US20060222508A1

US20060222508A1 - Multi-purpose condensate shut-off switch with maintenance port accessory

Info

Publication number: US20060222508A1
Application number: US11/073,208
Authority: US
Inventors: Christopher Cantolino
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-03-06
Filing date: 2005-03-06
Publication date: 2006-10-05

Abstract

A float switch assembly and maintenance port accessory each made from plastic and impervious to corrosion that are connected in-line to a fluid discharge line, but which are also adaptable to auxiliary applications. Improvements over the prior art include a more responsive operation resulting from use of a wide float switch body and a closely fitting inner wall within the float housing that allow for rapid shut-off of the condensate producing system after collection of only a very small amount of fluid, a simple design, the ability to handle a large fluid flow, a small float housing dimension for easy installation, protection of its float switch body from routine fluid flow, a removable bottom cap for rapid maintenance and inspection of its float switch body, a fluid deflecting member and/or design that resists upstream movement of fluids, and an air-lock preventing configuration that permits operation without air vent holes.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

None

BACKGROUND OF THE INVENTION

1. Field of the Invention
This invention relates to liquid-level float switches for in-line and auxiliary use, specifically to a system having a float switch assembly of sturdy construction that is primarily contemplated for in-line use with a condensate discharge line in condensate collection applications, but which is also useful in auxiliary and other applications, to send a shut-off signal to the fluid-producing system connected to the discharge line into which the float switch assembly is installed, so as to terminate the introduction of new fluid into the discharge line at the first sign of discharge line blockage (by algae, rust, mold, debris, etc.), and thereby prevent damage to the fluid-producing system as a result of fluid back-up and/or overflow. The present invention has a tubular member and a float housing that is either centered under, or off-set to one side, which is positioned relative to the tubular member so that the bottom of float switch body prior to deployment is lower than the bottom of the tubular member. Further, the housing of the present invention is configured to separate the float switch body from the fluid routinely flowing through the tubular member so as to maintain a high level of reliability of response when a blockage occurs. It is of simple design and can handle a large volume of fluid flow before its float switch body is affected. Both commercial and residential applications are contemplated. The present invention also includes a maintenance port accessory that can be connected into the same fluid discharge line with the float switch assembly. The maintenance port accessory can be mounted in vertically-extending or horizontally-extending orientations, upstream or downstream from the float switch assembly, as the application requires, and it has an internal structure that facilitates the flow of all fluids traveling through it away from the fluid-producing system to which it is connected. It also discourages cleaning agents from moving upstream and into the fluid-producing system. For the internal structure to be effective in directing fluid flow, its larger/wider end is positioned downstream during horizontal orientation, with a reverse positioning being required for vertical orientation. For lowered manufacturing cost, as well as ease in adding cleaning agents to the condensate discharge line to which it is connected, it is preferred that the same type of large cap used to seal the open bottom end of the float housing is also used to seal the threaded connections on the maintenance port accessory. For air conditioning condensate collection, the most preferred embodiment of the present invention is typically small in dimension and when one end of its tubular member is capped off or otherwise blocked or plugged, it is easily converted to auxiliary use as a redundant overflow prevention system, which is often required by local code in air conditioning applications. Thus it is possible for two present invention float switch assemblies to be used with an air conditioning system (as shown in FIG. 21), one installed in-line into the main fluid discharge line, and the other capped on one end and used in an auxiliary/back-up capacity. The present invention float switch assembly has an adjustable float switch body centrally positioned within the float housing with a large surface area for enhanced buoyancy and improved responsiveness that is guided in its vertical movement within the float housing by a vertically-extending shaft connected to either the upper portion of the float housing or the top of the tubular member. The present invention float housing also has an open bottom end that is sealed with an easily removable cap that gives prompt inspection/maintenance access to the float switch body and shaft, an opportunity for an operator to check for the presence of debris/mold/rust/algae in the connected fluid discharge line. The space between an inner wall in the float housing, or male threaded cap, and the float switch body creates a very small volume, so that even a very small amount of fluid therein, such as but not limited to 7.5 ml or 1.5 teaspoons, can cause the float switch body to rise and shut off the source of fluid production.
2. Description of the Related Art
When air conditioning condensate and other condensates are collected, there is often a risk of overflow and/or back-up into the system producing it. As a result, liquid-level float switches have been employed in-line and in an auxiliary capacity to shut-off the source of condensate flow when the amount of fluid surrounding it exceeds a predetermined depth. In air conditioning applications, an auxiliary line provides a redundant/back-up source of overflow prevention, which can be branched off from the main condensate collection line or be formed as a separate line connected to the condensing unit, depending upon local code. However, currently known float switches are deficient in many ways and thereby subject to malfunction, less responsive operation, more costly installation, and/or unstable installation. Many prior art float switches tend to be at risk for malfunction since they are in constant contact with the water in the condensate line, and subject to clogging with rust, algae, mold, and other debris during prolonged periods of use. Also, prior art liquid-level float switches tend to have float switch bodies that wobble relative to the shaft with which they are associated, a condition that can lead to less responsive operation or malfunction. In addition, some float switches are at risk for premature malfunction as a result of being made from materials that are not completely corrosion-resistant. In contrast, the present invention is made from plastic that is impervious to corrosion. Its float switch body is wider than those of known prior art float switches for greater water displacement, however, its float housing has a small width dimension so that it can be easily installed in the tight spaces allowed in residential applications for the connection of air conditioner condensate discharge lines. The present invention float housing and float switch body can have complementary cylindrical configurations, or any other configuration that accomplishes the intended purpose, such as but not limited to cross-sectional configurations that are rectangular, hexagonal, and elliptical. In addition, the close positioning of float switch body within the float housing, as well as the positioning of the bottom of the float housing lower than the fluid discharge line to which it is connected, allows less fluid accumulation before the present invention will activate an electrical shut-off signal, for a faster response time than prior art devices. Through use of bonding agents, and/or in combination with one or more optional connectors and/or caps, the float housing can be applied for in-line use, or be installed in auxiliary applications. Since the present invention is small and has a simple design, it is also cost effective to use. Within the next few years, higher rated air conditioning units will be required by law for fuel efficiency. The larger coils provided used will create more condensate. Further, since condensate continues to drip for ten to fifteen minutes after an air conditioning unit has been shut off, it is very important for in-line and auxiliary switches to be responsive to very small amounts of water and be subject to minimal risk of malfunction. The present invention is configured to be responsive to and meet the needs of the higher rated systems, as well as present air conditioning systems. No condensate switch is known with all of the features and advantages of the present invention.

