Determining heating element and water heater status based on galvanic current

Patent metadata

Field	Value
Publication number	US-9372012-B2
Application number	US-201313891250-A
Country	US
Kind code	B2
Filing date	May 10, 2013
Priority date	May 10, 2013
Publication date	Jun 21, 2016
Grant date	Jun 21, 2016

Abstract

Systems and methods for determining heating element and water heater status based on galvanic current are provided. An exemplary water heater includes a tank for holding a volume of water and an anode rod extending into the water. The anode rod has a core made of a conductive material. The water heater also includes at least one heating element configured to heat the water when energized. The water heater includes a current measurement circuit configured to generate a feedback signal describing a galvanic current flowing from the core of the anode rod to an electrical ground. The water heater also includes a controller configured to receive the feedback signal from the current measurement circuit and to control one or more operations of the water heater based on the feedback signal.

First claim

What is claimed is:

1. A method of operating a water heater, the method comprising:
receiving a feedback signal describing a galvanic current flowing from an anode rod included in the water heater to an electrical ground;
energizing a first heating element, the first heating element being configured to heat a volume of water stored in the water heater when energized;
monitoring, based on the feedback signal, for an increase in galvanic current when the first heating element is energized; and
heating the volume of water using only a second heating element when an increase in galvanic current is not detected when the first heating element was energized, the second heating element being located at a lower height within the water heater than the first heating element.

2. The method of claim 1 , further comprising discontinuing energization of the first heating element when an increase in galvanic current is not detected when the first heating element was energized.

3. The method of claim 1 , further comprising continuing energization of the first heating element when an increase in galvanic current is detected when the first heating element was energized.

4. The method of claim 1 , further comprising providing a dry tank indication when an increase in galvanic current is not detected when the first heating element was energized.

5. The method of claim 1 , further comprising:
receiving a full tank signal indicating that the water heater is generally filled with water; and
providing a heating element error indication when the full tank signal has been received and an increase in galvanic current is not detected when the first heating element was energized.

6. The method of claim 1 , wherein monitoring, based on the feedback signal, for an increase in galvanic current when the first heating element is energized comprises:
periodically sampling the feedback signal;
calculating, for each sample with respect to the previous sample; a percent increase; and
monitoring, when the first heating element is energized, for a percent increase greater than a threshold percentage.

7. The method of claim 1 , wherein monitoring, based on the feedback signal, for an increase in galvanic current when the first heating element is energized comprises:
periodically sampling the feedback signal;
calculating, for each sample with respect to the previous sample, a change in value of the feedback signal; and
monitoring, when the first heating element is energized, for a change in value indicating an increase in value greater than a threshold increase.

8. The method of claim 1 , further comprising:
energizing the second heating element, the second heating element being configured to heat the volume of water stored in the water heater when energized;
monitoring, based on the feedback signal, for an increase in galvanic current when the second heating element is energized; and
determining a water level in the water heater based on whether an increase in galvanic current was detected when the first heating element was energized and whether an increase in galvanic current was detected when the second heating element was energized.

9. The method of claim 1 , further comprising:
receiving a temperature signal describing a temperature adjacent to the first heating element; and
discontinuing energization of the first heating element when the temperature signal indicates that the temperature is increasing and an increase in galvanic current was not detected when the first heating element was energized.

10. A method of operating a water heater having a first heating element and a second heating element, the method comprising:
monitoring a galvanic current flowing from an anode rod positioned inside the water heater to an electrical ground; and
determining an energization status of each of the first heating element and the second heating element by comparing the galvanic current to a plurality of galvanic current profiles, the plurality of galvanic current profiles comprising:
a first galvanic current profile describing the behavior of the galvanic current when the neither the first heating element nor the second heating element are energized;
a second galvanic current profile describing the behavior of the galvanic current when the first heating element is energized and the second heating element is not energized;
a third galvanic current profile describing the behavior of the galvanic current when the second heating element is energized and the first heating element is not energized;
a fourth galvanic current profile describing the behavior of the galvanic current when both the first heating element and the second heating element are energized.

11. The method of claim 10 , further comprising determining a water level in the water heater by comparing the galvanic current to the plurality of galvanic current profiles.

12. A method of operating a water heater, the method comprising:
receiving a feedback signal describing a galvanic current flowing from an anode rod included in the water heater to an electrical ground;
energizing a first heating element, the first heating element being configured to heat a volume of water stored in the water heater when energized;
monitoring, based on the feedback signal, for an increase in galvanic current when the first heating element is energized;
energizing a second heating element, the second heating element being configured to heat the volume of water stored in the water heater when energized, the second heating element being at a different height within the water heater than the first heating element;
monitoring, based on the feedback signal, for an increase in galvanic current when the second heating element is energized; and
determining a water level in the water heater based on whether an increase in galvanic current was detected when the first heating element was energized and whether an increase in galvanic current was detected when the second heating element was energized.

13. The method of claim 12 , further comprising discontinuing energization of the first heating element when an increase in galvanic current is not detected when the first heating element was energized.

14. The method of claim 12 , further comprising continuing energization of the first heating element when an increase in galvanic current is detected when the first heating element was energized.

15. The method of claim 12 , further comprising providing a dry tank indication when an increase in galvanic current is not detected when the first heating element was energized.

16. The method of claim 12 , further comprising heating the volume of water using only the second heating element when an increase in galvanic current is not detected when the first heating element was energized, the second heating element being located at a lower height within the water heater than the first heating element.

17. The method of claim 12 , further comprising:
receiving a full tank signal indicating that the water heater is generally filled with water; and
providing a heating element error indication when the full tank signal has been received and an increase in galvanic current is not detected when the first heating element was energized.

18. The method of claim 12 , wherein monitoring, based on the feedback signal, for an increase in galvanic current when the first heating element is energized comprises:
periodically sampling the feedback signal;
calculating, for each sample with respect to the previous sample, a percent increase; and
monitoring, when the fi

Assignees

• Gen Electric

Inventors

• Farris Brett Alan

Classifications

• F24H9/0047

  Mechanical Engineering · mapped topic

• H05B1/0269

  For heating of fluids · CPC title

• F24H1/185

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

• F24H9/2021 Primary

  Storage heaters · CPC title

• H05B3/78

  Heating arrangements specially adapted for immersion heating · CPC title