GB2388422A

GB2388422A - Support platform for mounting control devices of a fluid system

Info

Publication number: GB2388422A
Application number: GB0210496A
Authority: GB
Inventors: Alan Clarke
Original assignee: Heatrae Sadia Heating Ltd
Current assignee: Heatrae Sadia Heating Ltd
Priority date: 2002-05-08
Filing date: 2002-05-08
Publication date: 2003-11-12
Also published as: GB0210496D0

Abstract

A support platform 10 for mounting control devices of a fluid system. The support platform has at least one fluid flow pathway, coupling means 13 for attaching pipework to the fluid flow path, and means to receive flow control elements and a controller 19. The platform may be attachable to the pipework of a central heating circulation system, and may also be secured to the sidewall of a water storage tank and may define the support of a "pre-plumbed" flow control module. The flow control elements may include at least one flow restrictor, which may be an isolation valve 15, a bypass valve 18, or a circulating pump 17. The flow path may include a chamber which includes an impeller connected to a motor driven shaft which sealingly penetrates the pathway wall. The coupling means 13 may be releasable, of the so called "quick-connect" or "quick-release" type. The controller 19 may be programmable and provide drive signals to electrically coupled control devices such as motorised valves 14. The electrically conductive paths between the controller and control devices may be embedded within the support platform.

Description

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Fieliof the Inyeon The present invention relates to a support platform for integrating system controls 5 of an appliance and more particularly relates to the provision of a single convenient control unit for a domestic or commercial heating system such as a central heating system.

Domestic and commercial central heating systems most commonly apply a 10 principle of indirectly heating a thermal fluid such as water or oil in a boiler. The fluid is then circulated around a network of heat exchangers or radiators to heat individual rooms or regions within a room. The provision of a source of hot water, retained in a storage tank, is commonly a feature of such systems.

Additionally and independently of the boiler hot water may be provided by 15 energising an electric immersion heater within the storage vessel.

Ancillary to the boiler, water storage vessel, radiators and interconnecting pipework, there is also the need for a plurality of supplementary devices. A motorised pump is required to provide a circulating flow within the system, a number of motor actuated valves may be used to isolate parts of the system where 20 heating is not required to increase the overall efficiency of the system and thermal controls are provided to prevent overheating of the fluid medium within the heating system, water in the storage tank and the surrounding air heated by the radiators. A programmable control device is often provided to select the times of

: i: À À -2 operation of the central heating, water heating or combination of both. In many systems it may be necessary to provide a system bypass to ensure minimum flow rates are maintained through the boiler.

Traditionally, these supplementary devices have been the responsibility of the 5 installer to specify and install within a complete domestic or commercial heating system. Such devices may be placed at one or more different positions within a system and the installation thereof requires experienced knowledge and plumbing competence to ensure that they are correctly placed within the system and adequately connected. Furthermore, a degree of competence in the connection of 10 electrical appliances is also required to ensure that the controller and the devices to be controlled are properly interconnected within the system to ensure the required functionality. As each individual component may be plumbed or installed separately into the system often by more than one individual technician, the installation can be time consuming and subject to variations in quality.

15 Where the thermal qualities flow rates and other parameters of a system are well established' it may be possible to provide certain pre- plumbed arrangements for connection to a central heating system thereby facilitating the realisation of factory assembled system control arrays.

The end result of many installations of supplementary appliances or the 20 installation of systems of any complexity is that the resultant system lacks aesthetic acceptability and may require an unacceptable length of time for upgrades to be performed or for simple maintenance to be conducted by any person other than the individual original installer.

It is an object of the present invention to seek to alleviate the above disadvantages 25 and to provide a means for providing an integrated system for controlling an appliance such as a domestic or commercial heating system.

It is further an object of the present invention to provide a means for simplifying the installation, repair and/or upgrade or replacement of control devices for a domestic or commercial control heating system.

