GB2265455A

GB2265455A - Prefabricated heating control unit

Info

Publication number: GB2265455A
Application number: GB9306332A
Authority: GB
Inventors: George Curtis
Original assignee: C & K Heating
Current assignee: C & K Heating
Priority date: 1992-03-28
Filing date: 1993-03-26
Publication date: 1993-09-29
Anticipated expiration: 2013-03-26
Also published as: GB9306332D0; GB2265455B; GB9206817D0

Abstract

A circulation and control module for use in a central heating system comprises a housing assembly (10) enclosing circulation and control components of a central heating system including a circulation pump (14), heating and hot water valve means (22, 24), flow and return pipework (16,17, 26,18) and electrical components (32, 36). The electrical components are pre-wired and the circulation and control components pre-fabricated and pre-fitted into the housing assembly. The housing assembly allows access to the circulation and control components. In alternative embodiments, the primary flow pipe (26) from the hot water valve 24 is connected to a heat exchanger which may be located internally or externally of the housing. Cold water passing through the heat exchanger is heated for supply to hot water draw-off points. The module may also include an expansion vessel (36) and associated components and piping (40, 42, 44, 46, 48, 49, 50, 52). <IMAGE>

Description

"Circulation and Control Module" This invention relates to a circulation and control module for use in a central heating system.

When assembling a central heating and hot water system, the various components such as a circulation pump, motorised hot water and heating valves, flow and return pipes and electrical components all have to be fitted separately which involves a substantial amount of labour costs and time.

Once fitted, the central heating and hot water system, with all the components, attached pipework and cables connected, leaves an unsightly appearance and, depending on its location, may not render easy access for maintenance procedures.

According to the present invention there is provided a circulation and control module for use in a central heating system, comprising a housing assembly and circulation and control components of a central heating system including a circulation pump, heating and hot water valve means, flow and return pipework and electrical components, said electrical components being pre-wired and said circulation and control components pre-fabricated and pre-fitted into the housing assembly, said housing assembly providing access to said circulation and control components.

Preferably, the heating and hot water valve means comprises a motorised heating valve and a motorised hot water valve.

Alternatively, the heating and hot water valve means comprises a three-port valve.

Preferably, the electrical components are pre-wired into a junction box.

Preferably, an easy to wire plug or socket, attached at the base of the housing assembly, is connected by cable to the junction box.

Preferably, a programmer, which is pre-wired, is fitted in the housing assembly.

Preferably, said circulation pump is connected to the heating and hot water valve means via a flow connection pipe.

Preferably also, a central heating outlet flow connection pipe extends out of the housing from the heating valve means.

Preferably, a primary flow pipe extends from the hot water valve means.

In accordance with a first embodiment of the invention, said primary flow pipe extends out of the housing.

In accordance with second and third embodiments of the invention, said primary flow pipe is connected to heat exchanger means.

Preferably, said heat exchanger means comprises a hot water jacket, to which said primary flow pipe is connected, and a coil enclosed within said jacket, through which water passes to be heated.

Preferably also, an outlet from said hot water jacket is connected to the system return connection pipe.

Preferably also, an inlet end of said coil is connected to a cold water mains supply pipe and an outlet end of said coil comprises a hot water draw-off pipe.

Preferably also a micro flow switch is fitted to the hot water draw-off pipe to sense when water is being used.

Preferably also, a small expansion vessel is fitted to the hot water draw-off pipe to take up the expansion in the pipework.

In accordance with the second embodiment of the invention, said heat exchanger is located inside said housing.

In accordance with the third embodiment of the invention, said heat exchanger is located externally of said housing.

Preferably also, a thermostat is fitted to the hot water heat exchanger to regulate the water temperature.

Preferably also, the module further includes a cold water mains supply inlet pipe.

When adapted for use in a sealed system, the module is preferably further provided with an expansion vessel and a pressure relief blow-off pipe.

Preferably, the module further includes pressure relief valve means attached to the expansion vessel.

Preferably also, said expansion vessel is connected to a cold water mains supply via a filling loop comprising a ball-ofix valve and a double non-return valve.

Preferably, said expansion vessel further includes a pressure gauge.

Preferably, a by-pass pipe connects the flow pipework and the return pipework.

Preferably, the by-pass pipe is operable by way of a manual balancing-valve.

Preferably, isolating valves with compression joints are fitted to the ends of all pipes leaving the housing assembly.

Preferably also, a drain off point is provided, allowing the draining of the module.

