GB2568072A - Gas Boiler Assembly and Method - Google Patents

Abstract

The invention relates to a gas boiler assembly for facilitating rapid installation and removal of a self-contained gas boiler unit 10. The assembly connects to a gas and water pipework array 20, and comprises a self-contained gas boiler unit, a bulkhead unit 18 and plural fluid couplings 22 which connect the bulkhead unit to the gas boiler unit. Each fluid coupling is flexible and provided with terminations which are releasably connectable to corresponding terminations on the gas boiler unit. The need for conventional copper pipework at replacement is eliminated, facilitating rapid disconnection of a defunct gas boiler unit without adversely affecting the subsequent reconnection of a different replacement or temporary gas boiler unit. The bulkhead unit may be mounted to the wall supporting the boiler and the assembly concealed within a domestic kitchen cupboard 12 having oversize blankable flue openings.

Description

GAS BOILER ASSEMBLY AND METHOD

The present invention relates to a gas boiler assembly and replacement method, and particularly, though not exclusively, to an assembly comprising a bulkhead for facilitating a rapid installation and removal method for a self-contained gas boiler unit.

In the United Kingdom, all domestic gas heating appliances should be safety checked and serviced annually by a licensed engineer appearing on the Gas Safe Register, i.e. the official gas registration body for the United Kingdom. Indeed, this is a legal requirement for landlords. The average lifespan of a domestic gas boiler has decreased from fifteen to twenty-five years, for old-style models having cast iron heat exchangers and basic functionality; down to ten to fifteen years for more modern versions having lightweight heat exchangers, electronic controls and sensors. The precise lifespan of any gas boiler depends on factors such as correct installation, maintenance, usage, manufacturer, and the availability of spare parts. Inevitably, all domestic gas boilers will reach a stage where either a complex repair is required which cannot be performed on-site or, if a repair is uneconomical, a replacement gas boiler becomes necessary.

In circumstances where a domestic gas boiler is not functional, or is deemed unsafe, the household will be left without space and water heating, perhaps for an extended period. The peak time of year for complex repairs or replacement occurs in the winter months when homeowners or tenants can least afford to be without space and water heating.

The process of removing and installing a domestic gas boiler is complex and time consuming and highly disruptive and stressful to a homeowner or tenant. Primarily this is due to size variation between the extant and replacement gas boilers units and consequent differences in pipe and flue configurations. Such differences will usually necessitate re-routing of existing copper pipework, a degree of minor building and redecoration work, and consequent post work clean up.

It is therefore an aim of the present invention to overcome, or at least ameliorate, one or more of the foregoing disadvantages by providing a a gas boiler assembly incorporating a manifold unit for facilitating rapid installation and removal of a domestic gas boiler apparatus. It is envisaged that such an assembly may be fitted either to a newly installed gas/water pipework system; or retrofitted to a pre-existing system.

According to a first aspect of the present invention there is provided a gas boiler assembly for connection to a gas and water pipework array, the assembly comprising:

(i) a self-contained gas boiler unit;

(ii) a bulkhead unit; and (iii) a plurality of fluid couplings for connecting the bulkhead unit to the gas boiler unit;

wherein each fluid coupling is flexible and is provided with terminations which are releasably connectable to corresponding terminations on the gas boiler unit.

It will be appreciated that, in the context of the present invention, the term self-contained domestic gas boiler unit” is intended to define a conventional one-piece complete boiler unit which, when installed to gas, water and flue connections in the conventional manner, would be fully-functional.

Optionally, the bulkhead unit is directly or indirectly mountable to a wall surface upon which the self-contained gas boiler unit is mountable.

Optionally, the bulkhead unit is partially or fully-enclosed within a housing comprising two or more of: (i) a left-side wall; (ii) a right-side wall; (iii) a base wall; (iv) a top wall; (v) a backwall; and (vi) a front wall or hinged or hooked door.

It will be appreciated that such a housing may serve to partially or completely conceal the gas boiler unit, the bulkhead unit, and the fluid couplings from sight. This may be particularly desirable when the gas boiler unit is, for example, wall-mounted within a domestic kitchen. The housing will be dimensioned to accommodate a wide range of manufacturers’ gas boiler units. The housing may also be designed to match the external style and colour scheme of surrounding kitchen cupboards and doors.

