Condensing Gas Package Unit Configured to Drain Condensate Through Inducer Fan and Method of Reducing Fuel Consumption
Air conditioning units packaged with condensing gas heat exchangers where condensate from the heat exchanger passes through the inducer fan, into an exhaust conduit, and out of the unit enclosure, and methods that reduce consumption of fossil fuels using air conditioning units with condensing gas heat exchangers by advertising that the units can be installed on the roof of a building or at ground level. Some embodiments include a drain hole extending through a collector attached to the heat exchanger to the inlet of the inducer fan. In some embodiments, a bifurcation in the exhaust conduit separates condensate from most combustion gasses. Some embodiments discharge condensate into a vertical standpipe in the ground that may extend below the frost line. Various methods include instructing an installer of the units regarding how to install the units and dispose of condensate into the ground or through a drain line into the building.
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This patent application is related to two other United States non-provisional patent applications filed on the same day, having at least three inventors in common, having a common assignee, and having the same drawings, brief description of the drawings section, and detailed description of examples of embodiments section, but having different claims, summary of the invention sections, abstracts, and titles. These two other patent applications are titled: “CONDENSING GAS PACKAGE UNIT FOR ROOF OR GROUND INSTALLATION, COLLECTOR, AND CONDENSATE DRAIN APPARATUS” and “CONDENSING GAS PACKAGE UNIT CONFIGURED TO DRAIN CONDENSATE THROUGH RETURN AIR DUCT OR FLOOR OF UNIT ENCLOSURE.” Further, to the extent not already included herein, the contents of both of these other two patent applications are incorporated herein by reference.
FIELD OF THE INVENTIONThis Invention relates to heating, ventilating, and air conditioning (HVAC) equipment and furnaces, and in particular, gas package units and condensing furnaces.
BACKGROUND OF THE INVENTIONHeating, ventilating, and air conditioning (HVAC) equipment has been used to heat, cool, and ventilate buildings and other enclosed spaces where people live and work. Air conditioning units have been used to provide cooling in the summer months. In addition, furnaces have been packaged separately and with air conditioning units and the furnaces have been operated in the winter months to provide heating. Furthermore, condensing furnaces have been used to reduce consumption of fossil fuels (e.g., natural gas or propane) burned in furnaces to provide heating. Condensing gas furnaces, however, have typically been located indoors. In such installations, condensate was typically drained into a sewer in a conventional manner. Many buildings, however, are configured to have an HVAC unit installed on the roof of the building or on the ground outside the building. In the past, such applications have typically not permitted use of a condensing furnace because condensate from the furnace would freeze when local ambient temperatures were below freezing. Frozen condensate would interfere with continued operation of the unit, collect causing a hazard or nuisance, or a combination thereof.
A number of reasons exist to reduce consumption of fossil fuels. These reasons may include, as examples, reducing fuel bills for the building owner, reducing greenhouse gas (e.g., carbon dioxide) production, reducing emissions of traditional pollutants such as carbon monoxide, hydrocarbons, and oxides of nitrogen, reducing dependency on limited fossil fuel reserves, reducing dependency on foreign sources of fossil fuels, reducing environmental damage and risk associated with extraction of fossil fuels, and qualifying for government incentives designed to reduce consumption of fossil fuels. Since many buildings are configured for HVAC units that are located outdoors, conversion of outdoor gas package units to condensing gas package units has the potential to significantly reduce consumption of fossil fuels. Consequently, needs or potential for benefit exist for equipment, apparatuses, and methods that allow condensing gas furnaces to be installed and used outdoors. In particular, needs or potential for benefit exist for equipment, apparatuses, and methods that prevent problems that result from the freezing of condensate from condensing furnaces that are installed outdoors. Needs or potential for benefit exist for equipment, apparatuses, and methods that prevent frozen condensate from interfering with continued operation of the HVAC unit, from collecting, from causing a hazard or nuisance, or a combination thereof, as examples.
Outdoor condensing gas furnaces have previously been contemplated and condensate drain lines for such units have been routed to avoid freezing. U.S. Pat. No. 6,684,878 (Ho et al.) illustrates an example. For various reasons, however, prior art outdoor condensing (e.g., gas) furnaces have not successfully been mass produced. Condensing gas furnaces, means and methods of disposing of condensate from gas furnaces, and devices that make such equipment and systems possible for outdoor installations are needed or would be beneficial that are sufficiently reliable, inexpensive, and easy to install and service so as to be practical in a mass-production context. Needs or potential for benefit or improvement exist for methods of manufacturing condensing gas package units, HVAC equipment and HVAC units having condensing furnaces, and systems and buildings having such devices. Other needs or potential for benefit or improvement may also be described herein or known in the HVAC or fossil fuel industries. Room for improvement exists over the prior art in these and other areas that may be apparent to a person of ordinary skill in the art having studied this document.
These drawings illustrate, among other things, examples of embodiments of the invention. Other embodiments may differ.
SUMMARY OF PARTICULAR EMBODIMENTS OF THE INVENTIONThis invention provides, among other things, various air conditioning units with condensing gas heat exchangers (i.e., condensing gas package units) for installation outdoors that can be mounted on the roof of a building or on the ground, condensing gas package units configured to drain condensate through the return air duct or through the floor of the unit, condensing gas package units configured to drain condensate through the inducer fan, collectors for condensing heat exchangers for HVAC units, apparatuses that pass a tube (e.g., a condensate drain line) through the wall of a duct and form a trap in the tube, and methods of reducing fuel consumption from widely used HVAC equipment by manufacturing, obtaining, or providing condensing gas package units and advertising that they can be installed, for example, on a roof or on the ground. Various examples include air conditioning units or HVAC units with condensing (e.g., gas) heat exchangers, and devices, systems, methods related to such air conditioning units or HVAC units.
Various embodiments provide, for example, as an object or benefit, that they partially or fully address or satisfy one or more needs, potential areas for benefit, or opportunities for improvement described herein, or known in the art, as examples. Certain embodiments provide, for example, equipment, apparatuses, units, and methods that allow condensing furnaces to be installed and used outdoors. In particular, various embodiments prevent, avoid, or reduce problems that result from the freezing of condensate from condensing furnaces that are installed outdoors. A number of embodiments prevent, or help to prevent, frozen condensate from interfering with continued operation of the HVAC unit, from collecting, from causing a hazard or nuisance, or a combination thereof, as examples. Certain embodiments provide, as objects or benefits, for instance, condensing furnaces, means and methods of disposing of condensate from condensing furnaces, and devices that make such equipment and systems possible or practical. Further, particular embodiments have as an object or benefit, for example, that they are sufficiently reliable, inexpensive, and easy to install and service to be practical for mass production, for instance, for residential applications. Moreover, some embodiments have as objects or benefits that they provide equipment or methods of manufacturing condensing gas package units, HVAC equipment and HVAC units having condensing furnaces, and systems and buildings having such devices.
