Removable Boiler

Abstract

A boiler assembly comprising a removable boiler unit (2) detachably connectable to a manifold unit (3), the arrangement being such that the manifold unit provides the boiler unit, in use, with a connection interface (7) to a pipework system, wherein boiler unit comprises a rear boiler unit section and a base boiler unit section (6), and there is provided a support structure (40) which extends from said base section to said rear section.

Claims

1. A boiler assembly comprising a removable boiler unit detachably connectable to a manifold unit, the arrangement being such that the manifold unit provides the boiler unit, in use, with a connection interface to a pipework system, wherein boiler unit comprises a rear boiler unit section and a base boiler unit section, and there is provided a support structure which extends from said base section to said rear section.

2. An assembly as claimed in claim 1 in which the support structure comprises a strut.

3. An assembly as claimed in claim 2 in which the strut is arranged at an incline.

4. An assembly as claimed in claim 3 in which two such struts are provided, spaced apart, one at each side region of the assembly.

5. An assembly as claimed in claim 1 in which the support structure is arranged to provide support to the rear section.

6. An assembly as claimed in claim 1 in which the rear boiler unit section comprises a back plate or back panel.

7. An assembly as claimed in claim 1 in which the manifold unit comprises multiple fluid connection interfaces to allow detachable connection to the removable boiler.

8. A boiler assembly comprising a removable boiler unit detachably connectable to a manifold unit, the arrangement being such that the manifold unit provides the boiler unit, in use, with a connection interface to a pipework system, wherein the manifold unit comprises a rear section and a base section, and a side of the base section arranged to allow the pipework system to pass therethrough. Put in other terms, this could be viewed as the pipe system having its point or area of entry to the boiler unit at the side of the manifold unit.

9. An assembly as claimed in claim 8 in which the manifold unit is such that the pipework system extends through a sidewall of the base section.

10. An assembly as claimed in claim 8 in which the pipework system comprises multiple pipes or conduits which are arranged to carry liquid to and from the manifold unit.

11. An assembly as claimed in claim 9 in which a side wall of the manifold unit is provided with multiple apertures to allow conduits of the pipe system to pass therethrough.

12. A removable boiler assembly comprising a removable boiler unit detachably connected to a manifold unit, the arrangement being such that the manifold unit provides the boiler unit, in use, with a connection interface to a pipework system, wherein the manifold unit comprises a rear section and a base section, and the base section comprises multiple feet, which are arranged to engage with a floor or basal surface to support the manifold unit.

13. An assembly as claimed in claim 12 in which in which the feet are adjustable in that the support height of some or all of the feet can be adjusted.

14. A boiler assembly comprising a removable boiler unit detachably connectable to a manifold unit, the arrangement being such that the manifold unit provides the boiler unit, in use, with a connection interface to a pipework system, and wherein a rearward section of the boiler unit comprises a combustion gas outlet and a combustion air inlet, and wherein internally of the boiler unit there is provided a conduit which connects from the combustion air inlet to a combustion assembly inlet and a conduit which connects from the combustion air outlet to a combustion assembly outlet, and wherein both conduits are substantially sealed from the internal space of boiler unit.

15. An assembly as claimed in claim 14 in which each of the conduits comprises a duct or ducting.

16. (canceled)

17. An assembly as claimed in claim 14 in which the manifold unit comprises: a cold water inlet; a hot water outlet; central heating water return; a central heating water outlet.

18. An assembly as claimed in claim 14 in which the boiler assembly is arranged to receive a pre-heater assembly, which is arranged to pre-heat water by way of heat from the combustion gas prior to the water being heated by the gas combustion.

19. An assembly as claimed in claim 18 in which the pre-heater comprises a heat exchanger which allows heat exchange between outgoing combustion gas and water to be heated.

20. An assembly as claimed in claim 14 in which a flue box is provided at an upper, or uppermost, part of the removable boiler assembly.

21. An assembly as claimed in claim 20 in which the flue box comprises internal passageways to divert and separate incoming air from outgoing combustion gas.

22. An assembly as claimed in claim 14 in which the boiler assembly comprises a connection interface, which comprises multiple liquid conduits, and said interface comprises a respective plurality of connections between the manifold unit and the boiler unit.

