Method for detecting a non-closing water heater main gas valve

1. A water heater system comprising:

a water tank;

a main gas burner disposed proximate the water tank and configured to heat water within the water tank;

a main gas valve configured to control a flow of gas to the main gas burner;

a pilot gas burner disposed proximate the main gas burner such that the pilot gas burner is positioned to ignite the main gas burner;

a water temperature sensor thermally coupled to water within the water tank, the water temperature sensor outputting a water temperature signal representative of a sensed water temperature within the water tank;

a thermopile having a first portion positioned proximate a pilot flame produced by the pilot gas burner and a second portion positioned proximate a main burner flame produced by the main gas burner, the thermopile outputting a thermopile signal that is representative of a temperature difference between the first portion of the thermopile and the second portion;

a controller operably coupled with the main gas valve and configured to receive the thermopile signal from the thermopile and the water temperature signal from the water temperature sensor, the controller configured to cycle the main gas burner ON when the sensed water temperature falls to a temperature set point minus a dead band, and to cycle the main gas burner OFF when the sensed water temperature reaches the temperature set point;

wherein after the sensed water temperature reaches the temperature set point, and the controller cycles the main gas burner OFF, the controller is configured to monitor for a possible main gas valve non-closure condition where: (1) the sensed water temperature continues to rise; and (2) the thermopile signal from the thermopile reaches a stable state, and when the possible main gas valve non-closure condition is detected, the controller is configured to toggle the main gas valve ON and determine whether the thermopile signal from the thermopile changes from the stable state or not by at least a predetermined amount.

2. The water heater system of claim 1 , wherein:

when the thermopile signal from the thermopile changes from the stable state by at least the predetermined amount, the controller is configured to: (1) lower the temperature set point; (2) increase a temperature cutoff temperature (TCO) in which the controller shuts down the main gas valve after the sensed water temperature reaches the TCO; and/or (3) increase the time that the sensed water temperature must remain above the TCO before the controller shuts down the main gas valve; and

when the thermopile signal from the thermopile does not change from the stable state by the predetermined amount, the controller is configured to shut down the main gas valve.

3. The water heater system of claim 1 , wherein when the possible main gas valve non-closure condition is detected, the controller is configured to toggle the main gas valve ON for a predetermined period of time before toggling the main gas valve OFF.

4. The water heater system of claim 1 , wherein when the possible main gas valve non-closure condition is detected, the controller is configured to toggle the main gas valve ON for a predetermined period of time regardless of whether there is a call for heat before toggling the main gas valve OFF.

5. The water heater system of claim 1 , wherein the pilot gas burner comprises an intermittent pilot, and wherein the intermittent pilot is turned ON when the controller is monitoring for the possible main gas valve non-closure condition.

6. The water heater system of claim 1 , wherein the controller is further configured to:

store a steady state ON value for the thermopile signal at a time when the main gas burner is ON for an extended time;

store a steady state OFF value for the thermopile signal at a time when the main gas burner is OFF for an extended time with only the pilot gas burner ON;

use the steady state OFF value and the steady state ON value to interpolate and/or extrapolate to a current position of the main gas valve based on the current the thermopile signal.

7. The water heater system of claim 6 , wherein the controller is further configured to periodically update the steady state ON value and the steady state OFF value in order to compensate for water heater performance changes over time.

8. The water heater system of claim 1 , wherein the controller is further configured to issue an alert when the possible main gas valve non-closure condition is detected.

9. A heating assembly for use with a water heater having a water tank, the heating assembly comprising:

a main gas burner configured to heat water within the water tank;

a main gas valve configured to control a flow of gas to the main gas burner;

a pilot gas burner disposed proximate the main gas burner such that the pilot gas burner is positioned to ignite the main gas burner;

a water temperature sensor configured to be thermally coupled to water within the water tank, the water temperature sensor outputting a water temperature signal representative of a sensed water temperature within the water tank;

a thermopile having a first portion positioned proximate a pilot flame produced by the pilot gas burner and a second portion positioned proximate a main burner flame produced by the main gas burner, the thermopile outputting a thermopile signal that is representative of a temperature difference between the first portion of the thermopile and the second portion;

a controller operably coupled with the main gas valve and configured to receive the thermopile signal from the thermopile and the water temperature signal from the water temperature sensor, the controller configured to cycle the main gas burner ON when the sensed water temperature falls to a temperature set point minus a dead band, and to cycle the main gas burner OFF when the sensed water temperature reaches the temperature set point;

wherein after the sensed water temperature reaches the temperature set point, and the controller cycles the main gas burner OFF, the controller is configured to monitor for a possible main gas valve non-closure condition where: (1) the sensed water temperature continues to rise; and (2) the thermopile signal from the thermopile reaches a stable state, and when the possible main gas valve non-closure condition is detected, the controller is configured to toggle the main gas valve ON and determine whether the thermopile signal from the thermopile changes from the stable state or not by at least a predetermined amount.

