Boiler unit for dual-function gas boilers and boiler with said unit

Abstract

 A boiler unit for realizing connections inside of gas boilers with primary exchanger and sanitary water and fluid heating functions for a radiator heating system includes joined in a single body (11) a first and a second series of unions for realizing all the connections to the main members of the boiler. A secondary exchanger (12) for heating sanitary water and having inlets (23, 29) and outlets (31) connected to other unions on the body (11) projects from the body (11). Inside the body there is in addition a valve unit (33) for realizing controlled connections for the radiator heating function and the sanitary water heating function. A boiler with said unit is also described.

Description

[0001] This invention relates to an innovative boiler unit (termed also 'manifold') for use in gas boilers with dual function of environment heating and sanitary water heating.

[0002] In dual-function boilers there are a primary exchanger traversed by the radiator heating system fluid that is heated by the boiler burner, and a secondary exchanger that heats the water of the sanitary system by exchanging heat with the fluid of the heating system. The boiler thus needs valves for switching the heating fluid from the primary to the secondary exchanger when hot sanitary water is required.

[0003] Then a pump for forced circulation of the heating fluid, flow and temperature sensors, filters et cetera are required.

[0004] To avoid having a multitude of connections between the various members, the prior art has proposed supplying a certain grouping of the various devices so as to supply basically two monobloc bodies arranged at the two ends of the secondary exchanger. This arrangement however is very constraining as regards the physical sizing of the parts, the distance between the units being in practice linked to the size of the secondary exchanger. In addition, various connections remain to be made between the two parts and the chances of hydraulic losses are not reduced.

[0005] The general purpose of this invention is to remedy the above mentioned shortcomings and other problems by making available a boiler and an innovative boiler unit bringing together in a single body the various union connections to members of the boiler and including a secondary exchanger with reduced space occupied.

[0006] In view of this purpose it was sought to provide in accordance with this invention a boiler unit for connections inside of gas boilers with primary exchanger and functions of sanitary water and radiator heating system fluid heating characterized in that it includes joined in a single body a first and a second series of unions with the first series including a union for connection to the delivery of the heating system and a union for connection to the return from the heating system and a union for sanitary water inlet and a union for outlet towards heated sanitary water users with the second series including a union toward the primary exchanger and a union for arrival from the primary exchanger with their projecting from the body a secondary exchanger for sanitary water heating with said secondary exchanger having inlets and outlets connected to other unions on said body and with the body realizing within it appropriate connections between the unions of the first and second series and with the other unions for connection with the secondary exchanger and with there being inside the body in addition a valve unit for controlled connections between unions of the first series, the second series and the other unions.

[0007] Again in view of the preset purposes it was sought to realize a gas boiler with primary exchanger and functions of heating and supply of sanitary water to users and of fluid for a radiator heating system characterized in that it includes within it a boiler unit realized in accordance with any one of claims 1 to 24.

[0008] To clarify the explanation of the innovative principles of this invention and its advantages compared with the prior art there is described below with the aid of the annexed drawings a possible embodiment thereof by way of non-limiting example applying said principles. In the drawings:

FIG 1 shows a perspective view of a boiler unit realized in accordance with this invention,

FIG 2 shows a plan view of the boiler unit of FIG 1,

FIG 3 shows a side view of the boiler unit of FIG 1,

FIG 4 shows a cross section of the unit along line of cut IV-IV of FIG 2,

FIG 5 shows a cross section of the unit along line of cut V-V of FIG 2,

FIG 6 shows a view taken from one end of the unit and partially cross sectioned, and

FIG 7 shows a block diagram of a boiler realized with the unit in accordance with this invention.

[0009] With reference to the figures, FIG 1 shows a boiler unit designated as a whole by reference number 10 for use in boilers for environmental and sanitary water heating. The unit 10 includes a single functional and connection body 11 from which a secondary exchanger member 12 projects in feathered position and in particular like plates. Advantageously the unit is based on a single main body molded in brass and machined. This ensures extremely high overall rigidity accompanied by a very compact overall size. The body extends longitudinally advantageously in the same direction of extension as the secondary exchanger 12.