Preferably, the housing assembly is in the form of a stove enamel finished unit.

Preferably, the housing assembly has a removable front facing to allow access to the inside of the housing assembly.

Preferably, the front facing is in two-parts with each part being hinged for access.

Preferably, the housing assembly has a plurality of fixing points for attaching the housing assembly to a wall.

Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings in which: Fig. 1 is a front view of a first embodiment of a circulation and control module with a front facing of a housing assembly removed; Fig. 2 is a front view of a second embodiment of the circulation and control module with the front facing of the housing assembly removed; and Fig. 3 is a front view of still another embodiment of the circulation and control module with the front facing of the housing assembly removed, in which the primary flow pipe of the module is connected to an external heat exchanger.

Referring to Fig. 1, a first embodiment of a circulation and control module 1 includes a housing assembly 10 in the form of a stove enamel finished unit. The stove enamel finished unit 10 has a removable front facing (not shown) with the front facing being in two parts. Each part of the front facing is hinged to allow access into the finished unit 10. Fixing points 12 are located at each corner of the finished unit 10 and are used for attaching the finished unit 10 to a wall.

Inside the unit 10 there is fitted a circulation pump 14, a 22mm flow connection pipe 16, a 22mm return connection pipe 18 and a heating and hot water valve assembly 20. The heating and hot water valve assembly 20 is in the form of a heating motorised valve 22 and a hot water motorised valve 24.

A hot water flow inlet 13 is adapted for external connection to a conventional boiler (not shown), and is connected to the circulation pump 14. The 22mm flow connection pipe 16 extends from the circulation pump 14 into one end of each of the heating and hot water motorised valves 22, 24.

A 22mm central heating outlet flow connection pipe 17 extends from the other end of the heating motorised valve 22 and out through the unit 10 to be connected to a central heating system. Extending from the other end of the hot water motorised valve 24 is a 15mm primary flow pipe 26 which extends out of the unit 10 to a hot water tank (not shown).

The 22mm return connection pipe 18 extends from the external central heating system into one end of the unit 10, through the unit 10 and out at an opposite end for connection to the boiler.

A by-pass pipe 28 extends from the 22mm flow connection pipe 16 inside the unit 10 and connects to the return connection pipe 18. A manual balancing valve 30 attached to the by-pass pipe 28 is operable to allow direct flow from the flow connection pipe 16 to the return connection pipe 18. This helps to regulate the rate of flow through the flow connection pipe 16 and consequently through the central heating system.

All electrical components are pre-wired into a junction box 32. The junction box 32 is connected to an easy-to-wire plug 34, located at the base of the unit 10, by cables 36. A programmer (not shown), which is also pre-wired is fitted at a lower end of the unit 10.

A lower part of the front facing (not shown) is hinged downwardly to allow access to the programmer.

In this embodiment of the circulation and control module 1, the central heating system is that of a sealed system. This requires that an eight litre expansion vessel 38 be fitted within the unit 10. (A larger expansion vessel may be applied to a larger central heating system). A three bar pressure relief valve 40 is attached to the expansion vessel 38. A filling loop 42 which comprises a ball-ofix valve 44 and a double non-return valve 46 connects the expansion vessel 38 and a 15mm cold water mains supply pipe 48.

A flexible casing 49 is located between the double non-return valve 46 and the ball-ofix valve 44 prior to an optimum pressure level in the system being obtained.

Once the optimum pressure level is obtained the flexible casing 49 is replaced by screw-threaded caps (not shown).

The cold water mains supply pipe 48 extends from the base of the unit 10 into the filling loop 42 via the ball-ofix valve 44. A 15mm pressure relief blow-off pipe 50 extends from the base of the unit 10 into the three-bar pressure relief valve 40 which connects to the expansion vessel 38. A pressure gauge 52 is attached to the expansion vessel 38 to regulate the pressure in the system.

All of the pipework is pre-fabricated and pre-fitted to the components of the circulation and control module 1.

All of the pipework and components are fitted into the unit 10 prior to installation of the circulation and control module 1 into the central heating system. The pre-fabricated pipework is provided with compression joints 54 and isolating valves 56 as the pipework leaves the unit 10. This allows for the removal of any of the pipework and/or components within the unit 10 if required. A drain-off point 58 is also provided allowing the module 1 to be drained when required.

