US20160313049A1 - Condensate Collector and Trap - Google Patents
Condensate Collector and Trap Download PDFInfo
- Publication number
- US20160313049A1 US20160313049A1 US15/134,129 US201615134129A US2016313049A1 US 20160313049 A1 US20160313049 A1 US 20160313049A1 US 201615134129 A US201615134129 A US 201615134129A US 2016313049 A1 US2016313049 A1 US 2016313049A1
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- United States
- Prior art keywords
- furnace
- condensate trap
- cold header
- condensate
- hvac
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H8/00—Fluid heaters characterised by means for extracting latent heat from flue gases by means of condensation
- F24H8/006—Means for removing condensate from the heater
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
- F25D21/00—Defrosting; Preventing frosting; Removing condensed or defrost water
- F25D21/14—Collecting or removing condensed and defrost water; Drip trays
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H3/00—Air heaters
- F24H3/02—Air heaters with forced circulation
- F24H3/025—Air heaters with forced circulation using fluid fuel
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H3/00—Air heaters
- F24H3/02—Air heaters with forced circulation
- F24H3/06—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators
- F24H3/08—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by tubes
- F24H3/087—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by tubes using fluid fuel
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H3/00—Air heaters
- F24H3/02—Air heaters with forced circulation
- F24H3/06—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators
- F24H3/10—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by plates
- F24H3/105—Air heaters with forced circulation the air being kept separate from the heating medium, e.g. using forced circulation of air over radiators by plates using fluid fuel
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
Definitions
- Heating, ventilation, and/or air conditioning (HVAC) systems often include a furnace in many commercial and residential applications for heating and otherwise conditioning interior spaces. Operation of a gas-fired furnace typically produces condensation that travels from a secondary heat exchanger to a cold header of the furnace and drains into a condensate trap. Current furnaces may only be installed in a single vertical or horizontal position, which limits the available applications for a particular furnace.
- a heating, ventilation, and/or air conditioning (HVAC) furnace comprising: a cold header comprising a plurality of drain ports; and a condensate trap configured to attach to each of the plurality of drain ports, each drain comprising at least one mounting position for the condensate trap, wherein at least one of the drain ports comprises a plurality of mounting positions for the condensate trap.
- HVAC heating, ventilation, and/or air conditioning
- a heating, ventilation, and/or air conditioning (HVAC) system comprising: a furnace, comprising a cold header comprising a plurality of drain ports; and a condensate trap configured to attach to each of the plurality of drain ports, each drain comprising at least one mounting position for the condensate trap, wherein at least one of the drain ports comprises a plurality of mounting positions for the condensate trap.
- HVAC heating, ventilation, and/or air conditioning
- FIG. 1 is an oblique exploded view of a furnace according to an embodiment of the disclosure
- FIG. 2 is an orthogonal side view of the furnace of FIG. 1 according to an embodiment of the disclosure
- FIG. 3 is a front oblique exploded view of a condensate collection system according to an embodiment of the disclosure.
- FIG. 4 is a back oblique exploded view of the condensate collection system of FIG. 3 according to an embodiment of the disclosure.
- HVAC heating, ventilation, and/or air conditioning
- a furnace in a heating, ventilation, and/or air conditioning (HVAC) system that includes a cold header that allows a furnace to be rotated in multiple orientations.
- HVAC heating, ventilation, and/or air conditioning
- the condensate trap may be located on one of three drain ports, and two condensate trap orientations do not require removal of the condensate trap from the cold header, only a rotation of the condensate trap from a pivot point on a drain port of the cold header.
- Multiple positions for the cold header and condensate trap increase the applications for which a particular furnace may be installed, despite the required orientation of the furnace within a particular application. Accordingly, the condensate trap can be easily removed for inspection and cleaning.
- the furnace 100 may comprise a partition panel 110 , a burner box 122 , a gas supply valve 124 , a manifold pipe 126 , a burner 128 and/or a plurality of burners 128 , at least one first or upstream heat exchanger 130 , a hot header 132 , a second or downstream heat exchanger 134 , a cold header 140 , an inducer blower 150 , an igniter 154 , and a flame sensor 156 .
- the burner box 122 may be mounted to the partition panel 110 to direct an air-fuel mixture received from the gas supply valve 124 and/or the manifold pipe 126 toward the burner 128 .
- the burner box 122 may promote even distribution of the air-fuel mixture across a cross-sectional area of an air-fuel mixture flow path and/or may promote even distribution of the air-fuel mixture across an upstream side of the burner 128 .
- the burner 128 may be thin and/or compact and may occupy little space within the burner box 122 and/or the furnace 100 , especially in the upstream/downstream directions of primary air-fuel mixture flow, thereby providing a space efficient furnace 100 .
- the mixing of the air and fuel prior to entering the burner box 122 may be aided by the manifold pipe 126 and/or the burner 128 to promote homogenous mixing of the air and fuel prior to the combusted air/fuel mixture entering the upstream heat exchanger 130 .
- fuel may be introduced directly into the burner box 122 by the gas supply valve 124 .