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-3 Surrimary of the Invention Accordingly, the present invention provides a support platform for system control devices for controlling a domestic or commercial central heating system, 5 the platform comprising: a support body including at least one fluid flow path; coupling means for attaching pipework to inlet and outlet ends of the at least one fluid flow path; receiving means for at least one flow control element such as a valve; and 10 receiving means for a controller wherein a plurality of essential system control devices are operably coupled in close physical proximity thereby facilitating pre-assembly.

The support platform pathways include external coupling ports for attachment to the pipework of a central heating circulation system. Preferably, the coupling 15 ports comprise quick-connect pipe couplings.

In one arrangement, the support platform is secured to a side wall of the storage tank so as to facilitate the pre-installation fitting of pipework, flow control devices, electrical connections and the like whereby minimal external connections and coupling are required at installation.

20 The internal pathways conveniently have defining walls which at the inlet and outlet ports protrude to present a set of pipe junctions, preferably comprising pipe couplings.

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-4-. The arrangements above are adapted to provide a flexible means for providing the necessary control functions for manipulating or regulating many of the control parameters of an appliance in a single convenient unit. Various combinations of flow control elements combined with an appropriate controller device will satisfy 5 differing system requirements using the support platform of the invention.

Conveniently, the flow pathways defined between said ports provide a "pre-

plumbed" arrangement the flow through which may be manipulated using flow control elements to effect the connections required or to alter the flow parameters within the system.

10 Advantageously, the flow control elements are electrically operable, preferably enabled by the controller. The flow control elements are selected from unidirectional and bi-directional valves, flow restrictors, pumps and the like.

In one arrangement, the flow path includes a chamber in which there is a motor drive shaft which, sealingly penetrates the pathway wall, the motor being 15 releasably mountable on the support platform.

This arrangement facilitates the inclusion within the support platform a pump impeller which can be connected to a pump having a rating selected in accordance with the requirements of the appliance or easily exchanged should the pump motor fail over time or if the appliance requires upgrading, for example, if 20 additional radiators are installed into an extended water heating system.

Conveniently, one of the flow control elements comprises a system bypass valve to ensure a minimum flow within the appliance. In a preferred arrangement, the bypass valve is of the differential pressure type.

Preferably, the receiving means for the controller includes a plurality of electrical 25 contacts, designated according to function, the contacts being adapted to engage corresponding contacts on a controller device. This arrangement allows for the elimination of certain wiring and enhances the modularity of the support platform.

Wiring or copper strips, for example, may be embedded within the body of the

a 4' tI! 441À support platform.

The controller device may comprise a simple switch, preferably activated and deactivated in accordance with a pre-determined timed sequence. Most preferably, the controller device comprises an electronic programmable controller 5 of the type adapted to provide drive signals to electrically coupled control devices such as the flow control elements. In a central heating system, the support platform should provide all necessary system control functions incorporated into a single unit. Various combinations of controls to satisfy differing system requirements can be utilised within the same basic unit and can be simply added 10 to or attached to the platform base. In an exemplifying arrangement the base would include a circulating pump, various combinations of motor actuated valves, a fixed or differential pressure type system bypass valves and coupling means to connect the pipe work of the circulating system thereto.

Conveniently, the support platform comprises a unitary body.

The present invention will now be described more particularly with reference to the accompanying Drawings which show, by way of example only, two arrangements of control system utilising the system platform of the present invention. In the drawings: 20 Figure 1 is a perspective view of the support platform having a circulating pump motor and a number of motional valves in place; Figure 2 is a diagrammatic horizontal crosssectional view through a support platform illustrating the application of two port motor actuated valves; Figure 3 is a diagrammatic horizontal cross-sectional view through a support 25 platform illustrating the application of a three port motor actuated valve; Figure 4 is an exploded perspective view of a support platform illustrating inlet

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and outlet pipe couplings, a pump and a number of flow control devices in their respective positions; Figure 5 is a table representing a bill of materials utilised in the support platform together with a brief description of part function, the reference numbers used

5 therein being consistent with the circled numerals of Figure 4; Figure 6 is a schematic flow diagram of the support platform; Figure 7 is a schematic diagram showing the integration of the support platform into a typical primary heating system; and Figure 8 is a schematic diagram of the electrical connections within and to the 1 0 platform.

