Water Heater Valves and Controllers and Methods of Mounting the Same

Abstract

Exemplary embodiments are disclosed of valves and controllers for water heaters. Also disclosed are mounting methods for valves and controllers for water heaters. In an exemplary embodiment, a gas valve and controller are mounted to and/or located at a burner door of a water heater.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 61/730,484 filed Nov. 27, 2012. The entire disclosure of the above application is incorporated herein by reference.

FIELD

The present disclosure generally relates to valves and controllers for water heaters.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

Water heater controllers are currently mounted to an immersion flange on or at the bottom of the water heater. Recently, water heaters moved to flammable vapor systems that have a sealed combustion system to prevent ignition of flammable vapors outside the water heater. The sealed system uses a burner door, through which the burner tube passes.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

Exemplary embodiments are disclosed of valves and controllers for water heaters. Also disclosed are mounting methods for valves and controllers for water heaters. In an exemplary embodiment, a gas valve and controller of are mounted to and/or located at a burner door of a water heater.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure

FIG. 1 is a perspective view of a water heater having a gas valve and controller mounted to or fixed to or at the burner door according to an exemplary embodiment;

FIG. 2 is an exploded perspective view showing the gas valve and controller aligned with a burner door of the water heater shown in FIG. 1 without the cover or housing that houses the controller and covers the burner door;

FIG. 3 is an exploded perspective view of the temperature selection control for adjusting the temperature setting or setpoint for water in the storage tank, where the knob, dial, and PCB are aligned with an opening in the storage tank of the water heater shown in FIG. 1;

FIG. 4 is an upper perspective view of the gas valve and controller of the water heater shown in FIG. 1, and also illustrating how the user interface items are upwardly facing such that various features and functions (e.g., knob, indicator light, mirrored surface to verify whether pilot light is lit, etc.) are visible to a user from above or standing position according to an exemplary embodiment;

FIG. 5 is a perspective view of the knob and dial for adjusting the temperature setting of the water heater shown in FIG. 1, and also illustrating the dial features including a vacation/warm setting, a very hot setting, and a factory test setting to allow a system functional test (e.g., at the factory, etc.) from a lower portion of the tank according to an exemplary embodiment;

FIG. 6 is an upper perspective view of a gas valve and controller having a side entry option for the gas supply according to an exemplary embodiment;

FIG. 7 is a perspective view of an exemplary embodiment of a water heater having a gas valve and controller mounted to or fixed to the burner door, where the water heater has the side entry option for the gas supply as shown in FIG. 6, and a knob and dial located towards a top of the water heater to be at or close to eye level of the user;

FIG. 8 is a perspective view of another exemplary embodiment of a water heater having a gas valve and controller mounted to or fixed to the burner door, where the water heater has the side entry option for the gas supply as shown in FIG. 6, and a knob and dial located towards a bottom of the water heater; and

FIG. 9 is a perspective view of another exemplary embodiment of a water heater having a gas valve and controller mounted to or fixed to the burner door, where the water heater has the side entry option for the gas supply as shown in FIG. 6 without a knob and dial dial mounted on the water heater tank jacket.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

As mentioned above in the background, water heater controllers or controls are currently mounted to an immersion flange on or at the bottom of the water heater. The inventors hereof have realized that such immersion mounting methods of the valve and controller require an expensive brass or engineering polymer to achieve mounting strength (e.g., 300 pounds per square inch (psi) burst, etc.) and water leakage tightness (e.g., over 15 years, etc.). This is a potential failure point for some systems and adds costs to the tank to weld the flange mounting spud to the hole.

The inventors have also recognized that the user interface is forward facing (e.g., about 18 inches off the ground, etc.) which is not user friendly. For example, the user may be unable view the user interface when standing up and may need to bend down to view the user interface. This mounting arrangement is due to the legacy of water heaters being open burner systems.

After recognizing the above, the inventors developed and disclose herein exemplary embodiments in which certain components typically used in a standing storage gas fired water heater (e.g., the burner assembly, pilot light assembly, flame sense rod, ignition device (e.g., spark to pilot light, spark to main burner, or hot surface igniter, etc.), and the gas valve and controller if the system is microprocessor controlled, etc.) are mounted to a burner door or opening of a sealed combustion water heater.

