GB2481319A

GB2481319A - Condensing boiler overflow device

Info

Publication number: GB2481319A
Application number: GB1110181.3A
Authority: GB
Inventors: Adrian Michael Morley
Original assignee: MORLEY LEWIS JAMES
Current assignee: MORLEY LEWIS JAMES
Priority date: 2010-06-17
Filing date: 2011-06-16
Publication date: 2011-12-21
Also published as: GB201110181D0; GB2481319A8; GB201010118D0

Abstract

A device 1 for a condensing boiler comprises a boiler port 30 configured to receive fluid flow from a condensing boiler, an outlet port 50 configured to expel fluid from the device during normal operation, and an overflow port 13 situated at a height above the outlet port. The boiler port can be coupled to a condensate drain pipe 2 of the condensing boiler, and the outlet port can be coupled to an outlet drain pipe 6. The outlet port is configured to prevent fluid flow into the device through the outlet port. Preferably, the outlet port comprises a one-way valve, such as a ball float valve 151. The device may further comprise a main chamber 104 and an overflow chamber 108, where the main chamber is coupled to the overflow chamber by the overflow port 113. The device may include an electric circuit in communication with a liquid level sensor, where the electric circuit is configured to produce a warning signal which may be audible and/or visual, or may be sent through a telecommunications network to a geographically remote location by using a modem. Preferably, the liquid level sensor comprises a float switch 114 or a light sensitive switch.

Description

A DEVICE FOR A CONDENSING BOILER

The present invention relates to the field of devices for condensing boilers, in particular, although not exclusively, to a device that can be coupled to a condensate drain pipe of a boiler.

GB 2,290,371 and GB 2,354,313 disclose boiler condensate traps employing a siphon connected to an external drain. When the condensate is at a critical level the siphon automatically starts to discharge water through the drain. The trap releases condensate in accumulated quantities to reduce possibility of the oufflow freezing. If the drain is blocked, the level rises to block a pressure-sensing point to restrict boiler operation, and a bypass drains water from the trap. Freezing of condensate in the drainpipe or the accumulation of other detritus can cause blocking of the drain pipe.

These devices only turn off the boiler when the main outlet pipe is blocked and offer no protection at all for floodwater backing up into the boiler. In addition, if these devices do not turn the boiler completely off when the outlet is blocked, the condensate formed will back up into the boiler. If the boiler is turned off in freezing weather further damage occurs to the boiler or system due to liquid freezing within the boiler and system.

According to a first aspect of the invention, there is provided a device for a condensing boiler, the device comprising: a boiler port configured to receive fluid flow from the condensing boiler; an outlet port configured to expel fluid from the device during normal operation; and an overflow port situated at a height above the outlet port when the device is in use, wherein the boiler port is couplable with a condensate drain pipe of the condensing boiler, the outlet port is couplable with an outlet drain pipe, and the outlet port is configured to prevent fluid flow into the device through the outlet port.

The outlet port being configured to prevent fluid flow into the device through the outlet port prevents the build up of fluid within the chamber and it backing up into the chamber from the drain pipe. This may ensure that storm water, for example, does not back up

I

into the boiler. The retention of water within the condensing boiler has been known to lead to the failure of boilers.

The outlet port provides an avenue for excess water to be released from the device in the event that the outlet port becomes blocked. This can also prevent the backing up of water in the device and into the condensing boiler. The device can enable the boiler to still be functional if the outlet drain pipe is blocked.

The use of the terms height', above', below', higher', lower', top', or bottom' is with reference to the orientation of the device when it is in use.

The outlet port may be a circumferential section of the outlet drain pipe.

The outlet port may comprise a one way valve. In some embodiments, the one way valve may comprise a pump.

The one-way valve may comprise a ball float valve. The outlet port may comprise an opening. The ball float valve may be configured to occlude the opening when water would otherwise flow into the main chamber through the outlet port. The ball float can act as a non-return valve preventing any flood or storm water being pushed back into the boiler.

The device may further comprise a main chamber and an overflow chamber. The boiler port, outlet port and overflow port may comprise openings into the main chamber. The main chamber may be coupled to the overflow chamber by the overflow port. The overflow chamber may comprise a second outlet port, which may be situated below the height of the overflow port when in use.