23. An assembly as claimed in claim 14 in which the connection interface is provided at a front or forward section of the removable boiler assembly.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Various embodiments of the invention will now be described, by way of example only, with reference to the following drawings in which:

[0048] FIG. 1 is a front perspective view of a removable boiler assembly (in situ),

[0049] FIG. 2 is a front perspective view of a manifold unit shown in FIG. 1,

[0050] FIG. 2a shows a perspective view of a manifold unit with a support tray in an extended condition,

[0051] FIG. 2b shows a perspective view of a boiler unit on the extended support tray,

[0052] FIG. 3 is a front perspective view of a removable boiler unit shown in FIG. 1,

[0053] FIG. 4 is a rear perspective view of the removable boiler unit of FIG. 3,

[0054] FIG. 5 is a first front perspective view of the innards of the removable boiler unit of FIG. 3,

[0055] FIG. 6 is a second front perspective view of the innards of the removable boiler of FIG. 3,

[0056] FIG. 7 is a perspective view of a floor-mount manifold unit, with the pipework system extending from a side of the base section thereof,

[0057] FIG. 8 shows two sub-assemblies of a boiler unit in a separated condition,

[0058] FIG. 9 shows the arrangement of a combination of multiple boiler assemblies, and

[0059] FIG. 10 is a perspective view of a manifold unit.

DETAILED DESCRIPTION

[0060] Reference is first made to FIG. 1 which shows a removable boiler assembly 1, which comprises a removable (combustion) boiler unit 2, mounted on a manifold unit 3. As will be described in detail below, the assembly comprises various innovative and beneficial features. In brief, the boiler unit 2 may be quickly and simply removed from the manifold unit 3 and taken away to be serviced or repaired. In order that the heating system may be used while the servicing is being carried out a replacement boiler unit is connected to the manifold unit 3.

[0061] The assembly 1 comprises a connection interface 7, conveniently provided at the front of the assembly for easy access, which allows the two units to be manually selectively fluidically connected. The connection interface 7 includes a gas supply connection (comprising connector parts 19a and 19b respectively) between the manifold and the boiler unit. The gas supply connection includes a gas cock and a gas test point 14. The gas test point is provided on the manifold unit 3 so that the gas pressure can be tested prior to installation of the boiler unit, and also with the boiler unit in situ.

[0062] The boiler unit 2 is generally (irregular) box-like shape comprising a removable front panel 4; two side panels 5 (each of which may be formed with a handle recess to aid lifting the unit onto and off the manifold); a top panel; a base panel (unreferenced) and a back panel 6. In some embodiments, the front panel and the side panels may form an integral/unitary (casing) component which is detachable as a whole from the boiler unit.

[0063] The boiler unit 2 contains, as internal componentry, an array of standard elements normally found in a (domestic) boiler, some of which are illustrated in FIGS. 5 and 6, including a burner unit (unreferenced), a heat exchanger 10, a combustion chamber 11 (as best seen in FIG. 8), a fluid pump (unreferenced), a fan 12, a pressure switch (unreferenced) for the fan, a gas valve 13, a diverter valve (unreferenced) for the heat exchanger, a water pressure switch (unreferenced) and a PCB control box (unreferenced).

[0064] The front panel 4 of the boiler unit 2 comprises a display panel 4a, which includes a visual display (to display operational information/status or user setting information), as well as user input keys or buttons (either physical or provided as virtual displayed buttons provided on a touch-sensitive screen).

[0065] The front of the manifold unit 3, and the front of the removable boiler 2, adjacent to the connection interface 7, comprises an electrical connector port 44 and an electrical connector port 14, respectively. The connector port 14 for data communication is externally accessible, and allows an operative or service personnel to connect equipment (such a monitor or a computer) to read or interrogate data stored in a memory of the controller of the boiler unit 2 (such as any operational status events), or to input updated operational settings or instructions, such as updating or overwriting firmware or software in the controller. The connector port 14 may comprise a socket for an electrical connector or plug. The connector port 44, which is provided with the manifold unit 3 conveniently, allows the operative to check, for example, electrical power levels present in the boiler unit at the time of installation or subsequently which the boiler unit in situ attached to the manifold unit. The external accessibility of the port 14 means that the outer panel of the boiler unit does not need to be removed in order for an operative to access required operational data via an internally located PCB of the controller. The port 14 may be described as a communications port. The connector port 44 also allows for an operative to check whether power is supplied to the assembly before the boiler unit is removed from the manifold unit (and thereby avoiding a potential electrocution risk). This may include connecting a multimeter to the port 44.

