Abstract: A flue system is provided for a water heater having improved heat exchange efficiency. The flue system includes an upstream heat exchange portion providing a first pass for heat exchange with water in the water heater. The flue system further includes a downstream heat exchange portion providing a second pass for heat exchange with water in the water heater and a blower positioned between the upstream heat exchange portion and the downstream heat exchange portion. The blower is configured to urge combustion products from the upstream heat exchange portion to the downstream heat exchange portion.

Abstract: A system and method for configuring a water heater to drain condensate from combustion products is provided. The water heater comprises a water tank, a burner for producing combustion products, a flue extending through an interior of the water tank to receive the combustion products, and an exhaust passageway positioned downstream of the flue and extending outside of the water tank to exhaust the combustion products. The exhaust passageway includes a first portion and a second portion positioned at an elevation above the first portion. A bypass conduit is coupled to the exhaust passageway and positioned to direct condensate in the exhaust passageway from the second portion toward the first portion. A drain port is positioned at or an elevation below the first portion of the exhaust passageway to drain condensate from the exhaust passageway.

Abstract: A collector assembly is provided for directing products of combustion between segments of a flue of a water heater. The assembly includes an insulator at least partially defining a chamber configured to direct products of combustion between the flue segments. The assembly also includes a cover configured to at least partially surround the insulator. The cover is also configured to be coupled to a water tank of the water heater. The insulator in an uncompressed state is dimensioned to extend outwardly from the cover when the insulator is positioned in the cover. The insulator in a compressed state is dimensioned to permit coupling of the cover to the water tank.

Abstract: A heat pump water heater system including a water storage tank and a heat exchange system. The heat exchange system includes a heat absorber positioned below the water storage tank and a heat rejecter in fluid communication with the heat absorber and positioned within the water storage tank. The heat absorber is configured to transfer heat to fluid in the heat exchange system, and the heat rejecter is configured to transfer heat from fluid in the heat exchange system to the water in the water storage tank.

Abstract: A method of improving hot water supply performance of a water heater is provided. The method includes coupling an outlet port of a water tempering device to the cold water inlet port of a water heater for delivering cold water from the cold water supply line into the water storage tank. The inlet port of the tempering device is coupled to the hot water outlet port of the water heater for receiving hot water from the water storage tank to the hot water supply line. A conduit of the tempering device is positioned between the inlet and outlet ports of the tempering device for diverting a portion of the cold water delivered from the cold water supply line into the conduit. The tempering device mixes the diverted cold water with the hot water received from the water storage tank, and delivers the mixed water into the hot water supply line.

Abstract: A water heater assembly includes a water storage tank configured for containing water; an inlet port positioned on the water storage tank for receiving cold water delivered from a cold water supply line; an outlet port positioned on the water storage tank for distributing hot water from the water storage tank toward a hot water supply line; and a water tempering device releasably coupled to both the inlet port and to the outlet port for diverting a portion of the cold water from the cold water supply line to the hot water supply line, wherein the water tempering device is configured to selectively mix the cold water with the hot water for delivery of mixed water into the hot water supply line.

Abstract: A system for monitoring water heaters. The system includes a central monitoring station and a plurality of water heater systems. The central monitoring station includes a computer, and each water heater system includes a water heater and one or more sensors for sensing one or more conditions of the water heater. The one or more conditions include one or more fault states, each indicating a reduced ability of the water heater to deliver hot water at a set temperature. The one or more sensors are in communication with the computer of the central monitoring station to provide data indicating the one or more conditions to the computer.

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: An insulation kit for use with a water heater is provided. The kit includes an insulating cover configured to be wrapped about an exterior surface of the water heater. The insulating cover includes a substantially rectangular body with opposed edges configured to overlap or abut one another when the insulating cover is wrapped about the exterior surface of the water heater and at least one downwardly facing flap configured to provide selective access to the water heater. The kit further includes a fastener packaged with the insulating cover and configured for fixing the opposed edges together, thereby securing the insulating cover adjacent the exterior surface of the water heater.