The addition of an overflow chamber may enable the device to channel overflow liquid and/or act as a coupling point for an overflow pipe. An overflow pipe may be directly connected to the overflow port in some embodiments. In other embodiments, no overflow pipe may be present and this can be advantageous as there is no pipe associated with the overflow chamber that can become blocked.

The device may further comprise a liquid trap configured to contain a liquid for providing a barrier to gaseous exchange between the main chamber and the overflow chamber.

The barrier may separate gasses in the main chamber and gasses in the overflow chamber. Separation of gasses within the main chamber from that in the overflow chamber may prevent the release of exhaust gases present within the condensate fluid or foul odours from the outlet drain pipe via the overflow port. Additionally, the separation of gasses within the main chamber from that in the overflow chamber may prevent cold air blowing in to the main chamber via the overflow port and freezing the condensate liquid within the main chamber. Freezing of this liquid may lead to the malfunctioning of the boiler.

The device may further comprise a weir extending upwardly from an internal bottom surface of the device. The overflow port may comprise an aperture above the weir. The weir may define a boundary of the main chamber.

The device may further comprise a lip extending upwardly from an internal bottom surface of the device. An aperture above the lip may define an opening into the overflow chamber. The lip may define a boundary of the overflow chamber.

The liquid trap may be a partially enclosed volume defined by a bottom surface, a front surface, a back surface, the weir on one side, and the lip on the other side. The water trap may have an opening at its top.

The lip may be shorter than the weir. In this way liquid flows from the main chamber to the liquid trap to the overflow chamber as liquid is added to the main chamber when the outlet port is blocked.

The device may further comprise a cold air baffle extending downwardly from an internal top surface of the device. The cold air baffle may be located above the liquid trap. The cold air baffle may be configured to condense gas or vapour and provide the condensed gas or vapour to the liquid trap. The cold air baffle may extend into the liquid trap.

In some examples, the cold air baffle may be used to generate liquid condensate with which to fill the liquid trap. When filled with liquid, the liquid in the liquid trap can extend to a lower portion of the cold air baffle. Liquid in the barrier section may be separated into two regions, one on either side of the cold air baffle. In this example, the liquid on one side of the cold air baffle is in contact with the air from the main chamber and the liquid on the other side of the cold air baffle is in contact with air from the overflow chamber. The body of liquid within the liquid trap may effectively isolate the air within the main chamber from the air in the overflow chamber.

The overflow port may comprise an opening between the cold air baffle and a wall of the liquid trap.

The device may further comprise a liquid level sensor. The device may further comprise an electric circuit in communication with the liquid level sensor. The electric circuit may be configured to produce a warning indicator (also referred to as a warning signal) when the liquid level sensor determines that a level of liquid is present within the device. The liquid level sensor may sense the liquid level in the main chamber and/or overflow chamber. The warning indicator can alert an owner or occupier of a property containing the condensing boiler that the outlet drain pipe has become blocked. It will be appreciated that prompt unblocking of the drain pipe can allow the system to return to normal operation more quickly than might otherwise be the case.

The warning signal may be a visible indicator (or signal), such as an LED or neon light, and/or an audible indicator. The visual indicator and audible indicator may operate from a 240 V, 50 Hz AC power supply.

The level of liquid may be the height of the overflow port above the outlet port when the device is in use.

The liquid level sensor may comprise a float switch. Alternatively, the liquid level sensor may be provided by a light source and a light sensitive switch. The light source may be an infrared light source. The light source and a light sensitive switch provide a way of detecting the water level which dispenses with the possible complications that may arise from having moving parts within the system.

The electric circuit may comprise a modem. The modem may be configured to send the warning indicator to a receiver at a geographically remote location. The electric circuit may be configured to communicate with a burglar alarm system or a fire alarm system.

The electric circuit may be configured to communicate with a remote sensor. The remote sensor may be, for example: a carbon monoxide sensor, a low temperature sensor, a smoke sensor, or a flood level sensor.