[0066] With reference to FIG. 4, disposed on the underside of the boiler unit 2 there are two rails or flanges 35 each of which is arranged to be detachably connected to support mechanism provided by the manifold unit. Each of the flanges is provided with a number of fasteners through apertures 35a which allow for the fasteners to ensure the attachment between the two units 2 and 3 and/or between the boiler unit 2 and its support tray (which is described below).

[0067] Reference is made to FIG. 2 in which the manifold unit 3 is a substantially L-shaped structure comprising a rear (box) section 3a and a base section 3b. The base section 3b contains an expansion chamber or vessel 25 which is used for the pipework, which in use contains heated water.

[0068] An uppermost section 3c comprises a flue box 23, which is provided with a coaxial flue outlet 23a atop thereof. Internally of the flue box 23 there are provided separated chambers or passageways for each of the combustion air and the outgoing combustion exhaust gas pathways. As described further below, the flue box 23 may comprise or be connected to a heat exchanger such that heat from exhaust gas can be used to pre-heat the incoming combustion air.

[0069] The manifold unit 3 further comprises a number of cut-out apertures 24 provided in each opposing a side of the lower section 3b. The use of the apertures is described in more detail below.

[0070] The manifold unit 3 comprises various features to ensure attachment of the boiler unit 2 to the manifold unit. Such features include a boiler unit support tray 26. The tray 26 enables the boiler unit 2 to slide into position on the manifold unit whilst being supported. The manifold unit also comprises a shoulder 32, one provided in each internal surface of the lower section 3b. The manifold unit also comprises a sprung locating clip 31. The referenced features 32, 26, 31 & 36 may be described as toggles to align the boiler unit as it is slid into the in situ position i.e. they ensure the flue and electrical connections align and engage correctly. The flanges 35 slot into the tray. This ensures that the movement of the boiler unit does not slide off the tray.

[0071] In use, for attaching the boiler unit 2 to the manifold 3, the boiler unit 2 is lifted onto the support tray 26. In doing so, the flanges 35 are inserted through side apertures 26a provided in the support tray. Reference is made to FIG. 3a which shows the elongate apertures 26a, and shows the support tray 26 in an outward or extended condition, ready to receive the boiler unit 2 therein. The boiler unit 2 can then be attached to the tray 26 by way of apertures provided in the depending portions 26b of the tray 26. It can be seen from FIG. 2a that there is provided a latch 27, which is pivotably attached to the tray 26. The latch 27 comprises a formation 27a, and locks the tray 26 in an extended condition to facilitate attachment or detachment from the tray 26.

[0072] The sidemost portions of the tray 26 are received and slidable within respective channels 22 which are fixed to an internal surface of the sides of the manifold unit 3. In use, with the boiler unit 3 attached to and supported by the tray 26, and when pushed home into position (as per FIG. 1), each support shoulder 36 of the boiler rests on the respective support flange 32. Also in this condition, the sprung location clips 31 engage against respective side regions of the boiler unit to ensure that the boiler is and remains correctly located in the in use position.

[0073] The back or rearward section 6 of the boiler unit is provided with two electrical connector elements 58a and 58b. These connector elements are aligned with counterpart connectors provided on the manifold unit 59a and 59b, form a mating connection when the boiler unit 2 is urged into position on the manifold unit. The connector elements provide data and power connectivity to/from the boiler unit via the manifold unit, when the two units are connected together.

[0074] The back, or rear, section 6 of the boiler unit 2 further comprises a combustion air port and a combustion (exhaust) gas port 20a and 20b. As can be seen with reference to FIG. 7, these are received by counterpart ports 21a and 21b, by way of a male-female fit. The ports 21a and 21b, communicate with separate(d) sub-chambers within the manifold unit and communicate with the flue port 23, which in turn is connected to a coaxial flue (not illustrated).

[0075] When the boiler unit 2 is installed on the manifold unit 4 the flue ports align and connect, as do the electrical connectors 58a, 58b, 59a, 59b.

[0076] The manifold unit 3 comprises a slidably removable drip tray 55, which is located underneath the boiler unit 2. The drip tray 55 serves to aid removal of the boiler unit from the manifold unit by catching water in valves and washers during the removal procedure. Internal shoulders or supports are provided to support the tray. It may be that the installation operative may provide his own tray, which is taken away with him once the replacement boiler unit has been installed, and does not remain with the installed boiler assembly.

