Note: Descriptions are shown in the official language in which they were submitted.
CA 02570601 2006-12-07
FLUID-HEATING APPARATUS, CIRCUIT FOR HEATING A FLUID, AND
METHOD OF OPERATING THE SAME
BACKGROUND
The invention relates to a fluid-heating apparatus, such as an electric water
heater,
that can determine a degradation of a heating element of the apparatus, and a
method of
operating the fluid-heating apparatus.
When an electric-resistance heating element fails in an electric water heater,
the
operation of the heater is diminished until the element is replaced. This can
be an
inconvenience to the user of the water heater.
SUMMARY
Failure of the electric-resistance element may not be immediate. For example,
the
element typically has a sheath isolated from an element wire by an insulator,
such as packed
magnesium oxide. If the sheath is damaged, the insulator can still insulate
the wire and
prevent a complete failure of the element. However, the insulator does become
hydrated over
time and the wire eventually shorts, resulting in failure of the element. The
invention, in at
least one embodiment, detects the degradation of the heating element due to a
damaged
sheath prior to failure of the heating element. The warning of the degradation
to the element
prior to failure of the element allows the user to replace the element with
little downtime on
his appliance.
A heating element generates heat that can be transferred to water surrounding
the
heating element. Water can dissipate much of the heat energy produced by the
heating
element. The temperature of the heating element rises rapidly initially when
power is applied
and then the rate of temperature rise slows until the temperature of the
heating element
remains relatively constant. Should power be applied to the heating element
prior to the
water heater being filled with water or should a malfunction occur in which
the water in the
water heater is not at a level high enough to surround the heating element, a
potential
condition known as "dry-fire" exists. Because there is no water surrounding
the heating
element to dissipate the heat, the heating element can heat up to a
temperature that causes the
heating element to fail. Failure can occur in a matter of only seconds.
Therefore, it is
desirable to detect a dry-fire condition quickly, before damage to the heating
element occurs.
CA 02570601 2006-12-07
2
In one embodiment, the invention provides a method of controlling a fluid-
heating
apparatus. The fluid-heating apparatus includes a heating element for heating
a fluid
surrounding the heating element and a control circuit connected to the heating
element and
connectable to a power source. The control circuit includes a switch connected
in a current
path from the power source to the heating element back to the power source,
and a current
sensor. The method includes initiating a heating state of the fluid-heating
apparatus by
establishing a current in the current path, the establishing act comprising
making the switch
to allow current in the current path; initiating a non-heating state and
ceasing the heating state
of the fluid-heating apparatus by ceasing the current in the current path, the
ceasing act
comprising breaking the switch to not allow current in the current path;
applying a voltage to
the heating element during the non-heating state; sensing a leakage current of
the heating
element during the application of the voltage; and determining a degradation
of the heating
element prior to a failure of the heating element with the sensed leakage
current.
In another embodiment, the invention provides a fluid-heating apparatus for
heating a
fluid. The fluid-heating apparatus includes a vessel, an inlet to introduce
the fluid into the
vessel, an outlet to remove the fluid from the vessel, a heating element at
least partially
surrounded by the fluid in the vessel. The heating element includes a wire, an
insulating
material surrounding at least a portion of the wire, and a sheath surrounding
at least a portion
of the insulating material. The fluid-heating apparatus further comprises a
ground contact in
electrical communication with the sheath, and a control circuit connectable to
a power source
and connected to the heating element. The control circuit includes a current
path having a
first leg connecting the power source to a first point of the heating element
and a second leg
connecting the power source to a second point of the heating element, a switch
connected in
circuit in the first leg, and a current sensor. In one construction, the
control circuit is
configured to initiate a heating state of the fluid-heating apparatus by
establishing a current in
the current path, the establishing act including making the switch to allow
current in the first
current path; initiate a non-heating state and ceasing the heating state of
the fluid-heating
apparatus by ceasing the current in the current path, the ceasing act
including breaking the
switch to not allow current in the first current path; connect the power
source to the second
point of the heating element during the non-heating state thereby allowing a
current in the
second leg during the non-heating state; sense a leakage current of the
heating element during
the connection of the power source to the second point of the heating element
during the non-
CA 02570601 2006-12-07
3
heating state; and determine a degradation of the heating element prior to a
failure of the
heating element with the sensed leakage current.
