Water heater control system with powered anode rod

Patent metadata

Field	Value
Publication number	US-11906203-B2
Application number	US-202017002609-A
Country	US
Kind code	B2
Filing date	Aug 25, 2020
Priority date	Sep 27, 2019
Publication date	Feb 20, 2024
Grant date	Feb 20, 2024

Abstract

A water heater control system comprising a temperature sensor, an anode rod, and a controller. The controller is configured to receive a signal indicative of a temperature from the temperature sensor and apply a voltage and/or current to the anode rod. A mounting bracket mates with a spud of a water heater and provides a conduit space for conductors providing connectivity among the controller, temperature sensor, and anode rod. The mounting bracket may provide mechanical support for the anode rod and the temperature sensor. The mounting bracket may comprise a housing mechanically supporting and surrounding the controller.

First claim

What is claimed is:

1. A water heating system comprising:
a tank defining an interior volume configured to hold water, the tank comprising a spud defining a specific opening through a vessel wall of the tank;
a heating apparatus configured to heat the water in the tank;
a temperature sensor extending into the interior volume of the tank,
wherein the temperature sensor is configured to detect a temperature of water in the interior volume of the tank;

an anode configured to extend into the interior volume of the tank;
a controller configured to:
control, based on a detected temperature of the water in the tank, the heating apparatus to heat the water in the tank to a selected temperature; and
control a power source to apply a voltage, a current, or a voltage and a current to the anode to at least one of reduce corrosion of a wall of the tank or reduce flocculant formation;

a sensor lead electrically connecting the controller and the temperature sensor,
wherein the sensor lead is configured to extend at least partially through the spud; and
an anode lead electrically connecting the controller and the anode,
wherein the anode lead is configured to extend at least partially through the spud;

wherein the temperature sensor and the anode are integrally formed on a unitary probe;
wherein at least a portion of the anode extends from the temperature sensor;
wherein the anode extends further into the tank than the temperature sensor.

2. The water heating system of any one of claim 1 , wherein the anode comprises at least one of titanium or stainless steel.

3. The water heating system of any one of claim 1 , wherein the heating apparatus comprises at least one of a burner configured to burn a fuel to heat the water in the tank, an electrical heating element, or a heat pump.

4. The water heating system of claim 1 , wherein the heating apparatus comprises an electrical heating element, and wherein the anode and the electrical heating element are integrally formed on a unitary component.

5. The water heating system of claim 1 , wherein the wall of the tank defines an inner vessel surface in fluid communication with the interior volume of the tank,
wherein the inner vessel surface comprises a metal without a ceramic or a polymeric coating.

6. The water heating system of claim 1 , wherein the anode is configured to generate an electric current from the anode to the wall of the tank when the interior volume of the tank holds the water and the power source applies the voltage, the current, or the voltage and the current to the anode.

7. A method of controlling a water heater comprising:
mechanically supporting a temperature sensor and an anode using a mounting bracket inserted into a spud of the water heater, wherein the temperature sensor and the anode are integrally formed on a unitary probe, the unitary probe comprising a single rigid body supported by the mounting bracket; wherein at least a portion of the anode extends from the temperature sensor; wherein the anode extends further into the water heater than the temperature sensor;
placing the temperature sensor in thermal communication with a body of water within a water tank of the water heater using the mounting bracket inserted into the spud of the water heater;
placing the anode in fluid communication with the body of water within the water tank of the water heater using the mounting bracket inserted into the spud of the water heater;
electrically connecting the temperature sensor and a controller using a sensor lead extending at least partially through the mounting bracket;
electrically connecting the anode and the controller using an anode lead extending at least partially through the mounting bracket;
receiving, using the controller and the sensor lead, a signal indicative of a temperature of the body of water within the water tank from the temperature sensor; and
delivering, using the controller and the anode lead, a voltage, a current, or a voltage and current to the anode.

8. The method of claim 7 , further comprising generating a current from the anode to a vessel wall of the water tank using the voltage, the current, or the voltage and the current delivered to the anode.

9. A water heater control system comprising:
a temperature sensor;
an anode;
a controller configured to:
receive a signal indicative of a temperature from the temperature sensor; and
apply a voltage, a current, or a voltage and a current to the anode;

a mounting bracket mechanically supporting the temperature sensor and the anode,
wherein the mounting bracket is configured to mate with a spud of a water heater tank;

an anode lead electrically connecting the anode and the controller,
wherein the anode lead extends at least partially through the mounting bracket; and a sensor lead electrically connecting the temperature sensor and the controller,
wherein the sensor lead extends at least partially through the mounting bracket;
wherein the temperature sensor and the anode are integrally formed on a unitary probe, and wherein the unitary probe comprising a single rigid body supported by the mounting bracket.

10. The water heater control system of claim 9 , wherein:
the temperature sensor is configured to extend into an interior volume defined by the water heater tank when the mounting bracket is configured to mate with the spud of the water heater tank, and
the anode is configured to extend into the interior volume defined by the water heater tank when the mounting bracket is configured to mate with the spud of the water heater tank.

11. The water heater control system of claim 9 , further comprising an electrical heating element,
wherein the anode and the electrical heating element are integrally formed on a unitary component.

12. The water heater control system of claim 9 further comprising a housing configured to mechanically support the controller,
wherein the mounting bracket is configured to mechanically support the housing.

13. The water heater control system of claim 9 , wherein the mounting bracket is configured to form a water-tight seal with the spud of the water tank when the mounting bracket is configured to mate with the spud of the water heater tank.

14. The water heater control system of claim 9 , further comprising a gas valve,
wherein the controller is configured to control the gas valve based on the signal indicative of the temperature.

15. The water heater control system of claim 14 , further comprising a housing configured to mechanically support the gas valve,
wherein the mounting bracket is configured to mechanically support the housing.

16. The water heater control system of claim 9 , wherein:
the anode is an anode rod comprising a first end and a second end,
wherein the first end is electrically connected to the anode lead, and
wherein the second end is configured to extend into an interior volume defined by the water heater tank when the mounting bracket is configured to mate with the spud of the water heater tank, and

the mounting bracket is located between the controller and the second end of the anode rod.

17. The water heater control system of claim 9 , wherein the mounting bracket comprises a mating surface surrounding a conduit space,
wherein the mating surface is configured to engage the spud of the water heater tank when the mounting bracket is configured to mate with the spud of a water heater tank, and
wherein an electrical connector and the anode lead extend at least partially into the conduit space.

18. The water heater control sy

Assignees

• Ademco Inc

Inventors

• Hazzard Frederick
• Young Gregory
• Myre Adam

Classifications

• F24H9/2021 Primary

  Storage heaters · CPC title

• F24H1/185 Primary

  using electric energy supply (F24H1/201 takes precedence) · CPC title

• F24H1/20

  with immersed heating elements, e.g. electric elements or furnace tubes · CPC title

• F24H9/45

  for preventing galvanic corrosion, e.g. cathodic or electrolytic means · CPC title

• F24H1/0018

  using electric energy supply · CPC title