Modular control system and method for water heaters

A method of upgrading the operation of a water heating system comprising a tank, a heating element mounted on the tank, and a first controller for controlling an operation of the heating element, the method comprising:

• mounting an upgrade controller on the tank;
• connecting the upgrade controller to a first communication port of the first controller;
• providing, by the upgrade controller, additional functionality related to the heating element, the additional functionality not enabled by the first controller when the upgrade controller is connected to the first controller;
• communicating wirelessly, through the upgrade controller, with a remote interface;
• and
• controlling, by the first controller, the heating element according to a first threshold value in an absence of the upgrade controller.

An apparatus comprising:

• an element configured to manipulate a temperature of a fluid;
• a temperature sensor configured to sense the temperature of the fluid;
• a first controller coupled to the element and the temperature sensor, the first controller including a communication port and a first logic configured to receive a sensed temperature from the temperature sensor and control the element based on the sensed temperature;
• and
• a second controller selectively communicatively coupled to the first controller, the second controller including a second logic configured to provide additional functionality when the second controller is connected to the first controller, the additional functionality related to control of the element and not enabled by the first controller.

A method of manufacturing a water heater, the method comprising:

• providing a water heater including
• an element configured to manipulate a temperature of a fluid
• a temperature sensor configured to sense the temperature of the fluid, and
• a first controller coupled to the element and the temperature sensor, the first controller including a communication port and a first logic configured to receive a sensed temperature from the temperature sensor and control the element based on the sensed temperature;
• and
• providing a second controller configured to be selectively coupled to the communication port of the first controller, the second controller including a second logic configured to provide additional functionality not enabled by the first controller when the second controller is connected to the first controller.