[0077] The boiler assembly 1 may be fitted to an existing domestic heating system or alternatively a complete new heating pipework network may be fitted and connected to the boiler assembly 1. The manifold unit 4 is fixed to the wall or floor of the building. The various water pipes of the heating network are connected to the manifold unit 4. If the boiler unit 2 uses gas then the gas pipe is connected to the manifold unit 4 and the gas exhaust flue is connected to the manifold unit 4. The skilled person will appreciate that the invention is applicable to any type of boiler, such as an electric boiler or an oil boiler. The boiler unit 2 receives electrical power via the electrical plug 59a and socket 58a.

[0078] The connection interface 7 comprises a number of fluid ports provided on each of the boiler unit and the manifold unit. Each fluid port of the boiler unit is arranged to be selectively connectable to a counterpart fluid port of the manifold unit, by way of union piece (shown generally in FIG. 1 by reference numeral 7a). Each union piece may comprise an internally threaded collar which can be rotated into position (by way or a suitable tool such as a wrench or spanner) so as to connect two fluid ports. Each fluid port (of each of the boiler and the manifold) comprises an isolator, depicted generally by reference numeral 7b, which may comprise a valve. The isolator allows for selectively preventing fluid flow through each fluid port when in a closed condition.

[0079] When the boiler unit 2 is due for servicing or requires repair or replacement, the maintenance operative first isolates the heating pipework system from the boiler unit 2 and the gas supply by closing the isolation valves 7b. The connections 7a between the respective isolation valves are then undone. The boiler unit 2 can then easily be detached and removed from the manifold unit 4. When removing the boiler unit 2 from the manifold unit 3, the electrical connections between the connectors 58a, 58b and 59a and 59b are disconnected/broken as are the connections between the flue parts 21a, 21b, 20a and 20b, port 52 and the flue port 66 is broken. There is no need to remove the front panel 8 of the boiler unit 2 as the work is carried out off-site.

[0080] Once the boiler unit 2 has been removed from the manifold unit 4 a replacement boiler unit may be assembled onto the manifold unit 3 and all the connections made so that the heating system may be used while the original boiler unit is being serviced off-site.

[0081] A particular benefit of the manifold unit 3 is that some of the elements of a boiler assembly, such as the expansion chamber and the flue port, which do not normally require servicing may be contained in or as part of the manifold unit. The boiler unit 2 may contain only those elements that require regular servicing or are likely to need repair. The other elements of a domestic boiler assembly can conveniently be left behind in situ when the boiler unit 2 is removed and taken away.

[0082] Reference is made to FIGS. 5 and 6, which show the inclusion in the boiler unit 2 of two inclined support members 40. These are in the form of struts, which extend at an incline between the rear structure of the boiler unit and the base section of the boiler unit, at respective fastening points. The support members are spaced apart and flank the innards of the boiler assembly. Advantageously, lower gauge back plate material (*such as plastic or lower grade metal) of the rear section 6 can be used in place of stronger materials as a result of use of the support members 40. Stronger materials are generally heavier and so use of the support members can reduce the overall weight of the boiler assembly.

[0083] Reference is now made to FIG. 7 which shows use of the side entry apertures 24 of the manifold unit for the pipework system, which are installed as passing through the series of apertures provided on both sides of the manifold unit. This is of particular use when the boiler assembly is to be floor mounted, as opposed to wall mounted. It will be appreciated that location of the pipework through the side entry necessitates relocation of the expansion vessel. However, this can straightforwardly be achieved by locating the expansion vessel remotely, and connecting the same to the boiler assembly by way of a conduit or flexible hose, or the like. The provision of side entry apertures 24 on both sides, allows for installation pipework to be installed either on the left-hand side or the right-hand side, whichever is more convenient or suitable.

[0084] Where the manifold unit is to be floor mounted, stabilisation feet 50 are provided. The feet may be of adjustable height to allow for an uneven support surface.