[0010] As may also be seen in FIG 2, two opposing series of mutually aligned unions project from opposite sides of the body 11 in the direction of the unit extension transversely to the main extension and generically on the same plane. A first series of aligned unions includes the union 13 for water delivery to the radiators, the union 14 for return of the water to the radiators, the union 15 for outlet of the sanitary hot water, and the union 16 for inlet of the sanitary water from the mains.

[0011] On the opposite side the second series includes a union 17 virtually aligned axially with the union 13 and connected thereto for inlet of water arriving from the primary exchanger of the boiler and a union 18 for sending of the water to the primary exchanger. On the same side there can also be provided a connection 19 for a temperature measurement probe of the sanitary hot water axially aligned with the opposite union 15 of outlet of the sanitary hot water.

[0012] On the upper face a motor reducer 20 for operation of a 3-way valve inside the body projects from the body 11 as clarified below.

[0013] A union 21 for filling the boiler can be provided above the sanitary water inlet union 16. At one end across the unions 13 and 17 there can also be provided a union 22 for connection of a known safety valve in communication with the unions 13 and 17 in case of overpressure in the heating circuit.

[0014] As may be seen in FIGS 2 and 3 the secondary exchanger 12 has its primary branch with inlet 23 connected through a union duct 24 made in the body 11 to the internal passage between the unions 13 and 17 of the heating circuit to receive the heating water therefrom. The outlet 25 of the primary branch is in turn connected through an underlying rigid tube 26 to an inlet 27 arranged beneath the body 11 to feed the water back into the circuit of the primary exchanger through the 3-way valve described below.

[0015] The secondary exchanger 12 has the inlet 28 for mains water to be heated connected to a union 29 that is beneath and transversal to the union 16 to flow into it as shown in FIG 5). To bring the inlet 28 back near the body 11 the connection between the inlet 28 and the union 29 is advantageously obtained by means of a deep-drawn member 30 placed as a seal on the upper external wall of the exchanger. The exchanger then has a heated water outlet that connects to a union 31 below and transversal to the union 15 to flow there into.

[0016] Advantageously the unions 23, 29, 31 are connected and sealed to the corresponding passages in the exchanger thanks to the resting of the exchanger against them with interposition of appropriate gaskets (not shown). Screws 32 hold the exchanger in position against the unions and compress the seals.

[0017] FIG 4 shows the 3-way valve with its passages and connections. The union 14 for return of the water from the radiator circuit extends in a straight line inside the body 11 until reaching a first inlet 34 of the 3-way valve 33.

[0018] The valve has a second inlet 35 facing opposed to the inlet 34 and connected directly the underlying inlet union 27 for inlet of water outlet from the primary branch of the secondary exchanger. The 3-way valve has a chamber 36 between the two inlets 34 and 35 that is connected directly to the outlet union 18.

[0019] In the chamber 36 there is a cut-off 37 moved by the motor reducer 20 and having an axially running shaft 38 for moving between the inlet 34 and the inlet 35 until closing them alternatively. Advantageously the movement can be continuous to realize a proportionate and not merely on-off valve.

[0020] FIG 5 shows the passage of the sanitary water from the mains inlet 16 to the inlet 29 in the secondary exchanger.

[0021] Advantageously at the inlet 16 there is a tubular pocket filter 39 of metal mesh inserted in the duct that is an extension of the union 16 toward the interior of the body of the unit so as to withhold any impurities from the mains.

[0022] Again advantageously, there is also a flow sensor 40 along the duct. Said sensor is realized by means of an impeller 41 made to move by the flow traversing the duct. A magnetic sensor (reed) 42 detects the rotation of the impeller from the outside and produces impulses signalling the existence of the sanitary water flow. The signalling will be proportionate to the sanitary water requirement and as clarified below can serve to control the proportional valve 33 to shunt a larger quantity of water from the heating circuit to the secondary exchanger accordingly.

[0023] There is a flow limiter 43 in series with the flow sensor 40. All is enclosed by a cap 44 allowing easy maintenance.

[0024] In some condensation exchangers ferrites are produced in the form of scale which is extremely harmful for the secondary exchanger. To avoid this, the unit 10 includes a cylindrical pierced-wall filter 45 inserted with its axis parallel to the passage 54 between the unions 13 and 17 (as may be seen in FIG 6) so as to not obstruct the flow between them but at the same time filter the heating circuit water directed to the duct 24 and towards the secondary exchanger. Thanks to the axial flow secured when the radiator heating circuit is active, the filter undergoes an effective cleaning function.

