity that matches casted pressure vessel 300. Once the material has solidified, the mold may be broken or ejected to remove the casting. The casting can then be used as a final product or undergo additional finishing treatments. Casted pressure vessel 300 may be manufactured from any ASME-approved material for pressure vessels. In some instances, casted pressure vessel 300 may be any suitable material having a minimum tensile strength of 65 kilopounds per square inch (ksi) (448 megapascals (MPa)), a yield strength of 45 ksi (310 MPa), and/or an elongation of 12% Preferably, casted pressure vessel 300 may be manufactured from ductile iron, such as 65-45-12 ductile iron.

As shown in FIG. 3A, casted pressure vessel 300 may comprise a water inlet 305, a first chamber 310, a second chamber 315, a third chamber 320, a fourth chamber 325, and a water outlet 330. Each chamber (a first chamber 310, a second chamber 315, a third chamber 320, a fourth chamber 325) may comprise a flow restriction ring and/or an opening to form a cavity to receive one or more heating elements. In this regard, first chamber 310 comprises first opening 311 and first flow restriction ring 312; second chamber 315 comprises a second opening 316 and second flow restriction ring 313; third chamber 320 comprises third opening 321 and third flow restriction ring 322; and fourth chamber 325 comprises fourth opening 326 and fourth flow restriction ring 327. As noted above, the openings (e.g., first opening 311, second opening 316, third opening 321, fourth opening 326) may be configured to receive one or more heating elements. In this regard, casted pressure vessel 300 may comprise one or more openings (not shown) to receive nuts and bolts to secure the one or more heating elements to casted pressure vessel 300.

The flow restriction rings may be configured to control the flow of water through each of the chambers. For example, first flow restriction ring 312 may ensure that water flows in one direction through first chamber 310. Each flow restriction ring may ensure the same for each respective chamber. In some instances, the flow restriction rings may reduce, limit, or prevent backflow. Each of the flow restriction rings may comprise one or more notches. As shown in FIG. 3B, first flow restriction ring 312 comprises a first notch at the top of the first chamber 310. The first notch may allow air to flow through each of the chambers until the air reaches an escape point (e.g., an opening). Preferably, the first notch may be V-shaped, however any suitable shape may be used for the first notch. In some instances, first notch may allow air to escape via first opening 313 in a top surface of first chamber 310. Each of the chambers (e.g., second chamber 315, third chamber 320, fourth chamber 325) may comprise a respective opening (e.g., second opening 318, third opening 323, fourth opening 328). In some instances, an air separator may be located (installed) in the openings. The air separator may be configured to allow air to escape from first chamber 310 while ensuring that little to no water escapes. While a single flow restriction ring is shown in each of the chambers, it will be appreciated that each of the chambers may comprise a plurality of flow restriction rings to improve the flow of water through the chambers and/or over the heating elements. When using a plurality of flow restriction rings, each ring may comprise a different diameter, thereby creating different size openings throughout the chamber, to artificially balance the flow through each section of the vessel. Because water is inlet and outlet to all four chambers via one opening each, the rings would marginally restrict flow to certain chambers and force higher flow through other chambers. Using this method, flow may be balanced to each chamber within a vessel. Having a balanced flow means that, if all four elements in a vessel are on at full output percentage, the temperature will be the same in each chamber because they all have the same power output and the same flow of water. This prevents overtemperature in specific chambers when others are within the acceptable range.

FIG. 3C shows an example of water flowing through casted pressure vessel 300. In operation, water may enter casted pressure vessel 300 via water inlet 305. After entering via inlet 305, water may flow into first chamber 310, second chamber 315, third chamber 320, and/or fourth chamber 325. In some examples, the flow restriction rings discussed above may be used to restrict the flow of water into certain chambers to ensure that water is distributed evenly through each of the chambers. In each of the chambers, the water may flow over one or more heating elements (e.g., first heating element 314, second heating element 319, third heating element 324, fourth heating element 329 in FIGS. 4A-4B) located therein. After being heated, the heated water may be provided to the supply line via water outlet 330.

FIGS. 4A and 4B shows the flow of water through the casted pressure vessel 300 at the same input pressure, but different flow rates. As shown in FIGS. 4A and 4B, water enters via water inlet 305 and is generally distributed through each of the chambers (e.g., first chamber 310, second chamber 315, third chamber 320, fourth chamber 325). Once in the chambers, the water flows over each of the one or more heating elements (e.g., first heating element 314, second heating element 319, third heating element 324, fourth heating element 329) before exiting casted pressure vessel 300 via outlet 330. As shown in FIG. 4A, water is evenly distributed throughout each of the chambers at expected and high-water pressures and/or flow rates. FIG. 4B shows the flow rate through casted pressure vessel 300 at a low flow rate. Generally, FIG. 4B shows a similar distribution at a low flow rate. The exception in FIG. 4B is that the second chamber appears to experience a lower flow rate than the other chambers. As discussed above with respect to FIG. 2, this may be resolved through the use of one or more flow control mechanisms. Additionally or alternatively, an extended gasket in each union connection between the header and pressure vessel may be used to control flow, as illustrated in FIGS. 1L and 1M discussed above.

