GB2562710A

GB2562710A - Cartridge extraction & replacement

Info

Publication number: GB2562710A
Application number: GB1705731.6A
Authority: GB
Inventors: Robert Weeks Donald
Original assignee: Individual
Current assignee: Individual
Priority date: 2017-04-10
Filing date: 2017-04-10
Publication date: 2018-11-28
Also published as: GB201705731D0

Abstract

A method and tools for replacing a cartridge in a diverter valve tube (2, Figure 2) typically used in combination boilers. The method includes placing a collar (Figure 3 or Figure 6) comprising lugs which fit around the diverter valve tube which engage cartridge locating holes 1 thus disengaging the cartridge from the tube; using a locator tool (Figures 7 and 8) which rotates the cartridge to ensure that it does not re-engage with the locating holes; and an extraction tool (Figure 9) to attach to the cartridge and remove it from the tube. The tools allow the diverter valve to be repaired while it is still in its functional position in the combination boiler. The internal cartridge holding the seals is removed using the collar, locator and extractor tools. Any worn seals can then be replaced and the cartridge returned using the locator tool.

Description

(71) Applicant(s):

Donald Robert Weeks

Heatherview, Southside, Gerrards Cross, Bucks,

SL9 8NJ, United Kingdom (51) INT CL:

E03C 1/02 (2006.01)

F16K11/00 (2006.01) (56) Documents Cited:

US 5970534 A

B25B 27/00 (2006.01)

US 4979530 A (58) Field of Search:

INT CL B25B, E03C, F16K, F24D Other: EPODOC, WPI, Internet (72) Inventor(s):

Donald Robert Weeks (74) Agent and/or Address for Service:

Donald Robert Weeks

Heatherview, Southside, Gerrards Cross, Bucks, SL9 8NJ, United Kingdom (54) Title of the Invention: Cartridge extraction & replacement

Abstract Title: Method and tools for replacing a cartridge in a diverter valve tube (57) A method and tools for replacing a cartridge in a diverter valve tube (2, Figure 2) typically used in combination boilers. The method includes placing a collar (Figure 3 or Figure 6) comprising lugs which fit around the diverter valve tube which engage cartridge locating holes 1 thus disengaging the cartridge from the tube; using a locator tool (Figures 7 and 8) which rotates the cartridge to ensure that it does not re-engage with the locating holes; and an extraction tool (Figure 9) to attach to the cartridge and remove it from the tube. The tools allow the diverter valve to be repaired while it is still in its functional position in the combination boiler. The internal cartridge holding the seals is removed using the collar, locator and extractor tools. Any worn seals can then be replaced and the cartridge returned using the locator tool.

Figure 4

1/6

Figure 2

2/6

Figure 3

3/6

Figure 5

4/6

Figure 6

5/6

Figure 8

6/6

Figure 9

Cartridge Extraction & Replacement

This invention relates to tools enabling extraction of a leaking cartridge from a diverter valve in a combination boiler. Engineers currently purchase a replacement diverter valve as tools are not available to extract the failed component and replace with a repaired unit.

The diverter valve controls the direction of hot water flowing from the primary heat exchanger to either the room heating source, or to a secondary heat exchanger for the supply of hot water. The diverter valve operates by electric motor moving a steel pin with a rubber sealing bung attached at one end. With the pin extended the sealing bung allows water to flow in one direction, with the pin retracted water flows in the other direction. To contain water within the diverter valve, the pin moves through 2 rubber seals contained within the cartridge. After a period of use the seals in the cartridge deteriorate and leak.

The design and construction of diverter valves varies by manufacturer. A number of designs allow for the removal of the leaking component or cartridge and replacement using conventional tools (e.g. screwdriver or spanner). However, the cartridge in the diverter valve referred to in this application is secured into place in such a way that it cannot be removed with conventional tools. It is industry practice for engineers to remove the entire diverter valve including the integral cartridge and fit a replacement.

Removing the valve from the boiler and fitting a replacement is time consuming, requires the use of new fixing seals and bolts to correctly secure the diverter valve back into the boiler and is uneconomic since only a minor component of the whole valve is faulty. It is also invasive and can lead to failure or faults with other components that are disturbed during the process.

