STORAGE-TYPE WATER HEATER HAVING TANK CONDITION MONITORING FEATURES

• US 20090056644A1
• Filed: 01/29/2008
• Published: 03/05/2009
• Est. Priority Date: 08/28/2007
• Status: Active Grant

• Current Assignee: A. O. Smith Corporation
• Original Assignee: AOS Holding Company (A. O. Smith Corporation)
• Inventors: Phillips, Andrew William, Caves, Andrew Robert, Knoeppel, Ray Oliver, Schulz, John Matthew, Van Sistine, Thomas Gerard
• Granted Patent: US 8,068,727 B2
• Time in Patent Office: Days
• US Class Current: 122/15.100
• CPC Class Codes: F24H 9/45 for preventing galvanic corrosion, e.g. cathodic or electrolytic means
• CPC Class Codes: F24H 9/455 for water heaters

Abstract

Methods and systems for evaluating the condition of a water tank having a powered anode protection system. The water heater includes a storage tank to hold water, a powered anode, and a control circuit. The control circuit includes a variable voltage supply, a voltage sensor, and a current sensor. The control circuit is configured to compare a measured parameter to a threshold. In some constructions, the threshold is indicative of a condition of the storage tank at which the powered anode is no longer able to protect the storage tank from corrosion. In other constructions, the threshold is predicative of a potential failure of the storage tank caused by corrosion. In some constructions, the control circuit is configured to estimate a time remaining until the predicted failure of the storage tank.

Claims

1. A storage-type water heater comprising:

a water storage tank including a metal and a lining coupled to the metal;

a powered anode at least partially disposed in the water storage tank;

a controller configured to

measure a first parameter having a relation to the operation of the powered anode;

adjust a current of the powered anode based on the first parameter;

measure a second parameter having a relation to the operation of the powered anode; and

generate a signal when the second parameter exceeds a threshold.

2. The storage-type water heater of claim 1, wherein the first parameter has a relation to an electric potential of the powered anode relative to a location.

3. The storage-type water heater of claim 2, wherein the controller is configured to adjust the current of the powered anode based upon the first parameter by adjusting the current of the powered anode until the electric potential of the powered anode relative to a location approaches a target electric potential.

4. The storage-type water heater of claim 2, wherein the location includes the metal of the water storage tank.

5. The storage-type water heater of claim 1, wherein the second parameter has a relation to the current of the powered anode.

6. The storage-type water heater according to claim 1, wherein the metal of the water storage tank is at least partially exposed and the second parameter is indicative of a condition of the water storage tank.

7. The storage-type water heater according to claim 6, wherein the condition of the water storage tank includes the surface area of exposed metal in the water storage tank.

8. The storage-type water heater according to claim 6, wherein the condition of the water storage tank includes an amount of corrosion of the metal in the water storage tank.

9. The storage-type water heater according to claim 1, wherein the controller is further configured to set the threshold as a value indicative of a condition of the water storage tank where the powered anode does not adequately protect the metal of the storage tank from corrosion.

10. The storage-type water heater according to claim 1, wherein the controller is further configured to store the threshold as a value indicative of a potential failure of the water storage tank.

11. The storage-type water heater according to claim 1, wherein the controller is further configured to initiate the draining of water in response to the signal.

12. The storage-type water heater according to claim 1, wherein the controller is further configured to associate the threshold with an estimated time remaining until a failure of the water storage tank.

13. The storage-type water heater according to claim 1, wherein the controller is further configured to associate the amplitude of the second parameter with an estimated time remaining until a failure of the water storage tank.

14. The storage-type water heater according to claim 1, further comprising

a computer readable memory containing a plurality of threshold values,

wherein the controller is further configured to

identify a type of water stored in the water storage tank;

and

select the threshold from the plurality of threshold values based upon the type.

15. The storage-type water heater according to claim 1, wherein the controller is further configured to

evaluate a condition of water in the water storage tank;

and

set the threshold based upon the condition.

16. The storage-type water heater according to claim 1, wherein the controller is further configured to set the threshold as a multiple of a baseline measurement of the second parameter.

17. The storage-type water heater according to claim 16, wherein the baseline measurement includes the second parameter at a first consumer use of the storage-type water heater.

18. The storage-type water heater according to claim 16,

further comprising a user input device,

wherein the controller is further configured to receive a baseline initialization command from the user input device, and

wherein the baseline measurement includes the second parameter when the baseline initialization command is received.

19. The storage-type water heater according to claim 1, wherein the controller is further configured to

set the threshold as a value indicative of a rate of change of the current of the powered anode, and

wherein the second parameter includes a present rate of change of the current of the powered anode.

20. The storage-type water heater according to claim 1, wherein the controller is further configured to

set the threshold as a value indicative of a condition of the water storage tank where the powered anode does not adequately protect the metal of the storage tank from corrosion;

set a second threshold as a value indicative of a potential failure of the water storage tank; and

generate a second signal when a third parameter exceeds the second threshold.

21. The storage-type water heater according to claim 20, wherein the third parameter is the first parameter or the second parameter.

22. The storage-type water heater according to claim 20, wherein the signal includes a warning and the second signal is directive to replace the water storage tank.

23. The storage-type water heater according to claim 22, wherein the controller is further configured to initiate the draining of water from the storage tank in response to the second signal.

24. The storage-type water heater according to claim 1, further comprising a communication interface, and wherein the controller is further configured to

connect to a remote database via the communication interface;

and

receive a value of the threshold from the remote database.

25. The storage-type water heater according to claim 24, wherein the controller is further configured to receive an estimated time remaining until failure of the water storage tank from the remote database.

26. The storage-type water heater according to claim 24, wherein the controller is further configured to send a last measurement of the second parameter before a failure of the water storage tank to the remote database.

27. A storage-type water heater comprising:

a water storage tank configured to hold water, the water storage tank including a metal and a lining coupled to the metal;

a powered anode at least partially disposed in the water storage tank;

a controller configured to

determine a threshold predicative of a failure of the water storage tank, the threshold being based upon a characteristic of the water storage tank and a characteristic of the water held in the water storage tank,

measure a current of the powered anode, the measured current being indicative of a degree of exposure of the metal of the water storage tank,

determine an estimated time remaining until a failure of the water storage tank,

display the estimated time remaining to a user, and

generate a signal when the measured current applied to the powered anode exceeds the threshold.

28. The storage-type water heater according to claim 27, wherein the characteristic of the water storage tank is an internal surface area of the water storage tank.

29. The storage-type water heater according to claim 27, wherein the characteristic of the water storage tank is a composition of the metal of the water storage tank.

30. The storage-type water heater according to claim 27, wherein the characteristic of the water storage tank is a model number of the water storage tank.

31. The storage-type water heater according to claim 27, wherein the characteristic of the water is a measurement of a conductivity of the water.

32. The storage-type water heater according to claim 27, wherein the characteristic of the water is a type of the water.

33. A method of predicting a failure of a water storage tank in a storage-type water heater, the storage-type water heater including

the water storage tank configured to hold water, the water storage tank including a metal and an internal lining coupled to the metal, and

a powered anode at least partially disposed in the water storage tank,

the method comprising:

determining a threshold predicative of a failure of the water storage tank, the threshold being based upon a characteristic of the water storage tank and a characteristic of the water held in the water storage tank;

measuring an electric potential of the powered anode relative to the metal of the water storage tank;

adjusting a current of the powered anode to have the measured electric potential emulate a target electric potential;

measuring the current of the powered anode; and

generating a signal when the measured current exceeds the threshold.

34. The method according to claim 33, further comprising estimating time remaining until failure of the water storage tank based on the measured current.