Instead of casting the pressure vessels, the pressure vessels described herein may be fabricated. FIGS. 5A and 5B show an example of fabricated pressure vessel 400. Fabricated pressure vessel may comprise an inlet manifold 405, first chamber 410, second chamber 415, third chamber 420, fourth chamber 425, and outlet manifold 430. Similar to casted pressure vessel 300, each chamber (first chamber 410, second chamber 415, third chamber 420, fourth chamber 425) of may fabricated pressure vessel 400 comprise an opening to form a cavity to receive one or more heating elements. FIGS. 5A and 5B show first heating element 414, second heating element 419, third heating element 424, and fourth heating element 429 installed in their respective chambers.

Similar to inlet 305, inlet manifold 410 may be configured to receive water from one or more returns and provide the water to chambers so that the water may be reheated by the one or more heating elements contained therein. Inlet manifold 410 may be connected to the return line via any suitable means, including via threaded connection. Inlet manifold 410 may connect to each of the plurality of chambers via one or more down tubes (not shown). Each of the one or more down tubes may be a different diameter to control the flow of water to each of the respective chambers. For example, a first downtube, comprising a first diameter, may connect inlet manifold 405 to first chamber 410; a second downtube, comprising a second diameter, may connect inlet manifold 405 to second chamber 415; and so on. The first diameter and the second diameter may be different. It will be appreciated that at least two of the down tubes may have the same diameter. By using down tubes of different diameters, fabricated pressure vessel 400 may ensure the even distribution of water through each of the chambers.

FIG. 5B shows an example of water flowing through fabricated pressure vessel 400. Similar to the process described above, water enters fabricated pressure vessel 400 via inlet manifold 400. Inlet manifold 400 may distribute water evenly to each of the chambers. The water then flows over each of the one or more heating elements (e.g., first heating element 414, second heating element 419, third heating element 424, fourth heating element 429) before exiting to a supply line via outlet manifold 430. Outlet manifold 430 may be connected to the supply line via any suitable connection, including, for example, threaded connections.

FIGS. 6A-6N show a plurality of user interfaces that may be used to configure and/or operate the modular electric boilers described herein. The plurality of user interfaces may be presented via a display (e.g., display 150) of a boiler. The interface shown in FIG. 6A illustrates the general screen layout for the interfaces described below, as well as depicts the opening display presented to the user upon startup. As shown in FIG. 6A, the interface may comprise a menu that displays a plurality of options for a user to select. As illustrated, the menu comprises a “Welcome” option, a “Status” option, a “Trend Data” option, an “Alarm Journal” option, a “Control Hardware” option, a “Settings” option, a “Boiler Data” option, and a “Security Login” option. For users logging in with higher (e.g., admin) credentials, a “Testing” option, a “Contactor Control 1” and, additionally for larger boilers, a “Contactor Control 2” option, and a “PID Setup” option may also be displayed further down the menu bar, which may be viewed scrolling through the menu options. As will be described further below, the “Status” option may allow a user to view the status of the boiler, the “Trend Data” option may allow the user to view and collect specified data points based on the operation of the boiler, the “Alarm Journal” option may bring a user to another page that will allow the user to view any active alarms that may be preventing the unit from running and/or any resolved alarms, the “Control Hardware” option may bring the user to an additional screen that depicts all standard hardware components encased in the boiler for ease of maintenance and understanding, the “Settings” option may bring the user to a page with some additional options not shown on the other standard pages, the “Boiler Data” option may bring the user to a page containing information regarding the configuration and application of the user's boiler, and the “Security Login” option may allow those with higher credentials to login to see additional configuration and testing options. Theses interfaces may provide details of how the overall system is performing and/or operating. As will also be described in greater detail below, the “Setup Wizard” button option, depicted in the lower middle section of the interface shown in FIG. 6A, may open a plurality of windows that will allow the user to configure the electric boiler. The interface shown in FIG. 6A may also include a status bar and/or alert notifications. Similarly, the interface may include space heat and domestic hot water (DHW) icons, connection mode icons, a settings button, a running unit indication text, current login credentials, and/or a date/time indicator.