BRIEF SUMMARY OF THE INVENTION—OBJECTIVES AND ADVANTAGES

The primary object of the present invention is to provide a multi-purpose float switch for in-line and auxiliary use to electrically shut-off the source of condensate flow when a blockage occurs in the main condensate discharge line transporting the condensate away from the system generating it. A further object of this invention is to provide a float switch with a compact housing designed for prompt and cost effective installation in the close-fitting areas used to accommodate residential air conditioning air handlers. It is a further object of the present invention to provide a float switch that is sturdy in construction and design for responsive and reliable operation. It is also an objective of the present invention to provide a float switch that is simple in design and can handle a large amount of fluid before its float switch body is affected. A further object of the present invention to provide a float switch that is readily capable of being installed in a level orientation for proper float switch operation. Another object of the present invention is to provide a float switch that will deploy to shut-off the associated fluid-producing system upon the collection of a very small amount of fluid. It is an object of the present invention to provide a float switch that is protected against air-lock without the use of vent openings. A further object of this invention is to provide a float switch that is protected against malfunction when debris is present in the condensate line. In addition, it is a further object of the present invention to provide a float switch that is made from corrosion-resistant materials that resist premature deterioration and malfunction. It is also an object of the present invention to provide a float switch that has cost-effective construction for widespread distribution and use.
As described herein, properly manufactured and installed, the present invention would provide a float switch assembly of sturdy construction that is primarily contemplated for use in in-line condensate collection applications, but which is also useful in auxiliary and other applications, to terminate the introduction of new fluid into the fluid discharge line to which it is connected at the first sign of a blockage so as to prevent damage from fluid back-up and/or overflow. During in-line installation, the float switch body of the present invention that is used to activate a signal to promptly shut off the fluid-producing system, deploys and upwardly rises when only a small amount of fluid starts to collect in the main discharge line as a result of a full or partial blockage of the main discharge line due to build up of algae, rust, mold, and/or other debris. Similarly, when one end of the present invention tubular member is capped and installed in an auxiliary capacity, it will be positioned to maintain fluid communication with the main discharge line, and when a blockage occurs in the main discharge line causing fluid to be suddenly directed toward the auxiliary float switch body, it will also deploy to activate a shut-off signal in response to only a very small amount of fluid accumulation. For air conditioning condensate collection, the most preferred embodiment of the present invention is typically small and, although not limited thereto, preferred dimensions include a maximum height dimension of approximately two inches, a maximum width dimension less than approximately three inches, and a maximum length dimension of approximately four to six inches. An adjustable float switch body is positioned for its vertical movement within a float housing that is under or adjacent to, and downwardly depends from, a horizontally-extending tubular member so that the bottom end of the float housing is in a position lower than the tubular member. A float switch body is guided for vertical movement by a concentrically positioned shaft secured through the top of the float housing or tubular member, with the amount of float switch body displacement being adjustably defined by an upper lock-nut and a disk-shaped bottom stop that are both connected to the shaft, and which make the float switch body readily adaptable to a wide variety of applications and changing needs. The threaded cap attached to the bottom open end of the float housing gives easy inspection/maintenance access to the float switch body and an opportunity for an operator to check for debris/rust/mold/algae in the connected condensate line. The float switch body has a large surface area for enhanced buoyancy and improved responsiveness during operation, with the float housing having an inner wall closely positioned around the float switch body to separate the float switch body from the main water flow during normal operation and provide an area between the wall and the float switch body of very small volume, so that even a very small amount of fluid can cause the float switch body to rise and shut off the source of fluid production. Although a circular cross-section is one possible configuration for the float switch body and its surrounding float housing, other configurations are also contemplated, such as but not limited to octagonal and a configuration whereby the center portion of the float switch body has a greater height dimension than its circumferential portion. The cap closing the open bottom end of the float housing is preferably threaded and securely sealed with an o-ring to provide a leak-resistant connection. Internally and externally threaded caps are contemplated as a part of the present invention. Further, the large dimension of the tubular member and wider end of the maintenance port accessory permit operation without air vent openings being required to prevent an airlock malfunction. Electrical wires extending through the top of the shaft provide the electrical connection needed with an associated fluid-producing system, so that collection of a very small amount of water (such as but not limited to 7.5 ml or 1.5 teaspoons) as a result of a blockage in a main fluid discharge line is able to deploy the float switch body and promptly cause a signal to be sent to the fluid-producing system to interrupt its operation. The present invention is typically made from plastic, and thereby impervious to corrosion, which in combination with its sturdy construction avoids premature deterioration.
Although the description herein provides preferred embodiments of the present invention, it should not be construed as limiting its scope. For example, variations in the height and diameter of the float housing, float switch body, and shaft used; the number of threads used on the upper portion of the shaft for housing connection; the perimeter configuration and dimension of the lock-nut used to tighten the shaft to the housing; the configuration of the connector attached distally to the threaded wider end of the maintenance port accessory; and the number and spacing of protrusions on the outside surface of the bottom cap used to facilitate hand manipulation during installation and removal; in addition to those variations shown and described herein, may be incorporated into the present invention. Thus, the scope of the present invention should be determined by the appended claims and their legal equivalents, rather than being limited to the examples given.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a front view of a first preferred embodiment of the present invention for use with a fluid discharge line, and which has a float housing adjacent to and depending downwardly from a horizontally-extending tubular member whereby the bottom end of the float housing is positioned lower than the tubular member, a threaded cap attached to the otherwise open bottom end of the float housing, a vertically-oriented shaft centrally within the float housing and having an upper threaded portion that is secured centrally to the top of the float housing by a lock-nut so that the shaft can be used as a guide for vertical movement of a float switch body also positioned centrally within the float housing, but which is hidden from view in this illustration.
FIG. 2 is a top view of the first preferred embodiment of the present invention.
FIG. 3 is an end view of the first preferred embodiment of the present invention with a fluid deflecting surface positioned within the tubular member adjacent to the float housing.