Specific embodiments of the invention include various air conditioning units, each packaged with a condensing gas heat exchanger, for example, for efficiently heating and cooling a space. Such a unit may include, for example, an enclosure, a return duct opening for connecting the unit to a return duct that delivers air to the unit from the space, and a supply duct opening for connecting the unit to a supply duct that delivers air from the unit to the space. Such a unit may also include, for instance, the condensing gas heat exchanger for heating the air, a collector connected to the condensing gas heat exchanger, and an inducer fan having an inlet connected to the collector and an outlet, and an exhaust conduit extending from the outlet of the inducer fan to outside of the enclosure. Furthermore, in a number of embodiments, the collector further has an exhaust hole for the inlet of the inducer fan, and a drain hole extending through the collector to the inlet of the inducer fan. In various embodiments, the drain hole is lower than the exhaust hole for the inducer fan, the drain hole has a smaller cross-sectional area than the exhaust hole for the inducer fan, and condensate formed in the condensing gas heat exchanger passes through the drain hole to the inlet of the inducer fan, through the inducer fan, and into the exhaust conduit with combustion gasses.
In some embodiments, the exhaust conduit has a bifurcation that separates the condensate from a majority of the combustion gasses, the bifurcation has a high path and a low path, and the high path has a larger cross sectional area than the low path. Further, in certain embodiments, the majority of the combustion gasses pass through the high path, and a minority of the combustion gasses pass through the low path with the condensate. In particular embodiments, the minority of the combustion gasses may keep the condensate from freezing when ambient temperature conditions are below freezing. Still further, some embodiments further include, for example, a vertical standpipe. In a number of embodiments, the low path discharges into the vertical standpipe and the condensate is allowed to drip into the vertical standpipe while the minority of the combustion gasses emerging from the low path are exhausted upward between the low path and the standpipe. In some embodiments, the standpipe extends into the ground and terminates with at least one opening to the ground below the frost line in the ground. Moreover, some embodiments further include, for example, a bed of porous alkaline material in the ground. In a number of embodiments, the condensate is directed to discharge into the bed of porous alkaline material in the ground to neutralize acidity of the condensate and to dispose of the condensate into the ground.
Other specific embodiments of the invention include various air conditioning units packaged with a condensing gas heat exchanger that include, for example, an exhaust conduit extending from the outlet of the inducer fan to outside of the enclosure. Such an exhaust conduit may have a bifurcation that separates the condensate from a majority of the combustion gasses. In various embodiments, the bifurcation has a high path and a low path, the high path has a larger cross sectional area than the low path, and the majority of the combustion gasses pass through the high path. Such embodiments may also include the enclosure, a return duct opening for connecting the unit to a return duct that delivers air to the unit from the space, and a supply duct opening for connecting the unit to a supply duct that delivers air from the unit to the space. These embodiments may also include the condensing gas heat exchanger for heating the air, a collector connected to the condensing gas heat exchanger, and the inducer fan, which may have an inlet connected to the collector as well as the outlet. In a number of embodiments, the collector further has an exhaust hole for the inlet of the inducer fan, and condensate formed in the condensing gas heat exchanger passes through the inducer fan, into the exhaust conduit, and out of the enclosure.
In some embodiments, the low path has a continually downward gradient, and a minority of the combustion gasses may pass through the low path with the condensate to keep the condensate from freezing when ambient temperature conditions are below freezing. Moreover, some embodiments may further include, for example, a vertical standpipe that may have a larger cross-sectional dimension than the low path. In a number of embodiments, the low path discharges into the vertical standpipe and the condensate is allowed to drip into the vertical standpipe while the minority of the combustion gasses emerging from the low path are exhausted upward between the low path and the standpipe.
Still other specific embodiments of the invention include particular methods, for example, of reducing consumption of fossil fuels, reducing emission of greenhouse gasses, or both, for instance, from widely used HVAC equipment. Various such methods may include, for example, in the order indicated or in another order, (e.g., in any order) at least certain acts. Such acts may include, for example, manufacturing, obtaining, or providing air conditioning units that have condensing gas heat exchangers, advertising that the air conditioning units can be installed on a roof of a building and condensate from the condensing gas heat exchangers can be disposed of by routing a drain line through the roof of the building for disposal inside the building, and advertising that the air conditioning units can be installed at ground level and condensate from the condensing gas heat exchangers can be disposed of into the ground.
In some embodiments, the act of manufacturing, obtaining, or providing the air conditioning units includes manufacturing, obtaining, or providing air conditioning units that include a condensing gas heat exchanger having at least one stage that has fins, a collector connected to the at least one stage that has fins, and an inducer fan having an inlet connected to the collector. In a number of embodiments, the collector has a drain line opening penetrating the collector. Moreover, in particular embodiments, the act of manufacturing, obtaining, or providing the air conditioning units includes manufacturing, obtaining, or providing units that include a drain hole extending through the collector to the inlet of the inducer fan. In a number of embodiments, the drain hole is higher than the drain line opening.
Further, some embodiments include, for example, an act of instructing an installer of the units that when they install the unit at ground level and dispose of condensate from the condensing gas heat exchanger into the ground, that they can leave in place, or install, a plug in the drain line opening penetrating the collector and allow the condensate to pass through the inducer fan. On the other hand, some embodiments include, for example, an act of instructing an installer of the units that when they install the unit on the roof of the building and dispose of condensate from the condensing gas heat exchanger in the building, that they can leave attached, or attach, the drain line to the opening penetrating the collector, route the drain line through the roof, and allow the condensate to pass through the drain line for disposal inside the building. Even further, some embodiments include, for example, an act of instructing an installer of the units that when they install the unit on the roof of the building and dispose of condensate from the condensing gas heat exchanger in the building, that they can provide a trap in the drain line inside the building.
Moreover, some embodiments include, for example, an act of instructing an installer of the units that when they install the unit on the roof of the building and dispose of condensate from the condensing gas heat exchanger in the building, that they can install the unit on a roof curb assembly and route the drain line through a tubular conduit that passes through the roof curb assembly and through the roof of the building. Certain embodiments may further include, for example, an act of instructing an installer of the units that when they install the unit on the roof of the building and dispose of condensate from the condensing gas heat exchanger in the building, that they can route the drain line through the roof of the building inside of a return duct that connects to the unit to deliver air from within the building to the unit.
In a number of embodiments, the act of manufacturing, obtaining, or providing the air conditioning units includes manufacturing, obtaining, or providing air conditioning units that include a return duct opening for connecting the unit to a return duct that delivers air to the unit from the building. In particular embodiments, the drain line is connected to the unit to receive the condensate and the drain line extends to the return duct opening and is stored at the return duct opening during shipment of the unit. This configuration may be, for instance, for routing the drain line through the return duct when the unit is installed on the roof of the building. Further, in some embodiments, the act of manufacturing, obtaining, or providing the air conditioning units may include manufacturing, obtaining, or providing air conditioning units that include a return duct opening for connecting the unit to a return duct that delivers air to the unit from the building and a tubular conduit that extends to the return duct opening. This conduit may be for routing the drain line through the return duct when the unit is installed on the roof of the building, for example.