In exemplary embodiments, the parts that pass through the sealed door into the combustion chamber are sealed. Exemplary embodiments may include a sealed door assembly in which a burner assembly, pilot light assembly, and flame sense rod may be mounted to the door of a sealed combustion water heater. By way of example, an exemplary embodiment may include a door assembly similar to that disclosed in U.S. Patent Application Publication US2010/0101510, U.S. Patent Application Publication US2010/0154724, U.S. Pat. No. 6,302,062, U.S. Pat. No. 6,439,171, and/or U.S. Pat. No. 6,554,610. Generally, these patent documents disclose various concepts of sealing the parts that pass through the sealed door into the combustion chamber. Significantly, aspects of the present disclosure may build upon and improve upon these concepts disclosed by adding a gas valve and controller to the components that may be typically fixed or mounted to the burner door.

In exemplary embodiments in which the gas valve and controller are also mounted or fixed to or at the burner door, this construction may necessitate the use of one or more surface mount temperature sensors to replace the immersion temperature sensors that are typically part of the tank mounted gas valves. In alternative embodiments, the temperature setting user interface (e.g., rotary switch, other switch, etc.) is located on the tank and connected to the surface mount sensor and also the main controller or control on the door.

With reference now to the figures, FIGS. 1 and 2 illustrate an exemplary embodiment of a sealed combustion water heater 100 embodying one or more aspects of the present disclosure. A gas valve and controller 104 is mounted to or fixed to a door 108 of the sealed combustion water heater 100. As shown in FIG. 2, the door 108 is an opening in the outside tank jacket 122 located at, adjacent, or towards a bottom of the water heater 100.

As shown in FIG. 1, the water heater 100 includes a gas (or other fuel) supply line 112. In this example, the gas supply thus enters the valve from the top. Also in this example, the controller or control has a built in trap for added protection.

The water heater 100 also includes a temperature selection assembly or control comprising a rotatable knob 116 (broadly, a switch or temperature setting user interface), a dial 120, and printed circuit board 148. The rotary knob 116 allow a user to select or adjust the temperature setting or setpoint for the hot water in the storage tank. By way of example, the temperature selection control may comprise a potentiometer on a circuit board and an actuating knob/dial for temperature setting at a sensor location. The circuit board may be the same circuit board as the sensor circuit board or a separate circuit board. The knob may be a cover for a plastic mounting that also is a foam dam.

In this exemplary embodiment, the knob 116 is located towards a top of the water heater 100 such that the knob 116 will be at or close to the eye level of the user (e.g., between about 5½ feet and 6 feet above floor level, etc.). The knob 116 and dial 120 are closer to the top than the bottom of the water heater 100. Alternative embodiments may include different means for adjusting the temperature settings and/or at different locations. See, for example, FIG. 7 in which the knob 416 and dial 420 are located towards a bottom of the water heater 400.

In FIG. 2, the gas valve and controller 104 is shown aligned with the burner door or opening 108 in the outside tank jacket 122. The gas valve and controller 104 is shown in FIG. 2 without a cover or housing 128. FIG. 1 illustrates the cover or housing 128 that may be used to house components of the gas valve and controller 104. The cover or housing 128 may also be used to cover and seal the burner door or opening 108 in the outer tank jacket 122. The housing 128 may comprise a plastic part or other suitable material that is configured to be snapped into the outside tank jacket 122 or mounted by some other mechanical means to the tank jacket 122.

The gas valve and controller 104 includes a rotatable knob 132 (broadly, a switch) for selectively changing the operational status or settings of the water heater between OFF, PILOT, and ON (FIG. 4). The outlet of the valve may be coupled to the burner tube 140 (e.g., valve outlet threaded onto or over the threaded portion of the burner tube 140 (FIG. 2), etc.) exiting the burner door 108. The valve may thus supply gas to the burner assembly within the combustion chamber via the burner tube 140. The combustion chamber is located beneath the water storage tank of the water heater 100.

