Water heater operation monitoring and notification

A water heater monitoring and notification method includes determining, by a controller of a water heater system, a deviation of a duration of a pre-purge operation from a pre-purge duration average value. The method further includes determining, by the controller of the water heater system, a deviation of a flame current from a flame current average value and determining, by the controller of the water heater system, a deviation of a pulse-width-modulation (PWM) parameter from a PWM parameter average value. The method also includes providing a notification related to a combustion system of the water heater system based on at least the deviation of the duration of the pre-purge operation from the pre-purge duration average value, the deviation of the flame current from the flame current average value, and the deviation of the PWM parameter from the PWM parameter average value.

TECHNICAL FIELD

The present disclosure relates generally to water heaters, and more particularly to notifications related to operations of water heaters.

BACKGROUND

Some water heater components may degrade over time, for example, from exposure to water, heat, etc. The degradation of some water heater components may result in inefficient operation of a water heater. In some cases, the degradation of some other water heater components may eventually lead to a failure of a water heater. For example, the efficiency of a blower of a water heater may degrade over time from basic wear and tear. As another example, the storage tank of a water heater may degrade over time and start leaking water, which can eventually cause damage to structures, such as a ceiling, flooring, etc. A consumer who is aware of inefficient operations and/or deterioration of a water heater or water heater components may be able to replace defective components, resulting in improved efficiency and a prolonged life of the water heater. However, in general, detecting inefficient or defective operations of a water heater may be challenging until a significant degradation or total failure has occurred. Thus, a solution that determines the state of a water heater and/or water heater components and that provides related notifications may be desirable.

SUMMARY

The present disclosure relates generally to water heaters, and more particularly to notifications related to operations of water heaters. In some example embodiments, a water heater monitoring and notification method includes determining, by a controller of a water heater system, a deviation of a duration of a pre-purge operation from a pre-purge duration average value. The method further includes determining, by the controller of the water heater system, a deviation of a flame current from a flame current average value and determining, by the controller of the water heater system, a deviation of a pulse-width-modulation (PWM) parameter from a PWM parameter average value. The method also includes providing a notification related to a combustion system of the water heater system based on at least the deviation of the duration of the pre-purge operation from the pre-purge duration average value, the deviation of the flame current from the flame current average value, and the deviation of the PWM parameter from the PWM parameter average value.

In some example embodiments, a water heater monitoring and notification method includes detecting, by a controller of a water heater system, an anode current of one or more anode rods of a water heater system. The method further includes comparing, by the controller, the anode current to a maximum protection current of the one or more anode rods. The method also includes providing, by the controller, a first notification in response to determining that the anode current equals approximately the maximum protection current of the one or more anode rods.

In some example embodiments, a water heater monitoring and notification method includes determining a minimum flame current from among multiple flame currents and determining a maximum flame current from among the multiple flame currents. The method further includes determining whether a subsequent flame current generated at approximately the maximum gas input rate meets an operational requirement, where the subsequent flame current meets the operational requirement if the subsequent flame current is more than the minimum flame current, less than the maximum flame current, and more than a threshold flame current.

The drawings illustrate only example embodiments and are therefore not to be considered limiting in scope. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or placements may be exaggerated to help visually convey such principles. In the drawings, the same reference numerals that are used in different drawings designate like or corresponding, but not necessarily identical elements.

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

In the following paragraphs, example embodiments will be described in further detail with reference to the figures. In the description, well-known components, methods, and/or processing techniques are omitted or briefly described. Furthermore, reference to various feature(s) of the embodiments is not to suggest that all embodiments must include the referenced feature(s).

Turning now to the figures, particular example embodiments are described.FIG. 1illustrates a water heater system100including a water heater monitoring and notification system according to an example embodiment. In some example embodiments, the water heater system100includes a controller102, a first group of water heat components104, a second group of water heat components106, and powered anodes108that are shown positioned in a water tank114. The water heater system100may also include a display device110that can be used to provide notifications and to receive user input. For example, the display device110may be a touch-sensitive LCD display device, an LED-based display that has a user input interface, etc.

In some example embodiments, the controller102may be part of the monitoring and notification system of the water heater system100. For example, the controller102may receive information from one or more of the first group of water heater components104, the second group of water heater components106, and the powered anodes108, and provide notifications via the display device110and/or by transmitting notifications wirelessly or via one or more wired connections.

In some example embodiments, the controller102may include one or more communication interfaces112. For example, the one or more communication interfaces112may include circuitry for wireless communication (e.g., Wi-Fi communication) and/or for wired communication. To illustrate, the controller102may communicate with a server116wirelessly (e.g., via a Wi-Fi router) or via a wired connection (e.g., Ethernet connection). For example, the server116may be a local server or a cloud server. The controller102may also communicate with a mobile device, such as a mobile phone, a control system, such as a building management system, etc.

In some example embodiments, the first group of water heater components104may include sensors, switches, etc. For example, the first group of water heater components104may include a flame sensor, thermistors, integrated and/or external leak sensors, an intake pressure switch, an exhaust pressure switch, an emergency cutoff switch, etc. To illustrate, the controller102may receive information from the flame sensor, the intake pressure switch, the exhaust pressure switch, etc. and use the received information to control one or more components of the second group of water heater components106. To illustrate, the second group of water heater components106may include a burner, a blower, valves, etc. that are controllable by the controller102. The controller102may also receive information from the second group of water heater components106, and some of the components of the first group of water heater components104may be controllable by the controller102.

