GB2583725A

GB2583725A - Heated water

Info

Publication number: GB2583725A
Application number: GB1906319.7A
Authority: GB
Inventors: Carel Van Der Merwe Willem
Original assignee: Tesla Uk Ltd
Current assignee: Tesla Uk Ltd
Priority date: 2019-05-03
Filing date: 2019-05-03
Publication date: 2020-11-11
Anticipated expiration: 2039-05-03
Also published as: GB201906319D0; GB2583725B

Abstract

A device 10 for receiving a condensate flow from a water heater. The device comprises a housing 20 having an inlet 21 for receipt of a condensate flow and an outlet 24 for delivery of the condensate flow. The housing comprises a housing wall having an aperture 23a therethrough, a first one-way valve 50 and a second one-way valve 30. The first one-way valve is upstream of the aperture. The first and/or second one way valve may permit flow once a threshold amount of water has accumulated thereon. The device may comprise a float switch 41 operable to complete an electric circuit, for example to trigger an alarm. The alarm may be in wired or wireless communication with a remote warning system, such as on a cellular device or computer. The switch may be located downstream of the first one-way valve, and upstream or downstream of the second one-way valve. The device may comprise a baffle 25, 26 which flares inwardly in a downstream direction to define a flow aperture 25a, 25b to direct condensate toward the outlet. Plural further apertures may extend through the housing wall.

Description

Heated Water This invention relates to heated water and, in particular, to the protection of equipment for delivering heated water. The equipment for delivering heated water may comprise, for example, boilers (e.g. condensing boilers, combination boilers, cylinder boilers, geysers) and water heaters (e.g. kettles, urns, immersion heaters).

Many devices for delivering hot water incorporate a drain for attending to the condensate generated by heating water. It is important that the condensate outlet pipe does not become blocked during use as that can lead to a back-up of water into the boiler which can stop the boiler working efficiently (or at all) and/or may cause damage to the boiler, sometimes irreparable damage.

Blockages in the condensate pipe may be due to freezing of condensate water in times of extreme cold weather, a backflow of water from a drain in times of extreme rainfall or other foreign matter occluding the outflow pipe. The condensate pipe may be plumbed into a water drainage system and incorrect plumbing may impinge on the ability to effectively drain the device.

It is known to fix a tundish to collect discharge water from an overflow pipe. The tundish has a receiving section which is separated from its outflow pipe by an air gap, which is open to the atmosphere. As a result, condensate fluid flow is visible, thereby allowing one to confirm the flow of fluid. The air gap prevents the backflow of fluid towards the overflow pipe.

Systems are known for protecting equipment for delivering heated water, an example is disclosed in GB 2,481,319. This document describes a condensing boiler overflow device which comprises a port to receive fluid flow from a condensing boiler and an outlet port to expel fluid from the device during normal operation. The device further comprises an overflow port above the level of the outlet port. The overflow port is coupled to an overflow chamber which is connected to an outflow pipe. The device may comprise a liquid level sensor capable of triggering an alarm.

GB 2,497,140 discloses a boiler condensate drain monitoring apparatus which also comprises an overflow port to facilitate drainage in the event of a blockage or insufficient 30 flow.

It will be appreciated that each of the prior art apparatus requires an overflow pathway which is situated in parallel relations to the principal flow conduit. Further, in each case, the overflow chamber can become occluded which can lead to accumulation of liquid within the overflow pathway, inhibiting or prohibiting drainage of the device.

Accordingly, it would be advantageous to provide a device which can be used to effectively drain liquid from equipment for delivering heated water in all operative states, i.e. even in times of high flow or backflow pressure on the device.

Accordingly, a first aspect of the invention provides a device for receiving a condensate flow from a water heater, the device comprising a housing having an inlet for receipt of a condensate flow and an outlet for delivery of the condensate flow, the housing comprising a housing wall having an aperture therethrough and having a one-way valve received therewithin.