10. The heating assembly of claim 9 , wherein:

when the thermopile signal from the thermopile changes from the stable state by the predetermined amount, the controller is configured to: (1) lower the temperature set point; (2) increase a temperature cutoff temperature (TCO) in which the controller shuts down the main gas valve after the sensed water temperature reaches the TCO; and/or (3) increase the time that the sensed water temperature must remain above the TCO before the controller shuts down the main gas valve; and

when the thermopile signal from the thermopile does not change from the stable state by the predetermined amount, the controller is configured to shut down the main gas valve.

11. The heating assembly of claim 9 , wherein when the possible main gas valve non-closure condition is detected, the controller is configured to toggle the main gas valve ON for a predetermined period of time before toggling the main gas valve OFF.

12. The heating assembly of claim 9 , wherein when the possible main gas valve non-closure condition is detected, the controller is configured to toggle the main gas valve ON for a predetermined period of time regardless of whether there is a call for heat before toggling the main gas valve OFF.

13. The heating assembly of claim 9 , wherein the pilot gas burner comprises an intermittent pilot, and wherein the intermittent pilot is turned ON when the controller is monitoring for the possible main gas valve non-closure condition.

14. The heating assembly of claim 9 , wherein the controller is further configured to:

store a steady state ON value for the thermopile signal at a time when the main gas burner is ON for an extended time;

store a steady state OFF value for the thermopile signal at a time when the main gas burner is OFF for an extended time with only the pilot gas burner ON;

use the steady state OFF value and the steady state ON value to interpolate and/or extrapolate to a current position of the main gas valve based on the current the thermopile signal.

15. The heating assembly of claim 14 , wherein the controller is further configured to periodically update the steady state ON value and the steady state OFF value in order to compensate for water heater performance changes over time.

16. The heating assembly of claim 9 , wherein the controller is further configured to issue an alert when the possible main gas valve non-closure condition is detected.

17. A control module for a heating assembly of a water heater with a water tank, wherein the heating assembly includes a main gas burner configured to heat water within the water tank, a main gas valve configured to control a flow of gas to the main gas burner, a pilot gas burner disposed proximate the main gas burner such that the pilot gas burner is positioned to ignite the main gas burner, a water temperature sensor configured to be thermally coupled to water within the water tank, the water temperature sensor outputting a water temperature signal representative of a sensed water temperature within the water tank, and a thermopile having a first portion positioned proximate a pilot flame produced by the pilot gas burner and a second portion positioned proximate a main burner flame produced by the main gas burner, the thermopile outputting a thermopile signal that is representative of a temperature difference between the first portion of the thermopile and the second portion, the control module comprising:

an output configured to provide control signals to the main gas valve;

a first input configured to receive the thermopile signal from the thermopile;

a second input configured to receive the water temperature signal from the water temperature sensor;

a controller operatively coupled to the output, the first input and the second input, the controller configured to cycle the main gas burner ON via the output when the sensed water temperature falls to a temperature set point minus a dead band, and to cycle the main gas burner OFF via the output when the sensed water temperature reaches the temperature set point;

wherein after the sensed water temperature reaches the temperature set point, and the controller cycles the main gas burner OFF, the controller is configured to monitor for a possible main gas valve non-closure condition where: (1) the sensed water temperature continues to rise; and (2) the thermopile signal from the thermopile reaches a stable state; and

when the controller detects the possible main gas valve non-closure condition, the controller is configured to toggle the main gas valve ON via the output and determine whether the thermopile signal from the thermopile changes from the stable state or not by at least a predetermined amount.

18. The control module of claim 17 , wherein:

when the thermopile signal from the thermopile changes from the stable state by the predetermined amount, the controller is configured to: (1) lower the temperature set point; (2) increase a temperature cutoff temperature (TCO) in which the controller shuts down the main gas valve after the sensed water temperature reaches the TCO; and/or (3) increase the time that the sensed water temperature must remain above the TCO before the controller shuts down the main gas valve; and

when the thermopile signal from the thermopile does not change from the stable state by the predetermined amount, the controller is configured to shut down the main gas valve.

19. The control module of claim 17 , wherein when the possible main gas valve non-closure condition is detected, the controller is configured to toggle the main gas valve ON for a predetermined period of time before toggling the main gas valve OFF.

20. The control module of claim 17 , wherein when the possible main gas valve non-closure condition is detected, the controller is configured to toggle the main gas valve ON for a predetermined period of time regardless of whether there is a call for heat before toggling the main gas valve OFF.