The device may include a switch configured to deactivate the warning indicator. This can be advantageous as a user can deactivate an audio and/or visual alarm when they know about the problem and have made arrangements to have it rectified.

The device may further comprise a water-proof chamber. The electric circuit may be at least partially situated within the water-proof chamber. The water-proof chamber may also be referred to as a dry chamber. The water-proof chamber may be detachable from the device. The water-proof chamber may be installed remotely from the main and or overflow chambers. In this way the water-proof chamber may be installed as a warning device remote from the wet chambers of the device.

The water-proof chamber can be mounted inside or outside of the main chamber (which may also be referred to as a water-proof float chamber).

The device may comprise a main chamber and an outlet chamber. The boiler port, outlet port and overflow port may be directly coupled to the main chamber. The outlet port may couple the outlet chamber to the main chamber. The outlet chamber may be couplable with the outlet pipe.

The liquid level sensor may be situated within the main chamber. The electric circuit may be configured to produce a warning indicator when the liquid level sensor determines that a level of liquid is present ri the outlet chamber. As an alternative, the liquid level sensor may be configured to detect if water is present in the main chamber.

As a further alternative, the liquid level sensor may be configured to detect if water is present in the main chamber at a level below the height of the overflow port. As a further alternative, the liquid level sensor may be configured to detect if water is present in the outlet chamber proximal to the outlet port. The liquid level sensor may be configured to detect if a presence of the amount of water within the outlet chamber is preventing the flow of water from the main chamber to the outlet chamber via the outlet port.

According to a further aspect of the invention, there is provided a condenser boiler system comprising any device as described herein.

According to a further aspect of the invention, there is provided a method of servicing a condensing boiler. The method comprises coupling a condensate drain pipe of the condensing boiler to the boiler port of any device described herein and coupling an outlet drain pipe to the outlet port of the device.

A description is now given, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a schematic view of an embodiment of the present invention; Figures 2a to 2j show a number of views of a further alternative embodiment of the present invention; Figure 3 shows a cross section of an alternative embodiment of the present invention; and Figure 4 shows the exterior casing of the embodiment of the present invention illustrated in Figure 3.

Embodiments of the present invention relate to a device for preventing condensate accumulating in, and causing damage to, a condenser boiler in the event of the condensate drain pipe becoming blocked.

Embodiments of the invention can prevent or reduce condensate from accumulating in, and causing damage to, a condenser boiler in the event of the condensate drainpipe becoming blocked. Also, embodiments can prevent or reduce water from another source, for example rain water, backing up a condensate drain pipe and into the boiler.

Furthermore, significant damage to a property by a heating system can be reduced or prevented by enabling prompt action to be taken in response to a boiler malfunction. For example, the boiler can still function when a problem with the drainage from the boiler occurs, and this can reduce the likelihood that a central heating system will freeze up and cause damage to the property. At least some of these advantages can be particularly significant for a vacant property.

Figure 1 shows a schematic view of an embodiment of the present invention. The device I comprises a boiler port 30 configured to receive fluid flow from a condensing boiler (not shown), an outlet port 50 configured to expel fluid from the device during normal operation. The outlet port 50 is also configured to prevent fluid flow into the device through the outlet port. For example, the outlet port 50 may include a one way valve. The device I also has an overflow port 13 situated at a height above the outlet port 50 when the device is in use. The boiler port 30 is couplable with a condensate drain pipe 2 of the condensing boiler. The outlet port 50 is couplable with an outlet drain pipe 6, which may also be referred to as a main outlet pipe or a condensing drain pipe.

When in-situ, fluid is fed into the device I from the condensing boiler through the boiler port 30. The delivery of this fluid can be via the condensate drain pipe 2, which may also be referred to as an inlet pipe when described in relation to the device 1. The fluid comprises liquid, which is pre-dominantly water, and can include exhaust gases from the boiler. In normal operating conditions, liquid from this fluid flows out of the outlet port 50.

The outlet port 50 of the device I is shown coupled to the outlet drain pipe 6 in Figure 1.

In this way condensate liquid is expelled from the device I through the outlet drain pipe.