The provision of an aperture through the wall of the housing allows for liquid failing to pass through the device to weir over the edge of the aperture and thence to the exterior of the device. Thus, flow of condensate backwards to the boiler is prevented. It will be appreciated that the size and position of the aperture will be selected so as to be able to effectively weir condensate to prevent backflow. By using an aperture, the device can be made from a single piece housing and will be simpler to manufacture and/or install and/or have a narrower profile than the devices of the prior art which are provided with by-pass chambers and overflow manifolds.

In this specification we refer to upstream and downstream to refer to the flow direction of condensate through the device in normal use, i.e. from the inlet of the device to the outlet.

The device may further comprise a trap to retain condensate which weirs from the aperture. Preferably the aperture is upstream of the one-way valve By locating the aperture upstream of the one-way valve a backflow of water from the outlet is prevented, for example in times of heavy rain or flood.

The device may further comprise a second one-way valve. The second one-way valve may be upstream of the aperture.

A second one-way valve upstream of the aperture may prevent flow into the boiler, for example if the apertures become blocked.

A switch, for example a float switch, may be provided. In an embodiment the switch is located upstream or downstream of the or a second one-way valve. Preferably, the switch is operable to complete an electric circuit, for example to trigger an alarm. A power source may also be provided. The power source may complete electric circuitry, for example electric circuitry which is open until the switch closes the circuit, for example to thereby trigger an alarm. The alarm may be in wired or wireless communication with a remote warning system, which may be a bespoke or integrated wall panel and/or may be in wired or wireless communication with a processor, for example on a cellular device (phone, tablet or so on) or a computer. The remote warning system may take the form of a mobile application, which is configured to provide an audible and/or visual and/or vibratory alarm. The mobile application may also be configured to provide functionality to mute or dismiss the alarm, or to communicate the alarm to a third party. The alarm may be activated on the device only, on the mobile application only, or on both the mobile application and on the device. The mobile application may be configured to mute the alarm on the device.

A baffle may be provided. The baffle may extend inwardly from the housing wall. For example, the baffle may flare inwardly in a downstream direction to define a flow aperture. The baffle may act to direct condensate away from the aperture.

A second baffle may be provided. The second baffle may be operable to direct condensate toward the outlet. In an embodiment the second baffle may flare inwardly in a downstream direction to define a second flow aperture.

The device may comprise one or more further apertures extending through the housing wall. The size and/or shape and/or position and/or number of apertures will typically be selected to accommodate the expected peak condensate flow.

In an embodiment the one-way valve and/or the second one-way valve is operable to permit flow once a threshold amount of water has accumulated thereon. Retention of liquid on the one-way valve is beneficial because it provides a gas or vapour trap, thereby at least partly inhibiting or prohibiting the passage of gases or vapours from a downstream location A further aspect of the invention provides a method of protecting a heated water source, the method comprising fitting a device according to the above condensate outlet pipe of the heated water source.

A yet further aspect of the invention provides a method of handling condensate from a heated water source, the method comprising receiving condensate from a heated water source through an inlet to a housing and passing the condensate through the housing via a one-way valve, if flow is not possible through the one-way valve allowing the condensate to exit the housing through an aperture in the wall of the housing.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. For the avoidance of doubt, the terms "may", "and/or", "e.g.", "for example" and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

The invention will now be described, by way of example only, and with reference to the following drawings: Figure 1 is a schematic of the first embodiment of the present invention; and Figure 2 is a schematic of the second embodiment of the present invention.

Referring to Figure 1, there is shown a device 10, which is attachable or attached to a condensate outflow pipe 11 of equipment for delivering heated water (not shown), which is referred to herein as a 'boiler'.

The device 10 comprises a tubular housing 20, which extends from an upstream connecting portion 20a at the upstream end to a downstream connecting portion 20b at the downstream end. The upstream connecting portion 20a has an external thread (not shown) and defines an inlet 21. The tubular housing 20 includes a stepped portion downstream of the upstream connecting portion 20a, which provides an internal shoulder 21a. The downstream connecting portion 20b has an external thread (not shown) and defines an outlet 21.