Other aspects of the invention will become apparent by consideration of the
detailed
description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a partial exposed view of a water heater embodying the invention.
Fig. 2 is a partial exposed, partial side view of an electrode capable of
being used in
the water heater of Fig. 1.
Fig. 3 is a partial block diagram, partial electric schematic of a first
control circuit
capable of controlling the electrode of Fig. 2.
Fig. 4 is a partial block diagram, partial electric schematic of a second
control circuit
capable of controlling the electrode of Fig. 2.
Fig. 5 is a partial block diagram, partial electric schematic of a third
control circuit
capable of controlling the electrode of Fig. 2.
Fig. 6A is a chart of a temperature curve of the electrode of Fig. 2 submerged
in
water.
Fig. 6B is a chart of a temperature curve of the electrode of Fig. 2 exposed
to air.
Fig. 7 is partial block diagram, partial electric schematic of a fourth
control circuit
capable of controlling the electrode of Fig. 2 and detecting a dry-fire
condition.
Fig. 8 is a flowchart of the operation of the control circuit of Fig. 7 for
detecting a
dry-fire condition.
Fig. 9A is a chart of a resistance curve of the electrode of Fig. 2 submerged
in water.
Fig. 9B is a chart of a resistance curve of the electrode of Fig. 2 exposed to
air.
CA 02570601 2006-12-07
4
DETAILED DESCRIPTION
Before any embodiments of the invention are explained in detail, it is to be
understood that the invention is not limited in its application to the details
of construction and
the arrangement of components set forth in the following description or
illustrated in the
following drawings. The invention is capable of other embodiments and of being
practiced
or of being carried out in various ways. Also, it is to be understood that the
phraseology and
terminology used herein is for the purpose of description and should not be
regarded as
limited. The use of "including," "comprising" or "having" and variations
thereof herein is
meant to encompass the items listed thereafter and equivalents thereof as well
as additional
items. The terms "mounted," "connected," "supported," and "coupled" are used
broadly and
encompass both direct and indirect mountings, connections, supports, and
couplings. Further,
"connected" and "coupled" are not restricted to physical or mechanical
connections or
couplings, and can include electrical connections or couplings, whether direct
or indirect.
Fig. 1 illustrates a storage-type water heater 100 including an enclosed water
tank 105
(also referred to herein as an enclosed vessel), a shell 110 surrounding the
water tank 105,
and foam insulation 115 filling the annular space between the water tank 105
and the shell
110. A typical storage tank 105 is made of ferrous metal and lined internally
with a glass-like
porcelain enamel to protect the metal from corrosion. However, the storage
tank 105 can be
made of other materials, such as plastic. A water inlet line or dip tube 120
and a water outlet
line 125 enter the top of the water tank 105. The water inlet line 120 has an
inlet opening 130
for adding cold water to the water tank 105, and the water outlet line 125 has
an outlet
opening 135 for withdrawing hot water from the water tank 105. The tank may
also include a
grounding element (or contact) that is in contact with the water stored in the
tank.
Alternatively, the grounding element can be part of another component of the
water heater,
such as the plug of the heating element (discussed below). The grounding
element comprises
a metal material that allows a current path to ground.
The water heater 100 also includes an electric resistance heating element 140
that is
attached to the tank 105 and extends into the tank 105 to heat the water. An
exemplary
heating element 140 capable of being used in the water heater 100 is shown in
Fig. 2. With
reference to Fig. 2, the heating element 140 includes an internal high
resistance heating
element wire 150, surrounded by a suitable insulating material 155 (such as
packed
CA 02570601 2006-12-07
magnesium oxide), a metal jacket (or sheath) 160 enclosing the insulating
material, and an
element connector assembly 165 (typically referred to as a plug) that couples
the metal jacket
160 to the shell 110, which may be grounded. For the construction shown, the
connector
assembly 165 includes a metal spud 170 having threads, which secure the
heating element
5 140 to the shell 110 by mating with the threads of an opening of the shell
110. The connector
assembly 165 also includes connectors 175 and 180 for electrically connecting
the wire 150
to the control circuit (discussed below), which provides controlled power to
the wire 150.