Optionally, a flue-opening is provided in an upper portion of two or more of: (i) the leftside wall; (ii) the right-side wall; (iii) the top wall; and (iv) the backwall.

It will be appreciated that by pre-forming a flue-opening in multiple surfaces around the upper portion of the housing an installing engineer is provided with the maximum degree of freedom to choose the optimal flue position in any given circumstances. Any unused flue-opening(s) may be closed off by a blanking plate to improve the external aesthetics of the housing.

Optionally, the bulkhead unit is indirectly mountable to a wall surface via the inner backwall and/or side walls of the housing.

Optionally, the backwall of the housing is formed from fire retardant material.

It will be appreciated that by forming the backwall of the housing from fire retardant material this will ensure that stricter mounting criteria specified by some gas boiler manufacturers is automatically met without the need for any further action on the part of an installing engineer.

Optionally, the bulkhead unit is in the form of a pedestal.

Optionally, the bulkhead unit defines a termination for a gas and water pipework array including one or more rigid pipes corresponding to a: (i) cold water supply; (ii) gas supply; (iii) hot water outlet; (iv) hot water return; (v) pressure relief; and (vi) condensate outlet.

Optionally, the bulkhead unit is provided with slots and/or apertures for locating the terminations of each rigid pipe within a gas and water pipework array.

Optionally, the termination-receiving slots and/or apertures are provided in a substantially horizontal base wall of the bulkhead unit.

Alternatively, the termination-receiving slots and/or apertures are provided in a substantially vertical upright wall of the bulkhead unit.

It will be appreciated that the bulkhead unit or pedestal defines a physical interface or boundary between a gas and water pipework array and the flexible fluid couplings.

Optionally, the flexible fluid couplings are in the form of flexible hoses.

It will be appreciated that any suitable types flexible hose having appropriate strength and fluid sealing characteristics may be employed such as braided, PVC or PEX hoses provided with compression, screw-fit, push-fit, or twist and lock fittings.

Optionally, an isolation valve is provided on at least one of the flexible fluid couplings at a position between the bulkhead unit and the gas boiler unit.

Optionally, each isolation valve is located at or proximate one, or both, distal ends of each fluid coupling.

It will be appreciated that by providing isolation valves somewhere along the lengths of the flexible couplings, this allows the gas boiler unit to be isolated and removed without the need to isolate and/or drain down the gas and water pipework array.

Optionally, each of the flexible fluid couplings are provided in lengths ranging from 100mm to 600mm.

It will be appreciated that such coupling lengths will, in most circumstances, eliminate the need to alter copper pipework by ensuring that the coupling lengths are sufficiently long to facilitate connection to gas boiler units of the smallest dimensions (i.e. where the distance between the bulkhead unit and boiler terminations is at a maximum). Similarly, such coupling lengths will, in most circumstances, avoid excessive bending of the couplings when connecting to larger gas boiler units (i.e. where the distance between the bulkhead unit and boiler terminations is at a minimum).

Optionally, the flexible fluid couplings and/or the bulkhead unit are provided with visually perceptible indicia to allow an installing engineer to match each pipe within a gas and water pipework array to its corresponding termination on a gas boiler unit.

It will be appreciated that the indicia may be in the form of alphanumeric and/or colour coding to assist an installing engineer with the process of matching each flexible fluid coupling to its corresponding termination on the gas boiler unit.

According to a second aspect of the present invention there is provided a method of replacing a defunct self-contained gas boiler unit forming part of a gas boiler assembly of the first aspect, the method comprising the steps of:

(i) isolating the flexible fluid couplings and/or the defunct gas boiler unit from a gas and water pipework array;

(ii) disconnecting the terminations of each flexible fluid coupling from the defunct gas boiler unit;

(iii) removing the defunct gas boiler unit from its mounting;

(iv) mounting a replacement gas boiler unit;

(v) reconnecting the terminations of each flexible fluid coupling to the corresponding terminations of the replacement gas boiler unit; and (vi) reversing the isolation to a gas and water pipework array.

