Condensate Pump
A condensate pump for an HVAC system includes a reservoir, a unitary top support plate, and a cover. A pump motor, an impeller pump, a float, and control electronics are mounted on the unitary top support plate. The transition from the cylindrical volute chamber to the tangential output port of the impeller pump has a swept diagonal surface that creates a gradual transition from the cylindrical volute chamber to the tangential output port. The gradual transition minimizes the pulsing. An intake profile with a concave surface extends from the center of the impeller and matches a complementary intake profile extending from the bottom of the reservoir. Vortex inhibiting vanes are molded into the bottom of the reservoir adjacent the central intake port of the impeller pump to break up any induced vortex within the reservoir.
This application claims priority from U.S. Provisional Patent Application Ser. No. 60/956,741 filed on Aug. 20, 2007, which is incorporated herein in its entirety.
FIELD OF THE INVENTIONThis invention relates to a condensate pump that collects condensate water from the evaporator of an HVAC system and pumps the condensate water to another location for disposal. More specifically, the condensate pump of the present invention includes an improved impeller pump, an improved component mounting assembly, and an improved reservoir attachment mechanism.
BACKGROUND OF THE INVENTIONA condensate pump is used in an HVAC system to collect condensate water from the evaporator of the HVAC system and to pump the condensate water to a remote location for disposal. Particularly, the condensate pump typically comprises a reservoir, an impeller pump for pumping the water out of the reservoir to the remote location, and an electric motor to drive the impeller pump. A float detects the level of condensate water in the reservoir and activates control circuitry to control the operation of the electric motor.
Condensate pumps are often located in extreme environments and are subjected to moisture, heat, and cold. Moreover, condensate pumps are often installed in inaccessible locations where maintenance is difficult, and therefore reliability over many years is necessary. Further, the condensate pump should operate quietly and without excessive buildup of heat from the operation of the electric motor.
SUMMARY OF THE INVENTIONThe present invention addresses the issues raised by the installation of a condensate pump in an extreme environment. Particularly, the condensate pump of the present invention is capable of operating reliably in such an extreme environment over an extended period of time. Further, the condensate pump of the present invention is designed to operate quietly and efficiently.
In order to achieve the objects outlined above, the condensate pump of the present invention embodies a number of features that together produce an improved condensate pump. The condensate pump of the present invention includes a reservoir and a unitary top support plate, which forms the backbone of the condensate pump. The major components of the condensate pump are mounted to the unitary top support plate. In order to mount the condensate pump components, the unitary top support plate has an impeller pump support structure, a pump motor support structure, a cover support structure, a control circuitry support structure, and a float assembly support structure. A pump motor, a motor cover, an impeller pump, a float assembly, and control circuitry are mounted on the unitary top support plate by means of the respective support structures.
With respect to quiet operation, the pump motor is mounted by means of rubber bushings to the unitary top support plate to isolate the vibrations of the motor and heat generated by the motor from the unitary top support plate. Further, the unitary top support plate is tightly mounted to the top of the reservoir by means of a snap connection so that the unitary top support plate, with its mounted components cannot vibrate on top of the reservoir.
Quiet operation is also enhanced by the design of the cylindrical volute chamber of the impeller pump. Particularly, the transition from the cylindrical volute chamber to the tangential output port of the impeller pump has a swept diagonal surface that creates a gradual transition from the cylindrical volute chamber to the tangential output port. The gradual transition minimizes the pulsing that occurs each time the water between successive blades of the impeller rushes through the output port of the volute chamber. The reduction of pulsing by the smooth transition to the tangential output port increases efficiency and reduces noise of the impeller pump.
In addition, in order to promote a constant flow of water into the central intake port of the volute chamber of the impeller pump, a reservoir intake profile with a concave surface and vortex inhibiting vanes are molded into the bottom of the reservoir adjacent the central intake port of the impeller pump. The vortex inhibiting vanes break up any vortex within the reservoir induced by the action of the impeller pump, and the reservoir intake profile directs the water upward in a smooth transition as it flows toward the central intake port of the impeller pump. In addition, the impeller has a matching impeller intake profile with a concave surface centered on the impeller and extending toward the reservoir intake profile to complete the flow transition of the water into the central intake port. The intake profiles and the vortex inhibiting vanes help assure a constant flow of water into the central intake port of the impeller pump thereby minimizing the intake of air by the impeller pump. Minimizing the intake of air by the impeller pump increases the efficiency of the impeller pump and reduces noise resulting from the intake of air.
Further objects, features and advantages will become apparent upon consideration of the following detailed description of the invention when taken in conjunction with the drawings and the appended claims.