Referring to the drawings and initially to Figure 1, a support platform 10 comprising a body portion 1 I for receiving a plurality of system control devices of a domestic or commercial heating system is shown. The body portion 11 is a 15 moulding within which there are formed a number of fluid pathways having inlet and outlet ports as will be described in more detail hereinbelow. Connection points 13 are provided with pipe couplers for connecting the pipework of the circulating fluid which is usually water. The pipe couplers are of the compression or "push fit" types for ease of installation of the system pipework, typically of the 20 "John Guest Speedfit" type. Corresponding to the connection points 13 there is provided a number of flow valve receivers for housing two-port or three-port zone valves to which actuating motors 14 are attached. Isolation valves 15 are incorporated to allow the platform to be isolated from the central heating circuit for servicing or maintenance. A circulating pump 17 is also removably fixed to 25 the body portion 11. The body portion also includes a valve receiver for a system bypass valve 18 and mounting points for an electronic programmable controller 19. Electrical contacts are provided for connection with corresponding contacts on the controller so that by simply placing the controller and fixing it to the

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- 7-. mounting points, electronic control of the pump 17 and one or more of the valve actuating motors 14 is facilitated. The controller 19 is optionally connectable to the platform 1 I via standard cabling, for example, so that should system design dictate, the controller 19 can be mounted remotely from the platform to give an 5 installer greater latitude or flexibility in siting.

Figure 2 is a schematic diagram of a support platform]0 including a twoport zone valve arrangement. Heated water from a boiler (not shown) is introduced into the body portion 11 via an inlet port 21. The pathway associated with the inlet port 21 includes a chamber 22 for housing the impeller 23 of the circulating 10 pump 17. The pathway will also include valves 15 either side of the pump chamber 22 to enable the pump to be isolated for maintenance or removal. It will be understood that the impeller 23 may be sealed within the chamber 22 and the pump simply connected to the drive shaft protruding through the wall of the chamber 22 or the pump 17 is a sealed unit into which the heated water flows 15 before being introduced to the inlet port 21 of the platform 10 under pressure.

The pump 17 is rated so as to provide sufficient force to drive the water around the entire circulation path of the heating system. The pumped water flows along pathways in the body portion 11 whereupon flow control valves 26a,26b,26c which are operably coupled to their respective actuating motors 14, under control 20 of the controller 19, regulate the flow to various heating circuit zones via outlet ports 25a,25b,25c. The water pathway to the hot water cylinder heat exchanged (immersion group) of a domestic water heating system also incorporates a valve 31 for the purpose of balancing the water flow through the heat exchanger to achieve the optimum temperature drop across the heat exchanger.

25 A system bypass channel 27 bypasses the outlet flow ports 25a,25b,25c and provides for a minimum flow rate around a boiler (not shown) should all flow control elements 26a,26b,26c be closed. A system bypass valve 28, which may have a fixed setting or be of the differential pressure type, controls flow through this channel. system bypass valve 28 of a differential pressure type, opens 30 progressively as the system back pressure increases.

The flow control valves are of the two or three port motor actuated type. Figure 2

ce À À q -8 shows the preferential arrangement whereby the actuating motors under the control of the controller 19 will either open or close valves 26a,26b or 26c allowing the heating water to flow to different zones of the heating circulation system. For example, zone 1 may be a domestic hot water tank heat exchanger 5 and zones 2 and 3 separate ports of a central heating circuit.