Once the pipework has been connected all that is required for the central heating system to be operable is for the boiler, a cylinder thermostat, a room thermostat and a three amp fused power supply to be wired into the easy to wire plug 34 and connected at the base of the module 1.

A second embodiment of the circulation and control module 1, as shown by Fig. 2, includes a hot water heat exchanger 60 which provides instantaneous hot water.

This also obviates the need for a hot water tank in the central heating system. The primary flow pipe 26 from the hot water motorised valve 24 is connected to an inlet of the hot water jacket of the heat exchanger 60, and an outlet from the jacket is connected to the return connection pipe 18 via a primary return pipe 68 and balancing valve 70. Water from the cold water mains supply pipe 48 is heated on passing through the heat exchange coil 61 enclosed in the hot water jacket of the heat exchanger 60. The heat exchange coil 61 is connected to a 15mm hot water draw-off pipe 63 for hot water to be directly drawn off.

A thermostat 62 is fitted to the heat exchanger 60 to maintain the temperature of the water between the boiler and the heat exchanger 60. The thermostat 62 activates the boiler, circulation pump 14 and hot water motorised valve 24 when the temperature in the heat exchanger 60 drops.

A micro-flow switch 64 is fitted to the hot water drawoff pipe 63 to sense when water is being used. The micro-flow switch 64 operates in response to water being drawn through the coil 61 of the heat exchanger 60 and serves to override the thermostat 62 and to close central heating motorised valve 22, activates the boiler and circulation pump 14, and opens the hot water motorised valve 24 to replenish the hot water in the heat exchanger 60.

A second, smaller expansion vessel 66 is fitted to the hot water draw-off pipe 63 to take up expansion in the pipe 63 when the heat exchanger 60 is operable. The primary return pipe 68 and balancing valve 70 connects the heat exchanger 60 and the return connection pipe 18. The balancing valve 70 prevents water returning to the boiler too quickly. This subsequently prevents the heat in the boiler becoming too great which would result in the boiler shutting down.

Fig. 3 shows a modification of the embodiment of Fig. 2 in which the heat exchanger 60 is located externally of the casing 10, and may be remote from the control unit.

The primary flow pipe 26 from the hot water motorised valve 24 extends out of the casing 10 and is connected to the hot water jacket of the heat exchanger 60 as before. The primary return pipe 68 from the heat exchanger 60 may be connected to the return connection pipe 18, via balancing valve 70, at any convenient location externally of the casing 10. The coil 61 of the heat exchanger 60 is supplied by a cold water mains inlet pipe 70, connected to the existing cold water mains supply pipe (not shown), and has a hot water draw-off outlet pipe 72 which may be connected to the existing hot water supply piping. (not shown).

In this embodiment the heat exchanger may be located remote from the circulation and control module and fitted as close as possible to the hot water draw-off points which are to be supplied. This reduces the amount of cold water drawn through the hot water taps before hot water becomes available, and also reduces water wastage.

The various components associated with the heat exchanger 60 are located in or adjacent to it, including the thermostat 62, micro-flow switch 64, and expansion vessel 66. The thermostat 62 and micro-flow switch 64 are wired to the control module.

With all the electrical components being pre-wired and the pre-fabricated pipework and components being pre-fitted into the unit 10 labour costs are cut down due to the ease of fitting the circulation and control module 1 into the central heating system. The stove enamel unit 10 greatly improves the appearance with all the components, pipework and cables being contained within the unit 10. The circulation and control module 1 is easily attached to kitchen walls by way of the fixing points 12 at the corners of the unit 10. With the front facing of the unit 10 being removable access to the pipework and components contained therein is easy for maintenance procedures.

Modifications and improvements may be incorporated without departing from the scope of the invention.

For example, the central heating system may be an open vented system which obviates the need for an expansion vessel and all the pipework and components related to the expansion vessel. This in turn would allow for a larger hot water heat exchanger to be fitted providing more hot water.

Also, a three-port valve for hot water and heating may be incorporated instead of separate heating and hot water motorised valves.

Claims

1. A circulation and control module for use in a central heating system, comprising a housing assembly and circulation and control components of a central heating system including a circulation pump, heating and hot water valve means, flow and return pipework and electrical components, said electrical components being pre-wired and said circulation and control components pre-fabricated and pre-fitted into the housing assembly, said housing assembly providing access to said circulation and control components.

2. A circulation and control module as claimed in Claim 1, wherein the heating and hot water valve means comprises a motorised heating valve and a motorised hot water valve.