FIG. 3 shows the temperature adjustment knob 116 and dial 120 aligned with an opening 144 in the outside tank jacket 122. Also shown in FIG. 3 is a temperature sensor printed circuit board (PCB) 148. The PCB 148 may include a temperature sensor, e.g., a thermistor attached to the PCB 148, etc. For example, the temperature sensor may be a surface mount thermistor for the purpose of detecting the temperature of the water in the storage tank. The sensed temperature input from the temperature sensor may be compared to a potentiometer input from the knob 116. The knob 116 may be used by the user of the water heater to select the desired temperature of the water being heated. The PCB 148 of FIG. 3 is connected (e.g., via a wired or wireless connection, etc.) to the PCB 136 of FIG. 2.

An electrically conductive, electrically insulating barrier may be applied to the PCB 148 or to a second part installed between the thermistor and the storage tank wall. The PCB 148 may be positioned such that the temperature sensor is against the outer surface of the storage tank wall, to thereby provide surface temperature sensing.

FIG. 2 shows a main control board 136 for the gas valve. The component 136 might also be considered or referred to as the combustion control. The purpose of this circuit or control 136 is to receive temperature information from the temperature selection assembly shown in FIG. 3 and begin a heating cycle of the water heater 100, if required or appropriate. The temperature information received from the temperature selection control shown in FIG. 3 may be in the form of a variable voltage signal or a discreet voltage level, e.g., depending on whether or not the logic for the temperature measurement is in the PCB of the main control board 136 (FIG. 2) or the PCB 148 (FIG. 3). In an exemplary embodiment, the comparison of sensed temperature to the selected setpoint (chosen by the knob 116 of FIG. 3) occurs in the temperature selection control of FIG. 3. In an alternative embodiment, the voltage of a thermistor (e.g., attached to PCB 148 in FIG. 3, etc.) and the voltage due to the selected setpoint (via knob 116) may be sent to the PCB of the main control board 136 (FIG. 2) for comparison.

The PCB 148 and temperature sensor thereof may be located at or adjacent the top, middle, or bottom of the water heater 100. Some embodiments include only one temperature sensor, while other embodiments may include two or more temperature sensors. For example, the temperature sensor of the PCB 148 and another temperature sensor may be located at or adjacent the respective top and bottom of the water heater 100, or vice versa. In which case, there is a first temperature sensor at or towards the bottom of the tank and a second temperature sensor at or towards the top of the tank.

Advantageously, mounting the gas valve and controller 104 to the burner door 108 may allow for the elimination of various costs associated with conventional mounting and immersion sensing. For example, costs associated with a conventional flange assembly, burner tube, Noryl plastic, threaded spud, knob/pot, and steel cover may be eliminated. Costs may be added to achieve surface sensing and to cover the burner door, such as costs associated with a harness, temperature sensor (T-sense) printed circuit board (PCB) and knob, T-sense PCB and cover, valve support bracket, and bottom cover.

As shown in FIG. 4, the gas valve and controller 104 includes user interface items that are upwardly facing such that various features and functions are visible to a user from above or standing position. For example, the rotatable knob 132, OFF, PILOT, ON settings, the pilot indicator light 152, and mirrored surface 156 are visible to a user from above, e.g., when standing above the gas valve and controller 104, etc. The pilot indicator light 152 illuminates to verify when sufficient heat to hold a pilot valve open has been attained. The mirrored surface 156 allows for easy verification that the pilot light is lit. The knob 132, the pilot indicator light 152, and the mirrored surface 156 are disposed within recessed portions on or along an upper surface of the housing or cover 128.

FIG. 5 shows the knob 116 and dial 120 for adjusting the temperature setting of the water heater 100. As shown, the dial features include a vacation/warm setting, a very hot setting, and settings therebetween. This example also includes a factory test setting 160 to allow a system functional test (e.g., at the factory, etc.) from a lower portion of the tank according to an exemplary embodiment. The knob 116 and dial 120 may be relatively large, easy to read, and located at eye level.

FIG. 6 shows a gas valve and controller 204 having a side entry option for the gas supply 212 according to another exemplary embodiment. Accordingly, the gas supply thus enters the valve from the side. Also in this exemplary embodiment, the gas valve and controller 204 also includes a rotatable knob 232 for selectively changing the settings between OFF, PILOT, and ON. There is also a pilot indicator light 252 and a mirrored surface 256. The pilot indicator light 252 illuminates to verify when sufficient heat to hold a pilot valve open has been attained. The mirrored surface 256 allows for easy verification that the pilot light is lit. A housing or cover 228 may be used to house components of the gas valve and controller 204. The cover or housing 228 may also be used to cover and seal the burner door.

