Span’s new smart electrical panel can plug right into utility meters
Five years ago, San Francisco–based startup Span debuted a smartphone-controllable electrical panel that allows homeowners to manage their solar panels, backup batteries, EV chargers, HVAC systems, and other major household appliances in real time. It was a high-end product for a high-end market.
But as more households purchase EVs, heat pumps, induction stoves, and other power-hungry devices, the demand for cheaper ways to control their electricity use is growing — not just from homeowners trying to avoid expensive electrical upgrades but utilities struggling to keep up with rising power demand, too.
Enter the Span Edge, unveiled at the Distributech utility trade show in Dallas this week. The device packs the startup’s core technology into a package that can be installed in about 15 minutes and plugged into an adapter that connects to a utility electric meter.
Span’s other products are targeted at homeowners; electrical contractors; and solar, battery, and EV charging installers. But the Span Edge, which requires a utility worker to install, is “expanding way beyond a homeowner or installer-led adoption of the product, to becoming part of the utility infrastructure,” said CEO Arch Rao.
That makes it one of a growing number of tools for utilities to manage the solar, batteries, EVs, controllable appliances, and other distributed energy resources that they must increasingly plan around.
If utilities manage these resources reactively, they could drive up the cost and complexity of managing the grid. But if utilities can get better information about when and how these devices use power — and if some customers are willing to adjust them sometimes to reduce grid stress — they could actually save ratepayers a lot of money.
That’s what Span’s new technology aims to allow. The company’s “dynamic service rating” control scheme can throttle or shift power use between household electrical loads, based on a homeowner’s preset or real-time priorities. That helps ensure total draw on the utility grid stays below a home’s top electrical service capacity, which typically ranges between 100 and 200 amps.
Households that want to exceed the limit of their electrical panel are often forced to upgrade to a larger one. Depending on where you live, that can cost from $3,000 to $10,000 and add days to weeks of extra time to a project, like installing an EV charger. If a utility determines a home’s new maximum power draw will trigger grid upgrades, the project could be even more expensive and take much longer to complete. In the worst case, that could kill households’ plans to do everything from switching to an EV to electrifying their heating and cooking.
It’s also expensive for utilities. “Where consumers are adding heat pumps and EV chargers, the existing solution has always been, ‘Let’s build more infrastructure — more poles and wires — to meet the maximum load,’” Rao said.
Installing a device like the Span Edge could well be a more cost-effective alternative, not just for the customers who get one but for customers as a whole. Utility rates are largely determined by dividing the amount of money earned from electricity sales by the amount of money utilities have to collect from customers to cover their costs. A big and rising portion of U.S. utility costs is tied up in upgrading and maintaining their power grids, including to meet rising demand for power from EVs and heat pumps. As a result, ratepayers in many parts of the country are seeing higher bills.
If devices like the Span Edge can cut those grid costs while allowing people to buy more electricity for EVs and heating, rates for everyone will drop over time, Rao said. While some utilities may balk at replacing profitable grid-upgrade investments with new technology, others that want customers to electrify to meet carbon-reduction mandates or to increase electricity sales may be eager to implement it, he argued.
A universe of home energy controls
Span’s smart electrical panel was among the first attempts to give the old-fashioned electrical panel a 21st-century makeover.
But similar products that also embed circuit-level controls are now available from major manufacturers, including Schneider Electric and Eaton; startups such as Lumin and Koben; and solar and battery vendors like FranklinWH, Lunar Energy, and Savant.
Utilities have been experimenting with such technologies for a while. Some plug directly into utilities’ existing electric meters, including the Span Edge, ConnectDER’s smart meter collar devices, or the Tesla backup switch.
Others are embedded elsewhere in a home’s electrical system, like the controls product startup Lunar Energy is developing using Eaton’s smart circuit breakers. Those digital, wirelessly connected breakers are “modular, interoperable, and retrofittable,” Paul Ryan, the company’s general manager of connected solutions and EV charging, told Canary Media in October. That’s helpful “as you add heat pumps and electric vehicle charging,” he said — and could be useful for utilities, a group of customers Eaton has worked with for many years.
The trick for all of these technologies is to combine the convenience and simplicity consumers demand with utility safety and reliability requirements, said Scott Hinson, chief technology officer of Austin, Texas–based nonprofit research organization Pecan Street.
In a 2021 report, Pecan Street estimated that about 48 million U.S. single-family homes with service below 200 amps might need to upgrade their electrical panels to support electric heating, cooking, and EV charging.
But not all of the technologies that allow customers and utilities to sidestep upgrades necessarily meet the needs of both parties, he said.