Turning to FIG. 6B-1 through 6B-10, the interfaces shown therein may provide the basic setup windows for the electric boiler, which are activated by pressing the “Setup Wizard” button shown in FIG. 6A (a similar button may also be located on the “Settings” page). Via these interface windows, a user may indicate how the boiler will be used. For example, in FIG. 6B-1, the user may be presented with options for defining the size and/or capacity (e.g., in KW) of their boiler. In FIG. 6B-2, the user may also be able to configure the set point function for the unit, whether that may be constant local/constant remote, or configured through an outdoor reset schedule. When the user selects the “Constant Local/Remote Set Point” button from FIG. 6B-2, the user may be directed to an interface to define the constant set point, such as the one depicted in FIG. 6B-3. Using the interface depicted in FIG. 6B-3, the user may be able to configure the constant set point value, as well as indicate which connection method the boiler may use while maintaining the constant set point. However, if the user selects the “Outdoor Reset Schedule Set Point” button option from FIG. 6B-2, the user may be directed to an interface that allows the user to configure the high and low values for set point and outdoor temperature, as shown in FIG. 6B-4. That is, the interface shown in FIG. 6B-4 may allow the user to configure the high and low values for set point and outdoor temperature that they would like the set point to self-indicate from. The graph depicted in the middle of this screen shown in FIG. 6B-4 may automatically change, for example, based on the user inputs. At the top of the interface shown in FIG. 6B-4, a button may allow the user to reset the schedule to factory standards. After the set point options are set, the setup wizard may direct the user to an interface, such as the one depicted in FIG. 6B-5, that allows the user to configure the water applications for which the boiler will be used. As shown in FIG. 6B-5, the water applications may include space heating, domestic hot water, or both space heating and domestic hot water. If the user selects either the “Maintain Domestic Hot Water Tank Only” option or the “Space Heating and Domestic Hot Water Tank” option, the user may be directed to another interface, such as the one depicted in FIG. 6B-6. The interface shown in FIG. 6B-6 may allow the user to configure the settings for maintaining a domestic hot water tank. These settings may include a target set point for the water in the domestic hot water tank and a “dead band,” which is a value that the actual water temperature in the tank is allowed to drift either above or below the tank set point. Via the interface shown in FIG. 6B-6, the user may also create a separate set point for the target outlet temperature of the boiler while in domestic hot water mode, or leave it the same as selected in FIG. 6B-3. To set the space heating settings (e.g., in response to selecting the “Space heating Only” option or “Space Heating and Domestic Hot Water Tank” option), the user may be shown the interface shown in FIG. 6B-7. The interface shown in FIG. 6B-7 depicts a window that allows the user to indicate whether the boiler will operate in a stand-alone manner or as part of a multi-boiler application. By selecting the “Yes” button option, the user will again be redirected to more options pertaining to a multiple-unit application. FIG. 6B-8 shows an example of a user interface that allows the user to select whether the boiler will operate as a primary boiler or a secondary boiler. A primary boiler is the boiler in control of all others in a multi-boiler system and will have authority in any action they take. A secondary boiler may receive commands, settings, orders, and/or controls from the primary boiler. According to some examples, the boilers described herein may be configured to operate as secondary boilers to boilers. The boilers described herein may operate as secondary boiler regardless of who manufactured the primary boiler. If the “Primary Boiler” option is selected in FIG. 6B-8, the user may be presented with an interface similar to the one shown in FIG. 6B-9 is then activated. The interface displayed in FIG. 6B-9 may allow the user to select how many boilers are in the multi-boiler system. Additionally or alternatively, the interface displayed in FIG. 6B-9 may allow the user to send boiler settings (e.g., previous boilers, primary boiler, etc.) to the secondary boilers.

If the user selects the “Secondary Boiler” button option from FIG. 6B-8 or the “No” button option from FIG. 6B-7, the control interface may display the interface shown in FIG. 6B-10. The interface shown in FIG. 6B-10 may allow the user to configure the flow options for the boiler. The flow options may include one or more of a flow switch and/or a flow meter. After configuring the steps shown in FIG. 6B-10, the set up may be completed and the user may be presented with an interface similar to the one shown in FIG. 6A.

After returning to the interface shown in FIG. 6A, the user may select the “Status” page. In response to selecting the “Status” page, the user may be shown an interface similar to the one depicted in FIG. 6C. The interface shown in FIG. 6C may show technical information for the current operation of the boiler. The technical information may include the current set point of the unit and an indicate of whether the current set point is the constant local, constant remote, domestic hot water priority, or the outdoor reset schedule derived set point. Additionally or alternatively, the technical information displayed via the interface shown in FIG. 6C may include a plurality of operating data, such as the current heating mode, the electrical panel temperature inside the jacketing of the unit, the current percentage output, the SCR percentage output, the number of elements currently running, and/or the current KW output amount based on the number of elements currently on and the SCR percentage. In accordance with the number of elements currently on, an array of boxes (i.e., below the text) may map to each element and indicate which elements are currently operating (e.g., on). The array displayed in FIG. 6C may change, for example, based on the size of the boiler (e.g., as defined via the interface shown in FIG. 6B-1). The array boxes may turn green (e.g., instead of black) to indicate that a specific element is operating. Additionally, the interface shown in FIG. 6C may include one or more gauges. FIG. 6C shows two gauges on the right side of the display, which depict the inlet and outlet temperatures of the boiler. A switch display button may be located in the top right corner of the interface shown in FIG. 6C. The switch display button may appear, for example, when the boiler is configured with outdoor reset schedule set point and/or domestic hot water application (whether that be domestic hot water only or both domestic how water and space heating). The switch display button may allow the display information to change while remaining on the same display page. The information shown for domestic hot water application and outdoor reset schedule set point are shown in the interfaces shown in FIG. 6D and FIG. 6E, respectively.