- the gas supply valve 124 may be controlled electrically, pneumatically, or in any other suitable manner to obtain a beneficial air to fuel ratio for increased efficiency and lower NO x emissions.
- the gas supply valve may be configured for either staged operation or modulation type operation.
- staged operation may have two flow rate and/or capacity settings, where modulation type operation may be incrementally adjustable over a large range of flow rates, for example from 40% to 100% output capacity of the furnace 100 .
- the burner 128 may extend across substantially an entire cross-sectional area of the air-fuel mixture flow path.
- the air-fuel mixture may flow from the burner box 122 through the burner 128 and into the upstream heat exchanger 130 .
- the burner 128 may be permeable, such as to allow the air-fuel mixture to travel through the burner 128 without a substantial pressure drop across the burner 128 .
- the burner 128 may comprise a great number of small perforations over a substantial portion of the upstream and downstream sides of the burner 128 .
- a substantial portion of the upstream and downstream sides of the burner 128 may comprise one or more layers of woven material configured to allow the air-fuel mixture to flow therethrough.
- the burner 128 may comprise a combination of both perforations and woven material.
- the burner 128 may be received within a cavity formed by the coupling of the burner box 122 and the upstream heat exchanger 130 .
- the upstream side of the burner 128 may face the burner box 122
- an opposing downstream side of the burner 128 may face the upstream heat exchanger 130 .
- the upstream heat exchanger 130 may be further configured to output the combusted air-fuel mixture into multiple parallel flow paths, as will be discussed further herein.
- the one or more upstream heat exchangers 130 may be configured to receive an at least partially combusted air-fuel mixture downstream of the burner 128 and each upstream heat exchanger 130 may form a separate flow path downstream relative to the burner 128 . While the upstream heat exchangers 130 are disclosed as comprising a plurality of tubes, in alternative embodiments, the upstream heat exchangers 130 may comprise clamshell heat exchangers, drum heat exchangers, shell and tube type heat exchangers, and/or any other suitable type of heat exchanger.
- the downstream heat exchanger 134 may be configured to receive the at least partially combusted air-fuel mixture from the upstream heat exchanger 130 through the hot header 132 .
- the downstream heat exchanger 134 may comprise a fin-tube type heat exchanger and/or plate-fin type heat exchanger, either of which may comprise one or more tubes. In other embodiments, the downstream heat exchanger 134 may comprise a so-called clamshell heat exchanger. It will further be appreciated that combustion of fuel within the furnace 100 may result in the formation of condensation on the downstream heat exchanger 134 . Accordingly, as will be discussed in greater detail herein, condensate from the downstream heat exchanger 134 may travel to the cold header 140 and drain into a condensate trap 142 .
- the at least partially combusted air-fuel mixture may be transferred from the one or more upstream heat exchangers 130 to downstream heat exchanger 134 through the hot header 132 .
- furnace 100 is described above as comprising one burner 128 , alternative furnace embodiments may comprise more than one burner 128 .
- additional burners 128 may be utilized to increase an overall heating capacity.
- several burners 128 may be aligned in parallel, so that multiple parallel air-fuel mixture flow paths may be formed through the upstream heat exchanger 130 .
- furnace 100 is disclosed as comprising at least one upstream heat exchanger 130 and a downstream heat exchanger 134
- alternative furnace embodiments may comprise only one upstream heat exchanger 130 , no downstream heat exchanger 134 , and/or multiple downstream heat exchangers 134 .
- An igniter 154 may be mounted partially within the burner box 122 proximal to the downstream side of the burner 128 to ignite the air-fuel mixture a short distance downstream from the downstream side of the burner 128 .
- the igniter 154 may comprise a pilot light, a spark igniter, a piezoelectric device, and/or a hot surface igniter and may be controlled by a control system and/or may be manually ignited.
- the flame sensor 156 may comprise a thermocouple, a flame rectification device, and/or any other suitable safety device and be configured to detect the presence of a flame within the furnace 100 . In this embodiment, igniter 154 and flame sensor 156 are disposed within the burner box 122 .
- the air-fuel mixture may be moved in an induced draft manner by pulling the air-fuel mixture through the furnace 100 and/or in a forced draft manner by pushing the air-fuel mixture through the furnace 100 .
- the induced draft may be produced by attaching a blower and/or fan downstream, such as inducer blower 150 relative to the cold header 140 and pulling the air-fuel mixture out of the system by creating a lower pressure at the exhaust of the cold header 140 as compared to the pressure upstream of the burner 128 .
- Inducing flow in the above-described manner may protect against leaking the at least partially combusted air-fuel mixture and related products of combustion to the surrounding environment by ensuring the at least partially combusted air-fuel mixture is maintained at a pressure lower than the air pressure surrounding the furnace 100 . With such an induced flow, any leak along the flow path of the air-fuel mixture may result in pulling environmental air into the flow path rather than expelling the at least partially combusted air-fuel mixture and related products of combustion to the environment.
