Modular control and heater assembly

Abstract

The present invention involves a water heater and method of manufacturing the same. The water heater includes a tank assembly and a base assembly. The base assembly includes a heater assembly, a control unit, a control circuit and at least one temperature sensor. The base assembly is a separate module that has at least the heater assembly and control unit mounted thereto.

Description

BRIEF DESCRIPTION S OF THE DRAWING(S)

FIG. 1 is a perspective view of a water heater assembly with portions broken away to show internal details.

FIG. 2 is an enlarged perspective view of the base assembly.

FIG. 3 is a schematic illustration of a control circuit.

FIG. 4 is a second enlarged perspective view of the base assembly.

Claims

1. A burner and controller assembly separate from and adapted for attachment to a water heater tank assembly to produce a water heater, said burner and controller assembly comprising: a base support adapted to be but not mounted to a water heater tank;a heater attached to the base support;an energy control unit mounted to the base support and connected in energy transfer relation with the heater;a temperature sensor and;a control circuit carried by the base support and connecting the temperature sensor to the energy control unit

2. A burner and controller assembly as set forth in claim 1 wherein the temperature sensor includes a signal transfer device to transfer a signal from a sensor element to a component of the control circuit.

3. A burner and controller assembly as set forth in claim 2 including a safety shut-off associated with the burner operable to selectively prevent flow of energy to the heater.

4. A burner and controller assembly as set forth in claim 3 wherein said safety shut-off includes a pilot light sensor and the heater includes a burner.

5. A burner and controller assembly as set forth in claim 4 including a pilot light burner associated with the burner.

6. A burner and controller assembly as set forth in claim 5 wherein the pilot light sensor includes a pilot light thermocouple operable to generate current when exposed to a pilot light flame.

7. A burner and controller assembly as set forth in claim 6 wherein the energy control unit includes the fuel inlet valve and an electromagnet operably connected to the pilot light thermocouple and other components of the control circuit to selectively open and close the fuel inlet valve.

8. A burner and controller assembly as set forth in claim 2 wherein the temperature sensor is at least one of a bimetallic element, thermocouple, resistance thermometer, thermistor, radiation and optical pyrometer and a temperature operated expansion device.

9. A burner and controller assembly as set forth in claim 2 wherein the temperature sensor is operable to generate current in response to sensed temperature change.

10. A burner and controller assembly as set forth in claim 9 wherein the temperature sensitive switch includes a thermocouple.

11. A burner and controller assembly as set forth in claim 10 wherein the thermocouple has a sensing element receivable in a well mounted to a water heater tank.

12. A burner and controller assembly as set forth in claim 2 wherein the temperature sensor has a sensing element adapted to be mounted to engage an exterior surface of a water tank.

13. A burner and controller assembly as set forth in claim 12 wherein the sensing element includes a bimetallic junction.

14. A method of making a water heater, said method comprising: forming a modular heater assembly by:attaching a heater to a base;attaching a control unit to the base and associating the control unit to the heater to control energy input to the heater;connecting a control circuit to the control unit, said control circuit being operable to provide a control signal to the control unit;connecting at least one temperature sensor to the control circuit to form a portion thereof; and thereafter:mounting a water tank assembly in heat transfer relationship to the heater; andpositioning said temperature sensor in a position to provide an output indicative of temperature of water in the water tank assembly.

15. The method as set forth in claim 14 wherein the temperature sensor provides an electrical signal.

16. The method as set forth in claim 15 wherein the temperature sensor includes a thermocouple providing an electrical current.

17. The method as set forth in claim 14 wherein said control unit includes a valve to control flow of fuel from a fuel inlet to a fuel outlet and, the method step of associating the control unit to a heater includes connecting the fuel outlet to a burner assembly.

18. The method as set forth in claim 17 wherein the at least one temperature sensor includes a first temperature sensor and the burner assembly includes a pilot and the method further includes positioning the first sensor in a position adjacent the pilot to sense a pilot flame.

19. The method as set forth in claim 17 wherein the at least one temperature sensor includes a second temperature sensor mounted in heat transfer relationship to the tank assembly and connected to components of the control circuit.

20. The method a set forth in claim 19 including the step of mounting the second temperature sensor to the tank assembly after the tank assembly is mounted to the modular heater assembly.

21. The method as set froth in claim 19 including the step of mounting the second temperature sensor to the tank assembly before the tank assembly is mounted to the modular heater assembly.

22. The method as set forth in claim 21 including connecting the second temperature sensor to components of the control circuit after the step of mounting the second temperature sensor to the tank assembly.