Figure 3 shows a second arrangement of support platform where a threeport motor operated valve 30 is incorporated into the base portion 11. The three-port valve is operably connected to an actuating motor which is under the control of the controller 19. The valve 30 diverts the heating water to either the domestic 10 hot water tank heat exchanger, the central heating circuit or both circuits simultaneously. A variant (not shown) on the three-port valve 30, in which primary heating flow is diverted to the central heating circuit except when a heating demand is placed on the domestic hot water tank, is also envisaged.

When installed, the support platform may be located at any convenient position 15 within the circulation system.

In use, heating medium flows into the base portion 11 of the support platform]0 at the inlet port 21 and past a pump impeller 23. If the system back pressure is below a pre-determined value, the system bypass valve 28 is in the closed position. In this instance, primary heating medium flows into a two or three-port 20 motor actuated valves 26a,26b, 26c,30 where it is directed to one or more of a number of flow circuits. The position of the motor actuated valve 26a,26b,26c.30 can be determined by a number of factors. These include time of day and temperature demands on hot water or radiators (the cost of electricity at any given time of day). The primary heating medium then flows to the relevant outlet flow 25 ports 25a,25b,25c via the relevant flow control element(s) 26a,26b,26c, 30 which are programmed to be in the 'open' position. The primary heating medium then flows out of the support platform 10. In a situation of high system back pressure, the system bypass valve 28 is in the 'open' position. A proportion of the heating medium entering the base portion 11 then flows along the system bypass channel 30 27. The system bypass channel is connected to the primary heating return pipe to the boiler for re-circulation.

. À it::.:e:I,:: ce . -9 - Regarding the manufacture of the support platform, a suitably inert and temperature-resistant material for constructing the system of channels would be a moulded engineering polymer. Alternatively the base could be a cast aluminium, lightweight alloy or ceramics material or a fabrication of stainless steel or other 5 corrosion resistant metal parts.

The base is optionally unitary but ordinarily will comprise two or more mouldings. Valves must meet the requirements of ease of use and durability. Preferably, standard proprietary motorised valves are incorporated into the platform 10, those 10 of proven construction and reliability, for example Honeywell V4043 series of two-part motor actuated valves having 230Volt ac, 6W motors which are removably mounted to the water flow control valve parts, are preferred. Other manufacturers valves of similar construction and specification may also be used.

The valves include means of manual operation or adjustment to allow for system 15 commissioning, service and replacement.

Referring now to Figure 4, the platform body 11 is shown in exploded perspective as a moulding formed with fluid pathways having ports which comprise receivers into which pipe couplers are secured for receiving standard domestic central heating pipes. Manually operable flow control valves are also provided to sit for 20 rotation in corresponding valve receiving apertures. Additional valve receiving apertures are provided having mounting points to secure the actuator heads of motor actuated valves. The circulation pump having an integral impeller is removably mounted in an aperture to provide sealing engagement between the platform and a proprietary pump. Figure 5 is a table comprising a bill of materials 25 which identifies all parts and elements making up the platform, together with a description of their function. The numerals in "balloons" in Figure 4 correspond

to the part numbers presented in Figure S. The assembled platform is coupled to the circulation pipework of a central heating system, as detailed in Figure 6 and as illustrated in Figure 7, in a position that 30 provides most effective concentration of the plumbing and electrical

À: se:: À:.:-.:: 4e . -10 interconnections of the system. In most domestic systems the platform is most conveniently disposed adjacent the hot water storage tank and may be mounted thereon. Installation offers many benefits over a traditional control system wherein all 5 common system controls and components are housed within or on the platform rather than being installed separately. The installation is therefore neater, more compact and more consistent. The installation time is also considerably reduced as less plumbing and wiring connections are necessary. There is less potential for incorrect installation as all controls and their interconnecting wiring, as shown in 10 Figure 8, are factory assembled and tested. It is envisaged that the level of skill necessary to install will be less.

Upon completion of the installation and set-up of the system a cover is fixed to the platform body 11 to present an aesthetically pleasing housing for the platform.