Some embodiments may further include, for example, an act of instructing an installer of the units that when they install the unit at ground level and dispose of condensate from the condensing gas heat exchanger into the ground, that they can install a bifurcation in an exhaust conduit extending from an outlet of an inducer fan of the unit to outside of an enclosure for the unit. In a number of embodiments, this act may include instructing that the bifurcation can be installed to provide a high path and a low path, and that the low path can be installed to discharge into a vertical standpipe, for instance. Further, certain embodiments may include, for example, an act of instructing an installer of the units that when they install the unit at ground level and dispose of condensate from the condensing gas heat exchanger into the ground, that they can provide a low path that discharges into a vertical standpipe that extends into the ground and terminates with at least one opening to the ground below a frost line in the ground. Still further, some embodiments may further include, for example, an act of instructing an installer of the units that when they install the unit at ground level and dispose of condensate from the condensing gas heat exchanger into the ground, that they can direct the condensate to discharge into a bed of porous alkaline material in the ground to neutralize acidity of the condensate.
In addition, various other embodiments of the invention are also described herein, and other benefits of certain embodiments may be apparent to a person of ordinary skill in the art.
DETAILED DESCRIPTION OF EXAMPLES OF EMBODIMENTSThe subject matter described herein includes, as examples, various condensing gas package units configured for installation outdoors. As used herein, a gas package unit is an air conditioning unit that is packaged with a gas furnace. A number of embodiments include, for example, with in the same enclosure, both a packaged air conditioning unit and a condensing gas heat exchanger. U.S. patent application Ser. No. 12/271,471, Publication 2010/0122806 (Halgash), illustrates an example of a heat exchanger that may be a condensing gas heat exchanger. Condensing heat exchangers extract more heat from the products of combustion, which makes them more efficient than non-condensing heat exchangers. As a result, air conditioning units packaged with condensing heat exchangers are typically more efficient in a heating mode than air conditioning units packaged with non-condensing heat exchangers. In the process of heat extraction, however, condensation from the products of combustion forms in condensing heat exchangers, and this condensation must be disposed of. Further, when ambient conditions are below freezing, the condensation must be disposed of without creating problems associated with freezing of the condensation.
Some embodiments of gas package units described herein can be mounted either on the roof of a building or on the ground (e.g., on a ground level slab). Certain embodiments are suitable for installation in both locations. Further, some of the condensing gas package units described herein are configured to drain condensate (e.g., liquid water condensed from the products of combustion) through a drain line that passes through the return air duct or through the floor of the unit. Such units may be installed on the roof of a building, for example. Other condensing gas package units described herein are configured to drain condensate through the inducer fan. Condensing gas package units described herein that are configured to drain condensate through the inducer fan may be used for installation on the ground or on a ground-level slab, for example.
Also described are particular collectors for condensing heat exchangers (e.g., for HVAC units such as gas package units), and apparatuses that pass a tube (e.g., a condensate drain line) through the wall of a duct and form a trap in the tube. Also described are various methods, for instance, of reducing fuel consumption from widely used HVAC equipment by manufacturing, obtaining, or providing condensing gas package units and advertising that they can be installed on a roof or on the ground. Described are various examples of air conditioning units and HVAC units with condensing (e.g., gas) heat exchangers, and devices, systems, methods related to such air conditioning units and HVAC units. Moreover, other embodiments include various buildings containing such devices, companies performing one or more of the methods described herein, computer-readable storage media, computers programmed to perform a method described herein, and computer software, as examples. Methods described herein include methods of improving HVAC units, methods of replacing HVAC equipment (e.g., which may provide better performance, efficiency, or both); methods of configuring HVAC units (e.g., air conditioning units), methods of providing HVAC equipment described herein, and methods of adapting and distributing HVAC equipment (e.g., gas package units), for instance.
As used herein, the term “HVAC unit” includes air conditioning units, heat pumps, and air conditioning units packaged with furnaces, including condensing furnaces. Further, “gas” furnaces and heat exchangers are mentioned and described herein. The “gas” may be natural gas or propane, as examples. Other condensing furnaces or heat exchangers, however, may burn, or may be configured to burn, other fossil fuels such as fuel oil, heating oil, gasoline, kerosene, diesel fuel, or coal, as examples. Further, some embodiments may burn a renewable fuel such as a bio fuel, wood, methane, or hydrogen, as other examples. Many aspects of equipment configured for such fuels may be the same or similar to equipment configured to burn natural gas or propane.
Furthermore, as used herein, if a device is said to be “configured” to perform a certain task or function, the term “configured” means that the device has been adapted specifically to perform that particular task or function, not merely that the device could be used for that particular task or function if doing so had been contemplated. For example, as used herein, a controller is “configured” to perform a particular task or function if the controller has been programmed with instructions that will, if executed, perform that specific task or function. A controller simply being made to control similar equipment and being capable of being programmed to perform the particular task or function is not enough, absent the software instructions to do so or other specific adaptation to accomplish the particular task or function recited.
The figures illustrate several specific embodiments of air conditioning units, each packaged with a condensing gas heat exchanger, for example, for efficiently heating and cooling a space. In a number of embodiments, the units are configured for installation at ground level and the units are also configured for installation on a roof of a building. Other embodiments, however, may be configured just for installation at ground level or just for installation on a roof of a building.
In the embodiments illustrated, air conditioning units 1 and 3 each include single outer enclosure 10, and air conditioning unit 2 includes single outer enclosure 20. In some embodiments, enclosures 10 and 20 may be similar or identical. As shown in
Unit 1 also includes supply duct opening 297 for connecting the unit to a supply duct that delivers air from the unit (e.g., from heating section 293) to the space (e.g., within the building). As used herein, unless stated or apparent otherwise, if two components are said to be “connected” (and variations thereof such as “connecting”) those components may be directly connected or may be indirectly connected via one or more other components (e.g., other than those parts shown or described herein) that may perform no other significant function beyond the connection described. For example, a duct is said to be “connected” to a unit even if there is an extension or flexible coupling between the duct and the unit. Similarly, a drain line is said to be connected to a collector or to an opening therein even if there is a fitting (e.g., 102) between the drain line and the collector.
In the embodiment illustrated, supply duct opening 297 is in heating section 293. In addition, in the embodiment shown, return section 292 contains return duct opening 296 for connecting the unit to a return duct that delivers air to the unit from the space (e.g., within the building).