FIG. 6D shows an example of a “Status” page with an adjusted interface for visualizing and/or configuring the boiler during domestic hot water usage. The interface shown in FIG. 6D may allow a user to adjust the current set point for the domestic hot water tank, as well as the dead band for the tank. The interface shown in FIG. 6D differs from the interface shown in in FIG. 6C in that the boiler outlet temperature is no longer displayed in a gauge. Rather, the interface shown in FIG. 6D shows the boiler outlet temperature as text at the bottom of the interface, next to the visuals. The visuals represent hot water flowing from the boiler unit through pipes via a pump, then to the domestic hot water tank. All visuals may be dynamic in the fact that they may change appearance, color, opacity, etc. as the system conditions change. At any time, the “Switch Display” button can be pressed in order to cycle through the rest of the display options for the current boiler configuration.

If the boiler is configured with an outdoor reset set point, the “Switch Display” button may display the interface shown in FIG. 6E as the next display in the cycle of interfaces being cycled. The interface shown in FIG. 6E may show the current outdoor temperature, as well as the current outdoor reset ratio via the graphical representation. The values shown in FIG. 6E may match the values defined in the configuration interface shown in FIG. 6B-4. By selecting the graph shown in FIG. 6E, the user may return to the interface shown in FIG. 6B-4 to change one or more of the reset schedule settings. At any time, the “Switch Display” button can be pressed in order to cycle through the rest of the display options for the current boiler configuration.

FIG. 6F shows an example of an interface for the operational data and/or operational trend curves. Via the interface shown in FIG. 6F, the user may be able to select data points from a list of, but not limited to, Inlet Temperature, Outlet Temperature, Current Set Point, Operation Mode (Space Heat/DHW/Idle), Current Output Percentage, SCR Output Percentage, and specific Element Outputs (ON/OFF). The interface shown in FIG. 6F may create a dynamic graph associated with the selected data points. The dynamic graph may display operational parameters of the boiler for the user to view while the boiler is in operation. The interface shown in FIG. 6F may also include several buttons that allow the user to save the selected data points and their values over the run time of the unit to a separate memory storage device to visualize at a later time.

FIG. 6G shows an interface related to the alarm journal. The alarm journal may display a list of faults, alarms, warnings, and/or errors that occurred with the boiler. The alarm journal may be sortable, for example, based on date/time of the alarm, the category of the alarm, and/or the description of the alarm. The interface shown in FIG. 6G may allow a user to troubleshoot problems and issues with the boiler.

The interface in FIG. 6H may provide information regarding the basic Input/Output control hardware associated with the boiler. The display shown in FIG. 6H may include visual representations of the Input/Output control hardware in order to better communicate the I/O locations of each control module, to help troubleshoot, and to better understand wiring diagrams. Each control module may have a short text description associated therewith to present the user with a concise statement as to what each module is used for and what devices/controls may be connected to it.

The interface of FIG. 6I may display the settings page of the digital controller. Via the interface of FIG. 6I, the user may change the screen brightness, go back through the Setup Wizard (show in FIG. 6B-1 through FIG. 6B-10), and/or change the security level (which would allow them to access more screen displays and options for troubleshooting and testing). The “Change Security Level” button option may direct the user to the display shown in FIG. 6K. On the “Boiler Data” display in FIG. 6I, the user may also have the option to turn ON/OFF the boiler.

The interface of FIG. 6J may provide general information about the boiler. The general information may include the unit model, the serial number, max power output, unit voltage, amperage needed, number of heating stages, number of heating elements, the unit number tasked with maintaining domestic hot water tank, and/or the unit operating set point function.

FIG. 6K shows the interface used to sign the user in with specific credentials. The credentials may be used to access different displays. The displays requiring login credentials may include the “Testing” page (FIG. 6L), the “Contactor Control 1” (FIG. 6M) and “Contactor Control 2” pages, and the “PID Setup” (FIG. 6N) page. The “Security Login” page pictured in FIG. 6K may also allow any user to logout of the specific login credentials they are currently using.

FIG. 6L shows an example of a testing and troubleshooting interface. Testing and troubleshooting interface may enable a user to enable/disable override functionality. Additionally, testing and troubleshooting interface may allow the user to toggle individual components of the boiler on and off for testing purposes. For example, the user may be able to switch control valves, the electrical panel fan, flow switches, the space heating pump, and/or the domestic hot water pump on and off. Similarly, the interface shown in FIG. 6L may allow a user to enable/disable the space heating and domestic hot water functionality. In this regard, the interface may be able to test whether the issue is with space heating, domestic hot water, or common to both. Moreover, the interface may allow floor testing to ensure all components are functioning correctly and/or all safety checks are cleared before final inspections.