[0085] As shown in FIGS. 5 and 6, the boiler unit 2 comprises two conduits 28 and 29 which connect the ports 20a and 20b, to respective regions of (what may be collectively termed) the heat generation sub-assembly. In particular, the conduit 28 carries exhaust gas and the conduit 29 carries combustion air. Each of the conduits comprises a duct, and may be of elbow form. The conduits 28 and 29 are sealed between the ports 20a and 20b, and the heat generation sub-assembly. With the external panels/casing of the boiler unit in position, the two fluid flows are this sealed from the (surrounding) enclosed internal space of the boiler unit. This may be viewed as providing a localised air circuit.

[0086] Highly advantageously, this avoids the need to seal the casing of the boiler unit, which can be damaged during transit. Therefore this arrangement is more robust during transit.

[0087] As a security measure, to limit access to the innards of the boiler unit the front panel 4 of the boiler unit, may be secured in place by way of a number of fastener access points 8, provided at the front of the boiler unit. These apertures 8 provide an entry point for a tool, such as a long non-standard screwdriver, to access fasteners located at the rear of the unit, which attach the exterior panels in place. This ensures that only those authorised to do so, for safety reasons, can gain access the innards of the boiler unit. The fasteners 9 may comprise clinch bolts which are provided with non-standard heads. Even when the front panel is removed, the fasteners remain secured to the front panel. Advantageously, enhancing the security aspect, the fastener heads are not easily visible, if at all, from the access points 8.

[0088] With reference to FIG. 1, the front panel of the boiler unit 2 is provided with an access aperture 8d. The access aperture 8a provides access to a gas valve to check Co2 levels, without any disassembly of the boiler unit. I should also be noted that a more accurate test of the efficiency is when the panel is in place.

[0089] Reference is made to FIG. 8, which shows the two major sub-assemblies of the removable boiler unit 2. Having these sub-assemblies provided eases manufacture and assembly of the boiler during manufacture/assembly, at which time the sub-assemblies are connected together. The referenced features 60a and 60b are return pipe connections to split the top sub-assembly of the boiler unit from bottom sub-assembly of the boiler unit. The referenced components 61a and 61c are connector or unions for flow pipes for 60a and 60b.

[0090] FIG. 8, the sub-assembly including the feature 35 is the hydraulic part of the boiler box unit and the sub-assembly including referenced feature 40 is the combustion and electrical part of the boiler unit. As access is restricted when both parts are connected and in situ, FIG. 8 discloses a way to manufacture the boiler unit in the two sub-assemblies so that tests can be completed on both parts before the final assembly.

[0091] In variant embodiments of the boiler assembly 1, each of the manifold unit and the boiler unit are provided with a hydraulic gauge to measure water pressure (of liquid in the external pipework system, such as for heated water and/or central heating, at the boiler assembly). This advantageously allows pre-installation of the manifold unit, and at that time for the necessary initial water pressure checks to be conducted. Thereafter, a gauge provided with the boiler unit can be used to check/monitor water pressure.

[0092] The performance of the boiler assembly may be enhanced by the incorporation of a pre-heater which serves to pre-heat the cold water based on heat exchange from the exhaust combustion gas. A space or region in the back section of the manifold is provided for incorporation of such a pre-heater at the time of installation, or as a retrofit upgrade to an already installed boiler assembly. The pre-heater may include heat conductive or heat filled rods which exchange heat to incoming cold water. This provides a heat recovery mechanism to beneficially use the heat within the exhaust gas. With reference to FIG. 10, a condenser may be provided within the manifold 3 at 120 (i.e. within the space provided). The condenser 120 may comprise a solar condenser, this heat exchanger pre-heats all return water and cold water mains entering the boiler via the expelling flue gas heat, after the flues gases exit the solar condenser, they then pass though the heat rod heat exchanger which extracts the remaining heat from the flue gases before exiting to atmosphere. This, and suitable internal routing/ducting, allows pre-heating of the water to be heated by the boiler, as shown by the broken arrows. A heat exchanger may be provided on the flue box 23 to recover further heat to the incoming air

[0093] Reference is made to FIG. 9, which shows how multiple boiler assemblies 1 can be used in combination or a cascade arrangement. Each of the boiler assemblies is connected to a supply pipework manifold 80 by way of connecting conduits 81. This enables all of the boiler assemblies to operate in a cumulative manner. A flue 90 connects the flue outlet 23 to each assembly to a common, or master, outlet flue 95. This arrangement of boiler assemblies may be used when larger volumes of heated water are required for particular applications, which a single boiler assembly would be inefficient.