Systems and methods for controlling a water heater

• US 7,647,895 B2
• Filed: 11/06/2007
• Issued: 01/19/2010
• Est. Priority Date: 02/07/2005
• Status: Expired due to Fees

• Current Assignee: Emerson Electric Company
• Original Assignee: Emerson Electric Company
• Inventors: Donelly, Donald E., Evans, Edward B., Vogel, G. Scott, Haefner, John S.
• Primary Examiner(s): Wilson; Gregory A
• Application Number:
  US11/936,080
• Publication Number:
  US 20080078337A1
• Time in Patent Office: 805 Days
• Field of Search: 122/14.2, 122/14.22, 340/577, 340/578, 340/581, 340/584, 340/588, 709/223, 709/224
• US Class Current: 122/14.21
• CPC Class Codes: F22D 1/12 Control devices, e.g. for regulating steam temperature
• CPC Class Codes: F23M 11/02 Preventing emission of flames or hot gases, or admission of air, through working or charging apertures
• CPC Class Codes: F23M 2900/11021 Means for avoiding accidental fires in rooms where the combustion device is located
• CPC Class Codes: F23N 2225/10 stack temperature
• CPC Class Codes: F23N 2231/20 Warning devices
• CPC Class Codes: F23N 2231/26 for clogging air inlet
• CPC Class Codes: F23N 2231/28 preventing flash-back or blow-back
• CPC Class Codes: F23N 5/242 using electronic means
• CPC Class Codes: F24H 1/205 with furnace tubes
• CPC Class Codes: F24H 15/174 Supplying heated water with desired temperature or desired range of temperature
• CPC Class Codes: F24H 15/184 Preventing harm to users from exposure to heated water, e.g. scalding
• CPC Class Codes: F24H 15/20 characterised by control inputs
• CPC Class Codes: F24H 15/223 in the water storage tank
• CPC Class Codes: F24H 15/242 Pressure
• CPC Class Codes: F24H 15/31 of valves having only one inlet port and one outlet port, e.g. flow rate regulating valves
• CPC Class Codes: F24H 15/36 of burners
• CPC Class Codes: F24H 15/395 Information to users, e.g. alarms
• CPC Class Codes: F24H 15/421 using pre-stored data
• CPC Class Codes: F24H 15/464 using local wireless communication
• CPC Class Codes: F24H 9/1836 using fluid fuel
• CPC Class Codes: F24H 9/2035 : using fluid fuel

Abstract

A control for a water heater is provided that comprises a pressure switch for sensing a predetermined level of airflow sufficient for maintaining proper burner operation, and a temperature sensing means for sensing the temperature of the water in the tank. The control further comprises a processor for controlling the operation of the burner to maintain the water temperature above a predetermined value. When the processor receives a signal from the pressure switch or temperature switch indicating a malfunction, the processor shuts down the burner and subsequently attempts to restart the burner. The processor will lock-out further burner operation after a predetermined number of consecutive shut downs occurs, and will communicate any malfunction information to a remote display device.

Claims

1. A controller for a gas-fired water heater appliance having a flame arrestor in the air inlet to a burner, the appliance comprising:

a pressure switch that closes to complete an electrical circuit when sensing a predetermined level of airflow sufficient for maintaining proper burner operation;

a water temperature sensor;

a universal serial bus interface adapted to connect to a universal serial bus device; and

a processor connected to the universal serial bus and configured to receive an input, of information relating to a service provider that includes at least a name and phone number of the service provider, from an electronic memory in communication with the universal serial bus interface, the processor being connected to the water temperature sensor and connected to a gas valve supplying a burner for controlling the operation of the burner for heating the water in the tank to a desired temperature, the processor being further connected to the pressure switch to detect an open pressure switch indicative of insufficient level of airflow, and configured to control the gas valve such that the burner is shut down within a predetermined time of initiating burner operation as a result of an open pressure switch, wherein the processor discontinues further burner operation after the occurrence of a predetermined number of shut downs before the water being heated reaches the desired temperature, and subsequently communicates information of the discontinued operation and the stored information relating to a service provider to a device external to the controller;

wherein the predetermined number of consecutive shut downs is at least two shut downs, and the predetermined time period is in the range of about 150 seconds to about 210 seconds.