In the event that the outlet drain pipe becomes blocked, the liquid may back up in the condensing drain pipe 6 and prevent the expulsion of liquid from the device through the outlet port 50. Therefore, liquid will collect within the device I as it continues to be fed into the device I from the condensing boiler through the boiler port 30. However, when the liquid reaches the height of the overflow port 13 any further liquid introduced into the device from the condensing boiler will flow out of the device 1 through the overflow port 13. The alternative flow path through the overflow port 13 prevents liquid backing up through the boiler port 30 into the condensate drain pipe of the boiler. The overflow port 13 can be considered as providing a temporary solution to the problem of a blocked condensate drain pipe and reduces the risk of consequential damage being inflicted on the boiler, due to the backing up of condensate liquid within the boiler. The condensate liquid may be corrosive to the internal workings of the boiler and so an accumulation of the liquid within the boiler can lead to failure of the boiler. Failure of the boiler can further lead to damage of the wider heating system, which may freeze during inclement weather if the boiler is damaged by condensate accumulation.

Figures 2a to 2j show a number of cross sectional views of a device 100 according to an alternative embodiment of the present invention.

The side view in Figure 2a shows a side view of an outer housing of the device 100. The device 100 is coupled by a boiler port 130 with an inlet pipe 102 (also referred to as a condensate drain pipe 102), at the top of a body 101 of the device 100. The device 100 is also coupled to an overflow pipe 110 by a second outlet port 140 situated at the bottom of the body 101 of the device 100. The overflow pipe 110 may be entirely optional; in some examples, the second outlet port 140 may simply be an opening that has no pipe connected to it. In this way, there is no pipe associated with the overflow chamber that can become frozen or otherwise blocked.

The overflow pipe 110, as it is shown in Figure 2a, obscures a view of a first outlet port situated at the bottom of the body 101 of the device 100. The first outlet port 150 may be coupled to a main outlet pipe (not shown).

The first outlet port 150 can be seen in Figure 2b. Figure 2b shows the internal components of the device 100 when viewed as a cross section taken through the inlet pipe 110, orthogonally to the side view shown in Figure 2a. Figure 2b shows the device through cross-section F-F shown in Figure 2a. The body 101 of the device 100 comprises a main chamber 104 and an overflow chamber 108. The main chamber 104 and overflow chamber 108 are connected by an overflow port 113. The boiler port 130 opens into the top of the main chamber 104 and the first outlet port 150 is an opening in the bottom of the main chamber 104. The second outlet port 140 is an opening in the overflow chamber 108. The second outlet port 140 is positioned so as to be below the height of the overflow port 113 in this example.

Fluid is fed into the main chamber 104 from a condensing boiler through the boiler port 130. In normal conditions, where there is no blockage in the outlet pipe 110, liquid will flow out of the main chamber 104 through the first outlet port 150. The first outlet port comprises a one way valve, which is provided as a ball float valve 151 in this embodiment. The one way valve prevents water from passing back up the main outlet pipe (which may also be referred to as an outlet drain pipe) into the main chamber 104 in the event of storm or flood water forcing liquid into the main outlet pipe, or if the outlet pipe becomes blocked. In these conditions liquid from the boiler will fill up in the main chamber 104 as the ball float valve 151 occludes the outlet port 150, preventing both the flow of liquid into the main chamber from the outlet pipe 110 and the drainage of liquid from the main chamber 104 into the outlet pipe 110.

The overflow port 113 that couples the main chamber 104 to the overflow chamber 108 is provided as an aperture, or opening, above a weir 112 in the embodiment shown in Figure 2b. The bottom of the aperture (or alternatively, the top of the weir 112) is positioned above a height of the outlet port 150 such that liquid only flows through the aperture when the outlet port 150 cannot drain liquid in the main chamber 104 quickly enough. When the outlet port 150 is blocked, the liquid level in the main chamber 104 will rise as more liquid is supplied to the main chamber 104 from the fluid expelled by the boiler. As the liquid level in the main chamber 104 increases such that it reaches the height of the weir 112, any further liquid supplied will cause liquid to flow over the weir 112, through the overflow port 113.

