Method of manufacturing a water heater with a leak detection system

1. A method of manufacturing and installing a water heater, the method comprising:

manufacturing an original equipment manufacturer water heater including:

a water tank including an inlet and an outlet;

means for heating water in the water tank;

a base pan at least partially supporting the water tank such that water leaked from the water tank collects in the base pan; and

a sensor positioned in the base pan, the sensor being configured to detect water, the sensor being battery-powered; and

installing the water heater by:

connecting a source of cold water to the water tank inlet;

installing a valve closable to prevent water from entering the water tank inlet from the source of cold water; and

connecting the sensor to the valve such that the valve closes when the sensor detects water and such that the valve closes in a low battery condition of the sensor.

2. The method of claim 1 , wherein the means for heating water includes a combustion chamber, a flue extending from the combustion chamber through the water tank, and a gas burner positioned in the combustion chamber.

3. The method of claim 2 , wherein manufacturing an original equipment manufacturer water heater further includes providing a flame arrestor such that combustion air flows through the flame arrestor before entering the combustion chamber.

4. The method of claim 1 , wherein manufacturing an original equipment manufacturer water heater further includes providing a jacket surrounding the water tank such that water leaked from the water tank flows between the water tank and the jacket and into the base pan.

5. The method of claim 4 , wherein manufacturing an original equipment manufacturer water heater further includes providing spacers between the water tank and the base pan to facilitate flow of leaked water into the base pan.

6. The method of claim 1 , wherein manufacturing an original equipment manufacturer water heater further includes providing an overflow port such that water collects in the base pan until reaching the overflow port, and installing the water heater includes routing the collected water from the overflow port to a suitable location.

7. The method of claim 1 , wherein manufacturing an original equipment manufacturer water heater further includes providing an override device that allows the valve to be open when the sensor detects water.

8. The method of claim 1 , wherein manufacturing an original equipment manufacturer water heater further includes providing a device that emits a visual and/or an audible signal upon detection of water or upon detection of the low battery condition.

9. The method of claim 1 , wherein manufacturing an original equipment manufacturer water heater includes providing means for heating water including a combustion chamber and a flue, and a sump for collecting condensation from the flue, the sump inhibiting condensation from flowing into the base pan.

10. The method of claim 1 , wherein manufacturing an original equipment manufacturer water heater includes providing means for heating water including a combustion chamber, and a base pan including a bottom wall and a side wall extending from the bottom wall, the side wall defining a water outlet port and an air inlet opening located above the outlet port, air flowing through the inlet opening and into the combustion chamber, leaked water flowing through the outlet port, and wherein the sensor is positioned in the base pan below the outlet port.

11. The method of claim 1 , wherein manufacturing an original equipment manufacturer water heater further includes providing an override device that allows the valve to be open in a low battery condition of the sensor.

12. A method of manufacturing and installing a water heater, the method comprising:

manufacturing an original equipment manufacturer water heater including:

a water tank including an inlet and an outlet;

means including a combustion chamber for heating water in the water tank, the combustion chamber having a lower surface defining an aperture;

a base pan at least partially supporting the water tank such that water leaked from the water tank collects in the base pan, the base pan including a bottom wall and a side wall extending from the bottom wall, the side wall defining a water outlet port and an air inlet opening, the inlet opening being located above the outlet port and below the aperture, air flowing through the inlet opening, through the aperture and into the combustion chamber, leaked water flowing through the outlet port; and

a sensor positioned in the base pan below the outlet port, the sensor being configured to detect water; and

installing the water heater by:

connecting a source of cold water to the water tank inlet;

installing a valve closable to prevent water from entering the water tank inlet from the source of cold water; and

connecting the sensor to the valve such that the valve closes when the sensor detects water.

13. The method of claim 12 , wherein manufacturing an original equipment manufacturer water heater further includes providing a jacket surrounding the water tank such that water leaked from the water tank flows between the water tank and the jacket and into the base pan.

14. The method of claim 13 , wherein manufacturing an original equipment manufacturer water heater further includes providing spacers between the water tank and the base pan to facilitate flow of leaked water into the base pan.

15. The method of claim 12 , wherein manufacturing an original equipment manufacturer water heater further includes providing a screen covering the inlet opening.

16. The method of claim 12 , wherein the means for heating water includes a flue extending from the combustion chamber though the water tank, and a gas burner positioned in the combustion chamber

17. The method of claim 12 , wherein manufacturing an original equipment manufacturer water heater further includes providing a flame arrestor supported in the aperture such that combustion air flows through the inlet opening and through the flame arrestor before entering the combustion chamber.

18. The method of claim 12 , wherein installing the water heater includes routing the collected water from the outlet port to a suitable location.

19. The method of claim 12 , wherein manufacturing an original equipment manufacturer water beater further includes providing an override device that allows the valve to be open when the sensor detects water.

20. The method of claim 12 , wherein the sensor is battery-powered, and wherein installing the water heater includes connecting the sensor to the valve such that the valve closes when the sensor detects water and such that the valve closes in a low battery condition of the sensor.