FIG. 4 is a sectional end view of float housing, threaded cap, and the tubular member in the most preferred embodiment of the present invention with the shaft and float switch body positioned centrally within the float housing.
FIG. 5 is a top view of the o-ring used in the first preferred embodiment of the present invention to provide a watertight connection between the threaded cap and the external threads shown on the bottom end of the float housing.
FIG. 6 is an exploded end view of float housing, threaded cap, and the tubular member in the first preferred embodiment of the present invention with a shaft for a float switch body positioned centrally within the float housing and the opening for fluid communication between the tubular member and float housing visible.
FIG. 7 is an end view of a second preferred embodiment of the present invention with a fluid deflecting surface positioned within the tubular member adjacent to the float housing, a float switch body mounted within the float housing, the male threaded cap used for sealing the open bottom surface of the float housing, and the upwardly extending wall used for creating a contained area for fluid collection.
FIG. 8 is a top view of the second preferred embodiment of the present invention.
FIG. 9 is a bottom perspective view of the second preferred embodiment of the present invention with an open bottom end with female threads, a flattened top surface, and a central aperture through the top surface.
FIG. 10 is a top perspective view of the float switch body and male cap of the second preferred embodiment of the present invention with the float switch body poised above the male threaded cap used for sealing the open bottom end of the float housing shown in FIG. 9.
FIG. 11 is a perspective view of a preferred cap configuration used to adapt the second preferred embodiment of the present invention for auxiliary use.
FIG. 12 is a sectional view of the second preferred embodiment of the present invention with the float switch body within the float housing, the bottom end of which is sealed by a male threaded cap, and tubular member in association with the float housing and positioned so that the bottom end of the float housing is positioned lower than the tubular member.
FIG. 13 is a perspective view of the most preferred embodiment of the maintenance port accessory of the present invention usable in-line with a fluid discharge line connected to the present invention float switch assembly, with the accessory oriented for horizontal fluid flow and having a threaded wider end and an opposed non-threaded narrower end, with the threaded wider end having a distally secured installation-assisting connector and a capped extension with a large distal opening that outwardly depends from the distal portion of the wider threaded end and is in substantially perpendicular orientation thereto.
FIG. 14 is a side view of the most preferred embodiment of the maintenance port accessory of the present invention oriented for vertical fluid flow and having a threaded wider end and an opposed non-threaded narrower end, with an installation-assisting connector poised for distal attachment to the threaded wider end and a cap poised for threaded connection to the large distal opening in an extension that outwardly depends in substantially perpendicular orientation from the distal portion of the wider threaded end.
FIG. 15 is an end view of the most preferred embodiment of the maintenance port accessory of the present invention with a fluid-deflecting internal structure between a threaded wider end and an opposed non-threaded narrower end that facilitates flow of fluid and cleaning agents away from the connected fluid-producing system.
FIG. 16 is a sectional view of the most preferred embodiment of the maintenance port accessory of the present invention with the fluid-deflecting internal structure between the threaded wider end and the opposed non-threaded narrower end being visible through the non-threaded narrower end.
FIG. 17 is a side view of two first preferred embodiments and one horizontally-extending maintenance port accessory of the present invention in association with an air conditioner system, with one of the first preferred embodiments capped on its distal end connected to a auxiliary line attached to the air conditioner unit, with the other first preferred embodiment and the maintenance port accessory connected to the main condensate discharge line with the first preferred embodiment connected upstream from the maintenance port accessory.
FIG. 18 is a side view of one first preferred embodiment and one vertically extending maintenance port accessory of the present invention in association with an air conditioner system, with both connected to the main condensate discharge line extending from the air conditioner and the first preferred embodiment positioned upstream from the maintenance port accessory.
FIG. 19 is a side view of one first preferred embodiment and one maintenance port accessory of the present invention in association with an air conditioner system, with the first preferred embodiment capped on its distal end connected directly to the air conditioner unit, with the maintenance port accessory connected to the air conditioner's main condensate discharge line.
FIG. 20 is a side view of the one first preferred embodiment of the present invention in association with an air conditioner system, with the first preferred embodiment connected II between the air conditioner unit and the main condensate discharge line.
FIG. 21 is a side view of two first preferred embodiments of the present invention in association with an air conditioner system, with one of the first preferred embodiments capped on its distal end and directly connected to the air conditioner unit in an auxiliary capacity, and the other first preferred embodiment connected to the main condensate discharge line extending from the air conditioner.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-6 show a first preferred embodiment of the present invention float switch assembly, while FIGS. 7-12 disclose a second preferred embodiment of the present invention. The float switch assembly of the present invention is simple in design and can handle a large amount of fluid before its float switch body is affected. In addition, FIGS. 13-16 show the most preferred embodiment of a maintenance port assembly usable in-line with the float switch assemblies of the present invention when they are installed in a fluid discharge line, and FIGS. 17-21 illustrate several combinations of the first preferred embodiment, second preferred embodiment, and the maintenance port assembly that can be used in differing applications. However, it is to be understood that many variations in the present invention are possible and also considered to be a part of the invention disclosed herein, even though such variations are not specifically mentioned or shown. Similarly, all of the possible combinations of first preferred embodiment, second preferred embodiment, and the maintenance port assembly are not shown in FIGS. 17-21. As a result, a reader should determine the scope of the present invention by the appended claims.