The tools covered by this patent allow for the extraction of the leaking cartridge whilst the diverter valve body is located in its operational position in the combination boiler. A repaired cartridge can then be inserted back into the diverter valve body using the tools covered by the patent. The procedure is simpler, less invasive and quicker than removing the whole diverter valve. It does not require the use of new fixing seals and bolts and allows for the leaking seals within the cartridge to be replaced at significantly reduced cost to that of purchasing the entire replacement valve.

The invention will now be described solely by way of example and with reference to the accompanying drawings in which:

Figure 1 shows a side view of the diverter valve body and position of one of the two cartridge retaining holes

Figure 2 shows a plan view of the diverter body and identifies the cartridge retaining tube

Figure 3 shows the collar design 1 with two wedge shape profiles

Figure 4 shows a side view of the extracted cartridge with the two retaining lugs and pin with rubber sealing bung

Figure 5 shows a plan view of the extracted cartridge with the two retaining lugs and locking teeth

Figure 6 shows the collar design 2 with the bridge

Figure 7 shows the locator with locking teeth (female) and screwdriver slot

Figure 8 shows the locator with the screwdriver slot

Figure 9 shows the extractor with female profile of the pin and sealing bung

There are 2 different designs of diverter valve that the tools and process can be applied to. Both diverter valves are identical with the exception that one valve type has an obstruction around the cartridge retaining tube which requires a bridge (figure 6, number 9) to be included in the collar design. The tools and process described below is common to both collar designs.

The collar is positioned around the diverter valve tube (figure 2, number 2) in a position where the 2 wedge shaped profiles (figure 3, number 3) engage in the cartridge locating holes (figure 1, number 1). The collar is tightened around the diverter valve tube using the integral nut and bolt (figure 3, number 4) so that the cartridge lugs are depressed by the wedges and disengaged from the locating holes. The collar is designed to limit the movement of both wedges to the optimal position where disengagement is achieved without damage to the cartridge lugs - the cartridge lugs have limited flex and will snap if subjected to excess force.

The locator is then inserted into the diverter valve tube so that the locking teeth (figure 7, number 10) mate with the locking teeth on the cartridge (figure 5, number 6). Using a screwdriver inserted into the screwdriver blade cut out on the locator (figure 8, number 11), the locator and the mated cartridge are turned 90 degrees.

With cartridge lugs now isolated from the locating holes, the collar is then removed. This ensures the wedges on the collar do not damage the cartridge as it is being withdrawn. The locator is also removed.

The female profile on the extractor (figure 9, number 12) is mated to the male profile at the end of the pin (figure 4, number 8). The pin and attached sealing bung (figure 4, number 7) can now be pulled using the extractor and in so doing the sealing bung draws out the cartridge from the diverter valve tube.

A replacement (repaired) cartridge is inserted into the diverter valve tube and using the locator and screwdriver the cartridge is correctly positioned and pressed home to click lock back into position in the locating holes.

Claims

1. Cartridge extraction from snap lock position and replacement to snap lock position while the body of the diverter valve is still in its functional position, comprising collar to disengage the cartridge from snap lock position, locator to rotate the cartridge and isolate from snap lock position, removal of cartridge from body of diverter valve using extractor, use of locator to align and locate the replacement cartridge into the snap lock position.

2. Cartridge extraction from snap lock position and replacement to snap lock position while the body of the diverter valve is still in its functional position according to claim 1, in which the collar is tightened around the valve applying inward force on the 2 wedge shaped profiles and thereby disengaging the cartridge securing lugs from their snap lock position.

3. Cartridge extraction from snap lock position and replacement to snap lock position while the body of the diverter valve is still in its functional position according to claim 1, in which the collar limits the inward movement of the wedge shaped profiles to ensure the cartridge securing lugs are not subjected to excess force and damaged.

4. Cartridge extraction from snap lock position and replacement to snap lock position while the body of the diverter valve is still in its functional position according to claim 1, in which the female teeth of the locator securely mate with the male teeth of the cartridge to allow the cartridge to be rotated and isolated from the snap lock position enabling removal of the collar.

5. Cartridge extraction from snap lock position and replacement to snap lock position while the body of the diverter valve is still in its functional position according to claim 1, in which the extractor secures on the profile at the end of the diverter valve pin enabling removal of the cartridge

6. Cartridge extraction from snap lock position and replacement to snap lock position while the body of the diverter valve is still in its functional position according to claim 1, in which the replacement cartridge is correctly aligned and returned to its snap lock position using the locator tool and screwdriver.

Intellectual

Property Office

Application No: GB1705731.6