FIGS. 7 through 9 illustrate exemplary embodiments of respective water heaters 300, 400, and 500 having a gas valve and controller 304, 404, 504 mounted to or fixed to the burner door and also having a side entry option for the gas supply 312, 412, 512 as shown in FIG. 6. A comparison of FIGS. 7 through 9 generally shows how aspects of the present disclosure allow for incremental features. And, surface sensing with dual sensors may also allow for control optional upgrades in some exemplary embodiments.

As shown in FIG. 7, the water heater 300 includes a knob 316 and dial 320 located towards a top of the water heater 300. The knob 316 and dial 320 will thus be at or close to eye level of the user. By comparison, the water heater 400 shown in FIG. 8 includes a knob 416 and dial 420 located towards a bottom of the water heater 400.

The water heater 500 shown in FIG. 9 does not include a knob and dial mounted on the water heater tank jacket. In this exemplary embodiment, a temperature selection control (e.g., knob, dial, etc.) may be located with the control 502 and mounted on the combustion door cover. This exemplary embodiment may include at least one surface mounted temperature sensor mounted on the storage tank near the cold water inlet at the bottom.

By way of example, the water heater may include only one surface mount temperature sensor if the temperature selection control shown in FIG. 3 is located towards a bottom of the water heater as shown in FIG. 8. If the temperature selection control (e.g., knob 116, dial 120, and PCB 148, etc.) is located towards a top of the water heater 300 as shown in FIG. 7, then there may be two surface mounted temperature sensors. For example, one sensor may be located behind the temperature selection control towards a top of the water heater, and another sensor may be located towards the bottom of the water heater, e.g., at about the same location that the temperature setpoint selection device is located in FIG. 8, etc. But the water heater 300 (FIG. 7) may also include only a single surface mounted temperature sensor. In which case, the single temperature sensor may be located towards a bottom of the tank (e.g., at about the same location that the knob 416 is located in FIG. 8, etc.) with a wired connection running up to the selection knob 316 as located in FIG. 7. For gas storage water heaters, there is typically at least one temperature sensor located near the bottom of the tank to detect the cold water entering the tank during a draw of hot water from the top of the tank. This helps ensure the heating process will start soon (e.g., as soon as possible, etc.) to avoid a shortage of hot water. In some exemplary embodiments, a second sensor may be added such that there at least two sensors, where one sensor is at or towards the bottom and another sensor is at or towards the top to help control or avoid a condition called “stacking”.

Conventional immersion flange/spud mounting for water heater controls generally has three functions. First is to structurally mount the control system, second is to sense water temperature, and third is provide a water seal for the immersion sensing. These three functions may be addressed in exemplary embodiments disclosed herein as follows. The structural mounting of the control system is moved to the burner door area. The outlet of the valve is mounted to the pipe or burner tube exiting the burner door. Extra brackets or features may be used to support the valve when necessary. A housing or cover (e.g., plastic part, etc.) may be used to cover the burner door area that also allows integration of the valve control knobs, LEDs, and other user interface items on the top of the cover, such that a user is able to see these items from a standing position. A mirrored surface may be provided to allow a user to see the pilot light or burner status from a standing position. The sensing function may be achieved using surface mount sensors. The sensors may be mechanical, electrical, or a combination of both. Lastly, the seal function is no longer needed because the tank no longer needs a hole for immersion sensing when the sensing is accomplished using surface mount sensors.

Typically, a surface mount sensor system on a gas water heater will have two sensors, specifically one sensor at the bottom of the tank and one sensor at the top. A method of achieving this temperature sensing that has cost and customer usage benefits may be provided as follows in exemplary embodiments. An electrically conductive, electrically insulating barrier could be applied to a circuit board having an attached thermistor. Or, an electrically conductive, electrically insulating barrier may be applied to a second part installed between the thermistor and the tank wall. A PCB may be positioned such that the PCB temperature sensor (e.g., thermistor, etc.) is against an outer surface of the storage tank wall, to thereby provide surface temperature sensing. A housing (e.g., plastic, etc.) may cover the area in the outside tank jacket and spring load the temperature sensor against the tank wall. The housing (e.g., plastic part, etc.) may be snapped into the outside tank jacket or mounted by some other mechanical means to the tank jacket.

