Abstract: A water heater appliance and a method of configuring or reconfiguring said appliance for connection to one or more external conduits located above or below said appliance is disclosed. The water heater appliance comprises a housing at least partially defining an interior. At least one conduit is positioned within the interior and has a fixable conduit section and a movable conduit section coupled at a joint and movable relative to the fixable conduit section. The joint permits rotation of the movable conduit section about an axis of the joint while remaining coupled to the fixable conduit section. The movable conduit section is movable for being oriented or reoriented for alignment with an opening in an upwardly-facing surface of the housing, or oriented or reoriented for alignment with an opening in a downwardly-facing surface of the housing, for the water heater appliance to be configured for connection to the external conduit.

Abstract: In one example, a system for collecting scale from water in a water heating appliance includes a reservoir having an interior, an inlet through which the water flows into the interior, and an outlet through which the water flows from the interior, the inlet, the outlet, and the interior defining a water pathway. A filter is positioned within the interior of the reservoir and the filter is oriented to traverse the water pathway and divide the interior of the reservoir into an upstream section into which the water flows from the inlet and a downstream section from which the water flows to the outlet. A collection chamber is configured to receive scale as the water flows along the water pathway through the interior of the reservoir and the water passes through the filter. The collection chamber is positioned in or adjacent the upstream section of the interior of the reservoir.

Abstract: A water heater including a tank having a wall with an external surface and an internal surface defining an interior, and a circuit board mounted to the external surface of the tank. The circuit board including a thermal path for conducting heat through the circuit board, where the thermal path of the circuit board is thermally coupled to the external surface of the tank. An electronic switch is mounted to the circuit board and electronically coupled to a heating element, where the electronic switch is thermally coupled to the thermal path of the circuit board so that heat generated by the electronic switch is transferred along the thermal path. A temperature sensor is thermally coupled to the circuit board to sense a temperature of the thermal path relating to a temperature of the electronic switch and relating to a temperature of water stored in the tank.

Abstract: A modular manifold for a tankless water heater includes a first cavity member having a first opening, a second opening, and a base wall; a second cavity member coupled to the first cavity member, the second cavity member having a first opening, a second opening, and a base wall; a first cover plate coupled to either the first cavity member or the second cavity member; and a second cover plate coupled to either the first cavity member or the second cavity member, wherein two openings in the first and second openings are covered by the first and second cover plates, respectively, and wherein the base walls of the first and second cavity members, the first and second cover plates, and the two openings in the first and second openings not covered by the first and second cover plates define a fluid flow path in the modular manifold.

Abstract: A heating element including a preformed ceramic tubular body having a hollow cavity centrally located within, a heat-generating component disposed within the hollow cavity, and an air-displacement material disposed within the hollow cavity. The preformed ceramic tubular body is one of aluminum oxide, aluminum nitride, and silicon nitride ceramic. The heat-generating component may be in electrical contact with the ceramic tubular body. The air-displacement material is magnesium oxide. Further, the heat-generating component and the air-displacement material are disposed within the hollow cavity of the preformed ceramic tubular body by way of at least one of a vibrating fill and a centrifuge for compaction.

Abstract: Water heaters, baffles for water heaters, and methods for manufacturing such baffles are disclosed, One baffle includes a core, an outer wall, and a plurality of fins. The outer wall surrounds the core and defines at least one flow path between the outer wall and the core. The plurality of fins extend from the outer wall toward the core. Each of the plurality of fins has a serpentine shape. One method for manufacturing a baffle includes extruding at least one portion of the baffle in one piece, the at least one portion of the baffle having an at least partially cylindrical outer wall u and a plurality of fins extending inward from the outer wall, each of the plurality of fins having a serpentine shape. One water heating system includes a burner, a vent, at least one flue tube, and at least one baffle as described above.

Abstract: Aspects of the invention relate to water heaters including a water storage tank having a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall; a combustion chamber extending below the bottom wall of the water storage tank and a heat exchanger configured to receive combustion gases and to transfer heat to water in the water storage tank. The heat exchanger includes a first pass flue extending through the water storage tank and a plurality of second pass flues coupled to receive combustion gases from the first pass flue. The second pass flues extending through the water storage tank and having a straight top portion, a curved bottom portion, and a longitudinal axis residing in a plane. The curved bottom portion of the second pass flues exits the water storage tank through at least one aperture defined in the side wall of the water storage tank.