As illustrated in
In the embodiment illustrated, outdoor section 291 further includes burners 431, 432, 433, 434, and 435, of burner assembly or gas manifold assembly 400 shown in FIGS. 6 and 11-18, and in detail in
In the embodiment depicted, outdoor section 291 further includes collector pan or collector 101 connected to condensing gas heat exchanger 300, and inducer fan 104 having inlet 1016 connected to collector 101 labeled by reference number in
Condensing heat exchanger 300 is shown in detail in
Further, in some embodiments, the heat exchanger tubes may have a different shape. In different embodiments there may be first a U shape and then an S shape, or there may be a W shape, as examples. Further, in some embodiments, there may be multiple passes or stages that include fins. Moreover, in the embodiment illustrated, the primary S tubes 341, 342, 343, 344, and 345 are larger in diameter than intermediate U-tubes 331, 332, 333, 334, and 335. Finned secondary heat exchanger 312 may have tubes that are smaller in diameter but more numerous than the intermediate tubes (e.g., U-tubes 331, 332, 333, 334, and 335). In the embodiment illustrated, condensation of some of the products of combustion (e.g., steam or water vapor) may take place in finned secondary heat exchanger 312. Finned secondary heat exchanger 312 may terminate at header plate 313, and condensate formed therein may flow to header plate 313. As described in more detail below, in the embodiment illustrated, flange 1015 (shown, for example, in
Further, in the embodiment illustrated, outdoor section 291 (e.g., shown in
In various embodiments, the drain line opening (e.g., 1012) penetrating the collector (e.g., 101), the fitting (e.g., 102) connected thereto, or both, are in the outdoor section (e.g., 291). In other embodiments, the drain line opening (e.g., performing a function similar to drain line opening 1012) is located in the heating section (e.g., 293) and may be connected to the heat exchanger (e.g., 300). Such a configuration avoids risk of condensate freezing at the drain line opening or in the drain line within the heating section due to the heat from the heat exchanger (e.g., 300). Locating the drain line opening (e.g., 1012) penetrating the collector (e.g., 101), the fitting (e.g., 102) connected thereto, or both, in the outdoor section (e.g., 291), however, may protect the fitting (e.g., 102), drain line, or both, from direct heat from heat exchanger 300, may provide easier access to the drain line opening (e.g., 1012), the fitting (e.g., 102) connected thereto, the connection to the drain line (e.g., 160, 161, 162, 163, 164, or 165) or a combination thereof, or may provide a combination of such benefits. Further, in a number of embodiments, the outdoor section (e.g., 291), near burner assembly or gas manifold assembly 400, may not get very cold (e.g., below freezing), at least when the unit is operating, due to heat from burner assembly 300 or gas manifold assembly 400, from collector assembly 100 (including inducer fan 104 and exhaust conduit 106 or 506), through partition 111 or 131 (shown, for example, in
In a number of embodiments, an example of which is illustrated in
Further, in the embodiments illustrated, after the condensate drain line (e.g., 163 or 164) attaches to drain line opening 1012 (e.g., via fitting 102) at collector 101, the condensate drain line passes into heating section 293 through jam nut 137 shown in
In the embodiments illustrated, inducer fan 104, when operating, draws air past burners 431, 432, 433, 434, and 435 (e.g., shown in
Collector 101 is an example of a collector for a condensing gas heat exchanger (e.g., 300) for an HVAC unit (e.g., air conditioning unit 1, 2, or 3). As shown in
In the embodiment shown, for example, in
Various embodiments include a condensate drain line connected to the drain line opening (e.g., 1012, for instance, via fitting 102) penetrating the collector (e.g., 101). Examples include drain line 162 shown in
In the embodiment illustrated in
As used herein, an object is considered to be protected from “direct heat” from a particular source of heat if there is a layer of solid material between the object and the source of heat. Most radiant heat from the heat source (e.g., heat exchanger 300) may be prevented from reaching the object (e.g., drain line 164) by the layer of solid material (e.g., conduit 135). But some heat from the heat source may reach the object despite the layer of solid material. For example, convective heat from the heat source (e.g., heat exchanger 300) may reach the object (e.g., drain line 164), or the layer of solid material (e.g., conduit 135) may absorb radiant heat from the heat source (e.g., heat exchanger 300) and then may re-radiate heat, or heat may be transferred by convection, or conduction to the object (e.g., drain line 164), as examples. Multiple modes of heat transfer may occur simultaneously.
Furthermore, in the embodiment shown, condensate drain line 164 passes through outdoor section 291 and tubular conduit 135 protects condensate drain line 164 from freezing where condensate drain line 164 passes through outdoor section 291. As shown in
In the embodiment illustrated, return duct opening 296 is open to return section 292. A blower or indoor air fan (not shown) located within enclosure 10 of unit 1 or 3 (e.g., above heat exchanger 300) blows indoor air from return section 292 into heating section 293. As a result, the static pressure within heating section 293 is higher than the static pressure within return section 292. This difference in static pressure causes the airflow from heating section 293, through inlet passageways 1351, 1352, 1353, and 1354, through interstitial space 310, along condensate drain line 164, and out outlet passageway 1355, for example, to return section 292. The flow through interstitial space 310, however, is small in comparison with the flow provided by the indoor air fan, and power losses resulting from the flow through interstitial space 310 are negligible.
Several of the figures illustrate embodiments in which the drain line passes through the return air duct (e.g., 63 or 71). Other embodiments, however, may pass the drain line through the supply duct (e.g., 62). A drain line inside the supply duct will typically also avoid freezing when outdoor air temperatures fall below freezing. In some embodiments, however, drain line routing to the supply duct opening (e.g., 297) may be more problematic, or sufficient pressure differential may not exist to provide flow through the interstitial space (e.g., 310) to avoid freezing where the drain line passes through the outdoor section (e.g., 291) of the unit. In some embodiments, for example, the drain line may be routed through the supply duct (e.g., 62), but the conduit for the drain line may terminate in the return section (e.g., 292) or an outlet passageway (e.g., analogous to 1355) may be provided from the interstitial space (e.g., 310) to the return section (e.g., 292), as other examples. In certain embodiments, as another example, the drain line may be routed through the supply duct (e.g., 62), and the conduit for the drain line may terminate in the heating section (e.g., 293) or near the supply duct opening (e.g., 297) or an outlet passageway (e.g., analogous to 1355) may be provided from the interstitial space (e.g., 310) to the heating section (e.g., 293) or to the supply duct opening (e.g., 297), as still other examples.
In the embodiment shown, inlet passageways 1351, 1352, 1353, and 1354, and outlet passageway 1355 are holes in conduit 135. In other embodiments, however inlet passageways, outlet passageways, or both, may be longer or may include tubing themselves, for instance, connected to the conduit, for example, with a tee. For example, in some embodiments, condensate drain line conduit may pass from the outdoor section (e.g., 291) directly to the return section (e.g., 292) without passing through the heating section. In some such embodiments, however, one or more tubes may extend from the heating section (e.g., 293) to the interstitial space between the drain line and the drain line conduit. These one or more tubes may constitute the inlet passageway(s) described herein, and may provide a pathway for heated air from the heating section to travel through the interstitial space to the return section, to keep the drain line from freezing or to thaw the drain line if it is already frozen. Further, as previously mentioned, in some embodiments, condensate drain line conduit might not go through the return section (e.g., 292), but one or more tubes may extend from the interstitial space (e.g., 310) between the drain line and the drain line conduit to the return section (e.g., 292). These one or more tubes may constitute the outlet passageway(s) described herein, and may provide a pathway for heated air from the heating section to travel through the interstitial space to the return section, to keep the drain line from freezing or to thaw the drain line if it is already frozen. For example, such a drain line may extend outside of the return and supply ducts, or may pass through the supply duct, as examples.