The upstream connecting portion 20a is attached or attachable to a condensate outflow pipe 11, and the downstream connecting portion 20b is attached or attachable to a drainage pipe 13.

As will be appreciated by those skilled in the art, the upstream and downstream connecting portions 20a, 20b are compatible with any number of pipe connection fittings. In the preferred embodiment the connections are formed via compression fittings.

The tubular housing 20 has a transition body portion 22 which joins to the downstream edge of the shoulder 21a. The transition body portion 22 increases in diameter in the downstream direction and has a convex surface facing the inside of the tubular housing 20. A cylindrical body portion 23 extends between the downstream end of the transition body portion 22 and the upstream end of the downstream connecting portion 20b.

Downstream of the transition body portion 22 but in the upstream portion of the tubular housing 20, the cylindrical body portion 23 has a plurality of apertures 23a therethrough.

The apertures 23a are equi-spaced about the circumference of the cylindrical body portion 23. In the present embodiment the apertures 23a are rectangular, with their long edges parallel with the axial dimension of the tubular housing 20.

The tubular housing 20 houses the following components, listed in order from the upstream end to the downstream end of the tubular housing 20 and arranged in series: an upstream one-way valve, a first baffle 25, a series of apertures 23, a float switch 41, a downstream one-way valve 30 and a second baffle 20.

The upstream one-way valve 50 is located downstream of and adjacent to the transition body portion 22. The upstream one-way valve 50 has a resiliently urged valve body 57 forming the valve. The first baffle 25 tapers inwardly from the wall of the housing 20 such that downstream (distal) end lies approximately level with the midpoint of the apertures 23a. Downstream of the first baffle 25 and the apertures 23a there is a float switch 41. The upstream end of the float switch 41 is proximate the downstream end of the apertures 23a. Downstream of the float switch 41 there is a downstream one-way valve 30, which is similar or identical to the upstream one-way valve 50. The second baffle 26 tapers inwardly from the wall of the housing 20. The downstream end of the second baffle 26 is approximately level with the upstream end of the downstream connecting portion 20b. The downstream end of the downstream one-way valve 30 is approximately level with the upstream end of the second baffle 26.

Mounted to or situated on the outside of the tubular housing 20 there is a power supply 41a and an optional alarm 41 b, which may be (and typically are) in electrical communication with each other and with the float switch 41.

Each of these components will now be described in more detail.

The first and second baffles 25, 26 are frustoconical in shape, and reduce in diameter in the downstream direction. The upstream portion of each baffle 25, 26 extends from the inside surface of the cylindrical body section 23, to each define a downstream central aperture, or orifice 25a, 26a, of decreased transverse dimension.

Each one-way valve 30, 50 has a valve seat which is made from frustoconical support members 31, 51 defining the outer circumference of the valve, and a valve body 37, 57 which seats on the valve seat or is unseated therefrom. Engagement of the one-way valve 30, 50 is via contact between the valve body 37, 57 and the support member 31, 51, and the valve is urged into engagement by a spring 36, 56. The valve body 37, 57 is mounted to a shaft 35, 55 and retained on the shaft 35, 55 by a platform 35b, 55b, which extends radially and perpendicularly to and at the end of the shaft 35, 55. The shaft 35, 55 is received by a hole in the centre of a hub 34, 54 and is moveable axially through the hub 34, 54 along the centreline of the one-way valve 30, 50. The hub 34, 54 is supported in the centre of and adjacent to the base of the valve body 37, 57 by a plurality of webs 33, 53. The spring 36, 56 is retained on the shaft 35, 55 and captivated between the hub 34, 54 at one end, and a retainer 35a, 55a at the end of the shaft 35, 55, opposite to the valve body 37, 57. Disengagement of the valve is achieved by the spring 35, 55 being compressed between the hub 34, 54 and the retainer 35a, 55a, such that the shaft 35, 55 moves through the hub 34, 54, and the valve body 37, 57 moves away from the support member 31, 51. The spring 36, 56 force constant is such that a residual force is present when the valve is engaged. This residual force must be overcome before the valve is disengaged.