Abstract: Aspects of the invention relate to water heaters including a water storage tank having a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall; a combustion chamber extending below the bottom wall of the water storage tank and a heat exchanger configured to receive combustion gases and to transfer heat to water in the water storage tank. The heat exchanger includes a first pass flue extending through the water storage tank and a plurality of second pass flues coupled to receive combustion gases from the first pass flue. The second pass flues extending through the water storage tank and having a straight top portion, a curved bottom portion, and a longitudinal axis residing in a plane. The curved bottom portion of the second pass flues exits the water storage tank through at least one aperture defined in the side wall of the water storage tank.

Abstract: A water heater system, including a water storage tank, an electrical heating element, a power switch, and a controller. The controller is configured to store a number of heating cycles completed to heat water in the tank. When electric power is applied to the water heater system, the controller controls the power switch to turn OFF power to the electrical heating element in response to the number of heating cycles being less than a threshold number of heating cycles, and controls a user output interface to output the indicator indicating that the controller is inhibiting operation of the electrical heating element, and control the power switch to turn ON power to the electrical heating element in response to receiving user input through a user input interface requesting power to be applied to the electrical heating element, and a sensed temperature of the tank being less than a setpoint temperature.

Abstract: Aspects of the invention relate to water heaters including a water storage tank having a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall; a combustion chamber extending below the bottom wall of the water storage tank and a heat exchanger configured to receive combustion gases and to transfer heat to water in the water storage tank. The heat exchanger includes a first pass flue extending through the water storage tank and a plurality of second pass flues coupled to receive combustion gases from the first pass flue. The second pass flues extending through the water storage tank and having a straight top portion, a curved bottom portion, and a longitudinal axis residing in a plane. The curved bottom portion of the second pass flues exits the water storage tank through at least one aperture defined in the side wall of the water storage tank.

Abstract: Disclosed is a water heater that has a water storage tank, a first pass flue tube extending from a top of the water storage tank to a bottom of the water storage tank, a down-fired burner assembly positioned to direct combustion gases into the first pass flue tube, a plurality of second pass flue tubes extending from the bottom of the water storage tank to a top of the water storage tank, and an expansion chamber positioned below the bottom of the water storage tank. The expansion chamber receives the combustion gases from the first pass flue tube and delivers the combustion gases to the second pass flue tubes. The water heater operates with a non-positive vent static pressure and with a vent gas temperature that avoids or reduces excessive condensate production in an exhaust vent connected to receive combustion gases from the water heater.

Abstract: Disclosed is a water heater that has a water storage tank, a first pass flue tube extending from a top of the water storage tank to a bottom of the water storage tank, a down-fired burner assembly positioned to direct combustion gases into the first pass flue tube, a plurality of second pass flue tubes extending from the bottom of the water storage tank to a top of the water storage tank, and an expansion chamber positioned below the bottom of the water storage tank. The expansion chamber receives the combustion gases from the first pass flue tube and delivers the combustion gases to the second pass flue tubes.

Abstract: A threaded weld fitting and a method of welding a threaded weld fitting to the tank wall of a water storage tank are provided. The threaded weld fitting comprises a body defining an aperture and having a facing surface configured to be positioned facing the tank wall. A female thread is formed along the aperture. A first beveled surface portion of the facing surface extends from an edge of the body. A landing surface portion of the facing surface extends from the first beveled surface portion toward a longitudinal axis of the aperture. A second beveled surface portion of the facing surface extends from the landing surface and to the female thread. The landing surface portion and the second beveled surface portion together define an open annular area positioned to receive a portion of a weld formed by welding the threaded weld fitting to the tank wall.