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 method of manufacturing a combustion chamber for use in a water heater is provided. A skirt is formed, and an edge portion of a plate is spot welded to the skirt. The edge portion of the plate is circumferentially welded to the skirt, thereby forming a seal between the plate and the skirt.

Abstract: A method of manufacturing a combustion chamber for use in a water heater is provided. A skirt is formed, and an edge portion of a plate is spot welded to the skirt. The edge portion of the plate is circumferentially welded to the skirt, thereby forming a seal between the plate and the skirt.

Abstract: A water heater is disclosed. The water heater includes a water storage tank and a heat source positioned to heat water within the water storage tank. A heat exchanger is positioned within the bottom end portion of the water storage tank. The heat exchanger is configured to contain a fluid medium for heat exchange with water in the bottom end portion of the water storage tank. A temperature sensor is positioned at an elevation above the heat exchanger for sensing a temperature of water within the tank. A control system is configured to selectively activate the heat source as a function of the water temperature sensed by the temperature sensor. The heat source can be either a heating element positioned within the water storage tank, or a burner positioned to deliver products of combustion into a flue positioned within the tank for heating water within the water storage tank.

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 and method of assembling the water heater are disclosed. The method includes the step of positioning an insulation member around a water tank. An expandable tube is positioned at an elevation between a top surface and a bottom surface of the insulation member. An outer shell is positioned over the water tank, the insulation member, and the expandable tube to at least partially encapsulate the water tank. The expandable tube is expanded to compress at least a portion of the insulation member against the water tank or the outer shell. Foam insulation is delivered into a space defined adjacent the top surface of the insulation member and between the water tank and the outer shell. The foam insulation is substantially limited from traveling past the expandable tube when the expandable tube is maintained in an expanded state.

Abstract: A water heater inlet conduit having a top end portion configured to be coupled to an inlet port of a water heater is provided. The bottom end portion of the inlet conduit is configured to extend into an interior of the water heater. A passage within the inlet conduit is provided for water flow from the top end portion to the bottom end portion. The top end portion of the inlet conduit defines at least one outlet opening configured to divert a portion of the water flow outwardly from the passage in the top end portion of the inlet conduit. The top end portion of the inlet conduit further defines at least one inlet opening configured to draw water inwardly into the passage in the top end portion of the inlet conduit.

Abstract: A flue system is provided for a water heater having improved heat exchange efficiency. The flue system includes an upstream heat exchange portion providing a first pass for heat exchange with water in the water heater. The flue system further includes a downstream heat exchange portion providing a second pass for heat exchange with water in the water heater and a blower positioned between the upstream heat exchange portion and the downstream heat exchange portion. The blower is configured to urge combustion products from the upstream heat exchange portion to the downstream heat exchange portion.

Abstract: An article configured to distribute foam insulation between a water tank and an outer shell of a water heater is provided. The article comprises a body portion configured to extend between the water tank and the outer shell of the water heater. The body portion at least partially defines a flow passage for foam insulation. Opposed flap portions extend from an end of the body portion. Means are provided on the flap portions for attaching each of the flap portions to the water tank.

Abstract: A system and method for configuring a water heater to drain condensate from combustion products is provided. The water heater comprises a water tank, a burner for producing combustion products, a flue extending through an interior of the water tank to receive the combustion products, and an exhaust passageway positioned downstream of the flue and extending outside of the water tank to exhaust the combustion products. The exhaust passageway includes a first portion and a second portion positioned at an elevation above the first portion. A bypass conduit is coupled to the exhaust passageway and positioned to direct condensate in the exhaust passageway from the second portion toward the first portion. A drain port is positioned at or an elevation below the first portion of the exhaust passageway to drain condensate from the exhaust passageway.

Abstract: A flue system is provided for a water heater having improved heat exchange efficiency. The flue system includes an upstream heat exchange portion having at least one substantially vertical flue tube. The flue system also includes a downstream heat exchange portion having at least one substantially vertical flue tube. The upstream heat exchange portion provides a first pass for heat exchange with water in a water heater. The downstream heat exchange portion provides a second pass for heat exchange with water in the water heater.