METHOD AND APPARATUS FOR DRAINING CONDENSATE FROM A GAS WATER HEATER EXHAUST SYSTEM

Abstract

A method and apparatus for conveying condensate from an exhaust system of a gas water heater to a drain. The method includes the steps of operating the gas water heater to produce products of combustion, operating a blower to cause the products of combustion to flow through the exhaust system to atmosphere, allowing condensate from the products of combustion to form within the exhaust system, using a drain conduit to connect a relatively high pressure zone of the exhaust system to a relatively low pressure zone of the exhaust system, using a pressure differential between the relatively high pressure zone and the relatively low pressure zone to convey condensate through the drain conduit from the relatively high pressure zone to the relatively low pressure zone, and conveying condensate from the relatively low pressure zone to the drain.

Description

RELATED APPLICATIONS

This application claims priority to co-pending U.S. Provisional Patent Application No. 61/407,778 filed on Oct. 28, 2010, the entire content of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to gas water heaters, and more particularly to gas water heaters including exhaust systems.

SUMMARY OF THE INVENTION

The present invention provides, in one aspect, a method of conveying condensate from an exhaust system of a gas water heater to a drain. The method includes the steps of operating the gas water heater to produce products of combustion, connecting an exhaust outlet of the gas water heater to the exhaust system such that the exhaust system receives the products of combustion, operating a blower to cause the products of combustion to flow through the exhaust system to atmosphere, allowing condensate from the products of combustion to form within the exhaust system, using a drain conduit to connect a relatively high pressure zone of the exhaust system to a relatively low pressure zone of the exhaust system, the relatively low pressure zone between the exhaust outlet and the blower and the relatively high pressure zone downstream of the relatively low pressure zone, using a pressure differential between the relatively high pressure zone and the relatively low pressure zone to convey condensate through the drain conduit from the relatively high pressure zone to the relatively low pressure zone, and conveying condensate from the relatively low pressure zone to the drain.

The present invention provides, in another aspect, a gas water heater including a storage tank for storing water, a combustion chamber, a burner positioned in the combustion chamber, the burner for producing products of combustion, a heat exchanger positioned in the storage tank for receiving the products of combustion from the combustion chamber and for transferring heat from the products of combustion to the water stored in the storage tank, the heat exchanger including an outlet that extends from the storage tank, and an exhaust system. The exhaust system includes a first exhaust conduit connected to the outlet to receive the products of combustion from the heat exchanger, a second exhaust conduit fluidly connected to atmosphere, a blower connected between the first exhaust conduit and the second exhaust conduit with the first exhaust conduit upstream of the blower and the second exhaust conduit downstream of the blower, a first drain fitting in the first exhaust conduit between the outlet and the blower and a second drain fitting downstream of the first drain fitting such that the first drain fitting is at a first pressure and the second drain fitting is at second pressure, the second pressure greater than the first pressure, and a drain conduit connected between the first drain fitting and the second drain fitting such that the difference between the second pressure and the first pressure causes condensate from the products of combustion to flow through the drain conduit from the second drain fitting to the first drain fitting.

Other features and aspects of the invention will become apparent by consideration of the following detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a gas water heater.

FIG. 2 is a perspective view of the gas water heater of FIG. 1 including a gravity-based condensate drainage system.

FIG. 3 is a schematic view of the gas water heater of FIG. 1 including a gravity-based condensate drainage system

FIG. 4 is a perspective view of the gas water heater of FIG. 1 including a pressure-based condensate drainage system.

FIG. 5 is a schematic view of the gas water heater of FIG. 1 including a pressure-based condensate drainage system.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION

FIG. 1 illustrates a gas water heater 100 including a storage tank 105, an outer case 110, a cold water inlet 115, a hot water outlet 120, a combustion chamber 125, a burner 130, and a flue or heat exchanger 135. The water heater 100 may also include additional conventional components of a gas-fired storage water heater, for example, a gas valve, a temperature and pressure (T&P) valve, a sacrificial anode, and a drain valve. The storage tank 105 is surrounded by the outer case 110. The cold water inlet 115 delivers cold water to the storage tank 105 and the hot water outlet 120 delivers hot water to an end-use location, for example, a faucet. The burner 130 is positioned in the combustion chamber 125 and combusts a fuel/air mixture to create products of combustion. The products of combustion flow from the combustion chamber 125 to the heat exchanger 135. As the products of combustion travel through the heat exchanger 135, heat is transferred from the products of combustion to the water stored in the storage tank 105. The heat exchanger 135 includes an outlet 140 that extends from the storage tank 105 through the outer case 110.