In some example embodiments, the controller102may process the information received from the first group of water heater components104and the second group of water heater components106to determine the particular notifications that may need to be provided to a user. For example, the controller102may provide notifications about the flame sensor of the water heater system100, pressure switches of the water heater system100, the blower of the water heater system100, the one or more powered anode rods108, etc. In some example embodiments, the controller102may process information provided by one or more components of the water heater system100to establish one or more reference ranges or thresholds that can be used to determine whether a component/system of the water heater system100is operating satisfactorily or efficiently during subsequent operations.

In some example embodiments, the controller102may include one or more microcontrollers or microprocessors that execute software code stored in one or more non-transitory memory devices to perform the functions of the controller102. For example, the controller102may include or may be communicably coupled to a non-volatile memory device containing executable software code.

By monitoring the different components of the water heater system100, the controller102may provide notifications to a user about the condition of a particular component of the water heater system100and/or the water heater system100in general. Such notifications may enable a user to take timely actions to improve efficiency of the water heater system100, more easily identify defects with the water heater system100, and avoid failures of the water heater system100.

In some example embodiments, the controller102, the display device110, and other components may serve as part of the monitoring and notification system of the water heater system100. In some example embodiments, the water heater system100includes components other than shown inFIG. 1without departing from the scope of this disclosure. In some example embodiments, the controller102, the groups of water heater components104,106, the display device110, and other components of the water heater system100may be at various locations on or near the water tank114. In some alternative embodiments, the display device110may be integrated with the controller102. In some alternative embodiments, the display device110may be omitted without departing from the scope of this disclosure. In some alternative embodiments, the controller102may include a user input interface separate from the communication interfaces112. In some example embodiments, one or more components of the water heater system100may be omitted without departing from the scope of this disclosure. For example, the water heater system100may include just one anode rod.

FIG. 2illustrates a water heater system200including a water heater monitoring and notification system according to another example embodiment. In some example embodiments, the water heater system200corresponds to the water heater system100ofFIG. 1. In some example embodiments, the water heater system200may include a central control circuit202, a display control circuit204, and an anode control circuit206. The water heater system200may also include a water tank208, combustion system components210, anode rods218,220,222. For example, the controller102ofFIG. 1may include the central control circuit202, the display control circuit204, and the anode control circuit206. In some example embodiments, the water tank208may correspond to the water tank114ofFIG. 1, and the anode rods218,220,222may correspond to the anode rods108ofFIG. 1.

In some example embodiments, the water tank208may include a water inlet opening212and a water outlet opening214. In some example embodiments, a water outlet opening216may be used instead of the water outlet opening214. In some alternative embodiments, the water inlet and water outlet openings of the water tank208may be at different locations than shown without departing from the scope of this disclosure.

In some example embodiments, the anode rods218,220,222may be positioned horizontally in the water tank208. For example, the water tank208may have side openings for the insertion of the anode rods218,220,222. In some alternative embodiments, the anode rods218,220,222may be vertical anode rods that are inserted through the top side of the water tank208.

In some example embodiments, the anode control circuit206may control and monitor the operation of the anode rods218,220,222. For example, the anode control circuit206may detect the amount of current for each of the anode rods218,220,222and process the information to determine whether one or more notifications should be provided to a user. For example, the anode control circuit206may compare a detected anode current to one or more thresholds to determine whether one or more notifications should be provided to a user. Alternatively, the anode control circuit206may provide the current information to the central control circuit202or to the display control circuit204that process the information to determine whether one or more notifications should be provided to a user. The one or more notifications may be provided to a user via the display interface of the display control circuit204and/or by transmitting the notifications wirelessly or via a wired connection to a server (e.g., the server116ofFIG. 1), a mobile device, a building management system, etc.

In some example embodiments, the central control circuit202may receive information from the combustion system components210. For example, the combustion system components210may include a blower (e.g., an inducer blower), a flame sensor, an intake pressure switch, an exhaust pressure switch, etc. The central control circuit202may process the received information to determine whether one or more notifications should be provided to a user by displaying at the water heater system200and/or transmitting (wirelessly or via a wired connection) the one or more notifications, for example, to a local, cloud and/or another server (e.g., the server116ofFIG. 1), to a building management system that may include a server (e.g., the server116ofFIG. 1), to a user's mobile device, etc.

In some example embodiments, the central control circuit202may provide the information received from the combustion system components210or the processed information to the display control circuit204that may process, display, and/or transmit the received and/or processed information. For example, the display control circuit204may include a touch-sensitive display that can be used to display information as well as to receive user input that can be used by the display control circuit204, the central control circuit202, etc. In some example embodiments, the display control circuit204may receive some information directly from the combustion system components210or from other components of the water heater system200.

In some example embodiments, the central control circuit202may process information provided by one or more components of the combustion system components210or other components of the water heater system200to establish one or more reference ranges or thresholds that can be used to determine whether a component/system of the water heater system100is operating satisfactorily or efficiently during subsequent operations.

By monitoring the different components of the water heater system200, the controller102may provide notifications to a user about the condition of a particular component of the water heater system200and/or the water heater system100in general. Such notifications may enable a user to take timely actions to improve efficiency of the water heater system200, more easily identify defects, and avoid failures of the water heater system200.

In some alternative embodiments, one or more of the central control circuit202, the display control circuit204, and the anode control circuit206may be integrated into a single circuit/device without departing from the scope of this disclosure. In some example embodiments, some components of the combustion system components210may be positioned at different locations on the storage tank208without departing from the scope of this disclosure. In some example embodiments, the water heater system200includes components other than shown inFIG. 2without departing from the scope of this disclosure. In some example embodiments, the water heater system200may include a user input interface (e.g., a keyboard, knob, etc.) integrated with one or more of the control circuits202,204,206. In some example embodiments, one or more components of the water heater system200may be omitted without departing from the scope of this disclosure. In some alternative embodiments, the water heater system200may include fewer or more anode rods than shown without departing from the scope of this disclosure.