[0025] When the union 13 is removed the filter is also easy to remove.

[0026] Above the duct between the unions 13 and 17 near the filter there is also advantageously a union 46 for a pressure gauge to measure the pressure in the heating circuit.

[0027] FIG 7 shows diagrammatically a boiler with the above-mentioned unit. Said figure clearly shows the connections of the unit 10 to the heating circuit (with the burner 47, the primary exchanger 48 and the circulation pump 49 on one side and the radiator system 50 on the other) and to the sanitary water circuit (with the inlet 51 from the mains and the outlet to the users 52).

[0028] The boiler will also include a know control circuit 53 controlling the circulation pump, lighting of the burner and the 3-way valve depending on the signals of different sensors as basically known for this type of boiler. In case of the presence of the flow sensor 40, the control system commands the valve 33 to shunt all or part of the heating circuit flow to the secondary exchanger so as to heat the sanitary water required. If the burner is extinguished, the control device 53 will relight it.

[0029] The control system can naturally be connected to a thermostat or a chrono-thermostat 55 to control the environmental heating. There can then be all the sensors that usually are present in boilers such as for example flame detectors, sensors of the temperature of the fluids circulating in the system, for example inlet to and/or outlet from the primary exchanger, and various block detectors et cetera.

[0030] It is now clear that the preset purposes have been achieved.

[0031] The plate-type heat exchanger with its flag arrangement allows very easy maintenance thereof and of the entire unit. In addition, being thus constructed, it can undergo without difficulty even large increases in volume.

[0032] The unit is made advantageously of a single molded and machined brass body to guarantee extremely high rigidity of the assembly accompanied by a very compact overall size and bringing together the components this way. In addition, the height dimension is very limited and allows reducing the height occupied by the boiler.

[0033] Machining of the unit is facilitated by the fact that there are only a few main ducts extended in straight lines from the unions or transversal to the unions and in any case rectilinear. In particular, there is a rectilinear duct between the unions 13 and 17 that also receives the filter 45, a rectilinear duct behind the union 15, and a rectilinear duct behind the union 16 with these ducts being all parallel to each other. Then there is a rectilinear and transversal duct 24 for connection to the exchanger and easily machinable chambers for the 3-way valve and the flow detection system. Simple plugs can close the accesses necessitated by the machining or useful for maintenance.

[0034] As clarified by the figures, a virtually monobloc body 11 can be obtained thus.

[0035] Naturally the above description of an embodiment applying the innovative principles of this invention is given by way of non-limiting example of said principles within the scope of the exclusive right claimed here. In the pump union, for example, there can be inserted a flow sensor of the type described for sanitary water flow so as to meet the requirements of known modulating pumps used in condensation boilers.

Claims

1. Boiler unit for connections to the interior of gas boilers with primary exchanger and heating functions for sanitary water and for fluid for a radiator heating system characterized in that it includes joined in a single body (11) a first and a second series of unions with the first series including a union (13) for connection to the delivery of the heating system and a union (14) for connection to the return from the heating system and a union (16) for input of sanitary water and a union (15) for outlet towards heated sanitary-water users with the second series including a union (18) toward the primary exchanger and a union (17) for arrival from the primary exchanger with their projecting from the body a secondary exchanger (12) for heating of the sanitary water and which secondary exchanger has inlets (23, 29) and outlets (31) connected to other unions on said body and with the body realizing within it appropriate connections between the unions of the first and second series and with the other unions for connection with the secondary exchanger with there being inside the body in addition a valve unit (33) for controlled connections between unions of the first series, the second series and the other unions.

2. Unit in accordance with claim 1 characterized in that the unions of the first and second series are on opposite sides of the body.

3. Unit in accordance with claim 2 characterized in that the unions of the two series have mutually parallel axes.

4. Unit in accordance with claim 2 characterized in that said other unions are on a lower face of the body and that it extends between the opposite sides of the body on which the first and second series of unions face.

