Acidic exhaust condensation leaking into the unit interior due to a gap between the burner and exhaust pipe is rapidly corroding the water heater, causing GFCI trips and posing a safety hazard.

Workarounds Described

• disconnected smart control unit to stop leak sensor from tripping
• relies on plumber inspection to identify exhaust gap after visible corrosion
• using GFCI tripping as makeshift alert despite safety hazard

Implied Software Gaps

• Predictive monitoring hardware and software that detects exhaust leaks before corrosion damage
• Visual inspection guidance tool for plumbers to check burner-to-exhaust gap
• Automated alert system for homeowners when corrosion risk exceeds threshold

CorroSense Prevent

CorroSense Prevent is a smart monitoring system for tankless water heaters that detects exhaust leaks and acidic condensation before they cause corrosion. It uses humidity and pH sensors near the exhaust to alert homeowners and plumbers of dangerous conditions, and integrates with a maintenance platform to schedule repairs. Unlike standard leak sensors, it predicts corrosion risk.