While a water heater 100 having the element 140 is shown, the invention can be
used with
other fluid-heating apparatus for heating a conductive fluid, such as an
instantaneous water
heater or an oil heater, and with other heater element designs and
arrangements.
A partial electrical schematic, partial block diagram for one construction of
a control
circuit 200 used for controlling the heating element 140 is shown in Fig. 3.
The control
circuit 200 includes a microcontroller 205. As will be discussed in more
detail below, the
microcontroller 205 receives signals or inputs from a plurality of sensors or
circuits, analyzes
the inputs, and generates one or more outputs to control the water heater 100.
In one
construction, the microcontroller 205 includes a processor and memory. The
memory
includes one or more modules having instructions. The processor obtains,
interprets, and
executes the instructions to control the water heater 100. Although the
microcontroller 205 is
described as having a processor and memory, the invention may be implemented
with other
controllers or devices including a variety of integrated circuits (e.g., an
application-specific-
integrated circuit) and discrete devices, as would be apparent to one of
ordinary skill in the
art. Additionally, the microcontroller 205 and the control circuit 200 can
include other
circuitry and perform other functions not discussed herein as is known in the
art.
Referring again to Fig. 3, the control circuit 200 further includes a current
path from a
power supply 201 to the heating element 140 back to the power supply 201. The
current path
includes a first leg 202 and a second leg 203. The first leg 202 connects the
power source
201 to a first point 206 of the heating element 140 and the second leg 203
connects the power
source 201 to a second point 207 of the heating element 140. A thermostat,
which is shown
as a switch 210 that opens and closes depending on whether the water needs to
be heated, is
connected in the first leg 202 between the power source 201 and the heating
element 206.
When closed, the thermostat switch 210 allows a current from the power source
201 to the
heating element 140 and back to the power source 201 via the first and second
legs 202 and
CA 02570601 2006-12-07
6
203. This results in the heating element 140 heating the water to a desired
set point
determined by the thermostat. The heating of the water to a desired set point
is referred to
herein as the water heater 100 being in a heating state. When open, the
thermostat switch 210
prevents a current flow from the power source 201 to the heating element 140
and back to the
power source 201 via the first and second legs 202 and 203. This results in
the water heater
100 being in a non-heating state. Other methods of sensing the water
temperature and
controlling current to the heating element 140 from the power source 201 are
possible (e.g.,
an electronic control having a sensor, the microcontroller 205 coupled to the
sensor to receive
a signal having a relation to the sensed temperature, and an electronic switch
such as a triac
controlled by the microcontroller in response to the sensed temperature).
As just stated, the thermostat switch 210 allows a current through the heating
element
140 when the switch 210 is closed. A variable leakage current can flow from
the element
wire 150 to the sheath 160 via the insulating material 155 when a voltage is
applied to the
heating element 140. The variable resistor 215 represents the leakage
resistance, which
allows the leakage path. The resistance between the wire and ground drops from
approximately 4,000,000 ohms to approximately 40,000 ohms or less when the
heating
element 140 degrades due to a failure in the sheath 160. This will be
discussed in more detail
below.
The control circuit 210 further includes a voltage measurement circuit 220 and
a
current measurement circuit 225. The voltage measurement circuit 220, which
can include a
filter and a signal conditioner for filtering and conditioning the sensed
voltage to a level
suitable for the microcontroller 205, senses a voltage difference between the
first and second
legs 202 and 203. This voltage difference can be used to determine whether the
thermostat
switch 210 is open or closed. The current measurement circuit 225 senses a
current to the
heating element 140 with a torroidal current transformer 230. The torroidal
current
transformer 235 can be disposed around both legs 202 and 203 to prevent
current sense signal
overload during the heating state of the water heater 100, and accurately
measure leakage
current during the non-heating state of the water heater 100. The current
measurement circuit
225 can further include a filter and signal conditioner for filtering and
conditioning the sensed
current value to a level suitable for the microcontroller 205.
During operation of the water heater 100, the sheath 160 may degrade resulting
in a
breach (referred to herein as the aperture) in the sheath 160. When the
aperture exposes the
CA 02570601 2006-12-07
7
insulating material 155, the material 155 may absorb water. Eventually, the
insulating
material 155 may saturate, resulting in the wire 150 becoming grounded. This
will result in
the failure of the element 140.