2. A controller for a gas-fired water heater appliance having a flame arrestor in the air inlet to a burner, the appliance comprising:

a pressure switch that closes to complete an electrical circuit when sensing a predetermined level of airflow sufficient for maintaining proper burner operation;

a water temperature sensor;

a universal serial bus interface adapted to connect to a universal serial bus device; and

a processor connected to the universal serial bus and configured to receive an input, of information relating to a service provider that includes at least a name and phone number of the service provider, from an electronic memory in communication with the universal serial bus interface, the processor being connected to the water temperature sensor and connected to a gas valve supplying a burner for controlling the operation of the burner for heating the water in the tank to a desired temperature, the processor being further connected to the pressure switch to detect an open pressure switch indicative of insufficient level of airflow, and configured to control the gas valve such that the burner is shut down within a predetermined time of initiating burner operation as a result of an open pressure switch, wherein the processor discontinues further burner operation after the occurrence of a predetermined number of shut downs before the water being heated reaches the desired temperature, and subsequently communicates information of the discontinued operation and the stored information relating to a service provider to a device external to the controller; and

a temperature switch that opens upon sensing a flue temperature above a predetermined temperature, wherein the controller is configured to communicate the sensing of a flue temperature above the predetermined threshold.

3. A controller for a gas-fired water heater appliance having a flame arrestor in the air inlet to a burner, the appliance comprising:

a pressure switch that closes to complete an electrical circuit when sensing a predetermined level of airflow sufficient for maintaining proper burner operation;

a water temperature sensor;

a universal serial bus interface adapted to connect to a universal serial bus device; and

a processor connected to the universal serial bus and configured to receive an input, of information relating to a service provider that includes at least a name and phone number of the service provider, from an electronic memory in communication with the universal serial bus interface, the processor being connected to the water temperature sensor and connected to a gas valve supplying a burner for controlling the operation of the burner for heating the water in the tank to a desired temperature, the processor being further connected to the pressure switch to detect an open pressure switch indicative of insufficient level of airflow, and configured to control the gas valve such that the burner is shut down within a predetermined time of initiating burner operation as a result of an open pressure switch, wherein the processor discontinues further burner operation after the occurrence of a predetermined number of shut downs before the water being heated reaches the desired temperature, and subsequently communicates information of the discontinued operation and the stored information relating to a service provider to an external device, wherein the controller is configured to communicate wireless signals, and

a device external to the controller comprising a thermostat that is configured to receive the wireless signals and to display the information relating to a service provider to the thermostat display.

4. A controller for a gas-fired water heater appliance having a flame arrestor in the air inlet to a burner, the appliance comprising:

a pressure switch that closes to complete an electrical circuit when sensing a predetermined level of airflow sufficient for maintaining proper burner operation;

a water temperature sensor;

a universal serial bus interface adapted to connect to a universal serial bus device; and

a processor connected to the universal serial bus and configured to receive an input, of information relating to a service provider that includes at least a name and phone number of the service provider, from an electronic memory in communication with the universal serial bus interface, the processor being connected to the water temperature sensor and connected to a gas valve supplying a burner for controlling the operation of the burner for heating the water in the tank to a desired temperature, the processor being further connected to the pressure switch to detect an open pressure switch indicative of insufficient level of airflow, and configured to control the gas valve such that the burner is shut down within a predetermined time of initiating burner operation as a result of an open pressure switch, wherein the processor discontinues further burner operation after the occurrence of a predetermined number of shut downs before the water being heated reaches the desired temperature, and subsequently communicates information of the discontinued operation and the stored information relating to a service provider to a device external to the controller;

wherein the processor is configured to receive a request to retrieve information relating to the number of occurrences of an open pressure switch, and is configured to respond by communicating information relating to the number of occurrences of an open pressure switch through the universal serial bus interface in a manner such that the information may be stored in a universal serial bus flash memory device connected to the universal serial bus interface.

5. A controller for a gas-fired water heater appliance having a flame arrestor in the air inlet to a burner, the appliance comprising:

a pressure switch that closes to complete an electrical circuit when sensing a predetermined level of airflow sufficient for maintaining proper burner operation;

a water temperature sensor;

a universal serial bus interface adapted to connect to a universal serial bus device;

a display device; and

a processor connected to the universal serial bus and configured to receive an input, of information relating to a service provider that includes at least a name and phone number of the service provider, from an electronic memory in communication with the universal serial bus interface, the processor being connected to the water temperature sensor and connected to a gas valve supplying a burner for controlling the operation of the burner for heating the water in the tank to a desired temperature, the processor being further connected to the pressure switch to detect an open pressure switch indicative of insufficient level of airflow, and configured to control the gas valve such that the burner is shut down within a predetermined time of initiating burner operation as a result of an open pressure switch, wherein the processor discontinues further burner operation after the occurrence of a predetermined number of shut downs before the water being heated reaches the desired temperature, and subsequently communicates the discontinued operation to a display device, and retrieves the stored information relating to a service provider for communication to a display device;

wherein the predetermined number of consecutive shut downs is at least two shut downs, and the predetermined time period is in the range of about 150 seconds to about 210 seconds.