- the air-fuel mixture may be forced along the air-fuel mixture flow path by placing a blower or fan upstream relative to the burner 128 and creating higher pressure upstream of the burner 128 relative to a lower pressure at the exhaust of the cold header 140 .
- a control system may control the inducer blower 150 to an appropriate speed to achieve desired fluid flow rates for a desired firing rate through the burner 128 . Increasing the speed of the inducer blower 150 may introduce more air to the air-fuel mixture, thereby changing the characteristics of the combustion achieved by the burner 128 .
- a so-called zero governor regulator and/or zero governor gas valve such as gas supply valve 124 , may be additionally utilized to provide a desired fuel to air ratio in spite of the varying effects of an induced draft and/or other pressure variations that may fluctuate and/or otherwise tend to cause dispensing or more or less fuel in response to the pressure variations and/or negative pressures relative to atmospheric pressure.
- the condensate collection system 200 may generally comprise a cold header 140 and a condensate trap 142 .
- the cold header 140 may generally be formed from a plastic material and form an inner cavity 207 between an inner surface of the cold header 140 and the partition panel 110 .
- the cold header 140 comprises a plurality of mounting holes 202 for securing the cold header 140 to the partition panel 110 of the furnace 100 .
- the mounting holes 202 may comprise mounting tabs and/or a combination of mounting holes and/or mounting tabs.
- the inducer blower 150 may be mounted to the cold header 140 by securing it to the opening 204 in the cold header 140 .
- the cold header 140 may also comprise a plurality of mounting positions to allow the inducer blower 150 to be rotated with respect to the cold header 140 and/or the furnace 100 in at least four different orientations. In some embodiments, each orientation and/or mounting orientation of the blower 150 to the cold header 140 may coincide with a different installation orientation of the furnace 100 .
- the opening 204 may provide a fluid flowpath through the furnace 100 for an airflow generated by the inducer blower 150 .
- a seal 206 may provide for a fluid tight boundary between the cold header 140 and the partition panel 110 and between the opening 204 of the cold header 140 and the inducer blower 150 .
- the seal 206 may comprise sealant that is injected into the mold of the cold header 140 during manufacturing.
- the sealant 206 may comprise a gasket and/or any other apparatus that is configured to form a fluid tight boundary between the cold header 140 and the partition panel 110 and between the opening 204 of the cold header 140 and the inducer blower 150 .
- the cold header 140 also comprises at least one pressure port 208 .
- the pressure port 208 may comprise and/or be connected to a pressure sensor that is configured to monitor the system pressure within the cold header 140 and/or the furnace 100 .
- the cold header 140 may also comprise a plurality of drain ports 210 .
- the drain ports 210 may generally comprise a cylindrically-shaped body that extends from an outer surface of the cold header 140 .
- the drain ports 210 may also comprise a drain hole 211 that extends from the inner cavity 207 through the drain port 210 to allow condensation that collects in the cold header 140 to escape from the inner cavity 207 through the drain ports 210 .
- the cold header 140 may comprise three drain ports 210 , one at each lower corner of the cold header 140 and an additional drain port 210 at an upper left corner of the cold header 140 .
- the cold header 140 may comprise three drain ports 210 , one at each lower corner of the cold header 140 and an additional drain port 210 at an upper right corner of the cold header 140 .
- the cold header 140 may comprise four drain ports 210 , one at each corner of the cold header 140 .
- the cold header 140 may comprise drain ports 210 at each of the upper corners of the cold header 140 and an additional drain port 210 at either of the lower corners of the cold header 140 .
- the condensate trap 142 comprises a body 214 and a complimentary-shaped cover 224 .
- the body 214 and the cover 224 may generally be formed from a plastic material and be joined together to form a single component. In some embodiments, the body 214 and the cover 224 may be ultrasonically welded together. In other embodiments, the body 214 and the cover 224 may be molded as a single component and/or joined together in any other appropriate way so that the condensate trap 142 forms a fluid tight assembly between the body 214 and the cover 224 .
- the body 214 of the condensate trap 142 comprises at least one mounting hole 216 for securing the condensate trap 142 to the cold header 140 , internal baffles 218 that prevent the need for priming the condensate trap 142 during the heating off-season, an inlet port 220 configured to receive condensate from the cold header 140 , and a plurality of outlet ports 222 , while the cover 224 of the condensate trap 142 also comprises an outlet port 226 .
- the condensate trap 142 may be configured to attach to any one of the plurality of drain ports 210 of the cold header 140 to allow condensate to drain from the internal cavity 207 through a drain hole 211 of the drain port 210 and into the condensate trap 142 through the inlet port 220 of the condensate trap 142 .
- the condensate may flow through the plurality of internal baffles 218 , which may prevent the need for priming the condensate trap 142 during the heating off-season.
- the internal baffles 218 may also prevent condensate from backing up into the internal cavity 207 of the cold header 140 .
- the baffles 218 may prevent condensate from backing up into the internal cavity 207 of the cold header 140 by creating a pressure drop through the condensate trap 142 .