In an alternative embodiment, a first housing (e.g., plastic housing, etc.) may be used as an insulation foam dam to protect this area from the insulation process to allow field service. In this alternative construction, the first housing may not cover the hole or opening in the tank jacket. Instead, an additional or second cover may be used to fill the hole or opening in the outside tank jacket.

Additionally, a sensor/plastic mounting assembly may also use a potentiometer on a circuit board and an actuating knob/dial for temperature setting at a sensor location. An optimal or preferred location is at the top sensor. The circuit board could be the same circuit board as the sensor circuit board, or a separate circuit board. The knob could be a cover for a plastic mounting that also is a foam dam.

Exemplary embodiments disclosed herein may provide one or more (but not necessarily any or all) of the following advantages, such as differentiation in the market, more feasible methodology to integrate flammable vapor ignition resistant (FVIR) sensing, placement of the main user interaction at eye level, and/or hide or conceal the gas valve and related components from view. Also by way of example, attaching the valve and control system to the burner door area reduces costs associated with mounting and sealing the water heater control to the tank. It also allows for a cover to be mounted over the control system that would allow user information, including pilot light status and visuals, to be seen from a standing position. The thermistor mounting method allows for the use of a low cost circuit board mounted thermistor, and provides the means to move the temperature control interface to the top of the heater, where it is easily accessed and seen. Mounting the valve and control system to the burner door allows for the elimination of costs associated with the conventional mounting and immersion sensing, such as the costs associated with a conventional flange assembly, burner tube, Noryl plastic, threaded spud, knob/pot, and steel cover.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. In addition, advantages and improvements that may be achieved with one or more exemplary embodiments of the present disclosure are provided for purpose of illustration only and do not limit the scope of the present disclosure, as exemplary embodiments disclosed herein may provide all or none of the above mentioned advantages and improvements and still fall within the scope of the present disclosure.

Specific dimensions, specific materials, and/or specific shapes disclosed herein are example in nature and do not limit the scope of the present disclosure. The disclosure herein of particular values and particular ranges of values for given parameters are not exclusive of other values and ranges of values that may be useful in one or more of the examples disclosed herein. Moreover, it is envisioned that any two particular values for a specific parameter stated herein may define the endpoints of a range of values that may be suitable for the given parameter (i.e., the disclosure of a first value and a second value for a given parameter can be interpreted as disclosing that any value between the first and second values could also be employed for the given parameter). For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, and 3-9.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The term “about” when applied to values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. For example, the terms “generally,” “about,” and “substantially,” may be used herein to mean within manufacturing tolerances.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements, intended or stated uses, or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A water heater comprising:

a storage tank;

a combustion chamber below the storage tank;

a burner assembly within the combustion chamber for heating water in the storage tank;

a burner tube for supplying fuel to the burner assembly;

a tank jacket disposed around the storage tank and including an opening through which the burner tube passes; and

a gas valve and controller located at the opening of the tank jacket and including a valve outlet coupled to the burner tube for controlling a supply of fuel to the burner assembly via the burner tube.

2. The water heater of claim 1, further comprising a housing coupled to the water heater that houses components of the gas valve and controller and covers the opening of the tank jacket.

3. The water heater of claim 1, wherein the gas valve and controller comprises one or more user interface items facing upward, whereby the one or more user interface items are visible from above.

4. The water heater of claim 1, wherein the gas valve and controller comprises one or more user interface items facing upward, whereby the one or more user interface items are visible from above by a user in a standing position.

5. The water heater of claim 4, wherein the one or more user interface items comprise:

a switch for selectively changing an operational setting of the burner assembly between OFF, PILOT, and ON;

a pilot indicator light configured to illuminate when there is sufficient heat to hold a pilot valve open; and

a mirrored surface configured to allow verification that a pilot light is lit.

