Abstract: An electrical coil assembly utilizing a bi-metallic two-piece terminal construction and a method of manufacturing same are provided. The inner terminal structure utilizes a material that aids in the touchless attachment of the fine gauge magnetic wire to the inner terminal structure. The low mass of the inner terminal structure allows for increased winding speeds during the manufacturing process. The outer terminal structure utilizes a material that provides good corrosion resistance and electrical conductivity. The inner and outer terminal structures are electrically attached after the winding and electrical attachment process of the fine gauge magnetic wire. The coil and two-piece terminal connectors may then be encapsulated to provide a final electrical coil assembly.

Abstract: A thermocouple mounting assembly is provided. A plurality of retainers includes portions that are interengageable, some portions carried by a body and some portions carried by a thermocouple assembly to effect releasable mounting of a thermocouple assembly to a body. The retainers are constructed and shaped to provide for their formation by a molding process such as die-casting or investment casting, eliminating or substantially eliminating the need for machining of the retainer components. Preferably, there is an audible sound, e.g., click, present to signify when the retainers are interengaged.

Abstract: A control circuit for a washing machine that avoids contact bounce short circuit failures is provided. A washing machine that utilizes an induction motor including a starting winding used to start rotation of the motor at the beginning of a cycle. Such washing machines require that the motor be operated in both directions during different cycles. To enable such operation, a mechanical timer uses a pair of single pole, double throw switches in a switching assembly to reverse the L1 and neutral connections to the starter winding. To avoid the contact shorting problem, the control wiring runs either the L1 or neutral side of the voltage source, or both, through the centrifugal switch to open the input contact(s) once the motor has reached its operating speed. Then, if the switching assembly has L1 and N contacts touching at the same time, it will not result in a dead short.

Abstract: A system and method manage delivery of energy from a distribution network to one or more sites. Each site has at least one device coupled to the distribution network. The at least one device controllably consumes energy. The system includes a node and a control system. The node is coupled to the at least one device for sensing and controlling energy delivered to the device. A control system is coupled to the node and distribution network for delivering to the node at least one characteristic of the distribution network. The node for controls the supply of energy to the device as a function of the at least one characteristic.

Abstract: A low voltage power supply circuit for intermittent pilot and/or direct spark ignition systems utilized in gas burning appliances is provided. The circuit utilizes a single transformer and a resonant circuit to supply power to both a flame sense circuit as well as the spark generation circuit. The resonant circuit allows the use of low power sources such as batteries or self-supplied voltage systems such as thermopiles or hydro generators. Recognizing that power draw from the low power source is high during a sparking event and recharging of a sparking capacitor, the flame sensing is suspended during the sparking event and for a short recharge time thereafter.

Abstract: An electrical coil assembly utilizing a bi-metallic two-piece terminal construction and a method of manufacturing same are provided. The inner terminal structure utilizes a material that aids in the touchless attachment of the fine gauge magnetic wire to the inner terminal structure. The low mass of the inner terminal structure allows for increased winding speeds during the manufacturing process. The outer terminal structure utilizes a material that provides good corrosion resistance and electrical conductivity. The inner and outer terminal structures are electrically attached after the winding and electrical attachment process of the fine gauge magnetic wire. The coil and two-piece terminal connectors may then be encapsulated to provide a final electrical coil assembly.

Abstract: An apparatus for determining a level of a liquid in a tank is provided. The apparatus comprises a probe and electronics. The probe passes into the tank and is immersed in the liquid. The probe includes a fiducial in spaced relation with a distal end. The electronics are operably coupled to the probe. The electronics include a signal generator propagating a signal along the probe and a signal receiver receiving the signal propagated along the probe. The electronics determine a velocity of propagation and/or an amount of time for the signal to travel between the fiducial and the distal end. The level of the liquid in the tank is then determined using the velocity of propagation and/or amount of time.

Abstract: An electrical coil assembly utilizing a bimetallic two-piece terminal construction and a method of manufacturing same are provided. The inner terminal structure utilizes a material that aids in the touchless attachment of the fine gauge magnetic wire to the inner terminal structure. The low mass of the inner terminal structure allows for increased winding speeds during the manufacturing process. The outer terminal structure utilizes a material that provides good corrosion resistance and electrical conductivity. The inner and outer terminal structures are electrically attached after the winding and electrical attachment process of the fine gauge magnetic wire. The coil and two-piece terminal connectors may then be encapsulated to provide a final electrical coil assembly.

Abstract: A water tight valve with sealed flying leads is presented. The sealing is provided by an adhesive heat shrink collar that is affixed to the insulation of the flying leads. An overmolding is used to provide further protection of the terminal/wire contact interface and to seal against the exterior surface of the collar. The profile of the collar also provides a tortuous path that further prevents the ingress of any conductive fluid to the wire/terminal contact area.

Abstract: A valve incorporates a device causing turbulents in the water stream just before passing over the turbine fins of the flow sensor. The device actually increases the Reynolds number or turbulence of the water stream increasing the contact of the water on the turbine. This causes the turbine to rotate more efficiently for the given flow volume passing over the flow measuring device. The improved efficiency results in better accuracy and performance over the entire flow range. In one embodiment the turbulent device forces the flow stream to rotate counter clockwise and hit the turbine fins causing higher force which makes the turbine turn more efficiently. The turbine is designed such that the major portion of the fin surface area is perpendicular to the turbulent flow stream. This opposed direction causes more force to be placed on the turbine fin by the water stream.