5. Unit in accordance with claim 4 characterized in that the body (11) is partially superimposed on the secondary exchanger (12) to place at least some of said other unions directly in contact with inlets or outlets made on the surface of the secondary exchanger.

6. Unit in accordance with claim 5 characterized in that between the unions and the inlets or outlets on the secondary exchanger (12) and in contact therewith hydraulic seal is assured with interposition of gaskets and compression of body and exchanger against each other by means of screws (32) for mutual tightening.

7. Unit in accordance with claim 1 characterized in that the secondary exchanger (12) extends from the body (11) in a direction transversal to the unions of the first and second series and in a plane virtually parallel to the axes of said unions.

8. Unit in accordance with claim 1 characterized in that in the body (11) is housed a flow sensor (40) for detection of a flow directed to the union (15) for outlet towards the users of heated sanitary water.

9. Unit in accordance with claim 8 characterized in that the flow sensor (40) includes an impeller (41) housed in a chamber arranged along the path between the inlet union and the sanitary water outlet union to be placed in rotation by the flow between these two unions, and a detector (42) on the body (11) to detect the rotation of the impeller.

10. Unit in accordance with claim 9 characterized in that the impeller (41) housing chamber is placed axially along a duct that extends in the body behind the sanitary water inlet union (16).

11. Unit in accordance with claim 10 characterized in that a flow limiter (43) is placed in the body (11) in series with the impeller (41).

12. Unit in accordance with claim 1 characterized in that the valve unit is driven by a motor reducer (20) projecting above the body (11) and with axis transversal to the axis of the union (14) for connection of the return from the heating system.

13. Unit in accordance with claim 1 characterized in that the valve unit includes within the body (11) a 3-way valve (33) connecting on command the union (14) connecting the return from the heating system or outlet (25) of the main branch of the secondary exchanger to the union (18) towards the primary exchanger.

14. Unit in accordance with claim 13 characterized in that the valve (33) allows varying uninterruptedly the percentage of connection between the ends consisting of the total connection of the union for return from the heating system to the union towards the primary exchanger and from the total connection of the return union from the heating system to the outlet of the main branch of the secondary exchanger.

15. Unit in accordance with claim 14 characterized in that the valve has a cut-off (37) that moves transversely to the axis of the union (14) for return from the heating system.

16. Unit in accordance with claim 1 characterized in that the body (11) contains a filter element (39) arranged in a duct extending axially in the body (11) behind the sanitary water inlet union (16).

17. Unit in accordance with claim 1 characterized in that the body (11) contains a filter element (45) along a connection between the heating circuit and the inlet of the main branch of the secondary exchanger (12).

18. Unit in accordance with claim 17 characterized in that the filter element (45) is housed in a rectilinear duct (54) extending inside the body axially between the union (17) from the primary exchanger and the union (13) for delivery to the heating system.

19. Unit in accordance with claim 18 characterized in that the filter element (45) is a pierced cylindrical-wall filter arranged coaxially with said rectilinear duct (54) between the primary exchanger union and the delivery union to the heating system and with pierced wall interposed between said rectilinear duct (54) and a duct (24) in the body (11) and directed to the inlet (23) of the main branch of the secondary exchanger (12).

20. Unit in accordance with claim 19 characterized in that the filter element (45) by means of the unscrewing from the body (11) of the heating system delivery union (13).

21. Unit in accordance with claim 19 characterized in that the duct (24) in the body (11) and directed to the inlet of the main branch of the secondary exchanger is transversal to the axes of the unions of the first and second series.

22. Unit in accordance with claim 1 characterized in that the secondary exchanger has the outlet (25) from the main branch connected to a corresponding inlet (27) in the body (11) through a rigid pipe (26) parallel to the extension of the exchanger.

23. Unit in accordance with claim 1 characterized in that the secondary exchanger has an outlet (29) of the heated sanitary water brought back near the body (11) by means of a duct made up of a deep-drawn element (30) on the external wall of the secondary exchanger.

24. Unit in accordance with claim 1 characterized in that the body (11) is obtained virtually monobloc.

25. Gas boiler with primary exchanger (48) and functions of heating and supply of sanitary water to users (52) and of fluid for a radiator heating system (50) characterized in that it includes within it a boiler unit (10) realized in accordance with any of the above claims 1 to 24.

Drawing