FIG. 6M shows a user interface for toggling individual contactors on and off. The interface shown in FIG. 6M may provide granular control of individual heating elements to help identify and troubleshoot problems. For example, the interface shown in FIG. 6M may allow certain heating elements to be turned off to determine whether the heating elements are working or not. This may be useful in identify individual heating elements, individual contactors, and/or wiring that may have malfunctioned and/or reached their end of life. Additionally or alternatively, the ability to cycle through heating elements via the interface shown in FIG. 6M may help identify pressure vessels that may be malfunctioning, for example, due to scale, build-up, cracks, etc.

FIG. 6N shows a user interface for changing PID settings. Here, the user will be able to individually manipulate each constant value of the PID controller used to maintain and control the outlet temperature of the boiler in regards to its proximity to current set point. As shown in FIG. 6N, an “Autotune PID” button option may be used to turn on the unit and/or operate with the application system for a period of time (dependent on the complexity and variability of the application) in order to tune the PID values to usable and functional inputs autonomously.

Although not shown, it will be appreciated that other interfaces may be used to convey additional data and/or information about the unit. For example, a preventative maintenance interface may be displayed. The preventative maintenance interface may provide the runtime of various components, such as the contactors and/or the heating elements. In another example, the preventative maintenance interface may indicate that one or more contactors will need to be replaced soon to prevent contactor failure. In a further example, the preventative maintenance interface may indicate that one or more heating elements will need to be replaced to prevent failure of the heating element. Status information may be displayed via the preventative maintenance interface to ensure that the boilers described herein continue to function efficiently, with little downtime as possible.

FIGS. 7A-7D show an example of a process for operating a modular electric boiler with a constant/remote set point in accordance with one or more aspects of the disclosure. After the boiler turns on, the boiler (e.g., control panel executing on the boiler) may perform one or more safety checks, in step 705. The safety checks may comprise determining if the water in the system is low, determining whether the operating temperature is high, determining the ambient temperature, etc. If the water is the system is low, the system may turn off the contactors and/or the heating elements and send an alert and/or notification to a user. If the operating temperature is high, the system may turn off the contactors and/or the heating elements and send an alert and/or notification to a user. If the ambient temperature is at or below a threshold value (e.g., maximum operating temperature), the system may operate normally. When the ambient temperature is within a certain range (e.g., +/−10° F.) of the threshold value, the system may turn off and enable a cooling system (e.g., one or more fans). When the ambient temperature exceeds the threshold value, the electrical panel may shut down system operations, including the control panel, the contactors, and the elements. The electrical panel may allow one or more fans to continue operating while shutting down system operations. When one or more safety checks fail, the system may require user input and/or a reset before resuming operations. When all the safety checks pass, the system may begin normal operations. The safety checks may run continuously during operation. That is, the control logic described above may continue to monitor for faults. If any faults occur, the procedures described above may be undertaken to prevent damaging the elements and/or components of the boiler.

In step 710, the system may determine the operating mode of the boiler. That is, the system may determine whether the boiler is providing domestic hot water, space heating, or both. It is important to note that domestic hot water takes priority over space heating. Accordingly, if the boiler is providing both domestic hot water and space heating, the system will prioritize calls for domestic hot water over requests (e.g., calls) for space heating. After the requests for domestic hot water, the system may respond to the space heating requests.

In step 715, the system may respond to requests for domestic hot water. In this regard, the system may disable (e.g., turn off) the space heating pump and enable (e.g., turn on) the domestic hot water pump. Next, the system may check to ensure that a flow switch is satisfied (e.g., the switch is closed and the circuit is complete) and change the set point priority temperature for domestic hot water. At various points while responding to the request for domestic hot water, the system may perform a plurality of safety checks, such as checking the tank temperature and others described above. As noted above, the safety checks may be executed continuously during operation of the boiler. Additionally or alternatively, the system may determine an output temperature using one or more temperature sensors. When in domestic hot water mode, the boiler may monitor a plurality of set points and a plurality of temperatures. The plurality of set points may comprise the DHW boiler set point and the DHW tank set point. The control unit may compare the outlet temperature of the boiler to the DHW boiler set point. Based on the comparison, the control unit may modulate the unit output to achieve the temperature associated with the DHW boiler set point. Modulating the unit may be completed using one or more Proportional Integral Derivatives (PID(s)). This allows for some overshoot, which means the outlet temperature may rise higher than the DHW boiler set point. When the output temperature rises above the DHW boiler set point, then the PIDs will control the elements and shut off a few contactors to lower the outlet temperature. This will eventually cause the output temperature to be below the DHW boiler set point. The control unit may then turn on elements until the output temperature exceeds the DHW boiler set point. This cycle of overshooting/undershooting the DHW boiler set point will eventually event out to the point that no more cycling of contactors/elements is required. While the output temperature is being compared to the DHW boiler set point, the control unit may also compare the DHW tank temperature to the DHW tank set point. Once the DHW tank temperature matches the DHW tank set point and satisfies the dead band, the call for domestic hot water will have been satisfied and the unit will either turn off or respond to a call for space heating, if necessary.