The float switch 41 comprises an annular float 42 through which is received a float shaft 43. At one end of the float shaft 43 there is a float retainer 44, which is a plate extending radially about the float shaft 43. The end of the float shaft 43 opposite to the float retainer 44 is suspended at the centre of a plurality of webs 46. The webs 46 extend perpendicularly to the axis of the float shaft 43 and suspend the float shaft 43 in the centre of a support section 47 which is frustoconical in shape. The webs 46 connect the upstream end of the float shaft 43 to the smaller downstream opening of the support section 47. The diameter of the support section 47 decreases in the downstream direction. The switch is activated by the annular float 42 moving along the float shaft 43 in the direction away from the float retainer 44. The float switch 42 is in electrical communication (not shown) with a power supply 41a and an alarm 41 b.

The power supply 41a is attached to the outside surface of the tubular housing 20 and is in electrical communication with the float switch 41 and the alarm 41b. In the preferred embodiment the power supply 41a is a battery, situated inside of a protective housing (not shown), although any suitable power supply could be used, such as a connection to mains power, or a connection to the boiler.

The alarm 41b is attached to the outside surface of the tubular housing 20 and is in electrical communication with the float switch 41 and the power supply 41a. The alarm 41b is situated inside of a protective housing (not shown) and is preferably of an audible or visual type. The alarm 41b could be of a wired or wireless transmission type to a remote warning or alarm system (not shown). This remote warning or alarm system could be in the form of a mobile application (not shown) on a cellular device or a computer (not shown).

The electrical communication between the float switch 41, the power supply 41a and the alarm 41b is preferably via electrical cables (not shown), which are insulated to protect them from fluid. The electrical cables pass through sealed apertures (not shown) in the tubular housing 20 to provide electrical communication between the float switch 41, and the power supply 41a and the alarm 41b.

The device 10 is installed between a condensate outflow pipe 11 and a drainage pipe 13 and receives condensate fluid flow from the boiler (not shown). Fluid flows into the inlet 21 from the condensate outflow pipe 11, and flows out of the outlet 24 into the drainage pipe 13. This defines a condensate fluid flow direction 12.

The condensate pipe 11 is preferably 22 mm in outer diameter, but it will be appreciated by those skilled in the art that a reducer, or any other suitable fitting, can be fitted between the condensate pipe 11 and the upstream connecting portion 20a to accommodate condensate pipes 11 of different diameters. The shoulder 21a receives the downstream end of the condensate pipe 11, or any other fitting such as a reducer.

The drainage pipe 13 is preferably 22 mm, 32 mm or 40 mm in outer diameter, and the downstream connecting portion 20b has a connection means suited to the drainage pipe 13. It will be appreciated by those skilled in the art that a reducer, or any other suitable fitting, can be fitted between the drainage pipe 13 and the downstream connecting portion 20b to accommodate drainage pipes 13 of different diameters.

In normal use the condensate fluid arrives at the upstream one-way valve 50. Once the weight of fluid in the valve 50 is enough to overcome the residual force created by the spring 56, the valve disengages. This allows the fluid to flow over the hub 54 and the webs 53, and past the valve body 57 in the condensate fluid flow direction 12. The force constant of the spring 56 is selected such that a predetermined level of fluid is required to disengage the valve 50. The force constant could be selected such that a small amount of fluid disengages the valve 50.

The fluid then engages the upstream baffle 25 and is directed away from the inside surface of the cylindrical body portion 23. The fluid is then expelled through the orifice 25a approximately midway along the apertures 23a. The upstream baffle 25 is present to guide a fluid away from the inside surface of the cylindrical body portion 23, which at least inhibits, and preferably prevents, fluid from flowing out through the apertures 23a.

Once past the baffle 25, the fluid then flows over the support section 47 of the alarm system 40, and over or past the webs 46. The fluid then flows over or past the internal components 40a of the alarm system 40 in the condensate fluid flow direction 12.