The device 100 contains a water trap 125 (also referred to as a liquid trap) which may provide a barrier to gaseous exchange between the main chamber 104 and overflow 108 chamber. The trap 125 is a partially enclosed volume defined by a bottom surface, front surface, back surface, the weir 112 on one side, and the lip 125 on the other side. One or more of the bottom, front, and back surfaces may be a continuation of a surface that defines the main chamber 104 or overflow chamber 108. The water trap 125 is open at its top. The lip 126 is shorter than the weir 112.

Liquid overflowing from the main chamber 104 will pass over the weir 112 and collect in the water trap 125. Over time, this will cause the liquid level in the trap 125 to rise and eventually flow over the lip 126, out of the water trap 125, and into the overflow chamber 108. The liquid can then leave the overflow chamber 108 through the second outlet port 140.

A cold air baffle 127 is disposed between the weir 112 and the lip ridge 126. The cold air baffle 127 extends downwardly in the device to a level at or below a height of the lip ridge 126. As a height of liquid between the lip ridge 126 and the weir 112 increases, the liquid level will eventually reach the lower end of the cold air baffle 127. At this point the liquid in the trap will form a barrier that separates air in the main chamber 104 and air in the overflow chamber 108. The trap 125 has the effect of preventing gases within the main chamber (fed from the condensing boiler) from escaping through the overflow chamber. This is desirable as in many embodiments of the invention it may be convenient for the second outlet port 140 of the overflow chamber 108 to be fed directly into a room that may be within a dwelling or workplace, rather than to a conventional drainage system. Therefore, the trap 125 can prevent exhaust gasses or foul odour from being expelled into the room.

Figure 2c shows a cross section of the chamber taken through a portion of the device 100 that does not encompass the condensate drain pipe 102 or the overflow pipe 110.

Figure 2c shows the device 100 through cross-section B-B shown in Figure 2a.

The main chamber 104 is visible within the body 101 of the device 100 in Figure 2c, as is a waterproof chamber 128 (also referred to as a dry housing) positioned above the body 101 of the device 100. A float switch 114 can be seen within the main chamber 104 in this view. The float switch 114 includes an arm 114' that floats on liquid in the main chamber 104.

The float switch 114 is configured to detect when the liquid in the main chamber 114 has reached a predetermined level by sensing the position of the arm 114'. This level may correspond to any fixed amount of liquid at, or lower than, the height of the weir 112.

When the level of liquid within the main chamber reaches the predetermined level, the float switch 114 will send a signal to an electronic circuit in the water-proof chamber 128.

The electronic circuit may, when receiving the signal from the float switch 114, produce a warning signal. The warning signal may be an audible signal or a visual signal, or both.

The electronics may convey the warning signal through a telecommunications network to a remote location. Conversion of the warning signal to a signal transmittable by the telecommunications network may be performed by a modem. The modem may be housed within the water-proof chamber 128 of the device 100. Alternatively, the electronics in the water-proof chamber 128 may be capable of communicating with another stand-alone system, such as a multipurpose computer, a fire alarm system or a burglar alarm system. In such a case, the electronics can utilise the functionality of these systems in order to convey the state of the device 100 to an interested party, or to convey the state of these other systems using a modem within the device 100. Such interested parties may include a property owner, resident, boiler servicing firm, boiler manufacturer, or an intermediary body providing monitoring services for the device 100.

Figure 2d shows a back view of the device 100. Figure 2e shows a side view of the device 100.

Figure 2f shows a cross-sectional view of the device 100 through A-A in Figure 2d. The arm 114' of the float switch is visible in Figure 2f.

Figures 2g to 2i show perspective views of the device 100 coupled with a length of condensate drain pipe 102 and overflow pipe 110. Figures 2i and 2j show a switch 123, mounted on a front of the water-proof housing 128. The switch 123 enables a user to silence an audible alarm generated by the electronic circuit in response to a signal received from the float switch 114. The silencing option may prevent annoyance to those inhabiting the property in which the device is installed in a situation where an alarm has been raised for an extended period of time.

In the embodiment of Figure 2, there are two indicator lights labelled 127a and 127b in Figure 2i. The electronic circuit of this embodiment is configured to illuminate indicator light 127a when the arm 114' of the float switch 114 has risen to a predetermined level.