- the pressure drop created by the baffles 218 when coupled with a gravitational pressure caused by condensate within the condensate trap 142 , drives the condensate from the condensate trap 142 , thereby preventing from the condensate trap 142 from becoming completely full of condensate.
- condensate may pass through one of a plurality of outlet ports 220 in the body 214 and/or an outlet port 226 in the cover 224 of the condensate trap 142 .
- the outlet ports 222 may be connected to a hose and/or other tubular device for carrying away condensate from the condensate trap 142 .
- the cold header 140 is designed to allow the furnace 100 to rotate, operate, and/or be installed in four orientations without removing the cold header 140 from the partition panel 110 and/or the downstream heat exchanger 134 while still providing proper drainage of the condensate from the furnace 100 .
- the condensate trap 142 may generally be configured to attach to any one of the plurality of drain ports 210 of the cold header 140 .
- the condensate trap 142 may be attached so that the inlet port 220 of the condensate trap 142 is axially aligned with one of the drain ports 210 of the cold header 140 to allow condensation within the internal cavity 207 of the cold header 140 to flow through a drain hole 211 of a respective drain port 210 and enter the condensate trap 142 through the inlet port 220 of the body 214 of the condensate trap 142 .
- a gasket 212 may be placed between the inlet port 220 and the respective drain port 210 to form a fluid tight boundary between the inlet port 220 and the drain port 210 .
- the gasket 212 may comprise a circular seal, such as an O-ring gasket.
- the other drain ports 210 may comprise a plug, bung, and/or any other appropriate seal inserted at least partially into the drain holes 211 of the respective drain ports 210 to prevent condensate within the internal cavity 207 of the cold header 140 from escaping the cold header 140 through the unused drain holes 211 of the drain ports 210 .
- the at least one mounting hole 216 is generally configured for securing the body 214 and/or the condensate trap 142 to the cold header 140 .
- the mounting hole 216 may generally comprise a clearance hole and be configured to receive a screw and/or any other appropriate fastener therethrough, and the screw may generally thread into a complimentary threaded hole 213 of the cold header 140 to secure the body 214 and/or the condensate trap 142 to the cold header 140 .
- the cold header 140 is designed to allow the furnace 100 to rotate in four orientations without removing the cold header from the partition panel 110 and/or the downstream heat exchanger 134 while still providing the furnace 100 with appropriate drainage of condensate from within the cold header 140 and the condensate trap 142 .
- one of the drain ports 210 comprise two threaded holes 213 that allow the condensate trap 142 to rotate about the drain port 210 and be attached in multiple positions. More specifically, the lower left drain port 210 may comprise a first threaded hole 213 ′ for attaching the condensate trap 142 to the cold header 140 in a first position and a second threaded hold 213 ′′ for attaching the condensate trap 142 to the cold header 140 in a second position while using the same drain port 210 .
- the furnace may be oriented in two different orientations without having to remove the condensate trap 142 from the cold header 140 .
- the condensate trap 142 may be installed in four positions on three drain ports 210 for a single cold header 140 , allowing the furnace 100 to be installed in multiple orientations without requiring removal of the cold header 140 from the furnace 100 .
- the condensate trap 142 does not require removal to be installed in the two positions for a drain port 210 having multiple mounting positions, the other two positions require removal of the condensate trap 142 from the cold header 140 , but do not require removal of the cold header 140 from the furnace 100 .
- the condensate trap 142 may be rotated and/or relocated to a proper drain port 210 that allows the furnace to properly drain the condensate that collects in the internal cavity 207 of the cold header 140 .
- the hose that connects to the outlet port 222 may be removed and/or relocated to the opposing outlet port 222 to ensure proper condensate drainage from the condensate trap 142 .
- the condensate collection system 200 may allow proper drainage of condensate from the cold header 140 and subsequently the condensate trap 142 when the furnace 100 is installed in various orientations and/or configurations.
- R R l +k*(R u ⁇ R l ), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Unless otherwise stated, the term “about” shall mean plus or minus 10 percent of the subsequent value.
- any numerical range defined by two R numbers as defined in the above is also specifically disclosed.
- Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim.
- Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims.
- Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention.
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Abstract
Description
- The present application claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application No. 62/152,601 filed on Apr. 24, 2015 by Rosario Totaro, and entitled “Condensate Collector and Trap,” the disclosure of which is hereby incorporated by reference in its entirety.
- Not applicable.
- Not applicable.
- Heating, ventilation, and/or air conditioning (HVAC) systems often include a furnace in many commercial and residential applications for heating and otherwise conditioning interior spaces. Operation of a gas-fired furnace typically produces condensation that travels from a secondary heat exchanger to a cold header of the furnace and drains into a condensate trap. Current furnaces may only be installed in a single vertical or horizontal position, which limits the available applications for a particular furnace.
- In some embodiments, a heating, ventilation, and/or air conditioning (HVAC) furnace is disclosed as comprising: a cold header comprising a plurality of drain ports; and a condensate trap configured to attach to each of the plurality of drain ports, each drain comprising at least one mounting position for the condensate trap, wherein at least one of the drain ports comprises a plurality of mounting positions for the condensate trap.