In step 720, the system may respond to requests for space heating. The system may disable (e.g., turn off) the domestic hot water pump and enable (e.g., turn on) the space heating pump. Next, the system may check to ensure that a flow switch has been satisfied and change the set point priority temperature for that of space heating. The system may determine an output temperature using one or more temperature sensors. When in space heating mode, the boiler may compare an outlet temperature of the unit to spacing heating set point. The boiler may modulate the unit until the output temperature matches, or satisfies a tolerance threshold associated with, the spacing heating set point. The boiler may run at the set point temperature until the call for space heating has been satisfied.

FIGS. 8A-8D show an example of a process for operating a modular electric boiler with an outdoor reset set point in accordance with one or more aspects of the disclosure. After turning on, boiler may perform a series of safety checks, in step 805. The safety checks performed in step 805, may be similar to the safety checks described in step 705, described above.

In step 810, the system may determine whether the boiler is providing domestic hot water, space heating, or both. As noted above, domestic hot water takes priority over space heating. Therefore, when the boiler is providing both domestic hot water and space heating, the system will prioritize calls for domestic hot water over requests (e.g., calls) for space heating. After the requests for domestic hot water, the system may respond to the space heating requests. In step 815, the system may respond to requests for domestic hot water using the same, or similar, techniques to those described above with respect to step 715.

In step 820, the system may respond to requests for space heating. As discussed above, the system may disable (e.g., turn off) the domestic hot water pump and enable (e.g., turn on) the space heating pump. Next, the system may check to ensure that a flow switch has been satisfied. After confirming that the flow switch has been satisfied, the system may determine an outdoor temperature, for example, using a temperature sensor. Based on the outdoor temperature, the system may default to a set point. Additionally or alternatively, the system may adjust the set point, for example, based on user input. Before outputting water for space heating, the system may determine an output temperature of the water, for example, using one or more temperature sensors. If the output temperature is greater than the set point, then the system may stage the contactors and/or elements on and/or off until the output temperature satisfies the set point, as discussed in greater detail below with respect to FIGS. 11 and 12, to provide hot water for space heating.

FIGS. 9A-9C show an example of a process for operating a plurality of modular electric boilers with a constant/remote set point in accordance with one or more aspects of the disclosure. After turning on, boiler may perform a series of safety checks, in step 905, similar to those discussed above with respect to steps 705 and 805. In step 910, the system may determine whether the boiler is providing domestic hot water, space heating, or both. As noted throughout, domestic hot water takes priority over space heating. Accordingly, the system may respond to requests for domestic hot water, in step 915, using the same, or similar, techniques to those described above with respect to steps 715 and 815.

In step 920, the system may respond to requests for space heating. The system may disable (e.g., turn off) the domestic hot water pump and enable (e.g., turn on) the space heating pump. Next, the system may confirm that a flow switch has been satisfied. After confirmation that the flow switch has been satisfied, the system may determine whether a primary unit is enabled. If the primary unit is enabled, then the system may determine an output temperature of the water, for example, using one or more temperature sensors. If the output temperature does not satisfy the set point, then the system may toggle the contactors and/or elements on and/or off until the output temperature satisfies the set point temperature.

When the primary unit is unable to satisfy calls for domestic hot water and/or space heating, the system may open a control valve so that space heating water may be provided by one or more secondary boilers. Before outputting water from the one or more secondary boilers, the system may determine an output temperature of the water from the one or more secondary boilers, for example, using one or more temperature sensors. If the output temperature is greater than the set point, then the system may toggle the contactors and/or elements on and off until the output temperature satisfies the set point.

FIGS. 10A-10C show an example of a process for operating a plurality of modular electric boilers with an outdoor reset set point in accordance with one or more aspects of the disclosure. After turning on, the system (e.g., the control panel executing on the boiler) may perform a series of safety checks, in step 1005, similar to those discussed above. In step 1010, the system may determine whether the boiler is providing domestic hot water, space heating, or both. As noted throughout, domestic hot water takes priority over space heating. In step 1015, the system may respond to requests for domestic hot water using similar processes to those described above.

In step 1020, the system may respond to requests for space heating. The system may disable (e.g., turn off) the domestic hot water pump and enable (e.g., turn on) the space heating pump. Next, the system may confirm that a flow switch has been satisfied. After confirming that the flow switch has been satisfied, the system may determine whether a primary unit is enabled. If the primary unit is enabled, then the system may determine an outdoor temperature, for example, using a temperature sensor. Based on the outdoor temperature, the system may default to a set point. Additionally or alternatively, the system may adjust the set point, for example, based on user input. Before outputting water for space heating, the system may determine an output temperature of the water, for example, using one or more temperature sensors. If the output temperature does not satisfy the set point, then the system may modulate or toggle the contactors and/or elements until the set point is satisfied.