When the insulating material 155 absorbs water, the material 155 physically
changes
as it hydrates. The hydrating of the insulating material 155 decreases the
resistance 215 of a
leakage path from the element wire 150 to the grounded element (e.g., the
heating element
plug 165 and the coupled sheath 160). The control circuit 200 of the invention
recognizes the
changing of the resistance 215 of the leakage path, and issues an alarm when
the leakage
current increases to a predetermined level.
More specific to Fig. 3, it is common in the United States to apply 240 VAC to
the
element wire 140 by connecting a first 120 VAC to the first leg 202 and a
second 120 VAC
to the second leg 203. The thermostat switch 210 removes the first 120 VAC
from being
applied to the heating element 140, thereby having the water heater 100 enter
a non-heating
state. However, as shown in Fig. 3, the second 120 VAC through the second leg
is still
applied to the heating element 140. As a consequence, a leakage current can
still flow
through the leakage resistance 215. The voltage measurement circuit 220
provides a signal to
the microcontroller 205 representing, either directly or through analysis by
the
microcontroller 205, whether the thermostat switch 210 is in an open state,
and the current
measurement circuit 230 provides a signal to the microcontroller 205
representing, either
directly or through analysis by the microcontroller 205, the current through
the circuit path
including the leakage current. The microcontroller 205 can issue an alarm when
the
measured leakage current is greater than a threshold indicating the heating
element 140 has a
degrading sheath 160. The threshold value can be set based on empirical
testing for the
model of the water heater 100. The alarm can be in the form of a visual and/or
audio alarm
250. It is even envisioned that the alarm can be in the form of preventing
further heating of
the water until the heating element 140 is changed.
In another construction of the water heater 100, the voltage measurement
circuit 220
may not be required if the control of the current to the heating element 140
is performed by
the microcontroller 205. That is, the voltage measurement circuit 220 can
inform the
microcontroller 205 when the water heater 100 enters a heating state. However,
in some
water heaters, the microcontroller 205 receives a temperature of the water in
the tank 105
from a temperature sensor and controls the current to the heating element 140
via a relay (i.e.,
CA 02570601 2006-12-07
8
directly controls the state of the water heater 100). For this construction,
the voltage
measurement circuit 220 is not required since the microcontroller knows the
state of the water
heater 100.
In yet another construction of the water heater 100, the microcontroller 205
(or some
other component) may control the current measurement circuit 225 to sense the
current
through the heating element 140 only during the "off' state. This construction
allows the
current measurement circuit 225 to be more sensitive to the leakage current
during the non-
heating state.
Referring to TABLE 1, the table provides the results of eight tests performed
on eight
different elements. Each of the elements where similar in shape to the element
140 shown in
Fig. 2. The elements were 4500 watt elements secured in 52 gallon electric
water heaters
similar in design to the water heater 100 shown in Fig. 1. Various
measurements of the
elements were taken during the tests. The measurements include the "Power 'On'
Average
Measured Differential Current", the "Power 'On' Maximum Measured Differential
Current",
the "Power 'Offl Average Measure Differential Current (ma)", and the "Power
'OfP
Maximum Measured Differential current." Aperture were introduced to the sheath
160 of
elements E, F, G, and H. The apertures resulted in the degradation of the
insulating materials
155. Measurements for the elements EFGH were taken while the insulators
degraded. The
data in TABLE 1 shows that the current measurements of elements with intact
sheaths 160
taken during the "on" state (or heating state), overlap with the current
measurements of
elements with a damaged sheath 160. For example, the element "Edge Hole G",
has a lower
average current than the good element C and the good element D. In contrast,
the current
measurements made during the "off' state (or non-heating state) indicate a
wide gap in
current readings for an element with a damaged sheath 160 versus the element
with an intact
sheath 160. For example, the lowest average current measured for a degraded
sheath 160,
Edge Hole G at 12.5 ma, is over six times higher than the highest average
current measured
for an uncompromised element, i.e., Good D.
CA 02570601 2006-12-07
9
[tl] TABLE 1-DIFFERENTIAL CURRENT MEASUREMENTS
F4.,FIVIDNT POWFR"ON" POWFR"ON" FOWIIt'4W' POWFR'~W'
AVERAGE MAXMUM AVERAGE MAXIMUM
MEASURFD MEASURED MFASURED MFASURFD
DIFFERNIIAL DIFFFREIVIIAL DIFFIIZNIi=<4L DIFFERNIIAL
CCJRREIVf ma) CURRFNT(rna. CURRF3V17ma CURRENr nia.