This is considered indicative of the condensate outlet port being blocked. The electronic circuit is further configured to illuminate indicator light 127b if the user has set the switch 123 to a position which causes the audible alarm to be silent.

The text next to each switch is highlighted in Figure 2j. The message printed next to indicator light 127a reads: "Warning! Blocked Condensate.

Overflow may leak.

Flick switch to turn off buzzer." The message printed next to indicator light 127b reads: "Boiler Condensate Guard is off Flick switch to activate".

In some examples, a pump may be coupled to the outlet port to direct water flow away from the device.

Figure 3 shows a device according to an alternative embodiment of the invention. Many of the components of the embodiment shown in Figure 3 are similar to those of the previous embodiments and so are discussed only briefly below. It will be appreciated that any of the features described in relation to one of the embodiments may be applicable to any embodiment of the invention.

In Figure 3 the device 200 is coupled to various elements of a pre-existing heating system. The figure illustrates an inlet pipe 202 for carrying condensate from a boiler (not shown) to a main chamber 204 of the device, and a main outlet pipe 206 for carrying condensate from the main chamber 204 to a drain (not shown).

A float switch 214, 216, 220 is disposed in the main chamber 204. When the main outlet pipe 206 becomes blocked, condensate accumulates in the main chamber 204 and the float rises 214, actuating a microswitch 220 and causing electric current to be supplied to a visible 222 warning (e.g. LED) and/or audible warning to alert a user of the boiler to investigate the blocked pipe. The device can additionally include a remote electrical relay to supply a heater 224 able to heat a portion of the main outlet pipe 206. If the main outlet pipe 206 is blocked by ice, then water backs up in the main outlet pipe 206. The backed up water causes the float 214 to rise, actuating the microswitch 220. The microswitch 220 can be configured to cause electric current to be supplied to the heater 224 to melt the ice in the main outlet pipe 206. The device 200 may also include a second microswitch (not shown) which is actuated under the same conditions as the microswitch 220 and allows an option to isolate the electric current to the central heating circuit, and therefore turn the heating off and reduce the amount of condensate formed by the boiler.

The arrangement shown in Figure 3 also includes an overflow chamber 208, an overflow pipe 210 and a weir 212 disposed between the main chamber 204 and the overflow chamber 208.

When a level of condensate in the main chamber 204 is greater than a height of the weir 212, condensate flows from the main chamber 204 into the overflow chamber 208 and out of an overflow pipe 210. The removal of this condensate from the system prevents damage to the boiler.

The device 200 can include a cold air baffle 227, similar to that described with reference to Figure 2, situated in the overflow chamber 208. Droplets of condensate form on the cold air baffle 227 and then collect in the base of the overflow chamber 208. The collected water forms an air barrier preventing cold air being blown through the overflow pipe 210 and into the main chamber 204, thus preventing ice forming on the float switch which could prevent the device from functioning correctly. The air barrier also prevents movement of any flue gases that may enter the main chamber from being emitted out through the overflow chamber 208, a precaution in case the overflow is not terminated externally.

Electronic circuitry such as connection blocks and visible and/or audible warning generators can be housed in a dry chamber 228 adjacent to the main chamber 204.

The electronics of this embodiment may perform any of the functions of the electronics described previously with reference to Figure 2. The dry chamber 228 is a water-proof housing. In some examples a float arm 216 may pass through a hole in a waIl 230 between the main chamber 204 and the dry chamber 228; movement of liquid through the hole between the main chamber 204 and the dry chamber 228 is prevented by a

suitable grommet.

The device 200 can include a float stop 226 in the main chamber 204. The stop 226 can be a horizontally extending projection that is located below a height of the weir 212 in order to prevent travel of the float 214 above the height of the weir 212.

The device 200 prevents flood or storm water returning up the outlet pipe 206 and into the boiler. This is achieved by the float 214 and stop 226 acting as a non-return valve preventing any flood or storm water being pushed back into the boiler.

Figure 4 shows a view of the exterior of the housing illustrated in Figure 3.