FIGS. 1-6 show a first preferred embodiment 2 of the present invention shut-off switch, wherein the float switch body 42 is separated from the main condensate flow in tubular member 4, float switch body 42 is centered within a float switch housing partially off-set from tubular member 4, with float switch body 42 depending from the top surface of housing 6, in contrast to second preferred embodiment 30 in which the float switch body 42 depends form the top surface of tubular member 4. FIG. 1 shows a first preferred embodiment 2 of the present invention for in-line use with a fluid discharge line (shown in FIGS. 17-21 by the number 74), and which has a float housing 6 adjacent to and depending downwardly from a horizontally-extending tubular member 4 whereby the bottom end of the float housing 6 is positioned lower than the tubular member 4. Typically, the opposing ends of tubular member 4 have no threads 18, although a threaded connection is considered within the scope of the present invention. Routinely, and in the absence of a blockage in the main fluid discharge line (sown as number 74 in FIGS. 17-21) to which it is connected, fluid flowing through opening 20 in one end of tubular member 4 exits through the opposing end of tubular member 4. The circular cross-sectional configurations for tubular member 4 and float housing 6 that are shown in FIG. 1 are not critical. However, the circular cross-sectional configuration of tubular member 4 is preferred for ease of its connection to existing plumbing lines, most of which are circular in cross-section. Further, irrespective of the cross-sectional configuration of float housing 6, the float switch body used with it (identified by the number 42 in FIG. 4) must have a complementary configuration that permits deployment of float switch body 42 when only a very small amount of fluid is collected in float housing 6 as a result of a fluid back-up due to a blockage in the connected fluid discharge line 74. FIG. 1 also shows a threaded cap 8 attached to the otherwise open bottom end (not shown) of float housing 6 and used to seal it. Cap 8 or other sealing means used should be removable for maintenance and inspection purposes, as well as for replacement of float switch body 42 and shaft 40 when needed, and threaded attachment is preferred. It is also preferred for additional sealing means to be used with cap 8 to seal the open bottom end of float housing 6, such as but not limited to the o-ring 26 shown in FIG. 5. Although not critical, it is further preferred for cap 8 to have outwardly-extending rotation-assisting projections 16 so that when a user grasps the top/outside surface 22 of cap 8 with his or her hand, installation and removal of cap 8 can be easily accomplished by most adults without the use of rotation-assisting tools. FIG. 1 also shows the upper threaded portion 10 of a vertically-oriented shaft (shown by the number 40 in FIG. 5) extending centrally through the top of float housing 6 and secured in place by a lock-nut 12 and washer 14 so that shaft 40 can be used as a guide for vertical movement of the float switch body 42 positioned centrally within the float housing 6, as shown in FIG. 4. A disk-shaped stop 44 (also shown in FIG. 4) is removably attached to shaft 40 to define the lower boundary for movement of the float switch body 42 within housing 6 in response to changing fluid levels within float housing 6. Since disk-shaped stop 44 is easily removable from shaft 40, once cap 8 is removed from the open bottom end of housing 6, float switch body 42 can be promptly removed for inspection and/or replacement, as needed, and the distance through which float switch body 42 moves during its deployment to activate a shut-off signal for an associated fluid-producing system can be adjusted according to changing needs by reattaching stop 44 in higher or lower positions on shaft 40. In addition to raising and lowering stop 44 relative to shaft 10, other means can be used to adjust the maximum vertical displacement of float switch body 42 according to a specific application or need. In the alternative, although not shown, a second stop 44 with the same or different thickness dimension could be used in addition to, or in place of the stop 44 in FIG. 5, or the connection of the upper threaded portion 10 of shaft 40 can be altered to adjust the maximum vertical displacement of float switch body 42. Any combination of the above mentioned vertical displacement adjusting means can also be used. Although not shown in FIGS. 1-6, when the present invention is electrically connected to a fluid-generating system, the lead wires would be made to extend upwardly through the open top end of the upper threaded portion 10 of shaft 40. FIG. 2 is a top view of the first preferred embodiment 2 of the present invention showing that the upper threaded portion 10 of shaft 40 is centrally connected to the top of float housing 6 by lock nuts 12 and washer 14. FIG. 2 also shows threaded cap 8 attached to the bottom end of float housing 6, rotation assisting projections 16 on cap 8, and the opposing ends of tubular member 4 having no threads 18. FIG. 3 is an end view of first preferred embodiment 2 and having a fluid-deflecting member 24 positioned within tubular member 4 that routinely prevents fluid from entering float housing 6. As can be seen in FIG. 6, an enlarged area 28 above fluid-deflecting member 24 allows fluid communication between tubular member 4 and float housing 6 when a blockage occurs in the associated discharge line 74 to which it is connected. Fluid deflecting member or surface 24 should be sufficiently large to prevent inadvertent splashing of fluid into float housing 6 during routine operation when no back-up of fluid is present in the associated discharge line 74, but not so large as to impede the routine fluid flow through tubular member 4. FIG. 4 shows the float switch body 42 within float housing 6 and tubular member 4 off-set to one side of float housing 6. Two lock nuts and two washers aid in attaching the upper portion 10 of shaft 40 to float housing 6. In FIG. 4, the top lock nut 12 and washer 14 are not tightly positioned against the top of float housing 6, which may be the result of modification of the total vertical displacement of float switch body 42 during its deployment. FIG. 4 shows float switch body in its pre-deployment position, lower than the bottom of tubular member 4. The opening through tubular member 4 is largely unobstructed, with the exception of fluid-deflecting member 24. Float switch body 42 substantially fills the interior space within float housing 6 and is prevented from moving downward beyond shaft 40 by a stop-disk 44. FIG. 4 further shows cap 8 being attached to float housing 6 an o-ring between housing 6 and cap 8, and rotation-assisting projections 16 on cap 6 that are used in combination with the outside surface 22 of cap 8 for ease in hand tightening and loosening of cap 8, as needed. Float switch body 42 is large compared to the interior space within float housing 6 and substantially fills it. However, float switch body 42 does not have to have the cylindrical configuration shown in FIG. 4 and other shapes are contemplated, such as a generally football-shaped float switch body 42 with a central height dimension that is greater than its circumferential height dimension, or a float switch body 42 that has a cross-sectional configuration of a triangle, ellipse, pentagon, hexagon, octagon, or other regular or irregular curvilinear shape, can be used as long as float housing 6 has a complementary shape that permits float switch body deployment when only a very small amount of fluid is collected in float housing 6. FIG. 5 shows the o-ring 26 used in most preferred embodiment 2 to provide a watertight connection between threaded cap 8 and the external threads 18 shown on the bottom end of float housing 6, as shown in FIG. 4. Although not shown, o-ring 26 can also be used in the threaded connections of the maintenance port accessory 56 shown in FIGS. 13-16. FIG. 6 shows first preferred embodiment 2 having tubular member 4 in fluid communication with float housing 6 via enlarged opening 28, and the fluid deflecting member 24 within tubular member 4 in a position that allows routine travel of fluid (not shown) through the bottom portion of tubular member 4, while simultaneously providing a threshold fluid depth beyond which fluid will spill over into float housing 6. When sufficient fluid enters float housing 6, which typically is only a very small amount of fluid, it causes vertical deployment of the float switch body 42 within housing 6 and activation of a signal that turns off the associated fluid-producing system such as but not limited to the air conditioning system 72 in FIGS. 17-21. Fluid-deflecting member 24 is also configured to block cleaning agents introduced into the associated fluid discharge line 74 from easily making their way into float housing 6 and interfering with the proper deployment of float switch body 42. FIG. 6 also shows threaded cap 8 separated from the bottom end of float housing 6 to expose threads 17. A sufficient number of threads 18 should be present to provide a leak-proof closure of the bottom end of float housing 6. In addition, FIG. 6 shows lock-nut 12 and washer 14 upon the upper threaded portion 10 of shaft 40, but not secured against the top of housing 6, as they would be during normal function. The distal end of the upper threaded portion 10 of shaft 40 extends upwardly beyond housing 6 for the passage of electrical wires (not shown) needed to carry the shut-off signal activated by deployment of float switch body 42 to the fluid-generating system such as the air conditioning system 72 in FIGS. 17-21. Although not shown, the configuration of float housing 6 is not limited to the substantially cylindrical shape illustrated in FIG. 6, and in the alternative it can have a cross-sectional configuration of a triangle, pentagon, or other regular or irregular curvilinear shape, can be used as long as float switch body 42 has a complementary shape that permits float switch body deployment when only a very small amount of fluid is collected in float housing 6. Further, although not shown, tubular member 4 can have any cross-sectional configuration, although use of the commonly available cylindrical tubing is preferred for cost considerations. To adapt first preferred embodiment to auxiliary applications, a cap 8 is attached to one of the opposing ends of tubular member 4, as shown in FIGS. 17, 19, and 21.