GoodA 0.45 2.78 0.56 3.15
GoodB 3.78 4.19 0.15 1.72
GoodC 4.41 5.15 0.10 0.12
GoodD 838 9.73 2.07 290
Cmtr 59.9 >4017 218.8 >407
HoleE
C'mtr 79.8 >407 1443 378
HoleF
Edgr 438 245 12.5 782
HoleG
Edge 9.44 14.7 13.8 152
HoleH
A partial electrical schematic, partial block diagram for another construction
of the
control circuit 200A used for controlling the heating element 140 is shown in
Fig. 4. Similar
to the construction shown in Fig. 3, the control circuit 200A includes the
microcontroller 205,
the thermostat switch 210A, the voltage measurement circuit 220, and the
current
measurement circuit 225. However, for the construction of the control circuit
in Fig. 4, the
first leg 202A of the circuit 200A is connected to 120 VAC or 240 VAC and the
second leg
203A of the control circuit 200 is connected to ground. As further shown in
Fig. 4, the
double pole thermostat switch 210A is electrically connected between the
current
measurement circuit 225 and 120 VAC or 240 VAC. The operation of the control
circuit
200A for Fig. 4 is similar to the control circuit 200 for Fig. 3. TABLE 2
demonstrates a
comparison between a heating element 140 initially having no apertures and the
element 140
having an aperture at the edge of the element 140. As can be seen, TABLE 2
demonstrates a
large difference in current between the degraded element and the good element
during the
non-heating state.
CA 02570601 2006-12-07
[t2] TABLE 2- DIFFERENTIAL CURRENT MEASUREMENTS DURING
POWER "OFF" CONDITION (240 VAC)
FI.,F1v11NrID StaningQ,mEnt(mA) C~aentat I Hoir(mA)
Good 0.04mA 0.15mA
CentrHole 560mA 693 mA
5 Before proceeding further, it should be understood that the constructions
described
thus far can include additional circuitry to allow for intermittent testing.
For example and as
shown in Fig. 2, a second switch 255 controlled by the microcontroller 225 can
be added to
attach the power source 201A to the heating element 140 when thermostat switch
210A is
open, allowing the microcontroller 225 to perform a leakage current
calculation.
10 A partial electrical schematic, partial block diagram for yet another
construction of
the control circuit 200B used for controlling the heating element 140 is shown
in Fig. 5.
Similar to the construction shown in Fig. 3, the control circuit 200B includes
the
microcontroller 205, a thermostat switch 210B, the voltage measurement circuit
220, and a
current measurement circuit 225B. However, for the construction of the control
circuit 200B
in Fig. 5, the arrangement and operation of the circuit 200B shown in Fig. 5
is slightly
different than the arrangement of the circuit 200 shown in Fig. 3. As shown in
Fig. 5, the
current measurement circuit 225B includes a current resistive shunt 500 that
is electrically
connected between a 12 VDC (or 12 VAC) power supply 505 and the thermostat
switch
210B. The thermostat switch 210B is controlled by the thermostat temperature
sensor and
switches between the 120 VAC (or 240 VAC) power source and the 12 VDC (or
12VAC)
power supply 505. The voltage measurement circuit 220 is electrically
connected in parallel
with the heating element to determine the state of the water heater 100. The
operation of the
control circuit 200B for Fig. 5 is somewhat similar to the control circuit 200
for Fig. 3.
However, unlike the control circuit 200 for Fig. 3, when the control circuit
200B moves to the
non-heating state, the thermostat switch 210B applies the voltage of the low-
voltage power
supply 505 to the heating element 140. TABLE 3 demonstrates a comparison
between a
heating element 140 initially having no apertures and the element 140 having
an aperture at
CA 02570601 2006-12-07
11
the edge of the element 140. As can be seen, TABLE 3 demonstrates a large
difference in
current between the degraded element and the good element during the non-
heating state.
