Abstract: A method and apparatus for mounting a water heater on the roof of a building or at another location outside of the building. A roof curb surrounds a hole in the roof, and a base member is mounted to the roof curb. Alternatively, the base member is mounted on a concrete pad at ground level. A water tank is mounted to the base member with the longitudinal axis of the water tank extending horizontally. Support rails are mounted to the base member, and wedge-shaped supports are mounted to the support rails. The wedge-shaped supports are interconnected with tank mounted brackets that are mounted to the sides of the water tank. Thermally insulated spacers are interposed between the wedge-shaped supports and the tank mounting brackets.

Abstract: A water heater that includes a tank, an electrical component, and an electrical circuit. The tank defines a water chamber and includes an outer surface. The electrical component is coupled to the outer surface of the tank and extends from the outer surface of the tank. The electrical circuit electrically connects the electrical component and provides electricity to the electrical component when the electrical circuit is closed and does not provide electricity to the electrical component when the electrical circuit is open. A door assembly is movable between an open position and a closed position, and the door assembly includes a connecting device mounted to the door assembly. The connecting device closes the electrical circuit when the door assembly is in the closed position and opens the electrical circuit when the door assembly is in the open position.

Abstract: A water heater includes a water tank adapted to contain water; a flue extending through the water tank and having a first end communicating with the water heater's combustion chamber for the flow of products of combustion through the tank; a damper communicating with the flue; and an apparatus for creating a flow of air proximate the second end of the flue to resist the flow of warm air out of the second end of the flue due to standby convection.

Abstract: A water heater that includes a tank, an electrical component, and an electrical circuit. The tank defines a water chamber and includes an outer surface. The electrical component is coupled to the outer surface of the tank and extends from the outer surface of the tank. The electrical circuit electrically connects the electrical component and provides electricity to the electrical component when the electrical circuit is closed and does not provide electricity to the electrical component when the electrical circuit is open. A door assembly is movable between an open position and a closed position, and the door assembly includes a connecting device mounted to the door assembly. The connecting device closes the electrical circuit when the door assembly is in the closed position and opens the electrical circuit when the door assembly is in the open position.

Abstract: A water heater adapted to be mounted on the rooftop of a building includes a substantially cylindrical tank having a horizontally-oriented longitudinal axis. A U-shaped flue tube has a burner end and an exhaust end, both ends being mounted in a head portion of the tank. The legs of the flue tube define a flue plane that is preferably angled 30°-60° with respect to vertical. An inlet tube and an outlet tube also extend through the head of the tank. The inlet tube is positioned at the bottom of the tank and has holes that open downwardly only; the outlet tube is positioned at the top of the tank and has holes that open upwardly only. The tank is weather-tightly enclosed by a cabinet. A base member of the cabinet is supported by a roof curb and supports the water tank. The base member includes a drain opening for draining water from the inside the cabinet to the sewage system of the building, and a water pipe opening through which extend a plurality of pipes communicating with the tank.

Abstract: A water heater adapted to be positioned outside of a building and to interface with the plumbing system of the building. The water heater includes a water storage tank adapted to store water outside of the building, a means for heating the water in the tank, a base member supporting the tank outside of the building, and a plurality of water pipes communicating with the water tank. The water heater also includes a manifold that is mounted to the base member and includes a plurality of pipe unions adapted to interface between the plumbing system and the plurality of pipes to provide cold water to the tank and to remove heated water from the tank for use in the building.

Abstract: A corrosion-resistant, copper-finned heat exchanger for a water heater is provided. The heat exchanger includes a conduit through which water runs, heat-transfer fins extending from the conduit and an anti-corrosive coating containing electroless nickel. The heat-transfer fins contain copper, and the coating is deposited directly onto at least one of the copper heat-transfer fins.

Abstract: A water heater includes a water tank adapted to contain water; a flue extending through the water tank and having a first end communicating with the water heater's combustion chamber for the flow of products of combustion through the tank; a damper communicating with the flue; and an apparatus for creating a flow of air proximate the second end of the flue to resist the flow of warm air out of the second end of the flue due to standby convection. The apparatus for creating airflow may be a fan or an ionic wind generator. Additionally, the airflow may be directed into or across the end of the flue at the top of the water heater to either create a downdraft or an air curtain for containing warm air within the flue.

Abstract: A water-resistant porcelain enamel coating and method of making the same is provided. The porcelain enamel coating is prepared using a borosilicate glass frit, and mill additions of silica and a zirconia compound. The mixture is applied to a metal substrate and fired, resulting in a water-resistant coating that resists cracking and crazing. The coating is particularly useful in water heaters. In one embodiment, the coating comprises a fine zirconia compound having a median particle size of less than 10 microns.

Abstract: A water heater includes a storage tank communicating with a cold water supply pipe and a hot water supply pipe for the respective supply of cold water to, and removal of hot water from, the tank. The water heater also includes an insulated heat recovery module communicating between the cold water supply pipe and the tank. The heat recovery module defines a cavity, and the cold water supply pipe communicates with a lower portion of the cavity. The heat recovery module has a smaller surface area-to-volume ratio than the cold water supply pipe. When water in the tank is heated, some water is thermally displaced from the tank and into the cavity. Consequently, water is displaced out of the lower portion of the cavity and into the cold water supply pipe. Therefore, only the coldest water is displaced out of the cavity, and thermal energy loss is reduced.

Abstract: A method and apparatus for mounting a water heater on the roof of a building or at another location outside of the building. A roof curb surrounds a hole in the roof, and a base member is mounted to the roof curb. Alternatively, the base member is mounted on a concrete pad at ground level. A water tank is mounted to the base member with the longitudinal axis of the water tank extending horizontally. Support rails are mounted to the base member, and wedge-shaped supports are mounted to the support rails. The wedge-shaped supports are interconnected with tank mounted brackets that are mounted to the sides of the water tank. Thermally insulated spacers are interposed between the wedge-shaped supports and the tank mounting brackets.