FIGS. 7-12 show a second preferred embodiment 30 of the present invention shut-off switch, wherein the float switch body 42 is also separated from the routine condensate flow (not shown) entering tubular member 4 through opening 20, however, the float switch body 42 is centered within tubular member 4 with fluid flow being diverted around it by upstanding wall 32 attached to removable male threaded cap 34 above its threads 18, as shown in FIG. 10. Second preferred embodiment 30 also has a simple design and permits a large amount of fluid flow through tubular member 4 before float switch body 42 is affected by the fluid flow. Also, the enlarged space in this and other present invention embodiments allows for operation of float switch body 42 without air lock malfunction or the need for air holes through tubular member 4 to prevent air lock. The upper portion 10 of shaft 40 is connected by two lock nuts 12 and two washers 14 to the top surface of tubular member 4, in contrast to first preferred embodiment 2 in which float switch body 42 is secured to the top surface of the off-set float housing 6. The number and type of fasteners used to secure the upper portion 10 of shaft 40 in place during use is not critical in any embodiment of the present invention, whether lock nuts 12 and washers 14 similar to those used in FIGS. 7 and 8 are used, or not. FIGS. 7 and 8 show second preferred embodiment 30 with its float housing 6 positioned between its tubular member 4 and male threaded cap 34, with tubular member 4 directly above float housing 6 and removable male threaded cap 34 directly below float housing 6. A flattened top area 36 in the upper surface of tubular member 4 provides for the secure tightening of lock nuts 12 to fixedly position shaft 40 centrally within tubular member 4 and float housing 6 for proper and responsive vertical movement of float switch body 42. FIGS. 7 and 8 further show male threaded cap 34 having a hexagonal perimeter so that an adult using a hand over the outer surface 22 of cap 34, or using a rotation-assisting tool such as a wrench (not shown), can easily remove cap 34 to inspect, maintain the proper operation of, and/or replace float switch body 42, as often as is needed. As shown in FIGS. 7 and 10, cap 34 has an upwardly extending wall 32 above threads 18 that is used for creating a contained area (shown in FIG. 12 by the number 46) for fluid collection when a blockage occurs in the main condensate line 74 to which it is connected. FIG. 9 show the second preferred embodiment 30 having a combined float housing 6 and tubular member 4, with float housing 6 centered under and depending downwardly from tubular member 4. FIG. 9 further shows float housing 6 having an open bottom end with female threads 18, and tubular member 4 having a flattened top surface 36 with a central aperture 50 therethrough. The amount of threads 18 within float housing 6 should be sufficient to provide a leak-proof seal with male threaded cap 34, or other plugging or sealing means that provides the same functions of male threaded cap 34. FIG. 10 shows float switch body 42 and male cap 34 of the second preferred embodiment 30 of the present invention, with float switch body 42 poised above the male threaded cap 34 that is used for sealing the open bottom end of the float housing 6 illustrated in FIG. 9. In FIG. 10 it can be seen that float switch body 42 is only slightly smaller in diameter than the upstanding wall 32, so that as fluid accumulates in the space surrounded by wall 32 when a blockage (not shown) in the main condensate discharge line 74 occurs, very little fluid accumulation is needed before float switch body is raised to activate a signal for shutting off the fluid-producing system, such as but not limited to the air conditioner system 72 in FIGS. 17-21. The stop-disk 44 shown in FIG. 12 and used to maintain float switch body 42 on shaft 40 prior to upward deployment, is hidden from view in FIG. 10. FIG. 11 shows a preferred configuration of cap 8 used over one end of tubular member 4 to adapt the second preferred embodiment 30 for auxiliary use, similar to the use of first preferred embodiment 2 in FIGS. 17, 19, and 21. In addition, FIG. 12 shows the second preferred embodiment 30 having its float switch body 42 in its pre-deployment position lower than the bottom of tubular member 4. Very little space is present between float switch body 42 and the adjacent upstanding wall 32. A stop disk 44 prevents float switch body from traveling downward beyond shaft 40. Since stop 44, as well as lock nuts 12 and washers 14, are removable from shaft 40, shaft 40 and float switch body 42 can be removed from tubular member 4 for maintenance, inspection, and/or replacement, once the male threaded cap 34 that seals the open bottom end of float housing 6 is removed. FIG. 12 shows male threaded cap 34 secured to the bottom portion of float housing 6 with the aid of o-ring 26, and cap 34 having a bottom configuration with cut-out areas 54 that conserve material expense and facilitate molded production. Routinely, fluid flowing through the end opening 20 in tubular member 4 is met by upstanding wall 32 and deflected around float switch body 42 in a channel 52. When the quantity of fluid entering end opening 20 exceeds the height of upstanding wall 32, typically as a result of a blockage in the main fluid discharge line 74 to which it is connected, fluid will enter the confined space 46 around float switch body 42 where the accumulation of a very small amount of fluid, such as but not limited to 7.5cc or 1.5oz., will cause float switch body 42 to upwardly deploy and cause a shut-off signal to be sent to the fluid-producing system. It is particularly important for the float switch body 42 deployment to occur as a result of only a small amount of fluid collected in air conditioning applications, since the condensate it produces can continue to enter a connected discharge line for as much as 10-15 minutes after the system is turned off. First and second preferred embodiments, respectively 2 and 30 both have a compact housing design for prompt and cost effective installation in the close-fitting areas used to accommodate residential air conditioning air handlers. In addition they have a sturdy construction and design for responsive and reliable operation, and its float switch body 42 is readily capable of being installed in a level orientation for proper and reliable operation. Debris/rust/mold/algae in the condensate line 74 to which it is connected typically will not affect the float switch body 42 of the present invention as it is generally protected during routine operation from the fluid flowing through tubular member 4 by upstanding wall 32 or fluid-deflecting member 24. In addition, float switch body 42, float housing 6, tubular member 4, shaft 40, caps 8 and 34, as well as lock nuts 12 and washers 14 are all made from corrosion-resistant materials that resist premature deterioration and malfunction.