FIG. 3illustrates a water heater monitoring and notification system300according to an example embodiment. In some example embodiments, the water heater monitoring and notification system300corresponds to the controller102alone or together with the display device110shown inFIG. 1. Referring toFIGS. 2 and 3, the water heater monitoring and notification system300may include the central control circuit202, the display control circuit204, and the anode control circuit206of the water heater system200ofFIG. 2. In some example embodiments, the central control circuit202includes a microcontroller308, a memory device310, and an onboard user interface312. The microcontroller308may execute code stored in the memory device310and may retrieve and/or store data in the memory device310to perform operations of the central control circuit202. For example, the memory device310may be a non-volatile memory device or another type of memory device. The onboard user interface312may be used to directly provide input the central control circuit202.

In some example embodiments, the display control circuit204includes a microcontroller314, a user interface316(e.g., a touch-sensitive LCD display interface), a Wi-Fi module318, and a building management system (BMS) interface320. In some example embodiments, the microcontroller314may execute code stored in a memory device of the display control circuit204or in another memory device to perform operations of the display control circuit204. The user interface316may be used to provide notifications to a user and to receive user input for use by the system300. The Wi-Fi module318may be used to wirelessly transmit notifications to a server, a mobile device, etc. In some alternative embodiments, the display control circuit204may include another wireless communication module instead of or in addition to the Wi-Fi module318. In some example embodiments, the BMS interface320may be used to communicate with a BMS in compliance with the BMS requirements. In some alternative embodiments, the display control circuit204or one or more of the components of the display control circuit204may be integrated with the central control circuit202without departing from the scope of this disclosure.

In some example embodiments, the anode control circuit206includes a microcontroller322that may execute code stored in a memory device of the anode control circuit206or in another memory device to perform operations of the anode control circuit206. The anode control circuit206may control the operation of the one or more anode rods, such as the anode rods218,220,222shown inFIG. 2. The anode control circuit206may also monitor the current (anode current) in each anode rod. For example, the anode control circuit206may detect the anode current in each anode rod and process the anode current to determine whether one or more notifications should be provided. Alternatively, the anode control circuit206may provide the anode current information to the central control circuit202that can process the anode current information to determine whether one or more notifications should be provided. The central control circuit202and the anode control circuit206may communicate the notification information to the display control circuit204for display and/or transmission to a user, etc. In some alternative embodiments, the anode control circuit206or one or more of the components of the anode control circuit206may be integrated with the central control circuit202without departing from the scope of this disclosure.

In some example embodiments, the central control circuit202receives inputs from an emergency cutoff switch, an upper thermistor, an inlet thermistor, a flue thermistor, an intake pressure switch, a proof-of-fan pressure switch, an exhaust pressure switch, and a flow detector of the water heater system200. The central control circuit202may also receive a flame current information from a flame sensor, leak information from a leak detector, and blower speed information from a blower of the combustion system of the water heater system200. The central control circuit202may receive the blower speed information in revolution per minute (RPM) of the blower or in another form.

In some example embodiments, the central control circuit202may control some operations of the water heater system200. For example, the central control circuit202may control the opening and closing of the gas valve and the igniting of the burner of the combustion system.

In some example embodiments, the central control circuit202may determine a number of pre-purge durations of the combustion system of the water heater system200for the same number of pre-purge cycles (e.g., 30 cycles) and may determine an average pre-purge duration of the number of pre-purge durations. The central control circuit202may use the average pre-purge duration as a reference to determine whether subsequent pre-purge durations of the combustion system indicate a problem with the combustion system and provide relevant notifications. A pre-purge duration or duration of a pre-purge as used in this specification can be considered as the time period that the blower operates, after being started, until the proof-of-fan pressure switch closes.

In some example embodiments, the central control circuit202may receive flame current from the flame sensor, where the flame current corresponds to the maximum gas input rate for the combustion system. The central control circuit202may receive flame current for a number of ignition cycles and determine the minimum and maximum flame currents from among the multiple flame currents. The central control circuit202may use the minimum and maximum flame currents to determine whether the flame sensor is degraded and to provide notifications.

In some example embodiments, the central control circuit202may determine a pulse width of a PWM signal when the blower reaches the maximum specified speed of the blower. The central control circuit202may determine the pulse width of the PWM signal, which may control the blower speed, for a number of ignition cycles (e.g., 30 cycles) and may determine the average pulse width from the multiple pulse widths. The central control circuit202may use the average pulse width as a reference to determine whether the pulse width of the PWM signal in subsequent operations is within one or more ranges of the average pulse width and provide relevant notifications about the combustion system of the water heater system200. In some alternative embodiments, the central control circuit202uses another parameter of the PWM signal instead of the pulse width to provide relevant notifications about the combustion system of the water heater system200.

In some example embodiments, the central control circuit202may receive information indicating that the intake pressure switch or the exhaust pressure switch is open. The central control circuit202may determine that the intake pressure switch or the exhaust pressure switch of the exhaust/combustion system of the water heater system200may be defective and may provide relevant notifications.

In some example embodiments, the central control circuit202, the display control circuit204, and the anode control circuit206may communicate with each other to perform the operations of the water heater monitoring and notification system300. In some alternative embodiments, two or more of the central control circuit202, the display control circuit204, and the anode control circuit206may be integrated into a single component/device such as the controller102ofFIG. 1. In some alternative embodiments, the water heater monitoring and notification system300may have other components in addition to and/or instead of the components shown inFIG. 3without departing from the scope of this disclosure. In general, the central control circuit202, the display control circuit204, and the anode control circuit206may include other components, such as an analog-to-digital and a digital-to-analog converter, as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure. In some alternative embodiments, one or more components of the water heater monitoring and notification system300may be omitted without departing from the scope of this disclosure.

