WATER HEATER LEAK DETECTION SYSTEM

• US 20070261241A1
• Filed: 04/13/2006
• Published: 11/15/2007
• Est. Priority Date: 04/13/2006
• Status: Active Grant

• Current Assignee: A. O. Smith Corporation
• Original Assignee: AOS Holding Company (A. O. Smith Corporation)
• Inventors: Akkala, Marc, Hoover, William
• Granted Patent: US 7,421,784 B2
• Time in Patent Office: Days
• US Class Current: 29/890.30
• CPC Class Codes: F24H 1/205 with furnace tubes
• CPC Class Codes: F24H 15/12 Preventing or detecting fluid leakage
• 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 15/395 Information to users, e.g. alarms
• CPC Class Codes: F24H 9/17 Means for retaining water leaked from heaters
• CPC Class Codes: F24H 9/20 Arrangement or mounting of control or safety devices
• CPC Class Codes: F24H 9/2035 using fluid fuel
• CPC Class Codes: F24H 9/25 of remote control devices or control-panels
• CPC Class Codes: Y10T 29/4935 Heat exchanger or boiler making
• CPC Class Codes: Y10T 29/49428 Gas and water specific plumbing component making

Abstract

An original equipment manufacturer water heater including a water tank including an inlet and an outlet, means for heating water in the water tank, a base pan at least partially supporting the water tank such that water leaked from the water tank collects in the base pan, a valve closable to prevent water from entering the water tank through the inlet, and a sensor positioned in the base pan, the sensor configured to close the valve upon detecting water.

Claims

1. A method of manufacturing and installing a water heater, the method comprising:

manufacturing an original equipment manufacturer water heater including;

a water tank including an inlet and an outlet;

means for heating water in the water tank;

a base pan at least partially supporting the water tank such that water leaked from the water tank collects in the base pan; and

a sensor positioned in the base pan, the sensor being configured to detect water; and

installing the water heater by;

connecting a source of cold water to the water tank inlet;

installing a valve closable to prevent water from entering the water tank inlet from the source of cold water; and

connecting the sensor to the valve such that the valve closes when the sensor detects water.

2. The method of claim 1, wherein the means for heating water includes a combustion chamber, a flue extending from the combustion chamber through the water tank, and a gas burner positioned in the combustion chamber.

3. The method of claim 2, wherein manufacturing an original equipment manufacturer water heater further includes providing a flame arrestor such that combustion air flows through the flame arrestor before entering the combustion chamber.

4. The method of claim 1, wherein manufacturing an original equipment manufacturer water heater further includes providing a jacket surrounding the water tank such that water leaked from the water tank flows between the water tank and the jacket and into the base pan.

5. The method of claim 4, wherein manufacturing an original equipment manufacturer water heater further includes providing spacers between the water tank and the base pan to facilitate flow of leaked water into the base pan.

6. The method of claim 1, wherein manufacturing an original equipment manufacturer water heater further includes providing an overflow port such that water collects in the base pan until reaching the overflow port, and installing the water heater includes routing the collected water from the overflow port to a suitable location.

7. The method of claim 1, wherein manufacturing an original equipment manufacturer water heater further includes providing an override device that allows the valve to be open when the sensor detects water.

8. The method of claim 1, wherein manufacturing an original equipment manufacturer water heater further includes providing a device that closes the valve upon detection of a low battery condition.

9. The method of claim 1, wherein manufacturing an original equipment manufacturer water heater further includes providing a device that emits a visual and/or an audible signal upon detection of water or upon detection of a low battery condition.

10. An original equipment manufacturer water heater comprising:

a water tank including an inlet and an outlet;

means for heating water in the water tank;

a base pan at least partially supporting the water tank such that water leaked from the water tank collects in the base pan;

a valve closable to prevent water from entering the water tank through the inlet; and

a sensor positioned in the base pan, the sensor configured to close the valve upon detecting water.

11. The water heater of claim 10, wherein the means for heating water includes a combustion chamber, a flue extending from the combustion chamber through the water tank, and a gas burner positioned in the combustion chamber.

12. The water heater of claim 11, wherein combustion air flows through a flame arrestor before entering the combustion chamber.

13. The water heater of claim 10, further comprising a jacket surrounding the water tank such that water leaked from the water tank flows between the water tank and the jacket and into the base pan.

14. The water heater of claim 13, further comprising spacers between the water tank and the base pan to facilitate flow of leaked water into the base pan.

15. The water heater of claim 10, wherein the base pan includes an overflow port such that water collects in the base pan until reaching the overflow port, and wherein water can be routed from the overflow port to a suitable location.

16. The water heater of claim 10, further including an override device that allows the valve to be open when the sensor detects water.

17. The water heater of claim 10, further including a device that closes the valve upon detection of a low battery condition.

18. The water heater of claim 10, further comprising a device that emits a visual and/or an audible signal upon detection of water or upon detection of a low battery condition.

19. A water heater comprising:

a base pan including a generally horizontal floor, and an annular side wall extending upwardly from the floor, the side wall having an upper end and having therein an overflow port and an air intake opening, the base pan also including an annular step extending outwardly from the upper end of the side wall;

a water tank defined in part by a generally cylindrical tank wall, the water tank including an inlet and an outlet;

a jacket substantially surrounding the water tank;

foam insulation between the water tank and the jacket;

a valve closable to prevent water from entering the water tank through the inlet;

a combustion chamber beneath the water tank, the combustion chamber being defined in part by a substantially flat bottom with a centrally located air inlet surrounded by a raised annular portion, and the combustion chamber being defined in part by a generally cylindrical chamber wall having a lower end supported by the step of the base pan;

a plurality of spacers between the step and the lower end of the chamber wall, the spacers transferring the weight of the combustion chamber and the water tank to the base pan and permitting water leaked into the space between the jacket and the water tank to flow into the base pan;

a gas burner in the combustion chamber;

a flame arrestor positioned in the raised annular portion and covering the air inlet such that flames cannot exit the combustion chamber via the air inlet;

an exhaust flue extending upwardly from the combustion chamber and through the water tank;

the base pan and the bottom of the combustion chamber forming an air plenum such that air flows into the combustion chamber via the air intake opening, the air plenum and the flame arrestor;

a first sump positioned in the combustion chamber and at least partially defined by the flat bottom and by the raised annular portion, the first sump collecting condensate formed in the flue;

an annular sump in the floor of the base pan such that water leaked from the water tank collects in the annular sump until the level of the water reaches the overflow port;

an electronic sensor positioned in the annular sump, the sensor configured to close the valve upon detecting water or upon detecting a low battery condition;

a device that emits a visual and/or an audible signal upon detection of water or upon detection of a low battery; and

an override device that allows the valve to be open when the sensor detects water, thus allowing normal operation of the water heater even while the water tank is leaking.