6. The water heater of claim 5, further comprising a housing that houses components of the gas valve and controller and covers the opening of the tank jacket, wherein the switch, the pilot indicator light, and the mirrored surface are on an upper surface of the housing.

7. The water heater of claim 1, further comprising one or more surface mount temperature sensors coupled to an outer surface of the storage tank for sensing a temperature of water in the storage tank without using immersion temperature sensors.

8. The water heater of claim 7, wherein the one or more surface mount temperature sensors comprise:

a first temperature sensor printed circuit board including a thermistor positioned against the outer surface of the storage tank adjacent a bottom of the storage tank; and/or

a second temperature sensor printed circuit board including a thermistor positioned against the outer surface of the storage tank adjacent a top of the storage tank.

9. The water heater of claim 1, further comprising a temperature selection control for selectively changing a temperature setpoint for water in the storage tank, and including one or more surface mount temperature sensors for sensing a temperature of water in the storage tank without using immersion temperature sensors, wherein the temperature selection control is located closer to a top of the water heater than to a bottom of the water heater, whereby the temperature selection control is at eye level.

10. A gas valve and controller for controlling a supply of fuel for a sealed combustion water heater having a burner door, the gas valve and controller comprising:

a valve outlet configured to be coupled to a burner tube passing through the burner door;

a housing in which components of the gas valve and controller are housed, the housing configured to be mounted to the water heater and to cover and seal the burner door; and

one or more user interface items facing upward and visible from above.

11. The gas valve and controller of claim 10, wherein the one or more user interface items comprise:

a switch for selectively changing an operational setting between OFF, PILOT, and ON;

a pilot indicator light configured to illuminate when there is sufficient heat to hold a pilot valve open; and

a mirrored surface configured to allow verification that a pilot light is lit.

12. The gas valve and controller of claim 11, wherein the switch, the pilot indicator light, and the mirrored surface are on an upper surface of the housing.

13. A water heater comprising the gas valve and controller of claim 10, the water heater further comprising:

one or more surface mount temperature sensors configured to be coupled to an outer surface of a storage tank of the water heater for sensing a temperature of water in the storage tank without using immersion temperature sensors; and

a temperature selection control for selectively changing a temperature setpoint for water in the storage tank, and including at least one of said one or more surface mount temperature sensors.

14. The water heater of claim 13, wherein the one or more surface mount temperature sensors comprise:

a first temperature sensor printed circuit board including a thermistor positionable against the outer surface of the storage tank adjacent a bottom of the storage tank; and/or

a second temperature sensor printed circuit board including a thermistor positionable against the outer surface of the storage tank adjacent a top of the storage tank, the temperature selection control including the second temperature sensor printed circuit board.

15. A sealed combustion water heater comprising:

a burner door;

a burner tube passing through the burner door;

a gas valve and controller located at the burner door and including a valve outlet coupled to the burner tube for controlling a supply of fuel to the burner tube; and

a housing in which components of the gas valve and controller are housed, the housing mounted to the water heater so as to cover and seal the burner door.

16. The water heater of claim 15, wherein the burner door is an opening in an outside tank jacket of the water heater.

17. The water heater of claim 15, further comprising one or more user interface items on an upper surface of the housing and facing upward, whereby the one or more user interface items are visible from above.

18. The water heater of claim 17, wherein the one or more user interface items comprise:

a switch for selectively changing an operational setting between OFF, PILOT, and ON;

a pilot indicator light configured to illuminate when there is sufficient heat to hold a pilot valve open; and

a mirrored surface configured to allow verification that a pilot light is lit.

19. The water heater of claim 15, further comprising:

one or more surface mount temperature sensors coupled to an outer surface of a storage tank of the water heater for sensing a temperature of water in the storage tank without using immersion temperature sensors; and

a temperature selection control for selectively changing a temperature setpoint for water in the storage tank, and including at least one of said one or more surface mount temperature sensors.

20. The water heater of claim 19, wherein:

the one or more surface mount temperature sensors comprise first and second thermistors positioned against the outer surface of the storage tank adjacent a respective bottom and top of the storage tank; and/or

the temperature selection control is located closer to a top of the water heater than to a bottom of the water heater, whereby the temperature selection control is at eye level.