FIG. 4illustrates a method400of monitoring and notification of water heater system conditions according to an example embodiment. Referring toFIGS. 1-4, in general, the method400determines whether the blower of the combustion system of a water heater system, such as the water heater system100,200, is degraded based on the pre-purge duration where the blower is energized to clear the combustion system until the proof-of-fan (PoF) switch is closed. Unless the PoF pressure switch is itself degraded, because the time for the PoF pressure switch to close should remain relatively constant in the absence of physical changes to the blower, the controller102or the monitoring and notification system300may use information related to the pre-purge duration (e.g., the time it takes for the PoF pressure switch to close after the blower is energized) to determine whether the blower is degraded.

In some example embodiments, the method400includes, at step402, determining an average value (i.e., pre-purge duration average value) of durations of pre-purge operations of a combustion system of a water heater system. For example, the controller102or the central control circuit202may determine an average value of durations of pre-purge operations. To illustrate, the controller102or the central control circuit202may determine durations for multiple pre-purge operations (e.g., 30 pre-purge durations) following a powering up of the water heater system100,200. For example, the controller102or the central control circuit202may use a timer or may perform the function of a timer to determine durations of the multiple pre-purge operations. The controller102or the central control circuit202may then determine the average value of the durations of the multiple pre-purge operations.

At step404, the method400may include determining a duration of a subsequent pre-purge operation that is performed after the average value of the durations of the multiple pre-purge operations is determined. For example, the controller102or the central control circuit202may determine the duration of the subsequent pre-purge operation.

At step406, the method400may include determining whether the duration of the subsequent pre-purge operation equals or exceeds the average value by more than a threshold, which may be performed by the controller102or the central control circuit202. The threshold may be, for example, 1 second, 1.5 seconds, 2 seconds, or another value that may be appropriate depending on the particular blower, combustion system, or water heater system. The controller102or the central control circuit202may to the same effect determine whether the duration of the subsequent pre-purge operation equals or is less than the sum of the average value and the threshold.

At step408, the method400includes providing a notification if the duration of the subsequent pre-purge operation exceeds (alternatively, equals or exceeds) the average value by more than the threshold. For example, the controller102or the display control circuit204may provide a notification indicating that the blower of the water heater system100,200may be degraded. The notification may be provided to a user, owner, etc. via a display of the water heater system (e.g., the display device110, the user interface316, or another display device). For example, the background color of the display may be changed to provide the notification. The notification may alternatively or in addition be transmitted wirelessly or via a wired connection to a BMS, a mobile device that may include a relevant software application, to a local or cloud server, etc. In some example embodiments, the notification may be an audio notification instead of or in addition to visual and/or transmitted notification.

In some example embodiments, the method400may include determining, for example, by the controller102or the central control circuit202, the extent of the deviation of durations of subsequent pre-purge operations from the average value (i.e., pre-purge duration average value). To illustrate, the deviation of duration of a subsequent pre-purge operation from the average value may be the difference between the duration of the subsequent pre-purge operation and the average value. In some example embodiments, the absolute value of the deviation may be considered for further processing such that the deviation above and below the average value are treated equally in determining whether the blower of the water heater system100,200or the combustion system is degraded or requires service. In some example embodiments, the deviation may be considered as a percentage of the average value. For example, considering normalized values where the average value is normalized to one (1), a duration of the subsequent pre-purge operation that is 0.95 has a deviation of 5% from the average value. In some example embodiments, one or more notifications may be provided based on the deviation(s) of the duration(s) of one or more subsequent pre-purge operations from the pre-purge duration average value. The notifications may be given using one or more methods described above.

In some example embodiments, the method400may continue with the steps404-408for further subsequent pre-purge operations. In some example embodiments, the method400may include clearing the displayed notification, for example, in response to a user input that may be received from a remote device/system or via the user interface of the water heater system100,200. In some example embodiments, the microcontroller308ofFIG. 3and/or another microcontroller may execute software code stored in the memory device310and/or in another memory device of the water heater system100,200, and/or retrieved from a local or cloud server (e.g., the server116) to perform the steps of the method400. The microcontroller308ofFIG. 3and/or another microcontroller may also use and store data from/to the memory device310and/or in another memory device of the water heater system100,200, and/or retrieved/store from/to a local or cloud server (e.g., the server116) to perform the steps of the method400. In some example embodiments, the method400may include steps other than shown inFIG. 4without departing from the scope of this disclosure.

In some example embodiments, one or more steps of the method500may be omitted without departing from the scope of this disclosure. In some example embodiments, the method500may include additional steps than described without departing from the scope of this disclosure. In some example embodiments, the steps of the method500may be performed in a different order than described above without departing from the scope of this disclosure.

FIG. 5illustrates a method500of monitoring and notification of water heater system conditions according to another example embodiment. Referring toFIGS. 1-3 and 5, in general, the method500determines the level of protection available to a water heater system from a powered anode system based on the current of the powered anode system. For example, a powered anode system may include one or more powered anode rods such as the one or more anode rods108, the anode rods218,220,222, or other powered anode rods. To illustrate, a relatively higher current of one or more powered anode rods may indicate that a relatively lower protection is provided by the one or more powered anode rods against corrosion of the water tank.

In some example embodiments, the method500includes, at step502, detecting/determine an anode current of one or more anode rods of a water heater system, such as the water heater system100,200. For example, the controller102or the anode control circuit206may determine/detect the anode current in the one or more powered anode rods, such as one of the anode rods108or one of the anode rods218,220,222.