[t3] TABLE 3- DIFFERENTIAL CURRENT MEASUREMENTS DURING
POWER "OFF" CONDITION (12 VDC)
ELEMENT ID Starting Current (mA) Current at 1 Hour (mA)
Good 0.0 mA 0.0 mA
Center Hole 18 mA 18 mA
When the temperature in the water heater 100 drops below a predetermined
threshold
the water heater 100 attempts to heat the water to a temperature greater than
the
predetermined threshold plus a dead band temperature by applying power to the
heating
element 140. The heating element 140 generates heat that can be transferred to
water
surrounding the heating element 140. Much of the heat energy produced by the
heating
element 140 can be dissipated by the water. Fig. 6A illustrates the
temperature of a heating
element 140 following application of power to the heating element 140 and
wherein the
heating element 140 is surrounded by water. The temperature of the heating
element 140
rises rapidly initially and then the temperature rise slows until the
temperature of the heating
element 140 remains relatively constant. The constant temperature maintained
by the heating
unit 140 can be below a temperature wherein the heating element 140 fails.
Should power be applied to the water heater 100 prior to the water heater 100
being
filled with water or should a malfunction occur in which the water in the
water heater 100 is
not at a level high enough to surround the heating element 140, applying power
to the heating
element 140 creates a condition known as "dry-fire." As shown in Fig. 6B,
during a dry-fire
condition the heating element 140 heats up and, because there is no water
surrounding the
heating element 140 to dissipate the heat, continues to heat up to a
temperature that causes
the heating element 140 to fail. Failure of the heating element 140 during a
dry-fire condition
can occur in only a matter of seconds. It is, therefore, desirable to detect a
dry-fire condition
quickly, before damage occurs to the heating element 140.
Fig. 7 illustrates a partial block diagram, partial schematic diagram of a
construction
of a fourth control circuit 600 that detects a dry-fire condition and prevents
power from being
applied to the heating element 140 when a dry-fire condition exists.
CA 02570601 2006-12-07
12
In some constructions, the control circuit 600 includes a relatively high-
voltage power
source (e.g., 120 VAC, 240 VAC, etc.) 201B, a heating element 140, a
relatively low voltage
power source (e.g., +12 VDC, 12 VAC, +24 VDC, etc.) 605, a current sensing
circuit 610, a
controller 205, a temperature sensing circuit 615, an alarm 620, a normally
open switch 625,
and a double-pole, double-throw relay 630
As shown in the construction of Fig. 7, the normally closed ("NC") contacts of
the
relay 630 are coupled to the high-voltage power source 201B through switch
625. The
normally open ("NO") contracts of the relay 630 are coupled to the low-voltage
power supply
605. The output contacts of the relay 630 are coupled to the heating element
140. When the
switch 625 is closed and power is not applied to the coil (indicated at 635)
of the relay 630,
the relay 630 remains in a state wherein the normally closed contacts remain
closed and high
voltage is applied to the heating element 140 enabling the heating element 140
to generate
heat. When power is applied to the coil 635 of the relay 630, the relay 630
closes the NO
contacts and +12VDC is applied to the heating element 140. The voltage of the
low-voltage
power supply 605 can be selected such that the heating element 140 would not
be harmed
from prolonged exposure in a dry-fire condition.
In this construction, the controller 205 is coupled to the temperature sensor
615 and
the current sensor 610, and receives indications of the temperature in the
water heater 100
and the current drawn from the low-voltage power supply 605 from each sensor
respectively.
The controller 205 is also coupled to the alarm 620, the switch 625, and the
relay 630.
Fig. 8 represents a flow chart of an embodiment of the operation of the
control circuit
600 for detecting a dry-fire condition. When the water heater 100 is powered
on (block 700),
the controller 205 applies power (block 705) to the coil 635 of the relay 630.
This opens the
NC contacts of the relay 630 and closes the NO contacts of the relay 630.
Closing the NO
contacts of the relay 630 couples the low-voltage power supply 605 to the
heating element
140.
In some constructions, the controller reads (block 710), from the current
sensor 610, a
first current being supplied by the low-voltage power supply 605 to the
heating element 140.
Other constructions of the dry-fire detection system 600 can read other
electrical
characteristics (e.g., voltage via a voltage sensor) of the circuit created by
the low-voltage
power supply 605 and the heating element 140.