- In other embodiments, a heating, ventilation, and/or air conditioning (HVAC) system is disclosed as comprising: a furnace, comprising a cold header comprising a plurality of drain ports; and a condensate trap configured to attach to each of the plurality of drain ports, each drain comprising at least one mounting position for the condensate trap, wherein at least one of the drain ports comprises a plurality of mounting positions for the condensate trap.
- For a more complete understanding of the present disclosure and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description:
-
FIG. 1 is an oblique exploded view of a furnace according to an embodiment of the disclosure; -
FIG. 2 is an orthogonal side view of the furnace ofFIG. 1 according to an embodiment of the disclosure; -
FIG. 3 is a front oblique exploded view of a condensate collection system according to an embodiment of the disclosure; and -
FIG. 4 is a back oblique exploded view of the condensate collection system ofFIG. 3 according to an embodiment of the disclosure. - In some instances, it may be desirable to provide a furnace in a heating, ventilation, and/or air conditioning (HVAC) system that includes a cold header that allows a furnace to be rotated in multiple orientations. For example, where a furnace may be appropriate for multiple different applications requiring different orientations, it may be desirable to provide a furnace with multiple mounting positions for the cold header and condensate trap to allow for proper condensate drainage from the cold header into the condensate trap. Additionally, the condensate trap may be located on one of three drain ports, and two condensate trap orientations do not require removal of the condensate trap from the cold header, only a rotation of the condensate trap from a pivot point on a drain port of the cold header. Multiple positions for the cold header and condensate trap increase the applications for which a particular furnace may be installed, despite the required orientation of the furnace within a particular application. Accordingly, the condensate trap can be easily removed for inspection and cleaning.
- Referring now to
FIGS. 1 and 2 , an oblique exploded view and an orthogonal side view of afurnace 100 are shown, respectively. Thefurnace 100 may comprise apartition panel 110, aburner box 122, agas supply valve 124, amanifold pipe 126, aburner 128 and/or a plurality ofburners 128, at least one first orupstream heat exchanger 130, ahot header 132, a second ordownstream heat exchanger 134, acold header 140, aninducer blower 150, anigniter 154, and aflame sensor 156. Theburner box 122 may be mounted to thepartition panel 110 to direct an air-fuel mixture received from thegas supply valve 124 and/or themanifold pipe 126 toward theburner 128. Theburner box 122 may promote even distribution of the air-fuel mixture across a cross-sectional area of an air-fuel mixture flow path and/or may promote even distribution of the air-fuel mixture across an upstream side of theburner 128. - The
burner 128 may be thin and/or compact and may occupy little space within theburner box 122 and/or thefurnace 100, especially in the upstream/downstream directions of primary air-fuel mixture flow, thereby providing a spaceefficient furnace 100. The mixing of the air and fuel prior to entering theburner box 122 may be aided by themanifold pipe 126 and/or theburner 128 to promote homogenous mixing of the air and fuel prior to the combusted air/fuel mixture entering theupstream heat exchanger 130. Alternatively, fuel may be introduced directly into theburner box 122 by thegas supply valve 124. Thegas supply valve 124 may be controlled electrically, pneumatically, or in any other suitable manner to obtain a beneficial air to fuel ratio for increased efficiency and lower NOx emissions. The gas supply valve may be configured for either staged operation or modulation type operation. For example, staged operation may have two flow rate and/or capacity settings, where modulation type operation may be incrementally adjustable over a large range of flow rates, for example from 40% to 100% output capacity of thefurnace 100. - In some embodiments, the
burner 128 may extend across substantially an entire cross-sectional area of the air-fuel mixture flow path. The air-fuel mixture may flow from theburner box 122 through theburner 128 and into theupstream heat exchanger 130. Theburner 128 may be permeable, such as to allow the air-fuel mixture to travel through theburner 128 without a substantial pressure drop across theburner 128. For example, theburner 128 may comprise a great number of small perforations over a substantial portion of the upstream and downstream sides of theburner 128. Alternatively, a substantial portion of the upstream and downstream sides of theburner 128 may comprise one or more layers of woven material configured to allow the air-fuel mixture to flow therethrough. Still further, in alternative embodiments, theburner 128 may comprise a combination of both perforations and woven material. - The
burner 128 may be received within a cavity formed by the coupling of theburner box 122 and theupstream heat exchanger 130. When theburner 128 is received within the above-described cavity, the upstream side of theburner 128 may face theburner box 122, and an opposing downstream side of theburner 128 may face theupstream heat exchanger 130. Theupstream heat exchanger 130 may be further configured to output the combusted air-fuel mixture into multiple parallel flow paths, as will be discussed further herein. - The one or more