At step504, the method500may include comparing the anode current to a maximum protection current of the one or more anode rods. For example, the controller102or the anode control circuit206may compare the anode current to the maximum protection current of the one or more anode rods. To illustrate, the maximum protection current of the one or more anode rods may be obtained from a memory device of the water heater system100, from a server (e.g., the server116), etc. or may be calculated from information from the memory device, from the server, etc.

At step506, the method500may include providing a first notification in response to determining that the anode current equals approximately the maximum protection current of the one or more anode rods. For example, the first notification may indicate that the protection limit provided by one or more anode rods has been reached.

At step508, the method500may include providing a second notification in response to determining that the anode current exceeds a threshold that is less than the maximum protection current of the one or more anode rods and is less than the maximum protection current of the one or more anode rods. For example, the threshold may be 90% or another percentage of the maximum protection current of the one or more anode rods. The method500may also include providing other notifications based on the comparison of the anode current to different thresholds.

At step510, the method500may include providing a third notification in response to determining that the anode current exceeds a threshold that is less than the maximum protection current of the one or more anode rods and is less than the maximum protection current of the one or more anode rods. For example, the threshold may be 98% or another percentage of the maximum protection current of the one or more anode rods. The method500may also include providing other notifications based on the comparison of the anode current to different thresholds.

In some example embodiments, the controller102, the display control circuit204, or another component of the water heater systems100,200may provide the first, second, and third notifications as well as other notifications to a user, owner, etc. via a display of the water heater system (e.g., the display device110, the user interface316, or another display device). For example, the color of the display (e.g., an icon or an area of the display) may be changed to a color associated with a particular notification. The notifications may alternatively or in addition be transmitted wirelessly or via a wired connection to a BMS, a mobile device that may include a relevant software application, to a local or cloud server, etc. In some example embodiments, the notifications may be audio notifications instead of or in addition to visual and/or transmitted notifications.

In some example embodiments, the method500includes determining an initial anode current of the one or more anode rods, for example, immediately the initial powering up of the water heater system or after installation of one or more new anode rods. After determining the initial anode current, the method500may also include comparing the initial anode current with one or more thresholds (e.g., a percentage of the maximum protection current of the one or more anode rods, etc.) to assess the condition of the water in the water tank of the water heater system and/or the condition of the water tank itself. For example, the controller102or the anode control circuit206may determine the initial anode current and perform the comparison to the one or more thresholds.

In some example embodiments, an initial anode current that exceeds an initial condition threshold may indicate that the water has low conductivity or that the lining of the water tank is damaged. An initial anode current that is less than the same initial condition threshold or another threshold may indicate that the water in the water tank may be hard water (i.e., water that has high conductivity). The information about the water and/or tank conditions may be stored in a memory device of the controller102, the system300, etc. and/or may be provided the information to a server, etc. In some example embodiments, data regarding the expected life of the one or more anodes and the water quality may be retrieved, for example, by the controller102, based on zip code or other location information provided to a user. In some example embodiments, notifications may be provided to a user in a similar manner as described above with respect to the water and/or tank conditions.

In some example embodiments, the microcontroller308ofFIG. 3and/or another microcontroller may execute software code stored in the memory device310and/or in another memory device of the water heater system100,200, and/or retrieved from a local or cloud server (e.g., the server116) to perform the steps of the method500. The microcontroller308ofFIG. 3and/or another microcontroller may also use and store data from/to the memory device310and/or in another memory device of the water heater system100,200, and/or retrieve/store from/to a local or cloud server (e.g., the server116) in performing the steps of the method500.

In some example embodiments, one or more steps of the method500may be omitted without departing from the scope of this disclosure. In some example embodiments, the method500may include additional steps than described above or shown inFIG. 5without departing from the scope of this disclosure. In some example embodiments, some steps of the method500may be performed in a different order than described above without departing from the scope of this disclosure.

FIG. 6illustrates a method600of monitoring and notification of water heater system conditions according to another example embodiment. Referring toFIGS. 1-3 and 6, in general, the method600determines if the flame rod of a water heater combustion system is degraded or degrading, for example, due to oxidation in the combustion environment. The method600may include establishing reference ranges or boundaries, for example, immediately after initial installation of the water heater system, such as the water heater systems100,200.

In some example embodiments, the method600includes, at step602, receiving multiple flame currents generated at approximately a maximum gas input rate. The multiple flame currents are produced during multiple ignition cycles. The multiple flame currents may be determined, for example, at initial powering up of the water heater system. To illustrate, during a particular ignition cycle following the powering up of the combustion system of a water heater system, a flame sensor of the water heater system may provide the flame current to, for example, the controller102or to the central control circuit202. By repeating the process of providing the flame current to the controller102, the central control circuit202, or another component, multiple flame currents corresponding to approximately the maximum gas input rate may be determined for multiple ignition cycles (e.g., 30 successful ignition cycles). The determination of whether the gas input rate has reached the maximum gas input rate may be made by the controller102, the central control unit202, or by another component, for example, based on the control of the gas input rate, an indicator from a sensor/switch, or by other means as can be readily contemplated by those of ordinary skill in the art with the benefit of this disclosure.

At step604, the method600may include determining a minimum flame current from among the multiple flame currents determined at step602. At step606, the method600may include determining a maximum flame current from among the multiple flame currents. At step608, the method600may include determining whether a subsequent flame current generated during a subsequent ignition/heating cycle at approximately the maximum gas input rate meets an operational requirement. The subsequent flame current may be determined in a similar manner as the multiple flame currents. In some example embodiments, the subsequent flame current meets the operational requirement when the subsequent flame current is more than the minimum flame current, less than the maximum flame current, or more than a threshold flame current (e.g., 0.5 microamperes). For example, the controller102or the central control logic202may determine whether the subsequent flame current meets the operational requirement.