FIG. 13 shows the most preferred embodiment of the maintenance port accessory 56 of the present invention usable in-line with a fluid discharge line (such as the line 74 in FIGS. 17-21) that is also connected to one or more of present invention float switch assemblies, or other float switches (not shown), with accessory 56 oriented for horizontal fluid flow and having a threaded wider end 66 downstream of an opposed non-threaded narrower end 62. FIG. 13 also shows the threaded wider end 66 having a distally secured installation-assisting connector 60 with a hexagonal end configuration 68, and an extension 58 with an enlarged distal opening (shown by the number 76 in FIG. 14) that outwardly depends from wider threaded end 66. Extension 58 is not centered within wider threaded end 66, but located in an off-set position toward its threads 18. Also, extension 58 is in substantially perpendicular orientation to wider threaded end 66. FIG. 13 further shows a threaded cap 8 in place on the distal end of extension 58, and cap 8 having rotation-assisting projections 16 to assist a hand (not shown) attempting to remove cap 8 by grasping its outside surface 22. Rotation-assisting projections 16 in all present invention embodiments are non-critical, but preferred. Information markings 64 that indicate the direction of fluid flow when maintenance port accessory 56 is in a horizontally-extending orientation are also shown in FIG. 13, and preferred. In contrast, FIG. 14 shows the most preferred embodiment of the maintenance port accessory 56 oriented for vertical fluid flow and having its threaded wider end 66 above its opposed non-threaded narrower end 62. An installation-assisting connector 60 is poised for attachment to threaded wider end 66 and a cap 8 is poised for removable threaded connection to the large distal opening 78 in extension 58 that outwardly depends in substantially perpendicular orientation from wider threaded end 66 in a position remote from non-threaded narrower end 62. Although FIG. 14 shows a vertical orientation wherein maintenance access to wider threaded end 66 is from its side and fluid flow is substantially vertical, FIG. 18 shows a different vertical application of maintenance port accessory 56 where the maintenance access to wider threaded end 66 is from its top and fluid flow makes a downward right angle and substantially changes direction from substantially horizontally-extending to vertical. FIG. 14 further shows information markings 64 that indicate the direction of fluid flow when maintenance port accessory 56 is in a vertically-extending orientation, which are preferred. Although connector 60 with its hexagonal tool-assisting collar 68 can be used with bonding agents to secure the threaded wider end 66 or extension 58 of second preferred embodiment 30 to a fluid discharge line, it is also contemplated for common plumbing connections to also be used. FIG. 15 looks through the non-threaded narrower end 62 of maintenance port accessory 56 toward its threaded wider end 66. The hexagonal tool-assisting collar 68 of connector 60 is visible behind threaded wider end 66. The downward direction of fluid flow from non-threaded narrower end 62 into threaded wider end 66 is evident in FIG. 15, which facilitates flow of fluid and cleaning agents away from the connected fluid-producing system, such as but not limited to air conditioning system 72 in FIGS. 17-21. FIG. 15 further shows maintenance port accessory 56 in a substantially horizontally-extending orientation, with cap 8 sealing the enlarged open end 76 of extension 58 via threads 18, and informational markings on the outside surface of cap 8. Although FIGS. 13-16 do not show any surface texture or additional informational markings 64 on threaded wider end 66, extension 58, or non-threaded narrower end 62, it is not contemplated for the informational markings 64 and surface texture in any embodiment of the present invention to be limited to that shown. FIG. 16 shows the most preferred embodiment of maintenance port accessory 56 with its fluid-deflecting internal structure 70 between its threaded wider end 66 and its opposed non-threaded narrower end 62. FIG. 16 also shows extension 58 on the wider threaded end 66 of maintenance port accessory 56 in a position remote from non-threaded narrower end 62. It is preferred that the positioning of extension 58 be as close to the threads 18 wider threaded end 66, while still allowing a cap 8 to be attached simultaneously to wider threaded end 66 and the distal end of extension 58. The closer extension 58 is to non-threaded narrower end 62, the more opportunity there is for fluids and cleaning agents (not shown) to move past fluid-deflecting internal structure 70 and make their way into non-threaded narrower end 62. Since maintenance port accessory 56 is in a horizontally-extending position, wider threaded end 66 would be positioned downstream from non-threaded narrower end 62 and fluid flow would move first through non-threaded narrower end 62. As any fluid passes beyond fluid-deflecting internal structure 70, the arcuate structure of internal structure 70 would deter casual movement of fluid back toward non-threaded narrower end 62. Also, where cleaning agents are added through the enlarged opening 78 in extension 58, fluid-deflecting internal structure 70 would also deter its movement toward non-threaded narrower end 62, and instead encourage movement through wider threaded end 66. The informational markings 64 on the outside surface 22 of cap 8 are not critical. The large size of opening 78 in extension 58, in combination with the enlarged diameter of wider threaded end 66, allows the addition of cleaning agents through opening 78 without air-lock malfunction and often without the need of a funnel. In horizontally-extending applications the fluid-deflecting internal structure 70 discourages back-flow of cleaning agents (not shown) added through opening 78 from reaching the connected fluid-producing system, while in vertical applications the fluid-deflecting internal structure facilitates splash-free downward flow of cleaning agents added through opening 78.
Although the outer surfaces of tubular member 4, housing 6, cap 8, threaded wider end 32, and narrower non-threaded end 30 are shown in FIGS. 1-21 to be generally unadorned, with the exception of informational markings 64, they may have any surface texture or other markings that do not interfere with the intended application. The configuration of connector 60 is not limited to that shown in FIGS. 13-16, and connector 60 may have any configuration appropriate to the application that adapts threaded wider end 66 for connection to the fluid discharge line (not shown). Also, for manufacturing ease and to reduce cost, although not limited thereto, it is contemplated for all caps 8 connected to the threads 18 on first preferred embodiment 2, second preferred embodiment 30, and maintenance port accessory 28 to be the same size. Adaptation of first preferred embodiment 2 or second preferred embodiment 30 from its usual in-line application to auxiliary use, can be accomplished by the use of a cap 8 or other conventional sealing or plugging means (not shown) to permanently or temporarily block one end of tubular member 4. Further, although the relative dimensions of housing 6 and tubular member 4 can be varied from that shown in FIGS. 1-12, and the relative dimensions of the components of maintenance port accessory 58 can be varied from that shown in FIGS. 13-16, such dimensions are not critical as long as each is sufficiently large to fulfill its intended function without undue material waste.
FIGS. 17-21 show several examples of present invention use with an air conditioning system, with the combined shut-off switch and float housing being used in both in-line and auxiliary applications. However, it is contemplated for other installation configurations to also be possible using varying combinations of first preferred embodiments 2, second preferred embodiments 30, maintenance port accessories 56, caps 8 and 34, and connectors such as but not limited to connector 60 with its hexagonal base 68 that facilitates tool-assisted connection. FIG. 17 shows two first preferred embodiments 2 and one horizontally-extending maintenance port accessory 56 of the present invention in association with an air conditioner system 72. One of the first preferred embodiments 2 has a cap 8 on the distal end of its tubular member (shown in FIG. 1 by the number 4), with the opposing end of tubular member 4 being connected to a auxiliary line 76 attached to air conditioner unit 72. The tubular member 4 of the other first preferred embodiment 2 and the maintenance port accessory 56 are connected to the main condensate discharge line 74, with first preferred embodiment 2 connected upstream from maintenance port accessory 56. In most applications it is preferred for first preferred embodiment 2 to be connected upstream from maintenance port accessory 56. Although not shown, it