Abstract: A water heater includes a water tank adapted to contain water; a flue extending through the water tank and having a first end communicating with the water heater's combustion chamber for the flow of products of combustion through the tank; a damper communicating with the flue; and an apparatus for creating a flow of air proximate the second end of the flue to resist the flow of warm air out of the second end of the flue due to standby convection. The apparatus for creating airflow may be a fan or an ionic wind generator. Additionally, the airflow may be directed into or across the end of the flue at the top of the water heater to either create a downdraft or an air curtain for containing warm air within the flue.

Abstract: A water heater includes a water tank, a combustion chamber below the tank and communicating with the flue tube, and a flue system. The flue system includes a flue tube, and V-shaped fins that are metallurgically bonded to the flue tube wall to divide the flue tube into four flue chambers extending substantially parallel to the longitudinal axis of the flue tube. The V-shaped fins include radially extending apertures that reduce the thermal expansion of the V-shaped fins with respect to the flue tube to reduce stress at the joint between the fins and the flue tube. The flue system also includes a removable baffle hanging in each flue chamber. The baffles include adjustable turbulation surfaces to control the quality of combustion in the water heater.

Abstract: A water heater includes a water tank, a combustion chamber below the tank and communicating with the flue tube, and a flue system. The flue system includes a flue tube, and V-shaped fins that are metallurgically bonded to the flue tube wall to divide the flue tube into four flue chambers extending substantially parallel to the longitudinal axis of the flue tube. The V-shaped fins include radially extending apertures that reduce the thermal expansion of the V-shaped fins with respect to the flue tube to reduce stress at the joint between the fins and the flue tube. The flue system also includes a removable baffle hanging in each flue chamber. The baffles include adjustable turbulation surfaces to control the quality of combustion in the water heater.

Abstract: An anti-microbial porcelain enamel coating and a method of preparing the coating is provided. The porcelain enamel coating contains an anti-microbial agent having an anti-microbial metal compound such as silver, zinc, or copper disposed on a particulate support. The resulting porcelain enamel coating can be used, for example, as a coating over steel for those appliances and sanitary ware fixtures that could benefit from an increased level of resistance to microbes, mold, bacteria, and fungus.

Abstract: A water heater including a water tank, a combustion chamber beneath the tank, a gas burner in the combustion chamber, an air plenum upstream of the combustion chamber, a flame arrestor located such that air in the air plenum passes through the flame arrestor to reach the combustion chamber, and a flue extending upwardly from the combustion chamber and through the water tank. An inner plate defines the lower boundary of the combustion chamber, and supports the flame arrestor. The inner plate is rolled around the bottom edge of the skirt. A raised ring is formed in the inner plate, and the flame arrestor is seated against the raised ring. An o-ring seal is positioned in a peripheral groove of the flame arrestor to substantially gas-tightly seal the periphery of the flame arrestor with respect to the inner plate. An access door is stamped and fit over a access opening in the skirt.

Abstract: A water heater includes a water tank, a combustion chamber below the tank and communicating with the flue tube, and a flue system. The flue system includes a flue tube, and a cruciform fin metallurgically bonded to the flue tube wall and dividing the flue tube into four flue chambers extending substantially parallel to the longitudinal axis of the flue tube. The flue system also includes a removable baffle hanging in each flue chamber. The baffles include adjustable turbulation surfaces to control the quality of combustion in the water heater.

Abstract: A potable water temperature management system includes a device that produces waste heat and that has a primary purpose other than heating potable water. The waste heat from the device is used to heat potable water in a tank. A heat shedding system is activated when the temperature of the potable water in the tank exceeds a selected maximum temperature. An auxiliary energy transfer system may be activated to heat the potable water in the tank when the potable water in the tank falls below a selected minimum temperature. A controller may be used to monitor the temperature of the potable water in the tank and activate either the heat shedding system or the auxiliary energy transfer system based on the potable water temperature.

Abstract: Combustion apparatus (10) includes a combustion chamber (12, 212), a cover (24, 208) covering an end wall (14, 210) of the combustion chamber and defining a buffer space (26, 206) therebetween, and a blower (32, 202) external to the cover and supplying air to the buffer space and pressurizing the buffer space to a higher pressure than the combustion chamber such that leakage at penetrations (46) and/or interface (334, 336) flows from the buffer space into the combustion chamber, rather than the reverse, eliminating the need for leak-tight seals, and instead permitting leakage in a desired direction. In one embodiment, a first conduit (58) supplies air along a path (34) from the blower to the mixer and burner assembly without passing through the buffer space, and a second conduit (60) independently supplies air from the blower to the buffer space. A pressure dropping orifice (36) is provided between the blower and the mixer and burner assembly.

Abstract: A multi-function controller for a water heater is advanced comprising a control panel and a plurality of sensors that monitor a variety of functions that impact the operation of a water heater. A flammable gas sensor, placed in proximity to the air intake, detects the presence of an unsafe concentration of gas and issues a signal to the control panel, which subsequently discontinues the operation of the burners. Detection of a blocked vent pipe is achieved by a carbon monoxide sensor placed near the draft hood. The control panel is equipped with circuitry which monitors usage of the heater for a specified time period to develop a pattern of use. Subsequent to the monitoring period, the controller will activate the burners a predetermined time prior to an anticipated period of high use. During periods of low use, the controller will decrease the temperature to which the water is to be heated, thereby resulting in a more efficient heater.