This will also give protection to the various valves, actuator motors, electronic 15 controller and interconnecting wiring whilst preventing inadvertent operation or misuse. System faults will be indicated by the electronic controller by means of fault codes displayed on the user programming interface. Adjustment or maintenance of any faulty part may be conducted by a skilled technician by removing the cover during servicing. The user programming interface may be 20 placed on the platform or remotely sited to give the user various programming options for the system such as time of operation and temperature control set points. Information on these programming options may be displayed on an LCD screen. In an additional (unillustrated) arrangement, a curved mounting bracket is 25 provided having four circular holes, one at each corner, to assist in the securing of the mounting bracket to the water tank, thereby to removably attach the platform to a tank.

It will be appreciated by the skilled addressee that power rails may be embedded into the moulding of the platform body 11 during manufacture.

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-1 1 - It will of course be understood that the present invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the invention.

Claims

( _1 ?_ CLAIMS

I A support platform for system control devices for control a domestic or commercial central heating s! stem the platform comprisin a support body including. at least one tiuid flow pathway 5 coupling means for attaching pipework to inlet and outlet ends of the at least one fluid flow pathway.
receiving means for at least one flow control element such as a valve' end receive means for a controller 10 wherein a plurality of essential system control devices are operably coupled in close physical proximity thereby facilitating pre-assembly.

? A support platform as claimed h, claim 1 ha which the or each platform pathway has defining walls which at the inlet and outlet ends include external coupling, ports for attachment to the pipevork of a central heatin, 15 circulation system.
3 A support platform as claimed in chains ?, hl which the coupling ports comprise quick-connect pipe couplings.
4 A support platform as claimed in any one of' the preceding claims ha \vhich the support platform is secured to a side mall of'a \vater storage tank 20 so as to facilitate the pre-installation fitting of' pipesvork flow control devices electrical compunctions and the like whereby minimal external connections and couplings are required at installation

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5. A support platform as claimed h any oe of claims 2 to 4, in which the flow pathways defined between said ports provide a "pre-plumbed" arrangement the flow through which may be manipulated using flow control elements to effect the connections required or to alter the tlo\v 5 parameters within the system.
6 A support platform as claimed in any one of the preceding claims, hi which the or each flow control element is electrically operable by the controller.
7 A support platform as claimed in any one of the preceding claims, in 10 which the or each flow control element is selected from unidirectional and bi-directional valves, flow restrictors, pumps and the like
8. A support platform as claimed in any one of the preceding claims, ha which at least one flow pathway includes a chamber which includes a motor drive shaft which sealer ly penetrates the pathway \vall, the Pliant 15 being operable coupled to a pump motor which is releasably mountable on the support platform.
9. A support platform as claimed in claim S. in which the drive shaft is connected to a pump impeller, the pump motor having a ratings selected ha accordance with the requirements of the heating system and which is 20 easily exchangeable should the pump motor tail over time or if the appliance requires upgradings 10 A support platform as claimed in any one of the preceding claims he which at least one of the or each flo\v control elements comprises a system bypass valve to ensure a minimum flow within the system

-14 I I A support platform as claimed in claim 1(), in which thc bypass valve is of the differential pressure type.

12 A support platform as claimed in any one of'the preceding claims, in which the receiving means for the controller includes a plurality of 5 electrical contacts, designated according to function, the contacts bein,, adapted to enya,ge corresponding contacts fin a controller device 13. A support platform as claimed in any one of the preceding claims, in which electrically conductive paths are embedded within the support body of the platform.

10 14 A support platform as claimed in any one of the preceding claims, in which the controller device comprises an electronic programmable controller of the type adapted to provide drive signals to electrically coupled control devices such as now control elements 15 A support platform as claimed in any one of' the preceding claims, in 15 \vhich the support platform comprises a unitary body 16 A support platform substantially as herein, desc)-ited with reference to and as shown in the accompanying drawings