The fluid next arrives at the downstream one-way valve 30, where, as in the upstream one-way valve 50, a predefined level of fluid is required to disengage the valve body from the valve seat of the one-way valve 50. This allows the fluid to pass through the downstream one-way valve 30 in the condensate fluid flow direction 12. The force constant of the spring 36 is selected such that a predetermined level of fluid is required to disengage the valve 50. The force constant could be selected such that a small amount of fluid disengages the valve 50.

The fluid then engages the downstream baffle 26 and is expelled through the orifice 26a, as in the upstream baffle 25. The downstream baffle 26 is present to guide fluid away from the inside surface of the cylindrical body portion 23 and towards the centre of the outlet 24.

The presence of the apertures 23a means that the flow of fluid through the downstream one-way valve 30 does not cause a reduction in pressure on the downstream side of the upstream one-way valve 50, relative to the upstream side. This could cause the upstream one-way valve 50 to disengage prematurely or could reduce the level of fluid required to disengage the valve.

The retention of the fluid before disengagement of the downstream one-way valve 30 prevents gases from travelling in the upstream direction and into the surrounding atmosphere through the apertures 23a. This also prevents odours from travelling out through the apertures 23a.

The retention of the fluid before disengagement of the upstream one-way valve 50 prevents gases from travelling in the upstream direction into the condensate outflow pipe 11.

Should an occlusion occur in the drainage pipe 13, fluid will accumulate inside of the device 10 as condensate fluid continues to flow into the device 10 from the boiler. As the drainage pipe 13 and the downstream end of the device 10 fill with fluid, the fluid level will reach the downstream one-way valve 30 which will prevent fluid from flowing in the upstream direction. Fluid flow is prevented from flowing in the upstream direction due to the engagement of downstream one-way valve 30.

Accordingly, once the fluid level reaches the downstream one-way valve body 37, fluid flowing from the boiler will accumulate on the upstream side of the downstream one-way valve 30, but will be unable to disengage the valve due to the presence of fluid on the downstream side. This will cause the fluid level within the device 10 to reach and submerge the annular float 42. The buoyancy of the annular float 42 in the fluid will cause the annular float 42 to travel in the upstream direction and activate the float switch 41. Upon activation of the float switch 41 the power supply 41a and the alarm 41b will be brought into electrical communication, causing the alarm 41 b to be activated. The annular float 42 will move to a maximum upstream position, where it will be prevented from moving further by the webs 46. Should the fluid level subsequently reduce to deactivate the float switch 41, the alarm could either be deactivated, remain activated, or be deactivated after a delay.

As fluid continues to flow into the device 10 from the boiler, the fluid will accumulate upstream of the internal components 40a of the alarm system 40 until the fluid level reaches the apertures 23a, where the fluid will weir over the downstream edges of the apertures 23a and out of the device 10.

Fluid from the boiler will continue to flow in the condensate fluid flow direction 12 passing through the upstream one-way valve 50, and will continue to weir over the downstream edges of the apertures 23a and out of the device 10.

A trap, tray, or other suitable fluid receptacle (not shown) may be present to receive any fluid which is expelled from the device 10 through the apertures 23a. This may be connected to a discharging circuit (not shown).

In a situation where the apertures 23a are occluded, the upstream one-way valve 50 will prevent any flow of fluid in the upstream direction, into the condensate outflow pipe 11. The upstream one-way valve 50 will also prevent any fluid which enters the device 10 through the apertures 23a from travelling into the condensate pipe 11 in the upstream direction.

Referring now to Figure 2, there is shown a device 100 according to a second embodiment of the invention, which is similar to the device 10 according to the first embodiment described above, wherein like features are denoted with a preceding '1', and these like features will not be described herein. The device 100 according to this embodiment differs from that of the first embodiment in that the internal components 140a of the alarm system and the downstream one-way valve 130 are in different locations. However, the operation of each component is the same and will not be described herein.

In the second embodiment of the invention the downstream one-way valve 130 is located inside of the tubular housing 120, downstream of the apertures 123a.