3. A circulation and control module as claimed in Claim 1, wherein the heating and hot water valve means comprises a three-port valve.

4. A circulation and control module as claimed in Claim 1, Claim 2, or Claim 3, wherein the electrical components are pre-wired into a junction box.

5. A circulation and control module as claimed in Claim 4, wherein an easy to wire plug or socket, attached at the base of the housing assembly, is connected by cable to the junction box.

6. A circulation and control module as claimed in any preceding Claim, wherein a programmer, which is pre-wired, is fitted in the housing assembly.

7. A.circulation and control module as claimed in any preceding Claim, wherein said circulation pump is connected to the heating and hot water valve means via a flow connection pipe.

8. A circulation and control module as claimed in any preceding Claim, wherein a central heating outlet flow connection pipe extends out of the housing from the heating valve means.

9. A circulation and control module as claimed in any preceding Claim, wherein a primary flow pipe extends from the hot water valve means.

10. A circulation and control module as claimed in Claim 9, wherein said primary flow pipe extends out of the housing.

11. A circulation and control module as claimed in Claim 9, wherein said primary flow pipe is connected to heat exchanger means.

12. A circulation and control module as claimed in Claim 11, wherein said heat exchanger means comprises a hot water jacket, to which said primary flow pipe is connected, and a coil enclosed within said jacket, through which water passes to be heated.

13. A circulation and control module as claimed in Claim 12, wherein an outlet from said hot water jacket is connected to the system return connection pipe.

14. A circulation and control module as claimed in Claim 12 or Claim 13, wherein an inlet end of said coil is connected to a cold water mains supply pipe and an outlet end of said coil comprises a hot water draw-off pipe.

15. A circulation and control module as claimed in Claim 14, further including a micro flow switch fitted to the hot water draw-off pipe to sense when water is being used.

16. A circulation and control module as claimed in Claim 14 or Claim 15, a small expansion vessel is fitted to the hot water draw-off pipe to take up the expansion in the pipework.

17. A circulation and control module as claimed in any one of Claims 11 to 16, wherein said heat exchanger is located inside said housing.

18. A circulation and control module as claimed in any one of Claims 11 to 14, wherein said heat exchanger is located externally of said housing.

19. A circulation and control module as claimed in any one of Claims 11 to 18, further including a thermostat fitted to the hot water heat exchanger to regulate the water temperature.

20. A circulation and control module as claimed in any preceding Claim, further including a cold water mains supply inlet pipe.

21. A circulation and control module as claimed in any preceding Claim, adapted for use in a sealed system, wherein the module is further provided with an expansion vessel and a pressure relief blow-off pipe.

22. A circulation and control module as claimed in Claim 21, wherein said expansion vessel further includes a pressure gauge.

23. A circulation and control module as claimed in Claim 21 or Claim 22, further including pressure relief valve means attached to the expansion vessel.

24. A circulation and control module as claimed in Claim 21, Claim 22 or Claim 23, wherein said expansion vessel is connected to a cold water mains supply via a filling loop comprising a ball-ofix valve and a double non-return valve.

25. A circulation and control module as claimed in any preceding Claim, wherein a by-pass pipe connects the flow pipework and the return pipework.

26. A circulation and control module as claimed in Claim 25, wherein the by-pass pipe is operable by way of a manual balancing-valve.

27. A circulation and control module as claimed in any preceding Claim, wherein isolating valves with compression joints are fitted to the ends of all pipes leaving the housing assembly.

28. A circulation and control module as claimed in any preceding Claim, wherein a drain off point is provided, allowing the draining of the module.

29. A circulation and control module as claimed in any preceding Claim, wherein the housing assembly is in the form of a stove enamel finished unit.

30. A circulation and control module as claimed in any preceding Claim, wherein the housing assembly has a removable front facing to allow access to the inside of the housing assembly.

31. A circulation and control module as claimed in Claim 30, wherein the front facing is in two-parts with each part being hinged for access.

32. A circulation and control module as claimed in any preceding Claim, wherein the housing assembly has a plurality of fixing points for attaching the housing assembly to a wall.

33. A circulation and control module for use in a central heating system, substantially as hereinbefore described with reference to Fig. 1 of the accompanying drawings.

34. A circulation and control module for use in a central heating system, substantially as hereinbefore described with reference to Fig. 2 of the accompanying drawings.

35. A circulation and control module for use in a central heating system, substantially as hereinbefore described with reference to Fight 3 of the accompanying drawings.