Abstract: Systems and methods for venting a water heater are disclosed. The system includes a water heater, a blower, a draft hood, and a thermal switch. The blower has a blower inlet positioned to receive combustion gas from the water heater and a blower outlet positioned to exhaust combustion gas. The draft hood defines a passageway positioned to receive combustion gas from the blower outlet. The draft hood defines a relief opening to allow gas to enter into or exit from the passageway of the draft hood. The thermal switch detects a blockage in the passageway of the draft hood and deactivates the water heater when a blockage is indicated. A method for venting a water heater includes blowing exhaust gas outward through a blower outlet of the water heater, and receiving the exhaust gas blown through the outlet with a draft hood positioned on top of the blower outlet.

Abstract: A threaded weld fitting and a method of welding a threaded weld fitting to the tank wall of a water storage tank are provided. The threaded weld fitting includes a body defining an aperture and having a facing surface configured to be positioned facing the tank wall. A female thread is formed along the aperture. A first beveled surface portion of the facing surface extends from an edge of the body. A landing surface portion of the facing surface extends from the first beveled surface portion toward a longitudinal axis of the aperture. A second beveled surface portion of the facing surface extends from the landing surface and to the female thread. The landing surface portion and the second beveled surface portion together define an open annular area positioned to receive a portion of a weld formed by welding the threaded weld fitting to the tank wall.

Abstract: A system for heating water including a water heater and a solar collector is provided. The water heater includes a water storage tank, a heating element positioned within the bottom end of the water tank and a lower thermostat configured to selectively activate the heating element as a function of the water temperature sensed by the temperature sensor of the thermostat. A tank heat exchanger is also positioned within the bottom end portion of the water storage tank. The tank heat exchanger is configured to contain a fluid medium for heat exchange with water in the bottom end portion of the water storage tank. The solar collector is fluidly coupled to the tank heat exchanger of the water heater for circulating the fluid medium through the tank heat exchanger.

Abstract: A water heater is provided that includes a tank for storing water and a combustion chamber in thermal communication with the tank for heating the water. The combustion chamber contains a pilot burner and at least one main burner. The water heater also includes a flue containing a flue damper to control the passage of exhaust gases from said combustion chamber. The water heater further includes an electrical control circuit connected to said flue damper. The electrical control circuit includes a thermal switch positioned proximal to the main burner The thermal switch is configured to prevent the flue damper from closing while the main burner is firing.

Abstract: A fuel-fired water heater includes a water storage tank, a flue positioned to receive combustion gases and transfer heat from combustion gases to water in the water storage tank, and a blower assembly. The blower assembly includes a housing defining an inlet positioned to receive combustion gases from the flue, an interior defined by the housing, and an outlet positioned to exhaust combustion gases from the interior of the housing. The blower assembly further includes a motor/impeller assembly that is positioned in the interior of the housing and is configured to direct combustion gases from the inlet of the housing toward the outlet of the housing. The housing of the blower assembly includes an interior wall portion, an exterior wall portion, and sound-absorbing material interposed between the interior and exterior wall portions. The interior wall portion defines perforations extending between the sound-absorbing material and the interior of the housing.

Abstract: A system for heating water including a water heater and a solar collector is provided. The water heater includes a water storage tank, a heating element positioned within the bottom end of the water tank and a lower thermostat configured to selectively activate the heating element as a function of the water temperature sensed by the temperature sensor of the thermostat. A tank heat exchanger is also positioned within the bottom end portion of the water storage tank. The tank heat exchanger is configured to contain a fluid medium for heat exchange with water in the bottom end portion of the water storage tank. The solar collector is fluidly coupled to the tank heat exchanger of the water heater for circulating the fluid medium through the tank heat exchanger.

Abstract: A threaded weld fitting and a method of welding a threaded weld fitting to the tank wall of a water storage tank are provided. The threaded weld fitting comprises a body defining an aperture and having a facing surface configured to be positioned facing the tank wall. A female thread is formed along the aperture. A first beveled surface portion of the facing surface extends from an edge of the body. A landing surface portion of the facing surface extends from the first beveled surface portion toward a longitudinal axis of the aperture. A second beveled surface portion of the facing surface extends from the landing surface and to the female thread. The landing surface portion and the second beveled surface portion together define an open annular area positioned to receive a portion of a weld formed by welding the threaded weld fitting to the tank wall.