For example, in some embodiments, condensate drain line conduit may pass through the roof outside of either duct and yet may be heated (e.g., through the interstitial space) with warm air from the heating section (e.g., 293) that is delivered to the return section (e.g., 292). In some such embodiments, one or more inlet tubes may extend from the heating section (e.g., 293) to the interstitial space between the drain line and the drain line conduit. These one or more inlet tubes may constitute the inlet passageway(s) described herein, and may provide a pathway for heated air from the heating section to travel through the interstitial space to keep the drain line from freezing or to thaw the drain line if it is already frozen. Further, in some such embodiments, one or more outlet tubes may extend from interstitial space between the drain line and the drain line conduit to the return section (e.g., 292) or to the return air duct (e.g., 61 or 63). These one or more outlet tubes may constitute the outlet passageway(s) described herein, and may provide a pathway for the heated air from the heating section to travel through the interstitial space to the return section or return duct. For example, such a drain line and drain line conduit may extend through the roof as shown in
Air conditioning unit 3, shown in
Various embodiments include a floor, for instance, of enclosure 10 or 20 or a unit base pan, for example, floor 112 shown in
In various embodiments, such as the embodiment illustrated, drain line hole 1635 is located substantially below the drain line opening (e.g., 1012). This location is for passage of drain line 160, 161, or 162 from drain line opening 1012 through drain line hole 1635, for disposal of the condensate (e.g., within the building). In this context, “substantially below” means within 30 degrees from vertical below opening 1012 or fitting 102. In certain embodiments, drain line hole 1635 is located below drain line opening 1012 or fitting 102 to within 60, 45, 20, 15, 10, 7.5, 5, 4, 3, 2, 1, or 0.5 degrees from vertical, as other examples. In the embodiments illustrated, floor 112 is for embodiments that have a vertical, nearly vertical, substantially vertical, or straight-down condensate drain line (e.g., 160, 161, or 162, for instance, through outdoor section 291) and floor 132 is for embodiments that have an internal drain line (e.g., 163, 164, or 165) or a drain line that passes through the return duct (e.g., 63 or 71). In some embodiments, however, the floor may be the same for both drain line configurations. In some embodiments, in fact, the floor and unit may be configured (e.g., with hole 1635) for a straight-down condensate drain line (e.g., 160, 161, or 162) and the floor and unit may also be configured for an internal drain line (e.g., 163, 164, or 165) or a drain line that passes through the return duct (e.g., 63). In some embodiments, for example, hole 1635 may be partially stamped so that it can easily be punched out in the field by an installer, or may be provided with a plug that the unit installer can install or leave in place if hole 1635 is not used and that the installer can remove or not use if hole 1635 is used for the condensate drain line (e.g., 160, 161, or 162).
In the embodiment illustrated in
In particular embodiments, when the unit (e.g., 1) is installed on the roof (e.g., 4), the tubular conduit (e.g., conduit 1612 shown in
On the other hand, in the embodiments shown in
Moreover, in the embodiment shown, tubular conduit 1622 extends from vertically below drain line opening 1012 (e.g., at floor 112), bends less than 90 degrees, and then continues at a slope through roof curb assembly 45 to supply duct 62 (shown in
As shown in
Further, as shown in
Further,
Further, as shown in
A number of embodiments include an exhaust conduit (e.g., 106, 506, or exhaust and drainage assembly 500) extending from the outlet (e.g., 105) of the inducer fan (e.g., 104) to the outside of the enclosure (e.g., 10 or 20). In the embodiment shown, a coupling at outlet 105 connects inducer fan 104 to pipe or exhaust conduit 106 or 506. See, for example,
In the embodiment illustrated, high path 508 of exhaust conduit or exhaust and drainage assembly 500 includes the vertical section of pipe shown, elbow 509, and horizontal pipe 510. Other embodiments may be routed differently. In a number of embodiments, however, such as the embodiment shown, the high path (e.g., 508 including 509 and 510) has a larger cross sectional area than the low path (e.g., 57), and the majority (i.e., by volume) of the combustion gasses pass through the high path (e.g., 508) when unit 2 is operating as a furnace. In the embodiment shown, a minority (i.e., by volume) of the combustion gasses pass through low path 57 with the condensate. This minority of the combustion gasses may keep the condensate within low path 57 from freezing when ambient temperature conditions are below freezing by warming low path 57 of exhaust and drainage assembly 500. In some embodiments, such as shown in
In the embodiment shown in
As shown in
In still other embodiments, standpipe 54 may connect to a trap below the frost line, and then into a sewer or septic system. Further, in certain embodiments, unit 2 may be installed on a roof and standpipe 54 may extend into a building, for example, for disposal into a sewer or septic system. Precautions may be advisable, however to prevent the minority of the combustion gasses that passes through the low path (e.g., 57) from entering a sewer, building, or other enclosed space where a sufficiently high concentration of combustion gasses (i.e., carbon dioxide) may pose a hazard to occupants. For this reason, the condensate drain line configurations illustrated in
As illustrated, the embodiments of
In many embodiments that have a trap and have the condensate drain line connected to the collector (e.g., 101) on the suction side of the inducer fan (e.g., 104), if there is not sufficient water in the trap, or if there is a breach in the drain line above the trap within the building, for example, air or sewer gasses would flow from within the building into the collector (e.g., 101) and out of the unit through the inducer fan (e.g., 104) and the exhaust conduit (e.g., 106), rather than combustion gasses from the heat exchanger (e.g., 300) and collector (e.g., 101) flowing into the building or sewer. If there is no water in the trap, airflow through the drain line may partially or fully prevent condensate from flowing through the drain line until the unit cycles off. When the unit cycles off, however, and the inducer fan (e.g., 104) turns off, condensate may flow from the collector though the drain line and fill the trap. Once the trap contains sufficient water (condensate) to prevent airflow though the drain line, in a number of embodiments, condensate will flow through the drain line unimpeded by airflow in an opposite direction.
Further, certain embodiments are or include a particular apparatus for passing a tube through a wall of a duct, for forming a trap with the tube, or both. Examples (e.g., apparatus 150 and 170) are illustrated in
In various embodiments, the first portion (e.g., 157 or 177) is at a non-zero angle to the second portion (e.g., 158 or 178), also at the bend (e.g., 156 or 176). As used herein, a non-zero angle is an angle of five degrees (measured from being straight) or more. Such a bend may be a sharp bend or may formed by curvature or multiple sharp bends, as examples. In a number of embodiments, for example, where the bend is formed by curvature or multiple sharp bends, the bend may extend over a dimension of the plate that is less than a particular fraction of an overall dimension of the plate (e.g., 155 or 175). That overall dimension may be length or width of the plate or length or width of the first portion (e.g., 157 or 177) or the second portion (e.g., 158 or 178), as examples. In certain embodiments, for instance, the fraction may be 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, or 50 percent of the overall dimension, as examples.
