Blower with integrated low current activated relay combination for use in a power vent gas water heater
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Solution Overview
Problem
Existing water heater appliances face potential hazards due to excessive current flow through the gas valve control printed circuit board, which can lead to arc tracking failures, risking damage to the circuit board.
Innovation Solution
A power circuit for the blower motor is designed to bypass the gas valve control printed circuit board using a relay, with a control signal communicated via a signal line, allowing the blower current to bypass the gas valve controller, and incorporating a fuse to protect the circuit board from high currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the blower is controlled directly through the gas valve control printed circuit board, then the control circuit is simple, but excessive current flow causes arc tracking failures and damages the circuit board
Solution Approach 1:
A relay is introduced as an intermediary component between the gas valve control printed circuit board and the blower motor. The relay's coil is controlled by the circuit board through a low-current signal line, while its contacts handle the high-current blower power circuit. This intermediary allows the control board to operate the blower without direct exposure to excessive current, preventing arc tracking failures and circuit board damage.
2Ease of operation
If high current flows through the gas valve control printed circuit board to operate the blower, then direct control is achieved, but arc tracking failures occur risking damage to the circuit board
Solution Approach 1:
The relay serves as a mediator that enables indirect control of the blower. The gas valve control printed circuit board sends a low-current control signal to the relay coil, which then switches the high-current power circuit to the blower motor. This indirect control mechanism maintains the ease of operation through automated control while eliminating the harmful arc tracking failures that would occur with direct high-current switching on the circuit board.
Solution Approach 2:
The control system is segmented into two separate circuits: a low-current control circuit that operates the relay coil from the printed circuit board, and a high-current power circuit that operates the blower motor through the relay contacts. This segmentation isolates the vulnerable circuit board from harmful high currents and arcing, while maintaining full control capability over the blower operation.
3Reliability
If a relay is added to bypass the circuit board for blower control, then circuit board protection is improved, but device complexity increases
Solution Approach 1:
While the relay does add a component to the system, it provides substantial protection to the circuit board by preventing arc tracking failures. The relay's compact design and integration into the existing power circuit minimize the increase in overall device complexity. The benefit of circuit board reliability and protection from catastrophic failure far outweighs the addition of a single relay component.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces the likelihood of failures by preventing high current from flowing through the gas valve control printed circuit board, ensuring the blower operates effectively without risking damage to the circuit board.
Implementation Method 1
a relay, wherein the relay is located off the gas valve controller printed circuit board, the relay having a coil and a set of contacts
Data Source
AI summary
A power circuit configuration for a water heater appliance is provided. The water heater appliance includes a tank, a gas valve, a blower, and a power circuit. The power circuit includes a gas valve controller on a gas valve control printed circuit board. The power circuit includes a first power conductor that is coupled to a blower motor of the water heater appliance. The power circuit also includes a second power conductor that is coupled to the blower motor of the water heater appliance through a relay such that the power circuit for the blower motor bypasses the gas valve control printed circuit board.