upstream heat exchangers 130 may be configured to receive an at least partially combusted air-fuel mixture downstream of theburner 128 and eachupstream heat exchanger 130 may form a separate flow path downstream relative to theburner 128. While theupstream heat exchangers 130 are disclosed as comprising a plurality of tubes, in alternative embodiments, theupstream heat exchangers 130 may comprise clamshell heat exchangers, drum heat exchangers, shell and tube type heat exchangers, and/or any other suitable type of heat exchanger. Thedownstream heat exchanger 134 may be configured to receive the at least partially combusted air-fuel mixture from theupstream heat exchanger 130 through thehot header 132. Thedownstream heat exchanger 134 may comprise a fin-tube type heat exchanger and/or plate-fin type heat exchanger, either of which may comprise one or more tubes. In other embodiments, thedownstream heat exchanger 134 may comprise a so-called clamshell heat exchanger. It will further be appreciated that combustion of fuel within thefurnace 100 may result in the formation of condensation on thedownstream heat exchanger 134. Accordingly, as will be discussed in greater detail herein, condensate from thedownstream heat exchanger 134 may travel to thecold header 140 and drain into acondensate trap 142. - In some embodiments, the at least partially combusted air-fuel mixture may be transferred from the one or more
upstream heat exchangers 130 todownstream heat exchanger 134 through thehot header 132. Whilefurnace 100 is described above as comprising oneburner 128, alternative furnace embodiments may comprise more than oneburner 128. In some cases,additional burners 128 may be utilized to increase an overall heating capacity. In some embodiments,several burners 128 may be aligned in parallel, so that multiple parallel air-fuel mixture flow paths may be formed through theupstream heat exchanger 130. Further, whilefurnace 100 is disclosed as comprising at least oneupstream heat exchanger 130 and adownstream heat exchanger 134, alternative furnace embodiments may comprise only oneupstream heat exchanger 130, nodownstream heat exchanger 134, and/or multipledownstream heat exchangers 134. - An
igniter 154 may be mounted partially within theburner box 122 proximal to the downstream side of theburner 128 to ignite the air-fuel mixture a short distance downstream from the downstream side of theburner 128. In some embodiments, theigniter 154 may comprise a pilot light, a spark igniter, a piezoelectric device, and/or a hot surface igniter and may be controlled by a control system and/or may be manually ignited. Additionally, theflame sensor 156 may comprise a thermocouple, a flame rectification device, and/or any other suitable safety device and be configured to detect the presence of a flame within thefurnace 100. In this embodiment,igniter 154 andflame sensor 156 are disposed within theburner box 122. The air-fuel mixture may be moved in an induced draft manner by pulling the air-fuel mixture through thefurnace 100 and/or in a forced draft manner by pushing the air-fuel mixture through thefurnace 100. The induced draft may be produced by attaching a blower and/or fan downstream, such asinducer blower 150 relative to thecold header 140 and pulling the air-fuel mixture out of the system by creating a lower pressure at the exhaust of thecold header 140 as compared to the pressure upstream of theburner 128. Inducing flow in the above-described manner may protect against leaking the at least partially combusted air-fuel mixture and related products of combustion to the surrounding environment by ensuring the at least partially combusted air-fuel mixture is maintained at a pressure lower than the air pressure surrounding thefurnace 100. With such an induced flow, any leak along the flow path of the air-fuel mixture may result in pulling environmental air into the flow path rather than expelling the at least partially combusted air-fuel mixture and related products of combustion to the environment. - In alternative embodiments, the air-fuel mixture may be forced along the air-fuel mixture flow path by placing a blower or fan upstream relative to the
burner 128 and creating higher pressure upstream of theburner 128 relative to a lower pressure at the exhaust of thecold header 140. In some embodiments, a control system may control theinducer blower 150 to an appropriate speed to achieve desired fluid flow rates for a desired firing rate through theburner 128. Increasing the speed of theinducer blower 150 may introduce more air to the air-fuel mixture, thereby changing the characteristics of the combustion achieved by theburner 128. In some embodiments, a so-called zero governor regulator and/or zero governor gas valve, such asgas supply valve 124, may be additionally utilized to provide a desired fuel to air ratio in spite of the varying effects of an induced draft and/or other pressure variations that may fluctuate and/or otherwise tend to cause dispensing or more or less fuel in response to the pressure variations and/or negative pressures relative to atmospheric pressure. - Referring now to
FIGS. 3 and 4 , a front oblique exploded view and a back oblique exploded view of acondensate collection system 200 are shown according to an embodiment of the disclosure. Thecondensate collection system 200 may generally comprise acold header 140 and acondensate trap 142. Thecold header 140 may generally be formed from a plastic material and form aninner cavity 207 between an inner surface of thecold header 140 and thepartition panel 110. Thecold header 140 comprises a plurality of mountingholes 202 for securing thecold header 140 to thepartition panel 110 of thefurnace 100. In some embodiments, the mountingholes 202 may comprise mounting tabs and/or a combination of mounting holes and/or mounting tabs. When thecold header 140 is secured to thepartition panel 110, theinducer blower 150 may be mounted to thecold header 140 by securing it to theopening 204 in thecold header 140. Additionally, thecold header 140 may also comprise a