In the embodiment shown, the non-zero angle at the bend (e.g., bend 156 or 176) is a right angle or a 90-degree bend. As used herein, a right angle is 90 degrees plus or minus 10 degrees. In other embodiments, the non-zero angle at the bend (e.g., bend 156 or 176) may be, for example, 10, 20, 30, 40, 50, 60, 70, 80, 85, 95, 100, 110, 120, 130, or 135 degrees, as examples, each plus or minus 5 degrees, measured from straight (no bend). In certain embodiments, the non-zero angle at the bend (e.g., bend 156 or 176) may be, for instance, between 45 degrees and 135 degrees, between 60 degrees and 120 degrees, between 70 degrees and 110 degrees, between 75 degrees and 105 degrees, or between 80 and 100 degrees, as examples.
In the embodiments illustrated, for example, in
Further, in the embodiments shown, second portion 158 or 178 has second hole 152 sized and shaped for passage of the tube (e.g., condensate drain line 164 or 165) and third hole 153, also sized and shaped for passage of the tube. Holes 152 and 153 may be sized and shaped as described above for hole 151, for example. In the case of holes 152 and 153, however, avoiding leakage between the inside of the hole and the tube may not be a consideration. But a sufficiently close fit or even an interference fit, in some embodiments, may be beneficial to hold the tube in position to form loop or trap 1641 or 1651. In some embodiments, the tube may be held in place (e.g., to form loop or trap 1641 or 1651) with a clamp, an adhesive, tape, a grommet, or a combination thereof, as examples.
Moreover, in the embodiments shown, first portion 157 or 177 also has multiple fourth holes 154 which are sized and shaped for passage of fasteners. Such fasteners may be sheet metal screws, for instance that pass through the multiple fourth holes 154 and screw into the wall of the duct (e.g., 63 or 73) from the outside of the duct to attach the first portion 157 or 177 to the duct. In other embodiments, on the other hand, the fasteners, or other fasteners described herein, may be clips (e.g., push clips, which may be plastic or metal wire, as examples), or pop rivets, for instance, and may attach to the wall of the duct (e.g., 63 or 73). Further, each of the multiple fourth holes 154 may be substantially smaller in diameter than first hole 151, second hole 152, third hole 153, or a combination thereof. In this context, substantially smaller in diameter means half of the diameter or less. In the embodiment illustrated, first portion 157 and first portion 177 each have four fourth holes 154. Further, in the embodiment illustrated, first portion 157 and first portion 177 are each rectangular and have one of the fourth holes 154 in each corner. Other embodiments may have 1, 2, 3, 5, 6, 7, 8, 9, 10, or 12 fourth holes that are sized and shaped for passage of fasteners, as other examples. Still other embodiments may have one or more tabs that fit inside the duct (e.g., 63 or 73) at one end of the first portion (e.g., 157 or 177) and one or multiple fourth holes 154 that are sized and shaped for passage of one or more fasteners at the other end. Even further, some embodiments may have tabs at both ends. Other embodiments may attach with an adhesive, with a clamp, or with tape, as other examples.
Furthermore, in the embodiment shown, the first portion (e.g., 157 or 177) of the apparatus (e.g., 150 or 170) is configured to seal an opening (e.g., access opening 631 shown in
Even further, in the embodiments illustrated, apparatuses 150 and 170 are configured to permit the tubing (e.g., condensate drain line 164 or 165) to penetrate the wall of the duct (e.g., 63 or 73) though first hole, then bend downward through second hole 152, and then bend upward, looping substantially 360 degrees around, to extend downward through third hole 153, forming helical loop 1641 or 1651 in the tubing (e.g., 164 or 165) with (i.e., the loop having) a substantially horizontal axis. In the embodiments shown, this loop 1641 or 1651 serves as a trap in the tubing (e.g., condensate drain line 164 or 165), for example, preventing air, combustion gasses from the furnace (e.g., HVAC unit 1), or sewer gasses from passing through the tubing (e.g., condensate drain line 164 or 165). As mentioned, such a trap (e.g., loop 1641 or 1651) also avoids the formation of a higher static pressure within the drain line (e.g., condensate drain line 164 or 165, for instance, below drain line opening 1012) that would interfere with proper drainage from collector 101, through drain line opening 1012, into the drain line (e.g., condensate drain line 164 or 165). In other embodiments, a trap may be formed in with a different number of holes in the apparatus, such as 2 or 4 holes. For instance, in some embodiments the tube may pass substantially horizontally through the first hole in the apparatus, and then may bend upward looping substantially 270 degrees around to extend downward through the second or third hole forming helical loop in the tubing with a substantially horizontal axis. As another example, in some embodiments the tube may pass substantially horizontally through the first hole in the apparatus, and then may bend upward looping substantially 270 degrees around to extend downward through the second hole, and then may bend upward, looping substantially 360 degrees around, to extend downward through third hole, forming two helical loops in the tubing with a substantially horizontal axis.
Moreover, in the embodiments depicted, the first portion (e.g., 157 or 177) is larger than the second portion (e.g., 158 or 178). Additionally, some embodiments further include, for example, a first grommet at first hole 151, a second grommet at second hole 152, a third grommet at third hole 153, or a combination thereof. In a number of embodiments, the first grommet, the second grommet, the third grommet, or a combination thereof, are (e.g., all) configured to protect the tubing (e.g., condensate drain line 164 or 165) from being damaged by edges of first hole 151, second hole 152, or third hole 153. The grommets may be so configured by having surfaces that contact the tubing that are larger or less sharp than holes 151, 152, and 153, for example. The grommets may also (or instead) provide a better seal around the tubing (e.g., at first hole 151) may help to grip the tubing better (e.g., at third hole 153), or a combination thereof. Such grommets may be plastic, for example. In some embodiments, the grommets may be made of an elastomeric material or rubber. An example of a grommet is grommet 1636 shown in
Furthermore, some embodiments may further include the tubing (e.g., condensate drain line 164 or 165), for example, which passes though first hole 151, then bends and passes through second hole 152, and then bends and loops 360 degrees around to extend through third hole 153 forming the helical loop (e.g., 1641 or 1651). In the embodiments shown and described, the tubing is a drain line (e.g., condensate drain line 164 or 165) for the HVAC unit (e.g., 1) and the tubing extends from the HVAC unit, through the duct (e.g., 63 or 73), and penetrates the wall of the duct though first hole 151, then bends downward through second hole 152, and then bends upward looping substantially 360 degrees around, and then extends downward through third hole 153 forming the helical loop in the tubing with a substantially horizontal axis that serves as a trap in the tubing. Still further, in some embodiments, the apparatus may include, for example, the HVAC system including, for instance, the duct (e.g., 63 or 73), the HVAC unit (e.g., HVAC unit 1), or both. In the embodiments shown, duct 63 and 73 are return ducts delivering air to the HVAC unit. Further, ducts 63 and 73 are the ducts that have the wall that has the opening (e.g., 631 shown in
Further, the embodiments in which the condensate is taken from the collector (e.g., 101) on the suction side of inducer fan (e.g., 104), may be installed at ground level in some applications. For example,
As mentioned previously, in a number of embodiments, HVAC units are configured for installation at ground level and are also configured for installation on a roof of a building. For example, HVAC units 1, 2, or 3 that include collector 101 shown in
Moreover, HVAC units 1, 2, or 3 that include collector 101 shown in
As mentioned, in some embodiments, when air conditioning unit 1 or 2 is installed and leveled properly in accordance with the manufacturer's installation instructions, drain hole 1011 is higher than drain line opening 1012. In certain embodiments, drain hole 1011 acts as an overflow for drain line opening 1012. Thus, if drain line opening 1012, fitting 102, the drain line (e.g., 160, 161, 162, 163, 164, or 165) is plugged, the unit may still operate, but condensate may pass through drain hole 1011 and inducer fan 104, and may be exhausted with the combustion gasses. Depending on the routing of the drain line, under freezing conditions, the drain line may be plugged with frozen condensate, for example, and may unplug on its own later when ambient temperatures increase. Further, in some embodiments, the drain line may freeze when the unit is turned off for an extended period under sufficiently cold conditions, but may thaw out after the unit has been operating in a heating mode for a sufficient period of time, as another example.