Turning to
As shown in
As shown in the
Motor control circuitry 54 and a float assembly 48 are mounted on the unitary top support plate 14 on plate segments 94 and 96 respectively (
With reference to
The unitary top support plate 14 supports all of the major components, the pump motor 50, the impeller pump 62, the motor control circuitry 54, the float assembly 48, the biostat tablet drawer 42, and the water outlet connector 72. Consequently, the unitary top support plate 42 provides the backbone for the condensate pump 10. By mounting the major components of the condensate pump to the unitary top support plate 14, the opportunities for vibration or damage to the major components are reduced. The assembly is then completed by attaching the cover 46 to the unitary top support plate 14 by means of four cover screws 47 through the cover 46 into the cover support legs 44 (
As illustrated in
Turning to
In order to reduce noise of the impeller pump 62, the tangential output port 58 has swept diagonal surfaces 76 (
Because of the reduced height of the reservoir 112, the condensate water entering the reservoir 112 through inlet openings 138 moves directly to the central intake port 160 (
While this invention has been described with reference to preferred embodiments thereof, it is to be understood that variations and modifications can be affected within the spirit and scope of the invention as described herein and as described in the appended claims.
Claims
1. A condensate pump for collecting condensate water and pumping the condensate water to a remote location comprising:
- a. a reservoir having an open top and a bottom panel;
- b. a unitary top support plate fixed on the open top of the reservoir and comprising: i. an impeller pump support structure extending into the reservoir; ii. a motor support structure on the unitary top support plate outside of the reservoir; iii. cover support structure on the unitary top support plate outside of the reservoir; iv. a control circuitry support structure on the unitary top support plate outside of the reservoir; and v. a float assembly support structure on the unitary top support plate;
- c. an impeller pump mounted to the impeller pump support structure of the unitary top support plate and having a cylindrical volute chamber, with an intake port, an output port, and an impeller mounted for rotation within the volute chamber;
- d. a motor mounted to the motor support structure of the unitary top support plate and connected to the impeller pump for driving the impeller of the impeller pump;
- e. a float assembly mounted to the float assembly support structure of the unitary top support plate for determining the level of water in the reservoir;
- f. control circuitry mounted to the control circuitry support structure of the unitary top support plate and operatively connected to the float assembly for controlling the operation of the motor based on the level of the water in the reservoir; and
- g. a cover mounted to the cover support structure of the unitary top support plate for covering the motor and the control circuit.
2. The condensate pump of claim 1, wherein the unitary top support plate is fastened to the top of the reservoir by a snap connection so that the unitary top support plate snaps onto the top of the reservoir.
3. The condensate pump of claim 1, wherein the output port of the volute chamber is oriented tangentially to the cylindrical volute chamber and wherein a transition region between the cylindrical volute chamber and the output port has a swept diagonal surface for extending the transition region.
4. The condensate pump of claim 1, wherein the impeller has an intake profile with a concave surface extending from the center of the impeller toward the intake port of the volute chamber, the reservoir has an intake profile with a concave surface that extends from the bottom panel of the reservoir toward the intake port of the volute chamber and that aligns with the impeller intake profile, and a set of vortex inhibiting vanes extending upward from the bottom panel of the reservoir to break up any induced vortex within the condensate water in the reservoir.
5. A condensate pump for collecting condensate water and pumping the condensate water to a remote location comprising:
- a. a reservoir having an open top;
- b. a unitary top support plate fixed on the open top of the reservoir and comprising: i. an impeller pump support structure extending into the reservoir; ii. a motor support structure on the unitary top support plate outside of the reservoir;
- c. an impeller pump mounted to the impeller pump support structure of the unitary top support plate and having a cylindrical volute chamber, with an intake port, an output port, and an impeller mounted for rotation within the volute chamber; and
- d. a motor mounted to the motor support structure of the unitary top support plate and connected to the impeller pump for driving the impeller of the impeller pump.
6. The condensate pump of claim 5, wherein the unitary top support plate is fastened to the top of the reservoir by a snap connection so that the unitary top support plate snaps onto the top of the reservoir.
7. A condensate pump for collecting condensate water and pumping the condensate water to a remote location comprising:
- a. a reservoir for collecting condensate water and having a bottom panel;
- b. a motor driven impeller pump disposed within the reservoir and having a cylindrical volute chamber, with an intake port, an output port, and an impeller mounted for rotation within the volute chamber, wherein the impeller has an intake profile with a concave surface extending from the center of the impeller toward the intake port of the volute chamber, the reservoir has an intake profile with a concave surface that extends from the bottom panel of the reservoir toward the intake port of the volute chamber and that aligns with the impeller intake profile, and a set of vortex inhibiting vanes extending upward from the bottom panel of the reservoir to break up any induced vortex within the condensate water in the reservoir.
8. The condensate pump of claim 7, wherein the output port of the volute chamber is oriented tangentially to the cylindrical volute chamber and wherein a transition region between the cylindrical volute chamber and the output port has a swept diagonal surface for extending the transition region.
9. An impeller pump for a condensate pump comprising a cylindrical volute chamber, with an intake port, an output port, and an impeller mounted for rotation within the volute chamber, wherein the output port of the volute chamber is oriented tangentially to the cylindrical volute chamber and wherein a transition region between the cylindrical volute chamber and the output port has a swept diagonal surface for extending the transition region.
Type: Application
Filed: Aug 12, 2008
Publication Date: Feb 26, 2009
Inventors: Charles Barry Ward (Alpharetta, GA), Kenneth Bertoli (Canton, GA)
Application Number: 12/190,212
International Classification: F04B 49/04 (20060101); F04D 15/00 (20060101);