plurality of mounting positions to allow theinducer blower 150 to be rotated with respect to thecold header 140 and/or thefurnace 100 in at least four different orientations. In some embodiments, each orientation and/or mounting orientation of theblower 150 to thecold header 140 may coincide with a different installation orientation of thefurnace 100. Theopening 204 may provide a fluid flowpath through thefurnace 100 for an airflow generated by theinducer blower 150. Additionally, aseal 206 may provide for a fluid tight boundary between thecold header 140 and thepartition panel 110 and between the opening 204 of thecold header 140 and theinducer blower 150. In some embodiments, theseal 206 may comprise sealant that is injected into the mold of thecold header 140 during manufacturing. However, in other embodiments, thesealant 206 may comprise a gasket and/or any other apparatus that is configured to form a fluid tight boundary between thecold header 140 and thepartition panel 110 and between the opening 204 of thecold header 140 and theinducer blower 150. - The
cold header 140 also comprises at least onepressure port 208. Thepressure port 208 may comprise and/or be connected to a pressure sensor that is configured to monitor the system pressure within thecold header 140 and/or thefurnace 100. Thecold header 140 may also comprise a plurality ofdrain ports 210. Thedrain ports 210 may generally comprise a cylindrically-shaped body that extends from an outer surface of thecold header 140. Thedrain ports 210 may also comprise adrain hole 211 that extends from theinner cavity 207 through thedrain port 210 to allow condensation that collects in thecold header 140 to escape from theinner cavity 207 through thedrain ports 210. In some embodiments, thecold header 140 may comprise threedrain ports 210, one at each lower corner of thecold header 140 and anadditional drain port 210 at an upper left corner of thecold header 140. However, in some embodiments, thecold header 140 may comprise threedrain ports 210, one at each lower corner of thecold header 140 and anadditional drain port 210 at an upper right corner of thecold header 140. In yet other embodiments, thecold header 140 may comprise fourdrain ports 210, one at each corner of thecold header 140. Still further, it will be appreciated that in some embodiments, thecold header 140 may comprisedrain ports 210 at each of the upper corners of thecold header 140 and anadditional drain port 210 at either of the lower corners of thecold header 140. - The
condensate trap 142 comprises abody 214 and a complimentary-shapedcover 224. Thebody 214 and thecover 224 may generally be formed from a plastic material and be joined together to form a single component. In some embodiments, thebody 214 and thecover 224 may be ultrasonically welded together. In other embodiments, thebody 214 and thecover 224 may be molded as a single component and/or joined together in any other appropriate way so that thecondensate trap 142 forms a fluid tight assembly between thebody 214 and thecover 224. Thebody 214 of thecondensate trap 142 comprises at least one mountinghole 216 for securing thecondensate trap 142 to thecold header 140,internal baffles 218 that prevent the need for priming thecondensate trap 142 during the heating off-season, aninlet port 220 configured to receive condensate from thecold header 140, and a plurality ofoutlet ports 222, while thecover 224 of thecondensate trap 142 also comprises an outlet port 226. - The
condensate trap 142 may be configured to attach to any one of the plurality ofdrain ports 210 of thecold header 140 to allow condensate to drain from theinternal cavity 207 through adrain hole 211 of thedrain port 210 and into thecondensate trap 142 through theinlet port 220 of thecondensate trap 142. After condensate passes through theinlet port 220 and into thecondensate trap 142, the condensate may flow through the plurality ofinternal baffles 218, which may prevent the need for priming thecondensate trap 142 during the heating off-season. In some embodiments, theinternal baffles 218 may also prevent condensate from backing up into theinternal cavity 207 of thecold header 140. More specifically, in some embodiments, thebaffles 218 may prevent condensate from backing up into theinternal cavity 207 of thecold header 140 by creating a pressure drop through thecondensate trap 142. The pressure drop created by thebaffles 218, when coupled with a gravitational pressure caused by condensate within thecondensate trap 142, drives the condensate from thecondensate trap 142, thereby preventing from thecondensate trap 142 from becoming completely full of condensate. Thereafter, condensate may pass through one of a plurality ofoutlet ports 220 in thebody 214 and/or an outlet port 226 in thecover 224 of thecondensate trap 142. In some embodiments, theoutlet ports 222 may be connected to a hose and/or other tubular device for carrying away condensate from thecondensate trap 142. - Still referring to
FIGS. 3 and 4 , thecold header 140 is designed to allow thefurnace 100 to rotate, operate, and/or be installed in four orientations without removing thecold header 140 from thepartition panel 110 and/or thedownstream heat exchanger 134 while still providing proper drainage of the condensate from thefurnace 100. Accordingly, thecondensate trap 142 may generally be configured to attach to any one of the plurality ofdrain ports 210 of thecold header 140. Thecondensate trap 142 may be attached so that theinlet port 220 of thecondensate trap 142 is axially aligned with one of thedrain ports 210 of thecold header 140 to allow condensation within theinternal cavity 207 of thecold header 140 to flow through adrain hole 211 of arespective drain port 210 and enter thecondensate trap 142 through theinlet port 220 of thebody 214 of thecondensate trap 142. Agasket 212 may be placed between theinlet port 220 and therespective drain port 210 to form a fluid tight boundary between theinlet port 220 and thedrain port 210. In some embodiments, thegasket 212 may comprise a circular seal, such as an O-ring gasket. Additionally, it will be appreciate that when thecondensate trap 142 is attached to one of thedrain ports 210, theother drain ports 210 may comprise a plug, bung, and/or any other appropriate seal inserted at least partially into the drain holes 211 of therespective drain ports 210 to prevent condensate within theinternal cavity 207 of thecold header 140 from escaping thecold header 140 through the unused drain holes 211 of thedrain ports 210. - The at least one mounting