It will be appreciated that the provision of flexible fluid couplings facilitates rapid disconnection of the defunct gas boiler unit without adversely affecting the subsequent reconnection of a replacement gas boiler unit. A replacement (or temporary) gas boiler unit may be rapidly installed in place of the defunct gas boiler unit irrespective of whether the respective boiler units are of different brands and/or dimensions and/or exhibit different termination or flue configurations.

Optionally, the method includes the additional steps of disconnecting any exhaust flue from the defunct gas boiler unit; and reconnecting the exhaust flue to the replacement gas boiler unit.

Typically, the exhaust flue would be reconnected to the replacement gas boiler unit prior to reconnecting the terminations of each flexible fluid coupling to the corresponding terminations of the replacement gas boiler unit. However, the precise sequence of the method steps is not crucial to the functioning of the invention.

Further features and advantages of the first and/or second aspects of the present invention will become apparent from the claims and the following description.

Embodiments of the present invention will now be described, by way of example only, with reference to the following diagrams, in which:

Fig. 1 is a schematic representation of a gas boiler assembly according to the present invention partially enclosed within a housing; and

Fig. 2 is a schematic multi-view projection showing front, underside, plan and two side views of a gas boiler assembly fully enclosed within a housing and provided with a rear flue exit position.

A self-contained conventional gas boiler unit 10 is shown in Fig. 1 enclosed within a housing 12 comprising a top wall 12a, a base wall 12b, a rear wall 12c, and two side walls 12d, 12e. At least the rear wall 12c may be formed of a fire-retardant material to thus satisfy installation requirements of certain gas boiler unit types. A front wall or door 12f has been omitted from Fig. 1 but may be hinged to the top wall 12a or one of the side walls 12d, 12e to fully conceal the gas boiler unit 10 during normal use, as shown in Fig. 2. The housing 12 may be appropriately dimensioned to accommodate a wide range of differently sized gas boiler unit models from different manufacturers. For example, in a non-limiting embodiment the housing measurements are: height = 1342mm; depth = 335mm; and width = 600mm. Preferably, the housing 12 may will be designed to match the external dimensions, style and colour scheme of existing cupboard units and doors within, for example, a domestic kitchen.

A series of four flue-openings 14 are provided in upper portions of the left-side wall 12d, the right-side wall 12e, the top wall 12a, and the backwall 12c to thereby provide an installing engineer with the freedom to connect the exhaust flue 16 in the most convenient manner in any given circumstances. In the non-limiting example of Fig. 1, the flue-opening 14 located in the upper portion of the rear wall 12c of the housing 12 has been selected in view of the overall dimensions of the gas boiler unit 10 and the relative location of an external wall. The remaining three unused flue-openings 14 may optionally be closed off by a blanking plate to improve the external aesthetics of the housing 12.

An over-sized flue-sleeve (not shown) may be provided for extending through an external wall to the external environment. In a non-limiting example, the over-sized flue-sleeve is provided with an internal diameter of 125mm, thus easily accommodating a typical exhaust flue 16, having a diameter of 100mm, whilst still allowing space for any required positional adjustment therein.

In the specific embodiment of Fig. 1 a bulkhead unit in the form of a horizontal pedestal 18 is attached between lower portions of the opposing inner side walls 12d, 12e of the housing 12. The pedestal 18 serves as a physical interface or boundary between a preexisting (or newly installed) gas and water pipework array 20 and a series of corresponding flexible hoses 22. The pipework array 20 may comprise conventional copper or otherwise rigid pipes corresponding to any or all of a: (i) cold water supply; (ii) gas supply; (iii) hot water outlet; (iv) hot water return; (v) pressure relief; and (vi) condensate outlet. Each of these pipes within the pipework array 20 extends through an aperture 24 formed in the base wall 12b of the housing 12 and terminates at, or proximate, the upper surface of the pedestal 18 within suitably dimensioned slots and/or apertures 18a (see Fig. 2). Some or all of the pipes within the pipework array 20 may terminate with an isolation valve (not shown). Additionally, or alternatively, a termination valve may be provided on each flexible hose 22 at a position between the pedestal 18 and the gas boiler unit 10.