The internal components 140a of the alarm system 140 are located downstream of the downstream one-way valve 130 such that the platform 135b is substantially level with the upstream end of the downstream baffle 126.

Normal operation of the device 100 is the same as that described in the first embodiment of the invention, except that the condensate fluid will flow through the downstream one-way valve 130 before flowing over or past the float switch 141.

In the event of backflow of fluid into the device, or an accumulation of condensate fluid in the device due to an occlusion in the drainage pipe 13, fluid will reach the float switch 141 before the downstream one-way valve 130.

This means that any accumulation of fluid in the device will be known earlier than in the first embodiment of the invention. It also means that back-flow of fluid from the drainage pipe can activate the float switch 141, as well as an accumulation of condensate fluid due to an occlusion. In the first embodiment of the invention only the accumulation of condensate fluid from the boiler could activate the float switch 41.

It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention. For example, the components inside of the housing 20, 120 may be arranged in a different order. Also, the upstream one-way valve 50, 150 may be omitted. Furthermore, the upstream connecting portion 20a, 120a and/or downstream connecting portion 20b, 120b may not contain external threads. The internal components may be provided separately, each with a separate, individual housing, and assembled together in any order. The power supply 41a, 141a and alarm 41b, 141b may be located within the housing 20, 120. The internal components may be installed inside a single tube, with this tube then installed inside the housing 20, 120. The upstream baffle 25, 125 and/or downstream baffle 31, 131 may not be present.

It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

Claims

CLAIMS1. A device for receiving a condensate flow from a water heater, the device comprising a housing having an inlet for receipt of a condensate flow and an outlet for delivery of the condensate flow; the housing comprising: a housing wall having an aperture therethrough; a first one-way valve and a second one-way valve; wherein the first one-way valve is upstream of the aperture.
2. A device according to Claim 1, further comprising a switch.
3. A device according to Claim 2, wherein the switch is a float switch.
4. A device according to Claim 2 or 3, wherein the switch is located downstream of the first one-way valve.
5. A device according to any one of Claims 2, 3 or 4, wherein the switch is located upstream of the second one-way valve.
6. A device according to any one of Claims 2, 3 or 4, wherein the switch is located downstream of the second one-way valve.
7. A device according to any one of Claims 2 to 6, wherein the switch is operable to complete an electric circuit, for example to trigger an alarm.
8. A device according to Claim 7, wherein the alarm is in wired or wireless communication with a remote warning system, such as on a cellular device or computer.
9. A device according to Claim 8, wherein the remote warning system is a mobile application which is configured to provide an audible or visual alarm.
10. A device according to Claim 9, wherein the mobile application is further configured to allow the alarm to be muted, dismissed or communicated to a third party.
11. A device according to any preceding Claim, further comprising a power source.
12. A device according to any preceding Claim, comprising a baffle.
13. A device according to Claim 12, wherein the baffle extends inwardly from the housing wall.
14. A device according to Claim 13, wherein the baffle flares inwardly in a downstream direction to define a flow aperture.
15. A device according to any one of Claims 12, 13 or 14, wherein the baffle is operable to direct condensate away from the aperture
16. A device according to any preceding Claim, further comprising a second baffle.
17. A device according to Claim 16, wherein the second baffle is operable to direct condensate toward the outlet.
18. A device according to Claim 16 or 17, wherein the second baffle flares inwardly in a downstream direction to define a second flow aperture.
19. A device according to any preceding Claim, comprising plural further apertures extending through the housing wall.
20. A device according to any preceding Claim, wherein the first and/or second one-way valve is operable to permit flow once a threshold amount of water has accumulated thereon.
21. A method of protecting a heated water source, the method comprising fitting a device according to any preceding Claim to a condensate outlet pipe of the heated water source.
22. A method of handling condensate from a heated water source, the method comprising receiving condensate from a heated water source through an inlet to a housing and passing the condensate through the housing via a first and second one-way valve, and, if flow is not possible through the second one-way valve allowing or causing the condensate to exit the housing through an aperture in the wall of the housing.