Abstract: An unregulated gas valve for a water heater that includes an inlet configured to receive a gas flow into the gas valve, an outlet configured to direct a portion of the gas flow to a combustion chamber, a pilot line configured to direct a portion of the gas flow to a pilot flame, and a dial configured to regulate the flow of gas into the gas valve, and further configured to select a water temperature setting.

Abstract: A variable flow valve is provided. The variable flow valve includes a housing, an actuator, a biasing agent, positioning coils, and a locking coil. The housing defines a bore, an inlet, and an outlet. The actuator is moveably disposed within the bore and configured to selectively obstruct and expose the outlet. The biasing agent is disposed within the bore. The biasing agent is also interposed between the housing and the actuator to bias the actuator toward the outlet. The positioning coils are disposed about the housing and operable to drive the biasing agent to a retracted position. The locking coil is disposed about the housing proximate the biasing agent. The locking coil is operable to capture the biasing agent in the retracted position. As such, the positioning coils are thereafter able to move the actuator free of the bias from the biasing agent.

Abstract: A shank mount assembly for a water heater that includes an annular nipple having an opening, the nipple configured to removably attach to an opening in a water heater tank. The shank mount assembly further includes an annular shank mount having an opening, the shank mount configured to removably attach to the nipple, wherein the shank mount is further configured to attach to a gas valve assembly.

Abstract: A variable flow rate gas control valve for use in consumer and commercial appliances is presented. The valve utilizes two or more solenoids to control the operating position of two different valve members whose orifices are sized in an exponential relationship with one another. By opening one or more of the valving members in various combinations, a variable flow rate of gaseous fuel may be controlled in integer multiple steps from full off to full on. The solenoid configurations may be in line, opposing, or symmetrical about an axis of the valve. The number of unique flow rates (F) is related to the number of solenoids (N) as F=2N. The relationship between the size (S) of the individual gas control orifices for each of the solenoids is related to N by the relationship S=2n?1 for each individual gas control orifice (n) numbered 1 to N.

Abstract: A control circuit for a washing machine that avoids contact bounce short circuit failures is provided. A washing machine that utilizes an induction motor including a starting winding used to start rotation of the motor at the beginning of a cycle. Such washing machines require that the motor be operated in both directions during different cycles. To enable such operation, a mechanical timer uses a pair of single pole, double throw switches in a switching assembly to reverse the L1 and neutral connections to the starter winding. To avoid the contact shorting problem, the control wiring runs either the L1 or neutral side of the voltage source, or both, through the centrifugal switch to open the input contact(s) once the motor has reached its operating speed. Then, if the switching assembly has L1 and N contacts touching at the same time, it will not result in a dead short.

Abstract: The system of the present invention provides energy saving control for a water heater via an intelligent thermostat. This intelligent thermostat provides programmatic control over the HVAC system as is conventional, and provides coordinated control over the water heater temperature set point. This control over the water heater is accomplished via a communications network between the intelligent thermostat and the water heater. In one embodiment the communications are wireless, although wired and network bus communications may also be utilized. Enhanced and coordinated control is also provided so that different operational temperature cycles can be provided to coordinate with the intelligent thermostat's programmatic control of the HVAC system. Separate programmatic control of the water heater is also provided whereby different operational temperature modes may be commanded, e.g. Wake, Sleep, and Demand modes of operation.

Abstract: A solenoid operated pilot valve utilizes an offset pilot opening and a lever arm to provide a mechanical advantage to multiply the opening force of the solenoid, thereby allowing the solenoid size to be reduced. The lever arm used to position the pilot valving member is mechanically positioned via a solenoid driven plunger in one embodiment, and is positioned by magnetic force alone in an alternative, plungerless embodiment. The lever arm pivots via a fixed fulcrum point, a profiled fulcrum providing continuously variable mechanical advantage, or a stepped fulcrum providing discreet different mechanical advantages as the pilot valving member is moved from its fully closed to its fully opened position.

Abstract: A flame sense circuit and method utilizing only a single pin of a microcontroller is provided. A flame sense circuit is used to vary the charge on a capacitor from a logic high indicating no flame to a logic low when a flame is detected. The microcontroller changes the state of the pin coupled to this circuitry from a high impedance input to detect when the capacitor is discharged indicating the presence of flame, to a logic high output to recharge the flame sense capacitor. Once this charging has been accomplished, the microcontroller again changes the status of the pin to a high impedance input and verifies that the capacitor has been charged. This pin is monitored to verify that the flame sense capacitor is again discharged to indicate the continued presence of flame. This process is repeated to ensure flame continues to be present during a combustion event.

Abstract: A gas control valve and method of controlling a gas control valve to provide infinite adjustability is provided. The gas control valve defines a fluid flow path. A flow adjustment arrangement within the fluid flow path has a plurality of discrete open configurations. Each discrete open configuration establishes a different flow rate through the fluid flow path. A controller operatively cyclically alternates the flow adjustment arrangement between different ones of the discrete configurations to provide an average flow rate through the fluid flow path that is between the flow rates permitted by the different ones of the discrete open configurations. The controller establishes residence times at the various ones of the discrete open configurations such that the resultant flow rate is the desired flow rate.

Abstract: A debris trap for use in a gas valve fitting is provided. The debris trap comprises an elongated body extending about a first axis. The elongated body forms a passage therein extending along the first axis between an inlet formed in a first end of the elongated body and at least one outlet formed in the elongated body. The at least one outlet is formed in a side wall of the elongated body to provide fluid communication with the passage about a second axis perpendicular to the first axis.