When drain hole 1011 acts as an overflow, and condensate is not able to drain though opening 1012, if ambient conditions are below freezing, ice may form beside the unit, for example, on the roof or on the ground. If such ice only forms for a short time, however, such ice formation may not be problematic. In some instances, the ice formation, or water if conditions are warmer, may serve to warn the owner or user of the unit that the drain line is plugged. Further, some embodiments may omit drain hole 1011, and instead, exhaust hole 1013 for inducer fan 104, may perform the role of drain hole 1011. In the embodiment illustrated, exhaust hole 1013 is also higher than drain line opening 1012 and extends through collector 101 to inlet 1016 of inducer fan 104. Thus, in such embodiments, exhaust hole 1013 may act as an overflow for drain line opening 1012. Further, in embodiments that have a drain hole 1011, exhaust hole 1013 may act as an overflow for drain hole 1011. In embodiments that have a drain hole 1011, however, drain hole 1011 may reduce the amount of condensate that will accumulate in the collector (e.g., in collector 101 with plug 203 installed in drain line opening 1012 rather than a drain line attached thereto). An accumulation of condensate in the collector could freeze, for example, if the unit is turned off for an extended period when ambient conditions are sufficiently below freezing.
Still other embodiments include particular methods, for example, of reducing consumption of fossil fuels, of reducing emission of greenhouse gasses, or both, for instance. Such reductions may be significant, for example, because they are from HVAC equipment that is widely used.
In a number of embodiments, act 325 includes manufacturing, obtaining, or providing air conditioning units with condensing (e.g., gas) heat exchanger such as units 1, 2, or 3 described herein, for example. Further, in various embodiments, act 326 may include advertising that the air conditioning units (e.g., with condensing heat exchangers) can be installed on a roof of a building and condensate from the condensing gas heat exchangers (e.g., 300) can be disposed of by routing a drain line (e.g., 160, 161, 162, 163, 164, or 165) through the roof (e.g., 4) of the building for disposal, for example, inside the building. Moreover, in many embodiments, act 326 may include advertising that the air conditioning units can be installed at ground level (e.g., 80 shown in
In some embodiments, the act (e.g., 325) of manufacturing, obtaining, or providing the air conditioning units (e.g., 1, 2, or 3) includes manufacturing, obtaining, or providing air conditioning units that include a condensing (e.g., gas) heat exchanger (e.g., 300 shown in
Further, in some embodiments, act 327 includes instructing an installer of the units that when they install the unit at ground level (e.g., 80 shown in
Moreover, in some embodiments act 327 includes instructing an installer of the units that when they install the unit on the roof (e.g., 4) of the building and dispose of condensate from the condensing (e.g., gas) heat exchanger (e.g., 300), for instance, in the building (e.g., as shown, in different embodiments, in
Even further, in some embodiments act 327 includes instructing an installer of the units that when they install the unit on the roof (e.g., 4) of the building and dispose of condensate from the condensing gas heat exchanger in the building, that they can provide a trap (e.g., 1601, 1611, 1621, 1641 or 1651 shown in
Still further, in some embodiments act 327 may include instructing an installer of the units that when they install the unit on the roof (e.g., 4) of the building and dispose of condensate from the condensing (e.g., gas) heat exchanger (e.g., 300) in the building, that they can install the unit on a roof curb assembly (e.g., 45 shown in
In a number of embodiments, act 325 of manufacturing, obtaining, or providing the air conditioning units includes manufacturing, obtaining, or providing air conditioning units that include a return duct opening (e.g., 296 or 171 shown in
Some embodiments may further include, for example, in act 327, instructing an installer of the units (e.g., 2) that when they install the unit at ground level (e.g., as shown in
Various methods may further include acts of obtaining, providing, or making various components described herein or known in the art. Other embodiments include a building that includes an air conditioning unit or HVAC unit or system described herein. Various methods in accordance with different embodiments include acts of selecting, making, positioning, or using certain components, as examples. Other embodiments may include performing other of these acts on the same or different components, or may include fabricating, assembling, obtaining, providing, ordering, receiving, shipping, or selling such components, or other components described herein or known in the art, as other examples. Further, various embodiments include various combinations of the components, features, and acts described herein or shown in the drawings, for example. Further, particular embodiments include various means for accomplishing one or more of the particular functions described herein or apparent from the structure described. Other embodiments may be apparent to a person of ordinary skill in the art having studied this document.
Claims
1. An air conditioning unit packaged with a condensing gas heat exchanger, the unit comprising:
- an enclosure;
- a return duct opening for connecting the unit to a return duct that delivers air to the unit from the space;
- a supply duct opening for connecting the unit to a supply duct that delivers air from the unit to the space;
- the condensing gas heat exchanger for heating the air;
- a collector connected to the condensing gas heat exchanger;
- an inducer fan having an inlet connected to the collector and an outlet; and
- an exhaust conduit extending from the outlet of the inducer fan to outside of the enclosure;
- wherein the collector further comprises: an exhaust hole for the inlet of the inducer fan; and a drain hole extending through the collector to the inlet of the inducer fan; wherein: the drain hole is lower than the exhaust hole for the inducer fan; the drain hole has a smaller cross-sectional area than the exhaust hole for the inducer fan; and condensate formed in the condensing gas heat exchanger passes through the drain hole to the inlet of the inducer fan, through the inducer fan, and into the exhaust conduit with combustion gasses.