6. A controller for a gas-fired water heater appliance having a flame arrestor in the air inlet to a burner, the appliance comprising:

a pressure switch that closes to complete an electrical circuit when sensing a predetermined level of airflow sufficient for maintaining proper burner operation;

a water temperature sensor;

a universal serial bus interface adapted to connect to a universal serial bus device;

a display device; and

a processor connected to the universal serial bus and configured to receive an input, of information relating to a service provider that includes at least a name and phone number of the service provider, from an electronic memory in communication with the universal serial bus interface, the processor being connected to the water temperature sensor and connected to a gas valve supplying a burner for controlling the operation of the burner for heating the water in the tank to a desired temperature, the processor being further connected to the pressure switch to detect an open pressure switch indicative of insufficient level of airflow, and configured to control the gas valve such that the burner is shut down within a predetermined time of initiating burner operation as a result of an open pressure switch, wherein the processor discontinues further burner operation after the occurrence of a predetermined number of shut downs before the water being heated reaches the desired temperature, and subsequently communicates the discontinued operation to a display device, and retrieves the stored information relating to a service provider for communication to a display device, wherein the controller is configured to communicate wireless signals

a thermostat external to the water heater appliance that is configured to receive the wireless signals and to display the information relating to a service provider to the thermostat display.

7. A controller for a gas-fired water heater appliance having a flame arrestor in the air inlet to a burner, the appliance comprising:

a pressure switch that closes to complete an electrical circuit when sensing a predetermined level of airflow sufficient for maintaining proper burner operation;

a water temperature sensor;

a universal serial bus interface adapted to connect to a universal serial bus device;

a display device; and

a processor connected to the universal serial bus and configured to receive an input, of information relating to a service provider that includes at least a name and phone number of the service provider, from an electronic memory in communication with the universal serial bus interface, the processor being connected to the water temperature sensor and connected to a gas valve supplying a burner for controlling the operation of the burner for heating the water in the tank to a desired temperature, the processor being further connected to the pressure switch to detect an open pressure switch indicative of insufficient level of airflow, and configured to control the gas valve such that the burner is shut down within a predetermined time of initiating burner operation as a result of an open pressure switch, wherein the processor discontinues further burner operation after the occurrence of a predetermined number of shut downs before the water being heated reaches the desired temperature, and subsequently communicates the discontinued operation to a display device, and retrieves the stored information relating to a service provider for communication to a display device;

wherein the processor is configured to receive a request to retrieve information relating to the number of occurrences of an open pressure switch, and is configured to respond by communicating information relating to the number of occurrences of an open pressure switch through the universal serial bus interface in a manner such that the information may be stored in a universal serial bus flash memory device connected to the universal serial bus interface.

8. A control system for a gas-fired water heater appliance having a flame arrestor in an air inlet to a burner of the gas fired water heater appliance, the control system comprising:

a burner;

a pressure switch that closes upon sensing a level of airflow to the burner that is sufficient for maintaining proper burner operation, and that opens upon sensing airflow below a predetermined level that is insufficient for maintaining proper burner operation;

a water temperature sensor for sensing the temperature of the water in the tank;

a water heater controller mounted on the gas fired water heater appliance, having a transceiver for wirelessly transmitting signals and a processor for controlling the operation of a gas valve supplying the burner of the gas fired water heater appliance, wherein the processor is connected to the water temperature sensor to detect when to initiate burner operation for heating the water in the water heater appliance to a desired temperature, and the processor is connected to the pressure switch to detect when the pressure switch is open and to configured control the gas valve such that burner operation is shut down when airflow to the burner is below the predetermined level;

wherein the processor discontinues initiation of burner operation after a predetermined number of shut downs, wherein the predetermined number of consecutive shut downs is at least two shut downs, and the transceiver transmits a signal that includes information indicating the inoperation of the gas fired water heater appliance;

a user-display control that is mounted in a location remote from the water heater controller, the user-display control having a transceiver that receives the signal transmitted by the water heater controller transceiver that includes information relating to the inoperation of the gas fired water heater appliance and further includes a display device that displays the information relating to the inoperation of the gas fired water heater appliance;

wherein the user-display control further includes information stored thereon relating to a service provider, which information includes at least a name and phone number of the service provider, where upon receipt of a signal transmitted from a water heater controller indicating inoperation of the gas fired water heater appliance due to at least two consecutive shut downs, the display device responsively displays on the display device the information relating to a service provider.