At step610, the method600may include providing a first notification in response to determining that the subsequent flame current fails to meet the operational requirement and if a combustion system of the water heater is degraded. For example, whether the combustion system is degraded may be determined as described with respect toFIG. 7. The first notification may indicate that the combustion system or the flame sensor may be degraded, defective, etc.

At step612, the method600may include providing a second notification indicating the flame sensor is degraded in response to determining that a threshold number of subsequent flame currents generated at approximately the maximum gas input rate during the threshold number of ignition/heating cycles each failed to meet the operational requirement. For example, the threshold number may be three, four, or a higher or lower number that may be suitable for the particular type of combustion system. The second notification may indicate that the flame sensor may be degraded, defective, etc.

In some example embodiments, the controller102, the display control circuit204, or another component of the water heater systems100,200may provide the notifications to a user, owner, etc. via a display of the particular water heater system (e.g., the display device110, the user interface316, or another display device). For example, the color of the display (e.g., an icon or an area of the display) may be changed to a color associated with a particular notification. The notifications may alternatively or in addition be transmitted wirelessly or via a wired connection to a BMS, a mobile device that may include a relevant software application, to a local or cloud server, etc. In some example embodiments, the notifications may be an audio notification instead of or in addition to visual and/or transmitted notifications.

In some example embodiments, the method600includes determining, for example, by the controller102or the central control circuit202, an average value of the multiple flame currents (i.e., flame current average value), where the multiple flame currents are generated at approximately a maximum gas input rate during the multiple ignition cycles, such as following initial powering up of the water heater system as described above. For example, the multiple flame currents used to determine the average flame current value may correspond to 30 or another number of successful ignition cycles.

In some example embodiments, the method600may include determining, for example, by the controller102or the central control circuit202, the extent of the deviation of subsequent flame currents (for example, flame currents determined during ignition cycles after the multiple ignition cycles corresponding to the flame currents used to determine the flame current average value) from the flame current average value, where the subsequent flame currents are determined at approximately a maximum gas input rate. To illustrate, the deviation from the average value may be the difference between a subsequent flame current determined at approximately a maximum gas input rate and the flame current average value. In some example embodiments, the absolute value of the deviation may be considered for further processing such that the deviation above and below the flame current average value are treated equally in determining whether the combustion system is degraded or requires service. In some example embodiments, the deviation may be considered as a percentage of the average value. For example, considering normalized values where the average value is normalized to one (1), a subsequent flame current that is 0.85 has a deviation of 15% from the average value. In some example embodiments, one or more notifications may be provided based on the deviation(s) of one or more subsequent flame currents from the flame current average value. The notifications may be given using one or more methods described above.

In some example embodiments, the microcontroller308ofFIG. 3and/or another microcontroller may execute software code stored in the memory device310and/or in another memory device of the water heater system100,200, and/or retrieved from a local or cloud server (e.g., the server116) to perform the steps of the method600. The microcontroller308ofFIG. 3and/or another microcontroller may also use and store data from/to the memory device310and/or in another memory device of the water heater system100,200, and/or retrieve/store from/to a local or cloud server (e.g., the server116) in performing the steps of the method600.

In some example embodiments, one or more steps of the method600may be omitted without departing from the scope of this disclosure. In some example embodiments, the method600may include additional steps than described above or shown inFIG. 6without departing from the scope of this disclosure. In some example embodiments, some steps of the method600may be performed in a different order than described above without departing from the scope of this disclosure.

FIG. 7illustrates a method700of monitoring and notification of water heater system conditions according to another example embodiment. Referring toFIGS. 1-3 and 7, in general, the method700determines if the combustion system of a water heater system, such as the water heater systems100,200, is degraded based on the relationship between the speed of the blower of the combustion system and a pulse width modulation (PWM) signal that can be used to adjust the speed of the blower.

In some example embodiments, the method700includes, at step702, determining an average value of a parameter of a PWM signal (i.e., PWM parameter average value), where the average value is determined from multiple values of the parameter at approximately a maximum speed of the blower. The multiple values of the parameter correspond to multiple ignition cycles of the combustion system. To illustrate, the multiple values of a parameter of the PWM signal may be determined during multiple ignition cycles (e.g., 30 successful ignition cycles) of the combustion system when the blower is operating at a maximum speed (e.g., revolution per minute (RPM)) during each ignition cycle. The parameter may be the pulse width of the PWM signal, where the blower speed may depend on the value of the pulse width. In some example embodiments, the controller102or the central control circuit202may determine the multiple values of the parameter and the average value of the parameter from the multiple values. For example, the controller102ofFIG. 1may receive from the blower an input indicating the blower speed.

At step704, the method700may include determining a value of the parameter during a subsequent ignition/heating cycle, where the subsequent value is determined at approximately the maximum speed of the blower.

At step706, the method700may include determining whether the subsequent value of the parameter is outside of a first range that includes the average value of the parameter, which may indicate that the combustion system is degraded. For example, the controller102or the central control circuit202may determine pulse width of the PWM signal during subsequent ignition/heating cycle, at approximately the maximum speed of the blower, and whether the subsequent value of the parameter is outside of the first range. The first range may be defined by a particular percentage (e.g., 5%) of the average value above and below the average value. Alternatively, the first range may be defined by other limits that may be the same or different above and below the average value.