2. The air conditioning unit of claim 1 wherein:
- the exhaust conduit comprises a bifurcation that separates the condensate from a majority of the combustion gasses;
- the bifurcation comprises a high path and a low path;
- the high path has a larger cross sectional area than the low path;
- the majority of the combustion gasses pass through the high path; and
- a minority of the combustion gasses pass through the low path with the condensate to keep the condensate from freezing when ambient temperature conditions are below freezing.
3. The air conditioning unit of claim 2 further comprising a vertical standpipe wherein the low path discharges into the vertical standpipe and the condensate is allowed to drip into the vertical standpipe while the minority of the combustion gasses emerging from the low path are exhausted upward between the low path and the standpipe.
4. The air conditioning unit of claim 3 wherein the standpipe extends into the ground and terminates with at least one opening to the ground below a frost line in the ground.
5. The air conditioning unit of claim 1 further comprising a bed of porous alkaline material in the ground wherein the condensate is directed to discharge into the bed of porous alkaline material in the ground to neutralize acidity of the condensate and dispose of the condensate into the ground.
6. An air conditioning unit packaged with a condensing gas heat exchanger, the unit comprising:
- an enclosure;
- a return duct opening for connecting the unit to a return duct that delivers air to the unit from the space;
- a supply duct opening for connecting the unit to a supply duct that delivers air from the unit to the space;
- the condensing gas heat exchanger for heating the air;
- a collector connected to the condensing gas heat exchanger;
- an inducer fan having an inlet connected to the collector and an outlet; and
- an exhaust conduit extending from the outlet of the inducer fan to outside of the enclosure;
- wherein: the collector further comprises an exhaust hole for the inlet of the inducer fan; and condensate formed in the condensing gas heat exchanger passes through the inducer fan, into the exhaust conduit, and out of the enclosure; the exhaust conduit comprises a bifurcation that separates the condensate from a majority of the combustion gasses; the bifurcation comprises a high path and a low path; the high path has a larger cross sectional area than the low path; and the majority of the combustion gasses pass through the high path.
7. The air conditioning unit of claim 6 wherein the low path has a continually downward gradient and a minority of the combustion gasses pass through the low path with the condensate to keep the condensate from freezing when ambient temperature conditions are below freezing.
8. The air conditioning unit of claim 7 further comprising a vertical standpipe having a larger cross-sectional dimension than the low path, wherein the low path discharges into the vertical standpipe and the condensate is allowed to drip into the vertical standpipe while the minority of the combustion gasses emerging from the low path are exhausted upward between the low path and the standpipe.
9. A method of reducing consumption of fossil fuels and reducing emission of greenhouse gasses from widely used HVAC equipment, the method comprising in any order at least the acts of:
- manufacturing, obtaining, or providing air conditioning units having condensing gas heat exchangers;
- advertising that the air conditioning units can be installed on a roof of a building and condensate from the condensing gas heat exchangers can be disposed of by routing a drain line through the roof of the building for disposal inside the building; and
- advertising that the air conditioning units can be installed at ground level and condensate from the condensing gas heat exchangers can be disposed of into the ground.
10. The method of claim 9 wherein the act of manufacturing, obtaining, or providing the air conditioning units comprises manufacturing, obtaining, or providing air conditioning units that include:
- a condensing gas heat exchanger having at least one stage that has fins;
- a collector connected to the at least one stage that has fins, wherein the collector comprises a drain line opening penetrating the collector; and
- an inducer fan having an inlet connected to the collector.
11. The method of claim 10 wherein the act of manufacturing, obtaining, or providing the air conditioning units comprises manufacturing, obtaining, or providing air conditioning units that include a drain hole extending through the collector to the inlet of the inducer fan wherein the drain hole is higher than the drain line opening.
12. The method of claim 10 further comprising an act of instructing an installer of the units that when they install the unit at ground level and dispose of condensate from the condensing gas heat exchanger into the ground, that they can leave in place, or install, a plug in the drain line opening penetrating the collector and allow the condensate to pass through the inducer fan.
13. The method of claim 10 further comprising an act of instructing an installer of the units that when they install the unit on the roof of the building and dispose of condensate from the condensing gas heat exchanger in the building, that they can leave attached, or attach, the drain line to the opening penetrating the collector, route the drain line through the roof, and allow the condensate to pass through the drain line for disposal inside the building.
14. (canceled)
15. The method of claim 13 further comprising an act of instructing an installer of the units that when they install the unit on the roof of the building and dispose of condensate from the condensing gas heat exchanger in the building, that they can install the unit on a roof curb assembly and route the drain line through a tubular conduit that passes through the roof curb assembly and through the roof of the building.
16. The method of claim 9 further comprising an act of instructing an installer of the units that when they install the unit on the roof of the building and dispose of condensate from the condensing gas heat exchanger in the building, that they can route the drain line through the roof of the building inside of a return duct that connects to the unit to deliver air from within the building to the unit.
17. The method of claim 9 wherein the act of manufacturing, obtaining, or providing the air conditioning units comprises manufacturing, obtaining, or providing air conditioning units that include a return duct opening for connecting the unit to a return duct that delivers air to the unit from the building, wherein the drain line is connected to the unit to receive the condensate and the drain line extends to the return duct opening and is stored at the return duct opening during shipment of the unit for routing the drain line through the return duct when the unit is installed on the roof of the building.
18. The method of claim 9 wherein the act of manufacturing, obtaining, or providing the air conditioning units comprises manufacturing, obtaining, or providing air conditioning units that include a return duct opening for connecting the unit to a return duct that delivers air to the unit from the building and a tubular conduit that extends to the return duct opening for routing the drain line through the return duct when the unit is installed on the roof of the building.
19. The method of claim 9 further comprising an act of instructing an installer of the units that when they install the unit at ground level and dispose of condensate from the condensing gas heat exchanger into the ground, that they can install a bifurcation in an exhaust conduit extending from an outlet of an inducer fan of the unit to outside of an enclosure for the unit, that the bifurcation can be installed to provide a high path and a low path, and that the low path can be installed to discharge into a vertical standpipe.
20. The method of claim 9 further comprising an act of instructing an installer of the units that when they install the unit at ground level and dispose of condensate from the condensing gas heat exchanger into the ground, that they can provide a low path that discharges into a vertical standpipe that extends into the ground and terminates with at least one opening to the ground below a frost line in the ground.
21. The method of claim 9 further comprising an act of instructing an installer of the units that when they install the unit at ground level and dispose of condensate from the condensing gas heat exchanger into the ground, that they can direct the condensate to discharge into a bed of porous alkaline material in the ground to neutralize acidity of the condensate.
Type: Application
Filed: Feb 11, 2011
Publication Date: Mar 1, 2012
Applicant: NORDYNE Inc. (O'Fallon, MO)
Inventors: Allan J. Reifel (Florissant, MO), Russell W. Hoeffken (Millstadt, IL), Aaron D. Herzon (Ballwin, MO), David W. Garvin (Troy, MO)
Application Number: 13/026,014
International Classification: F24H 3/02 (20060101); F24H 9/16 (20060101);