The series of flexible hoses 22 having lengths in the range of 100mm to 600mm are connected between corresponding terminations on the pedestal 18 and on the underside of the gas boiler unit 10, respectively. Alphanumeric and/or colour coding may be provided on the pedestal 18 and/or on each flexible hose 22 to assist an installing engineer in matching each flexible hose 22 to its corresponding termination (not shown) on the gas boiler unit 10. Each flexible hose 22 may be formed from an appropriate flexural material suitable for the overriding purpose of conveying water and/or gas in a safe and reliable manner. For example, steel braided or PVC/PEX hoses with appropriate terminations may be utilised.

The gas boiler assembly of the present invention may be installed within a new build property, or retrofitted later such as when removing or replacing a gas boiler unit. The housing 12 is attached to a wall in the desired location such as within a domestic kitchen. Mounting holes may be pre-formed in, for example, the backwall 12c to facilitate such attachment. Conveniently, the aperture 24 formed in the base wall 12b of the housing 12 allows the distal ends of a pipework array 20 of, for example, conventional copper piping to be routed to the underside of the pedestal 18. Suitable terminations are provided at, or immediately above, the horizontal upper surface of the pedestal. These may include isolation valves.

The housing 12 is now ready to receive a new (or replacement) gas boiler unit 10 which may be mounted to its rear wall 12c by means of any supplied wall mounting bracket kit in a conventional manner. The precise mounting position of the gas boiler unit 10 within the housing 12 will take account the optimal flue exit. Once the gas boiler unit 10 is secure position, an over-sized flue-sleeve may be extended through the nearest external wall, and an exhaust flue 16 located therethrough. The over-sized nature of the fluesleeve allow a degree of tolerance for positional adjustment when the exhaust flue 16 is positioned therein, extended through the appropriate flue-opening 14, and attached to the flue vent of the gas boiler unit 10. The remaining three unused flue-openings may be closed off using blanking plates and/or air vents to improve the overall external aesthetics of the housing 10.

The gas boiler unit 10 is now ready to be connected to the gas and water pipework array

20. Crucially, this pipework array 20 terminates at the pedestal 18 and hence avoids the time-consuming and skilled task of bending, cutting (or lengthening), and terminating each individual copper pipe leading to the gas boiler unit. Instead, an installing engineer is faced with the significantly more straightforward task of connecting the flexible hoses 22 which extend from the pedestal 18 to the corresponding terminations on the underside of the gas boiler unit 10. The isolation valves between the pedestal and the gas boiler unit may then be opened to allow flow of gas and water.

It will be appreciated that the greatly simplified installation task facilitated by the gas boiler assembly of the present invention can be performed with basic tools and without the need for any specialist skills or techniques such as may be required to accurately and safely bend and terminate conventional copper piping. The reduced time and skillset required on the part of the installing engineer translates into a significant reduction of onsite time and hence a reduced overall installation cost for the customer.

It will also be appreciated that the gas boiler assembly of the present invention also facilitates easy disconnection and removal of a gas boiler unit 10 requiring off-site repair or replacement. The process of removing a gas boiler unit 10 involves isolating the gas and water flow through each flexible hose 22 using the appropriate isolation valves. The flexible hoses 22 which extend from the pedestal 18 to the corresponding terminations on the underside of the gas boiler unit 10 may then be disconnected. Similarly, the exhaustflue 16 may also be disconnected from the flue vent on the upper part of the gas boiler unit. The gas boiler unit 10 may then be demounted from any support bracket attached to the rear wall 12c and removed from the housing 12.

If a like-for-like replacement is being made, the replacement boiler is simply re-installed by means of the process already described above. Even if a new gas boiler unit of a different size and/or type is being fitted as a replacement, this will only require minimal amount of additional work on the part of the installing engineer. For example, a new mounting bracket may be required, and new flue exit and pipe configurations may need to be taken into account. Importantly, all works performed by the installing engineer are contained within the housing 12.

Such is the simplicity of the task of removing and replacing a gas boiler unit 10 that complex repairs need no longer be performed in-situ within the customer’s premises. Instead, a defective gas boiler unit 10 may be removed for repair in a controlled environment where space, tools and spare parts are readily available, and a temporary gas boiler unit installed in its place whilst the repair is in progress. This arrangement ensures almost uninterrupted water and space heating capability which may be particularly beneficial during winter months. Furthermore, this capability will be particularly attractive to both private and social landlords who may be contractually obliged to provide alternative means of heating and/or to compensate tenants who are left without a functioning system for an extended period.