At step708, the method700may include determining whether the subsequent value of the parameter is outside of a second range that includes the average value, where the second range may be larger than the first range, which may indicate that the combustion system is degraded. The second range may be defined by another percentage (e.g., 10%) of the average value above and below the average value. For example, the controller102or the central control circuit202may determine whether the subsequent value of the parameter is outside of the second range in response to determining that the subsequent value of the parameter is outside of the first range.

At step710, the method700may include providing a first notification if the subsequent value of the parameter is outside of the first range and within the second range. For example, the first notification may indicate that the operation of the combustion system is sub-optimal. At step712, the method700may include providing a second notification if the subsequent value of the parameter is outside of the second range. For example, the second notification may indicate that the combustion system requires an inspection, for example, by a service provider.

In some example embodiments, the controller102, the display control circuit204, or another component of the water heater systems100,200may provide the notifications to a user, owner, etc. via a display of the particular water heater system (e.g., the display device110, the user interface316, or another display device). For example, the color of the display (e.g., an icon or an area of the display) may be changed to a color associated with a particular notification. The notifications may alternatively or in addition be transmitted wirelessly or via a wired connection to a BMS, a mobile device that may include a relevant software application, to a local or cloud server, etc. In some example embodiments, the notifications may be audio notifications instead of or in addition to visual and/or transmitted notifications.

In some example embodiments, the method700may include determining, for example, by the controller102or the central control circuit202, the extent of the deviation of the value of the parameter during subsequent ignition/heating cycles from the average value of the parameter of the PWM signal (i.e., the PWM parameter average value) determined based on the multiple ignition/heating cycles as described above. To illustrate, for each subsequent ignition/heating cycle, the deviation from the PWM parameter average value may be the difference between the value of the parameter during the subsequent ignition/heating cycle and the PWM parameter average value. In some example embodiments, the absolute value of the deviation may be considered for further processing such that the deviation above and below the PWM parameter average value are treated equally in determining whether the combustion system is degraded or requires service. In some example embodiments, the deviation may be considered as a percentage of the PWM parameter average value. For example, considering normalized values where the average value is normalized to one (1), a value of the parameter of the PWM signal during a subsequent ignition/heating cycle that is 0.93 has a deviation of 7% from the average value of the parameter of the PWM signal. As described above, the parameter of the PWM signal may be the pulse width of the PWM signal, which may be expressed in one of several forms including duty cycle, time, etc. In some example embodiments, one or more notifications may be provided based on the deviation of the value of the parameter of the PWM signal during one or more subsequent ignition/heating cycles from the PWM parameter average value.

In some example embodiments, the microcontroller308ofFIG. 3and/or another microcontroller may execute software code stored in the memory device310and/or in another memory device of the water heater system100,200, and/or retrieved from a local or cloud server (e.g., the server116) to perform the steps of the method700. The microcontroller308ofFIG. 3and/or another microcontroller may also use and store data from/to the memory device310and/or in another memory device of the water heater system100,200, and/or retrieve/store from/to a local or cloud server (e.g., the server116) in performing the steps of the method700.

In some example embodiments, one or more steps of the method700may be omitted without departing from the scope of this disclosure. In some example embodiments, the method700may include additional steps than described above or shown inFIG. 7without departing from the scope of this disclosure. In some example embodiments, some steps of the method700may be performed in a different order than described above without departing from the scope of this disclosure.

FIG. 8illustrates a method800of monitoring and notification of water heater system conditions according to another example embodiment. Referring toFIGS. 1-3 and 8, in general, the method800determines whether an intake or exhaust pressure switch may be defective. To illustrate, the intake and exhaust pressure switches are closed under normal operations. The intake and/or exhaust pressure switches become opened if exhaust pressure or inlet vacuum is too high, for example, because of blocked vent piping. The resulting unloading effect on the blower should normally be accompanied by a decrease in the pulse width of the PWM signal.

In some example embodiments, the method800includes, at step802, determining whether an intake pressure switch of a combustion system of a water heater or an exhaust pressure switch of the combustion system of the water heater is open. For example, the controller102or the central control circuit202may receive one or more electrical signals from the intake pressure switch and/or the exhaust pressure switch and determine whether switches are open.

At step804, the method800may include determining whether a combustion system of the water heater is degraded, for example, as described with respect toFIG. 7. At step806, the method800may include providing a first notification indicating a possible defect with the combustion system in response to determining that the intake pressure switch or the exhaust pressure switch is open and the combustion system is degraded. At step808, the method800may include providing a second notification indicating a possible defect with the intake pressure switch or the exhaust pressure switch in response to determining that the intake pressure switch or the exhaust pressure switch is open and the combustion system is not degraded. At step810, the method800may include shutting down the blower of the combustion system in response to determining that the intake pressure switch or the exhaust pressure switch is open. In some example embodiments, the method800may also include locking down the combustion system or the water heater system after shutting down the blower.

In some example embodiments, the controller102, the display control circuit204, or another component of the water heater systems100,200may provide the notifications to a user, owner, etc. via a display of the particular water heater system (e.g., the display device110, the user interface316, or another display device). For example, the color of the display (e.g., an icon or an area of the display) may be changed to a color associated with a particular notification. The notifications may alternatively or in addition be transmitted wirelessly or via a wired connection to a BMS, a mobile device that may include a relevant software application, to a local or cloud server, etc. In some example embodiments, the notifications may be audio notification instead of or in addition to visual and/or transmitted notifications.