CA 02570601 2006-12-07
13
Next, the controller 205 closes (block 715) the switch 625 and couples the
high-
voltage power supply 201B to the NC contacts of the relay 630. The controller
205 also
removes (block 720) power from the coil 635 of the relay 630. This opens the
NO contracts
of the relay 630 which decouples the low-voltage power supply 605 from the
heating element
140 and closes the NC contacts of the relay 630 coupling the high-voltage
power supply
201B to the heating element 140. Coupling the high-voltage power supply 201B
to the
heating element 140 causes the heating element 140 to heat up. The controller
205 delays
(block 725) for a first time period (e.g., three seconds).
Following the delay (block 725), the controller 205 applies (block 730) power
to the
coi1635 of the relay which opens the NC contacts of the relay 635 and
decouples the high-
voltage power supply 201B from the heating element 140. The first time period
can be a
length of time that allows the heating element 140 to heat up but can be short
enough to
ensure the heating element 140 does not achieve a temperature at which it can
fail if a dry-
fire condition were to exist. Applying power to the coil 635 of the relay 630
also enables the
NO contacts of the relay 630 to close and couples the low-voltage power supply
605 to the
heating element 140.
The controller 205 delays (block 735) for a second time period (e.g., ten
seconds).
During the delay, the heating element 140 begins to cool. The rate at which
the heating
element 140 cools can be faster if the heating element 140 is surrounded by
water. The
controller 205 reads (block 740), from the current sensor 610, a second
current being supplied
by the low-voltage power supply 605 to the heating element 140. The controller
205
compares (block 745) the first sensed current to the second sensed current and
determines if
the second sensed current is greater than the first sensed current by more
than a threshold. If
the second sensed current is not greater than the first sensed current by more
than the
threshold, the controller 205 determines that a dry-fire condition does not
exist and continues
(block 750) normal operation.
If the second sensed current is greater than the first sensed current by more
than the
threshold, the controller 205 determines that a potential dry-fire condition
exists and opens
(block 755) the switch 625. Opening the switch 625 ensures that the high-
voltage power
supply 201B is decoupled from the heating element 140 and prevents the heating
element
from being damaged. The controller 205 then signals (block 760) an alarm to
inform an
operator of the potential dry-fire condition. In alternative to block 760, the
controller 205 can
CA 02570601 2006-12-07
14
perform a second test for a potential dry-fire condition after a time delay to
verify the
accuracy of the first test (e.g., in the situation the tank was in the process
of filling). If the
second test results in the determination of a potential dry-fire condition,
the controller may
then issue the alarm.
Figs. 9A and 9B illustrate the resistance of the heating element 140 at
different points
during the dry-fire detection process for a wet-fire condition (Fig. 9A) and a
dry-fire
condition (Fig. 9B). At block 720, the high-voltage power is applied to the
heating element
140. The temperature of the heating element 140 rises which increases the
resistance of the
heating element 140. After a delay (block 725) the high-voltage power is
disconnected from
the heating element 140 (block 730). In a wet-fire condition, Fig. 9A, the
heating element
140 cools relatively rapidly causing the resistance of the heating element 140
to drop
relatively rapidly to near the level of resistance of the heating element 140
prior to originally
applying the high voltage as shown at block 740.
Referring to Fig. 9B, the resistance of the heating element 140 in a dry-fire
condition
is similar to the resistance of the heating element 140 in a wet-fire
condition (Fig. 9A) for
blocks 720 to 730. Following disconnection of the high-voltage power at block
730 the
heating element 140, in a dry-fire condition, retains more heat and has a
higher resistance for
a relatively longer period of time. Testing an electrical characteristic of a
circuit including
the heating element 140 as explained at block 740 results in, when a dry-fire
condition exists,
a relatively large differential between the first reading at block 710 and the
second reading at
block 740.
The control circuit 600 can execute the dry-fire detection process once, when
power is
first applied to the water heater 100, each time the temperature sensing
circuit 615 indicates
that heat is needed, or at some other interval. Other constructions of the
control circuit 600
can execute the dry-fire detection process at other times where it is
determined that the
potential for a dry-fire condition exists (e.g., following a period of time
wherein the heating
element 140 has been coupled to the high power signal).
Thus, the invention provides, among other things, a new and useful water
heater and
method of controlling a water heater. Various features and advantages of the
invention are
set forth in the following claims.