hole 216 is generally configured for securing thebody 214 and/or thecondensate trap 142 to thecold header 140. The mountinghole 216 may generally comprise a clearance hole and be configured to receive a screw and/or any other appropriate fastener therethrough, and the screw may generally thread into a complimentary threadedhole 213 of thecold header 140 to secure thebody 214 and/or thecondensate trap 142 to thecold header 140. As stated, thecold header 140 is designed to allow thefurnace 100 to rotate in four orientations without removing the cold header from thepartition panel 110 and/or thedownstream heat exchanger 134 while still providing thefurnace 100 with appropriate drainage of condensate from within thecold header 140 and thecondensate trap 142. Accordingly, one of thedrain ports 210 comprise two threadedholes 213 that allow thecondensate trap 142 to rotate about thedrain port 210 and be attached in multiple positions. More specifically, the lowerleft drain port 210 may comprise a first threadedhole 213′ for attaching thecondensate trap 142 to thecold header 140 in a first position and a second threadedhold 213″ for attaching thecondensate trap 142 to thecold header 140 in a second position while using thesame drain port 210. - By providing two positions for a
single drain port 210, the furnace may be oriented in two different orientations without having to remove thecondensate trap 142 from thecold header 140. Accordingly, thecondensate trap 142 may be installed in four positions on threedrain ports 210 for a singlecold header 140, allowing thefurnace 100 to be installed in multiple orientations without requiring removal of thecold header 140 from thefurnace 100. Further, it will be appreciated that while thecondensate trap 142 does not require removal to be installed in the two positions for adrain port 210 having multiple mounting positions, the other two positions require removal of thecondensate trap 142 from thecold header 140, but do not require removal of thecold header 140 from thefurnace 100. Thus, based on the installation orientation of thefurnace 100 required for a particular application, thecondensate trap 142 may be rotated and/or relocated to aproper drain port 210 that allows the furnace to properly drain the condensate that collects in theinternal cavity 207 of thecold header 140. Additionally, the hose that connects to theoutlet port 222 may be removed and/or relocated to the opposingoutlet port 222 to ensure proper condensate drainage from thecondensate trap 142. It will also be appreciated that by providing thecold header 140 with multiple mounting positions for thecondensate trap 142, thecondensate collection system 200 may allow proper drainage of condensate from thecold header 140 and subsequently thecondensate trap 142 when thefurnace 100 is installed in various orientations and/or configurations. - At least one embodiment is disclosed and variations, combinations, and/or modifications of the embodiment(s) and/or features of the embodiment(s) made by a person having ordinary skill in the art are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, Rl, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=Rl+k*(Ru−Rl), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Unless otherwise stated, the term “about” shall mean plus or minus 10 percent of the subsequent value. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention.
Claims (22)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US15/134,129 US20160313049A1 (en) | 2015-04-24 | 2016-04-20 | Condensate Collector and Trap |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US201562152601P | 2015-04-24 | 2015-04-24 | |
US15/134,129 US20160313049A1 (en) | 2015-04-24 | 2016-04-20 | Condensate Collector and Trap |
Publications (1)
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US20160313049A1 true US20160313049A1 (en) | 2016-10-27 |
Family
ID=57148421
Family Applications (1)
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US15/134,129 Abandoned US20160313049A1 (en) | 2015-04-24 | 2016-04-20 | Condensate Collector and Trap |
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US11125439B2 (en) | 2018-03-27 | 2021-09-21 | Scp Holdings, An Assumed Business Name Of Nitride Igniters, Llc | Hot surface igniters for cooktops |
US20220316755A1 (en) * | 2021-03-30 | 2022-10-06 | Johnson Controls Technology Company | Condensate pan for a heat exchanger |
US11725888B2 (en) * | 2019-10-07 | 2023-08-15 | Johnson Controls Tyco IP Holdings LLP | Multi-position condensation kit and bracket |
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US11125439B2 (en) | 2018-03-27 | 2021-09-21 | Scp Holdings, An Assumed Business Name Of Nitride Igniters, Llc | Hot surface igniters for cooktops |
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US20220316755A1 (en) * | 2021-03-30 | 2022-10-06 | Johnson Controls Technology Company | Condensate pan for a heat exchanger |
US11761674B2 (en) * | 2021-03-30 | 2023-09-19 | Johnson Controls Tyco IP Holdings LLP | Condensate pan for a heat exchanger |
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