In some example embodiments, the microcontroller308ofFIG. 3and/or another microcontroller may execute software code stored in the memory device310and/or in another memory device of the water heater system100,200, and/or retrieved from a local or cloud server (e.g., the server116) to perform the steps of the method800. The microcontroller308ofFIG. 3and/or another microcontroller may also use and store data from/to the memory device310and/or in another memory device of the water heater system100,200, and/or retrieve/store from/to a local or cloud server (e.g., the server116) in performing the steps of the method800.

In some example embodiments, one or more steps of the method800may be omitted without departing from the scope of this disclosure. In some example embodiments, the method800may include additional steps than described above or shown inFIG. 8without departing from the scope of this disclosure. In some example embodiments, some steps of the method800may be performed in a different order than described above without departing from the scope of this disclosure.

FIG. 9illustrates a method900of monitoring and notification of water heater system conditions according to another example embodiment. Referring toFIGS. 1-4, 6, 7, and 9, in some example embodiments, the method900includes, at step902, determining, by a controller of a water heater system100,200, a deviation of a duration of a pre-purge operation from a pre-purge duration average value. For example, the controller102or the central control circuit202may determine the deviation of the duration of the pre-purge operation from the pre-purge duration average value. For example, the controller102or the central control circuit202may determine the deviation as described above with respect toFIG. 4and the method400.

At step904, the method900may include determining, by the controller of the water heater system100,200, a deviation of a flame current from a flame current average value. For example, the controller102or the central control circuit202may determine the deviation of the flame current from the flame current average value. For example, the controller102or the central control circuit202may determine the deviation as described above with respect toFIG. 6and the method600.

At step906, the method900may include determining, by the controller of the water heater system100,200, a deviation of a PWM parameter from a PWM parameter average value. For example, the controller102or the central control circuit202may determine the deviation of the PWM parameter from a PWM parameter average value. For example, the controller102or the central control circuit202may determine the deviation as described above with respect toFIG. 7and the method700.

At step908, the method900may include providing a notification related to a combustion system of the water heater system100,200based on at least the deviation of the duration of the pre-purge operation from the pre-purge duration average value, the deviation of the flame current from the flame current average value, and the deviation of the PWM parameter from the PWM parameter average value.

In some example embodiments, the method900may include determining, by the controller of the water heater system100,200, a ratio of a number successful ignition cycles of the combustion system to a number of total ignition cycles. For example, the controller102or the central control circuit202may determine the ratio of the number successful ignition cycles of the combustion system to the number of total ignition cycles. For example, the number of total ignition cycles may be the sum of successful ignition cycles and failed ignition cycles (i.e., ignition failed). In some example embodiments, the provided notification may also be based on the ratio of the number successful ignition cycles of the combustion system to the number of total ignition cycles. For example, a combustion system condition may be calculated using Equation 1 shown below:
C_health=300+che_svfi−che_pscd−che_fcdv−che_bpdv  Eq. 1
where,
C_health=combustion system condition;
che_svfi=the ratio of the number successful ignition cycles of the combustion system to the number of total ignition cycles
che_pscd=the deviation of the duration of the pre-purge operation from the pre-purge duration average value;
che_fcdv=the deviation of the flame current from the flame current average value; and
che_bpdv=the deviation of the PWM parameter from a PWM parameter average value.

In Equation 1, the value,300, is used for convenience to keep the combustion system condition non-negative and may otherwise be omitted or replaced by another value.

In some example embodiments, the method900may include calculating the combustion system condition, C_health, as shown in Equation 1 or in a similar manner and comparing the calculated value of the combustion system condition against one or more thresholds to determine the condition of the combustion system. One or more visual, audio and/or transmitted notifications may be provided based on the comparison against the one or more thresholds in a similar manner as described above.

To illustrate, considering the combustion system condition as a percentage value (for example, for Equation 1, a percentage with respect to400), the combustion system condition, C_health, may indicate that the combustion system of the water heater system100,200is in a good working condition when the combustion system condition, C_health, above a first threshold (e.g., 79%). In some example embodiments, the combustion system condition, C_health, may indicate that the combustion system of the water heater system100,200is in a sub-optimal working condition when the combustion system condition, C_health, greater than a second threshold (e.g., 55.5%) and less than the first threshold. In some example embodiments, the combustion system condition, C_health, may indicate that the combustion system of the water heater system100,200is needs to be serviced when the combustion system condition, C_health, greater than the second threshold. For each of the above determinations, a respective visual, audio, and/or transmitted notification may be provided.

In some example embodiments, the controller102, the display control circuit204, or another component of the water heater systems100,200may provide the notifications to a user, owner, etc. via a display of the particular water heater system (e.g., the display device110, the user interface316, or another display device). For example, the color of the display (e.g., an icon or an area of the display) may be changed to a color associated with a particular notification. The notifications may alternatively or in addition be transmitted wirelessly or via a wired connection to a BMS, a mobile device that may include a relevant software application, to a local or cloud server, etc. In some example embodiments, the notifications may be audio notification instead of or in addition to visual and/or transmitted notifications.

In some example embodiments, the microcontroller308ofFIG. 3and/or another microcontroller may execute software code stored in the memory device310and/or in another memory device of the water heater system100,200, and/or retrieved from a local or cloud server (e.g., the server116) to perform the steps of the method900. The microcontroller308ofFIG. 3and/or another microcontroller may also use and store data from/to the memory device310and/or in another memory device of the water heater system100,200, and/or retrieve/store from/to a local or cloud server (e.g., the server116) in performing the steps of the method900.

In some example embodiments, one or more steps of the method900may be omitted without departing from the scope of this disclosure. In some example embodiments, the method900may include additional steps than described above or shown inFIG. 9without departing from the scope of this disclosure. In some example embodiments, some steps of the method900may be performed in a different order than described above without departing from the scope of this disclosure.