When the primary unit is unable to satisfy calls for domestic hot water and/or space heating, the system may open a control valve to provide space heating water from one or more secondary boilers. The system may determine an outdoor temperature, for example, using a temperature sensor. Based on the outdoor temperature, the system may default to a set point for the one or more secondary boilers. Additionally or alternatively, the system may adjust the set point, for example, based on user input. Before outputting water for space heating from the one or more secondary boilers, the system may determine an output temperature of the water, for example, using one or more temperature sensors. If the output temperature does not satisfy the set point, then the system may modulate the contactors and/or elements until the output temperature satisfies the set point.

FIGS. 11A and 11B show an example of an element staging process in accordance with one or more aspects of the disclosure. The process shown in FIGS. 11A and 11B corresponds to a 300 kW boiler with ten (10) 30 kW elements connected to six (6) single element contacts and two (2) dual element contactors, which would provide the boiler with ten (10) stages. Each stage may be 10% of capacity of the boiler, for example, based on 100% capacity divided by ten (10) stages. The boiler may be operating at 480 volts without a solid-state switching device, as discussed in greater detail below. Accordingly, the boiler output may begin with enabling a first contactor to satisfy between 0-10% capacity. Between 10.1% and 20% capacity, the boiler may enable the first element and a second element. At each new stage, an additional element and/or contactor may be enabled. The same elements and/or contactors may not be enabled at every stage. Rather, the boiler may cycle through the elements and/or contactors to prolong the life of the elements and/or contactors. The elements and/or contactors may be selected, for example, based on a number of cycles of one or more contactors associated with each of the plurality of heating elements.

FIGS. 12A and 12B show another example of an element staging process in accordance with one or more aspects of the disclosure. The process shown in FIGS. 12A and 12B corresponds to a 300 kW boiler with ten (10) 30 kW elements connected to six (6) single element contacts and two (2) dual element contactors, which would provide the boiler with ten (10) stages. The boiler may be operating at 480 volts with a Silicon Controlled Rectifier (SCR), or other suitable solid-state switching device, application attached to the eighth stage. In this regard, one or more electric elements may be attached to the solid-state switching device. Once turned on, the solid-state switching device may act like a dimmer in accordance with the PID controller in order to modulate the power of the connected elements from 1-99% power. The solid-state switching device may allow the PIDs to better control temperature, for example, when close to a set point because the solid-state switching device may modulate the output to control, thereby eliminating the need for contactor cycling at steady system/load conditions.

The eighth stage may be referred to as an “SCR Dual Element Stage” or “SCR DES,” which may be the leading element when staging up to satisfy a load. The control panel may be configured to have a cycle counting procedure for counting the cycling of each contactor. The cycling of each contactor may be used to determine the on/off state for each contactor and/or heating element in order to preserve and/or prolong contactor life. Based on the ten (10) stages, each stage would be associated with 10% output of a single element contactor. Dual element contactors may be associated with 20% output. Accordingly, the boiler output may begin with the SCR DES stage, which may be realized by enabling a first dual element contactor of the two dual element contactors. The dual element contactor may operate between 0-20% capacity. Between 20.1% and 40% capacity, the boiler may enable the first dual element contact and a first contactor. Between 40.1 and 50% capacity, the boiler may enable the first dual element contact, the first contactor, and a second contactor. Each stage may be associated with 10% of the output capacity based on 100% capacity divided by ten (10) stages. At each new stage, an additional element and/or contactor may be enabled. As noted throughout this disclosure, the same elements may not be enabled at every stage. That is, the boiler may cycle through the elements and/or contactors that are enabled to prolong the life of the elements and/or contactors. In this regard, the elements and/or contactors that are selected to be enabled may be determined, for example, based on a number of cycles of one or more contactors associated with each of the plurality of heating elements.

As noted above, the electrical boilers described herein may be controlled and/or operated using control panel 145. Control panel 145 may be implemented, in whole or in part, using one or more computing devices described with respect to FIGS. 1A-1B. Turning now to FIG. 13, a computing device 1300 that may be used with one or more of the computational systems is described. The computing device 1300 may comprise a processor 1303 for controlling overall operation of the computing device 1300 and its associated components, including RAM 1305, ROM 1307, input/output device 1309, accelerometer 1311, global-position system antenna 1313, memory 1315, and/or communication interface 1323. A bus 1302 may interconnect processor(s) 1303, RAM 1305, ROM 1307, memory 1315, I/O device 1309, accelerometer 1311, global-position system receiver/antenna 1313, memory 1315, and/or communication interface 1323.