is contemplated for the tubular member 4 of the first preferred embodiment 2 and maintenance port accessory 56 to be secured to air conditioner unit 72, auxiliary line 76, and/or main condensate discharge line 74 using conventional plumbing connection means. As shown in FIG. 2, the external threads 18 (shown in FIG. 14) on maintenance port accessory 56 can be used to aid the secure connection between maintenance port accessory 56 and main condensate discharge line 74, or, as shown in FIG. 1 the secure connection between maintenance port accessory 56 and main condensate discharge line 74 can be achieved by means other than external threads 18. FIG. 18 shows one first preferred embodiment 2 and one vertically extending maintenance port accessory 56 of the present invention in association with an air conditioner system 72, with both connected to the main condensate discharge line 74 extending from the air conditioner system 72 and the first preferred embodiment 2 positioned upstream from the maintenance port accessory 56. FIG. 19 shows one first preferred embodiment and one maintenance port accessory 2 of the present invention in association with an air conditioner system 72, with the first preferred embodiment 2 having a cap 8 on the distal end of its tubular member 4 and its other end connected directly to the air conditioner system 72, and further with the maintenance port accessory 56 connected to the air conditioner's main condensate discharge line 74. FIG. 20 shows one first preferred embodiment 2 of the present invention in association with an air conditioner system 72, with the first preferred embodiment 2 having one of the ends of its tubular member connected directly to the air conditioner system 72 and the main condensate discharge line 74 connected to the other end of its tubular member 4. FIG. 21 shows two first preferred embodiments 2 of the present invention in association with an air conditioner system 72, with one of the first preferred embodiments 2 having a cap 8 on the distal end of its tubular member 4 and the other end of its tubular member 4 directly connected to the air conditioner system 72 in an auxiliary capacity. The tubular member of the other first preferred embodiment 2 in FIG. 21 is connected to the main condensate discharge line 74 that extends from the air conditioner system 72.
The materials from which the first preferred embodiment 2, second preferred embodiment 30, and maintenance port accessory 58 are made can vary, but must be impervious to corrosion. Preferably for cost considerations, although not limited thereto, it is contemplated for housing 6, float switch body 42, stop 44, shaft 40, lock-nuts 12, and washers 14 to all be made from plastic. Resistance to UV radiation is not necessarily a contemplated feature of the present invention, unless dictated by the application. Manufacture of the present invention first preferred embodiment 2, second preferred embodiment 30, and the associated but optional maintenance port accessory 58 could be accomplished by blow molding, injection molding, assembly of pre-formed individual components, or a combination thereof, with the choice of manufacturing being determined by the anticipated purchase cost to consumers and the expected duration of use without maintenance, parts replacement, or repair. Although size of the present invention is not critical, for many condensate collection applications, the width and height dimensions of the combined housing 6 and bottom cap 8 would be less than three inches. Embodiments of the present invention can be used for residential or commercial applications, and in new construction as well as retrofit applications.
Prior to use of the most preferred embodiment 2 of the present invention float switch assembly for an in-line installation in a main fluid discharge line 74, float switch body 42 would be positioned on shaft 40 so that electrical wires (not shown) extend upwardly beyond its upper threaded portion 10. Preferably, the upper threaded portion 10 of shaft 42 would then be inserted through the central opening in the top surface of housing 6 with the two lock-nuts 12 so that the remainder of shaft 40 is vertically extending through housing 6 with float switch body 42 substantially filling the interior space within housing 6. Washers 14 can also be optionally used in association with lock-nuts 12. Stop 44 would be fixed to the bottom portion of shaft 40 to adjustably define the lower boundary of float switch body 42 displacement vertically along shaft 40 during use, with adjustment further being possible through the repositioning of lock-nuts 12. The adjustment and positioning of float switch body 42 would be governed by the application and the depth of fluid needed to cause float switch body 42 to rise and send a signal to the system producing the fluid so as to cause termination of fluid flow through the main discharge line 74 to which housing 6 is connected. Any connector or combination of connectors, such as but not limited to connector 60, can be used to facilitate the in-line connection of the opposing ends of tubular member 4 to main fluid discharge line 74. Once housing 6 is in a secured and usable position, the installer or operator would check it for the stable and level positioning required for reliable and uninhibited vertical movement of float switch body 42, and make any adjustment needed to ensure that float switch body 42 moves freely using shaft 40 as a guide for its up and down movement. It is important to note that in the absence of water or other fluid in housing 6, float switch body 42 is positioned lower than the bottom of the main fluid discharge line 74, so that only a very small amount of condensate or other fluid is needed to activate float switch body 42 and cause it to rise to the level needed to activate a fluid terminating signal. The electrical wires (not shown) extending from the upper threaded portion 10 of shaft 40 would then be connected to the system providing the water, condensate or other fluid traveling through the main discharge line 74 in fluid communication with housing 6. Then, when collected fluid fills housing 6 beyond a pre-determined depth that is considered to be safe to prevent a risk of back-up into the fluid-producing system and indicates at least a partial blockage of main fluid discharge line 74, the present invention float switch body 42 is lifted by the rising fluid to the height that interrupts the system's operation and stops the introduction of new fluid into the main discharge line 74. The inner configuration of the connection of tubular member 4 to housing 6 prevents the creation of an airlock within housing 6 that could potentially interfere with the proper vertical movement of float switch body 42. Such inner configuration also protects float switch body 42 from the fluid in main fluid discharge line 74 until a blockage occurs in main fluid discharge line 74 causing a portion of the fluid therein to enter housing 6. Minimal maintenance is contemplated. If housing 4 is made from translucent, transparent, or partially transparent materials, an operator could visibly assess the effective operation of float switch body 42 without removing it from housing 6 for inspection. For adaptation of most preferred embodiment 2 of the present invention float switch assembly for an auxiliary installation (not shown), one of the ends of tubular member 4 would be sealed with a cap 8 or other conventional means (not shown). Other installation and operation of preferred embodiment 2 would be similar to that already noted for in-line applications. Installation of maintenance port accessory 58 would also be similar to that already noted for in-line applications of preferred embodiment 2, with connector 60 or other connector (not shown) being used with wider threaded end 66 according to the application to complete the in-line connection. The non-threaded narrower end 62 of maintenance port accessory 58 would be bonded via conventional means to the fluid discharge line 74. Maintenance port accessory 58 can be positioned upstream or downstream from first preferred embodiment 2 or second preferred embodiment 30 in its connection to a fluid discharge line 74. Further, maintenance port accessory 58 is not limited to use only in main fluid discharge line 74 applications, and can be used in auxiliary line 76 or other applications when a need for its presence is recognized.