Embodiments of the device may be used in combination with a condensate pump for a condensing boiler. Prior art condensate pumps comprise a mechanism which detects if the pump has become blocked and turn off the boiler, leading to possible damage of the heating system due to freezing pipes. Embodiments of the present invention may be coupled in fluid communication between the outlet of the condensate pump and a drain.

Such embodiments can provide an overflow channel in the event of blockage of the drain, or a pipe from the drain, and prevent fluid backing up into the condensate pump.

These embodiments may remove the necessity to turn off the boiler and so reduce the possibility of consequential damage to the system from freezing.

It will be appreciated that any of the features described herein in one or more of the embodiments may be provided in any embodiment.

There may be provided a device for preventing condensate from a condensing boiler from accumulating in and causing damage to the boiler in the event of a condensate drain pipe becoming blocked may comprise: (a) an inlet pipe carrying the condensate from the boiler; (b) a main chamber for receiving the condensate; (c) a main outlet pipe carrying condensate from the first chamber to a drain; (d) an overflow chamber; (e) an overflow pipe; and (f) a well disposed between the main chamber and the overflow chamber; characterised by: a float switch disposed in the main chamber; and connected by an arm to an actuator, the actuator able to actuate a first microswitch; whereby when the main outlet pipe is blocked, condensate accumulates in the main chamber and the float rises actuating the first microswitch and causing electric current to be supplied to a warning signal light and sounder; when a level of condensate in the main chamber is greater than a height of the weir, condensate flows into the overflow chamber; whereby damage to the boiler is prevented.

The device may further comprise a heater able to heat a portion of the main outlet pipe, whereby when the main outlet pipe is blocked by ice, actuating the microswitch causes electric current to be supplied to the heater to melt the ice.

The device may further comprise a second microswitch able to isolate electric current from the boiler, the actuator able to actuate the second microswitch and turn off the central heating, allowing the boiler to continue to supply smaller output circuits, for example, hot water and frost protection circuits.

The device can include a stop which prevents the float from moving above the weir. The stop can be located below a height of the weir.

The device may further comprise a stop which prevents the float from moving above the weir. The float may act as a non-return valve which prevents any flood/storm water being pushed back into the boiler.

The stop may be ocated below a height of the weir, in the main outlet pipe of the water chamber.

The device may comprise a cold air baffle situated in the overflow chamber, the cold air baffle can cause droplets of condensate to form on it and collect in the overflow chamber, thereby forming an air barrier preventing cold air being blown through the overflow pipe and into the main chamber.

The air barrier may also prevent flue gases in the main chamber from being emitted out of the overflow pipe.

The device may comprise a detachable dry chamber adjacent to the main chamber.

The warning signal lights, sounder and sounder isolation switch may be located in the dry chamber. An additional warning signal can be located remote of the device.

When the warning signal is activated, a rocker switch may be used to turn off the warning light and sounder and at the same time activate a second warning light indicating the device has been turned of.

A label may be located by the first warning light advising "Warning! Blocked Condensate.

Overflow may leak. Flick switch to turn off buzzer." A label may be located by the second warning light advising "Boiler Condensate Guard is off. Flick switch to activate".

An arm may pass through a hole in a wall between the main chamber and the dry chamber.

The device may comprise a grommet located in the hole in the wall in order to prevent movement of water through the hole between the main chamber and the dry chamber.

The warning signal may be a visible signal. The visible signal may be a neon light or an LED. The warning signal may be an audible signal.

The float and the stop may act as a non-return valve preventing any flood or storm water being pushed back into the boiler.

The dry chamber may comprise a modem that can send text and/or email communication to advise a condition of one of the following conditions: condensate blockage; property temperature; carbon monoxide level; fire; smoke; flood water; another warning signals received from remote sensors.

The electrical warning dry chamber may be detached and mounted remotely from the water chamber.

Embodiments disclosed herein relate to a device for preventing condensate accumulating in, and causing damage to, a condenser boiler in the event of the boiler's main condensate drain pipe becoming blocked. The device can also prevent flood/storm water entering the boiler via the condensate drain pipe. The device can provide a warning indicator when the condensate drain pipe becomes blocked.