Input/output (I/O) device 1309 may comprise a microphone, keypad, touch screen, and/or stylus through which a user of the computing device 1300 may provide input, and may also comprise one or more speakers for providing audio output and a video display device for providing textual, audiovisual, and/or graphical output. Software may be stored within memory 1315 to provide instructions to processor 1303 allowing computing device 1300 to perform various actions. For example, memory 1315 may store software used by the computing device 1300, such as an operating system 1317, application programs 1319, and/or an associated internal database 1321. The various hardware memory units in memory 1315 may comprise volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules, or other data. Memory 1315 may comprise one or more physical persistent memory devices and/or one or more non-persistent memory devices. Memory 1315 may comprise random access memory (RAM) 1305, read only memory (ROM) 1307, electronically erasable programmable read only memory (EEPROM), flash memory or other memory technology, optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that may be used to store the desired information and that may be accessed by processor 203.

Accelerometer 1311 may be a sensor configured to measure accelerating forces of computing device 1300. Accelerometer 1311 may be an electromechanical device. Accelerometer may be used to measure the tilting motion and/or orientation computing device 1300, movement of computing device 1300, and/or vibrations of computing device 1300. The acceleration forces may be transmitted to the processor 1303 to process the acceleration forces and determine the state of computing device 1300.

GPS receiver/antenna 1313 may be configured to receive one or more signals from one or more global positioning satellites to determine a geographic location of computing device 1300. The geographic location provided by GPS receiver/antenna 1313 may be used for navigation, tracking, and positioning applications. In this regard, the geographic may also include places and routes frequented by the first user.

Communication interface 1323 may comprise one or more transceivers, digital signal processors, and/or additional circuitry and software, protocol stack, and/or network stack for communicating via any network, wired or wireless, using any protocol as described herein. Preferably, the one or more communication interfaces may be comprise one or more ethernet connections configured for Modbus and BACnet IP and MSTP communications.

Processor 1303 may comprise a single central processing unit (CPU), which may be a single-core or multi-core processor, or may comprise multiple CPUs. Processor(s) 1303 and associated components may allow the computing device 1300 to execute a series of computer-readable instructions (e.g., instructions stored in RAM 1305, ROM 1307, memory 1315, and/or other memory of computing device 1300, and/or in other memory) to perform some or all of the processes described herein. Although not shown in FIG. 13, various elements within memory 1315 or other components in computing device 1300, may comprise one or more caches, for example, CPU caches used by the processor 1303, page caches used by the operating system 1317, disk caches of a hard drive, and/or database caches used to cache content from database 1321. A CPU cache may be used by one or more processors 1303 to reduce memory latency and access time. A processor 1303 may retrieve data from or write data to the CPU cache rather than reading/writing to memory 1315, which may improve the speed of these operations. In some examples, a database cache may be created in which certain data from a database 1321 is cached in a separate smaller database in a memory separate from the database, such as in RAM 1305 or on a separate computing device. For example, in a multi-tiered application, a database cache on an application server may reduce data retrieval and data manipulation time by not needing to communicate over a network with a back-end database server. These types of caches and others may provide potential advantages in certain implementations of devices, systems, and methods described herein, such as faster response times and less dependence on network conditions when transmitting and receiving data.

Although various components of computing device 1300 are described separately, functionality of the various components may be combined and/or performed by a single component and/or multiple computing devices in communication without departing from the disclosure.

One or more features discussed herein may be embodied in computer-usable or readable data and/or computer-executable instructions, such as in one or more program modules, executed by one or more computers or other devices as described herein. Program modules may comprise routines, programs, objects, components, data structures, and the like. that perform particular tasks or implement particular abstract data types when executed by a processor in a computer or other device. The modules may be written in a source code programming language that is subsequently compiled for execution, or may be written in a scripting language such as (but not limited to) Python, Perl, or any equivalent thereof. The computer executable instructions may be stored on a computer readable medium such as a hard disk, optical disk, removable storage media, solid-state memory, RAM, and the like. The functionality of the program modules may be combined or distributed as desired. In addition, the functionality may be embodied in whole or in part in firmware or hardware equivalents such as integrated circuits, field programmable gate arrays (FPGA), and the like. Particular data structures may be used to more effectively implement one or more features discussed herein, and such data structures are contemplated within the scope of computer executable instructions and computer-usable data described herein. Various features described herein may be embodied as a method, a computing device, a system, and/or a computer program product.

Although the present disclosure has been described in terms of various examples, many additional modifications and variations would be apparent to those skilled in the art. In particular, any of the various processes described above may be performed in alternative sequences and/or in parallel (on different computing devices) in order to achieve similar results in a manner that is more appropriate to the requirements of a specific application. It is therefore to be understood that the present disclosure may be practiced otherwise than specifically described without departing from the scope and spirit of the present disclosure. Although examples are described above, features and/or steps of those examples may be combined, divided, omitted, rearranged, revised, and/or augmented in any desired manner. Thus, the present disclosure should be considered in all respects as illustrative and not restrictive. Accordingly, the scope of the disclosure should be determined not by the examples, but by the appended claims and their equivalents.