Claims

1. A multi-purpose float switch assembly for use in-line with a main fluid discharge line connected to a fluid-producing system, to shut off the system when blockage of the main fluid discharge line occurs so that fluid in the main fluid discharge line will be prevented from backing up and damaging the system producing it, said assembly comprising:

a tubular member with opposing ends and an interior fluid-diverting member;

a housing having a top surface and an open bottom end, said housing depending from said tubular member and in fluid communication therewith, with said open bottom end being positioned lower than said tubular member, said housing also being positioned relative to said tubular member so that said interior fluid-diverting member prevents said fluid communication between said tubular member and said housing during routine fluid flow in the associated main fluid discharge line when no blockage occurs;

watertight closure means adapted for sealing said open bottom end of said housing;

a shaft with an upper threaded portion;

fastening means adapted for removably securing said shaft in a fixed position centrally within said housing;

a float switch body concentric with said shaft and positioned for free movement along said shaft; and

stop means adapted for removable attachment to said shaft and maintaining said float switch body on said shaft prior to upward float switch body deployment whereby the amount of upward vertical movement of said float switch body needed to activate a signal for shutting off the fluid-producing system in fluid communication with said assembly is adjusted in advance of deployment via said fastening means and said stop means according to a threshold fluid level pre-determined to pose a risk of harm to the fluid-producing system so that when electrical wires are connected between said float switch body and the fluid-producing system, and an amount of fluid accumulates in said housing to exceed the pre-determined threshold fluid level, said float switch body is caused to rise sufficiently to activate a signal that is sent via the connected electrical wires to the fluid-producing system to shut it off before it suffers any harm.

2. The assembly of claim 1 wherein said closure means is selected from a group consisting of caps having female threads, closures having male threads, and closures having male threads and an upstanding wall.

3. The assembly of claim 1 wherein said watertight closure means comprises an o-ring.

4. The assembly of claim 1 wherein said tubular members and said housings are selected from a group consisting of tubular members centered above a depending housing and tubular members adjacent to a laterally depending housing.

5. The assembly of claim 4 wherein said laterally depending housing is substantially centered between said opposing ends of said tubular member.

6. The assembly of claim 1 wherein said tubular member is centered above said housing and said fastening means secures said upper threaded portion of said shaft to said tubular member.

7. The assembly of claim 1 wherein said housing is laterally depending from said tubular member and said fastening means secures said upper threaded portion of said shaft to said top surface of said housing.

8. The assembly of claim 1 wherein said fastening means comprises at least one lock-nut.

9. The assembly of claim 1 wherein said upper threaded portion of said shaft has a top opening configured for the passage of electrical wires.

10. The assembly of claim 1 further comprising a sealing means adapted for watertight closing of one of said opposing ends of said tubular member to adapt said assembly for auxiliary application.

11. The assembly of claim 1 wherein said interior fluid-diverting member is selected from a group consisting of upstanding walls connected to a cap and fluid-diverting members connected to said tubular member.

12. The assembly of claim 1 further comprising a maintenance port accessory configured for in-line connection with said assembly in a fluid discharge line, said accessory having an enlarged threaded opening configured for the addition of fluids therethrough without the need for a funnel to prevent airlock that otherwise would block fluid entry, said accessory also having an easily removable closure means adapted for watertight sealing of said enlarged threaded opening.

13. The assembly of claim 1 further comprising a maintenance port accessory configured for in-line connection with said assembly in a fluid discharge line, said accessory having a wider threaded end, a narrower non-threaded end, and a fluid-deflecting internal structure between said wider threaded end and said narrower non-threaded end.

14. The assembly of claim 1 further comprising a maintenance port accessory configured for in-line connection with said assembly in a fluid discharge line, said accessory having a wider threaded end, a narrower non-threaded end, and a fluid-deflecting internal structure between said wider threaded end and said narrower non-threaded end, said accessory also having an extension substantially perpendicular to said wider threaded end and depending therefrom in a position remote from said narrower non-threaded end, said extension also having an enlarged opening configured for the addition of fluids therethrough without the need for a funnel to prevent airlock that blocks fluid entry, said accessory also having an easily removable closure means adapted for watertight sealing of said enlarged opening.

15. The assembly of claim 14 wherein said easily removable closure means of said accessory has a threaded connection to said extension.

16. The assembly of claim 14 wherein said narrower non-threaded end of said accessory has a bonded connection to the associated discharge line.

17. The assembly of claim 14 wherein said fluid-deflecting internal structure of said accessory is configured for positioning of said wider threaded end downstream from said narrower non-threaded end in horizontally-extending applications and upstream from said narrower non-threaded end in vertically-extending applications.

18. The assembly of claim 7 wherein said fluid communication between said tubular member and said housing occurs immediately above said interior fluid-diverting member.

19. The assembly of claim 1 wherein said tubular member is centered above said housing, said tubular member further comprises a flattened top area, and said fastening means secures said upper threaded portion of said shaft to said flattened top area.

20. The assembly of claim 19 wherein said flattened top area has a central aperture, and said fastening means secures said upper threaded portion of said shaft to said flattened top area so that said upper threaded portion extends at least partially through said central aperture.