Claims

Claims 1. A device for a condensing boiler, the device comprising: a boiler port configured to receive fluid flow from the condensing boiler; an outlet port configured to expel fluid from the device during normal operation; and an overflow port situated at a height above the outlet port when the device is in use, wherein the boiler port is couplable with a condensate drain pipe of the condensing boiler, the outlet port is couplable with an outlet drain pipe, and the outlet port is configured to prevent fluid flow into the device through the outlet port.
2. The device of claim 1, wherein the outlet port comprises a one-way valve.
3. The device of claim 2, wherein the one-way valve comprises a ball float valve.
4. The device of any preceding claim, further comprising a main chamber and an overflow chamber, wherein the boiler port, outlet port and overflow port comprise openings into the main chamber, wherein the main chamber is coupled to the overflow chamber by the overflow port, and the overflow chamber comprises a second outlet port.
5. The device claim 4, further comprising a liquid trap configured to contain a liquid for providing a barrier to gaseous exchange between the main chamber and the overflow chamber.
6. The device of claim 5, further comprising a weir extending upwardly from an internal bottom surface of the device, wherein the overflow port comprises an aperture above the weir.
7. The device of claim 6, further comprising a lip extending upwardly from an internal bottom surface of the device.
8. The device of claim 7, wherein the liquid trap is a partially enclosed volume defined by a bottom surface, a front surface, a back surface, the weir on one side, and the lip on the other side, and the water trap has an opening at its top.
9. The device of claim 7 or claim 8 wherein the lip 126 is shorter than the weir 112.
10. The device of any one of claims 5 to 9, further comprising a cold air baffle extending downwardly from an internal top surface of the device, wherein the cold air baffle is located above the liquid trap, wherein the cold air baffle is configured to condense gas or vapour and provide the condensed gas or vapour to the liquid trap.
11. The device of claim 10, wherein the cold air baffle extends into the liquid trap.
12. The device of any preceding claim, further comprising a liquid level sensor and an electric circuit in communication with the liquid level sensor, wherein the electric circuit is configured to produce a warning indicator when the liquid level sensor determines that a level of liquid is present within the device.
13. The device of claim 12, wherein the liquid level sensor is situated within the main chamber, and the electric circuit is configured to produce a warning indicator when the liquid level sensor determines that a level of liquid is present in the main chamber.
14. The device of claim 12 or 13, wherein the liquid level sensor comprises a float switch.
15. The device of claim 12 or 13, wherein the liquid level sensor comprises a light source and a light sensitive switch.
16. The device of any one of claims 12 to 15, wherein the electric circuit comprises a modem, the modem configured to send the warning indicator to a receiver at a geographically remote location.
17. The device of any one of claims 12 to 16, further comprising a switch configured to deactivate the warning indicator.
18. The device of any one of claims 12 to 17, wherein the electric circuit is configured to communicate with a burglar alarm system, a fire alarm system, a carbon monoxide sensor, a low temperature sensor, a smoke sensor, and/or a flood level sensor.
19. The device of any one of claims 12 to 18, further comprising a water-proof chamber, wherein the electric circuit is at least partially situated within the water-proof chamber.
20. The device of claim 19, wherein the water-proof chamber is detachable from the device.
21. The device of any preceding claim, further comprising a main chamber and an outlet chamber, wherein the boiler port, outlet port and overflow port are directly coupled to the main chamber; wherein the outlet port couples the outlet chamber to the main chamber; and wherein the outlet chamber is couplable with the outlet pipe.
22. The device of claim 21, wherein the outlet port comprises an opening; and wherein the outlet chamber comprises a ball float configured to occlude the opening when an amount of water is present in the outlet chamber.
23. A condensing boiler system comprising the device of any preceding claim.
24. A condensing boiler system comprising a condensate pump in fluid communication with the device of any of claims I to 22.
25. A method of servicing a condensing boiler, the method comprising: coupling a condensate drain pipe of the condensing boiler to the boiler port of the device of any of claims I to 22; coupling an outlet drain pipe to the outlet port of the device.
26. A device as described herein and as illustrated in the accompanying figures.