Although specific embodiments of the invention have been disclosed herein in detail, these are not intended to be limiting with respect to the scope of the appended claims. Indeed, it is contemplated by the inventor that various substitutions, alterations, and modifications may be made to the invention without departing from the scope of the invention as defined by the claims.

Claims (18)

1. A gas boiler assembly for connection to a gas and water pipework array, the assembly comprising:

(i) a self-contained gas boiler unit;

(ii) a bulkhead unit; and (iii) a plurality of fluid couplings for connecting the bulkhead unit to the gas boiler unit;

wherein each fluid coupling is flexible and is provided with terminations which are releasably connectable to corresponding terminations on the gas boiler unit.

2. A gas boiler assembly according to claim 1, wherein the bulkhead unit is directly or indirectly mountable to a wall surface upon which the self-contained gas boiler unit is mountable.

3. A gas boiler assembly according to claim 1 or 2, wherein the bulkhead unit is partially or fully-enclosed within a housing comprising two or more of: (i) a left-side wall; (ii) a right-side wall; (iii) a base wall; (iv) a top wall; (v) a backwall; and (vi) a front wall or hinged door.

4. A gas boiler assembly according to claim 3, wherein a flue-opening is provided in an upper portion of two or more of: (i) the left-side wall; (ii) the right-side wall; (iii) the top wall; and (iv) the backwall.

5. A gas boiler assembly according claim 3 or 4, wherein the bulkhead unit is indirectly mountable to a wall surface via the inner backwall and/or side walls of the housing.

6. A gas boiler assembly according to any of claims 3 to 5, wherein the backwall of the housing is formed from fire retardant material.

7. A gas boiler assembly according to any preceding claim, wherein the bulkhead unit is in the form of a pedestal.

8. A gas boiler assembly according to any preceding claim, wherein the bulkhead unit defines a termination for a gas and water pipework array including one or more rigid pipes corresponding to a: (i) cold water supply; (ii) gas supply; (iii) hot water outlet; (iv) hot water return; (v) pressure relief; and (vi) condensate outlet.

9. A gas boiler assembly according to claim 8, wherein the bulkhead unit is provided with slots and/or apertures for locating the terminations of each rigid pipe within a gas and water pipework array.

10. A gas boiler assembly according to claim 9, wherein the termination-receiving slots and/or apertures are provided in a substantially horizontal base wall of the bulkhead unit.

11. A gas boiler assembly according to claim 9, wherein the termination-receiving slots and/or apertures are provided in a substantially vertical upright wall of the bulkhead unit.

12. A gas boiler assembly according to any preceding claim, wherein the flexible fluid couplings are in the form of flexible hoses.

13. A gas boiler assembly according to any preceding claim, wherein an isolation valve is provided on at least one of the flexible fluid couplings at a position between the bulkhead unit and the gas boiler unit.

14. A gas boiler assembly according to claim 13, wherein each isolation valve is located at or proximate one, or both, distal ends of each fluid coupling.

15. A gas boiler assembly according to any preceding claim, wherein each of the flexible fluid couplings are provided in lengths ranging from 100 mm to 600 mm.

16. A gas boiler assembly according to any preceding claim, wherein the flexible fluid couplings and/or the bulkhead unit are provided with visually perceptible indicia to allow an installing engineer to match each pipe within a gas and water pipework array to its corresponding termination on a gas boiler unit.

17. A method of replacing a defunct self-contained gas boiler unit forming part of a gas boiler assembly of the first aspect, the method comprising the steps of:

(i) isolating the flexible fluid couplings and/or the defunct gas boiler unit from a gas and water pipework array;

(ii) disconnecting the terminations of each flexible fluid coupling from the defunct gas boiler unit;

(iii) removing the defunct gas boiler unit from its mounting;

(iv) mounting a replacement gas boiler unit;

(v) reconnecting the terminations of each flexible fluid coupling to the corresponding terminations of the replacement gas boiler unit; and (vi) reversing the isolation to a gas and water pipework array.

18. A method according to claim 17, including the additional steps of disconnecting any exhaust flue from the defunct gas boiler unit; and reconnecting the exhaust flue to the replacement gas boiler unit.