FIGS. 2-3 illustrate an exhaust system 145 that conveys the products of combustion from the outlet 140 of the heat exchanger 135 to atmosphere. The exhaust system 145 includes a blower 150, an exhaust conduit 155 upstream of the blower 150, and an exhaust conduit 160 downstream of the blower 150. A vent attenuation assembly 165 in the exhaust conduit 160 is optional. The exhaust conduit 155 connects the outlet 140 to the blower 150. The exhaust conduit 155 extends vertically along the side of the water heater 100 and is spaced apart from the storage tank 105 and the outer case 100. The exhaust conduit 160 connects the blower 150 to an exhaust vent (not shown). The vent attenuation assembly 165 is positioned between the blower 150 and the exhaust vent to reduce fan noise created by the blower 150. When the water heater 100 and the blower 150 are operating, the products of combustion travel from the outlet 140 through the exhaust conduit 155, through the blower 150, and through the exhaust conduit 160 and vent attenuation assembly 165 to the exhaust vent to be vented to the atmosphere outside of the building containing the water heater 100, as shown by the dashed arrows in FIG. 3.

As the products of combustion cool in the exhaust system 145, condensate is formed. The condensate must be drained from the exhaust system 145. A conventional method of draining the condensate is to use gravity to drain condensate from several locations in the exhaust system 145. The blower 150 includes drain fittings 170 and 175. The drain fitting 170 is in the housing of the blower 150 and the drain fitting 175 is in the outlet portion of the blower 150. The vent attenuation assembly 165 includes a drain fitting 180. A drain hose or conduit 185 is connected to each drain fitting 170, 175, and 180. The exhaust conduit 155 includes a lower portion with a trap 190. The trap 190 is u-shaped and is positioned below the outlet 140 of the heat exchanger 135. A main drain conduit 195 is connected to the trap 190 and runs to a suitable drain 200. All of the drain conduits 185 are in fluid communication with the main drain conduit 195. The drain conduits 185 from the drain fittings 170 and 175 are connected to one another by a tee 205 and then to the main drain conduit 195 by an intermediate conduit 208 and another tee 205. The drain conduit 185 from the drain fitting 180 is connected to the main drain conduit 195 by a tee 205. Each of the drain conduits 185 includes a trap loop 210 located upstream of any tee 205 connected to that drain conduit 185. As condensate forms in the exhaust system 145, the condensate is drawn by gravity towards one of the drain fittings 170, 175, and 180. From each drain fitting 170, 175, and 180, the condensate is drawn by gravity through a corresponding drain conduit 185 to the main drain conduit 195 and through the main drain conduit 195 to the drain 200, as shown by the solid arrows in FIG. 3. Alternatively, each of the drain conduits 185 and the main drain conduit 195 are individually routed to the drain 200.

The drawbacks of the gravity-based condensate drainage system as shown in FIGS. 2-3 include installation, appearance, setup, and function. For installation, the installer can be confused about how to connect and route the drain conduits 185, even when provided with instructions. For appearance, the multiple drain conduits 185 and loops 210 outside of the water heater 100 and exhaust system 145 can look messy. For setup, each individual drain conduit 185 has to be primed and each individual loop 210 must be formed and positioned correctly. For function, gravity does not ensure complete drainage of the condensate from the exhaust system 145, which causes nuisances in the field. When the blower 150 is operating, the exhaust conduit 155 is at a first pressure P1, the housing of the blower 150 including drain fitting 170 is at a second pressure P2, the outlet portion of the blower 150 including drain fitting 175 is at a third pressure P3, and the vent attenuation assembly 165 including drain fitting 180 is at a fourth pressure P4. Pressures P1, P2, P3, and P4 all are lower than the ambient pressure at the drain 200, which causes the drain conduits 185 to not drain well because the pressure differentials between the pressures P1, P2, P3, and P4 and ambient pressure work against the effect of gravity on the condensate in the drain conduits 185. Furthermore, as shown in FIG. 3, any rise 215 in a drain conduit 185 upstream of a loop 210 traps condensate and air upstream of the loop 210, thereby inhibiting the flow of condensate through the loop 210 and drain conduit 185.

FIGS. 4-5 illustrate the gas fueled water heater 100 and an exhaust system 245 similar to the exhaust system 145 shown in FIGS. 2-3. The components of the exhaust system 245 similar to those described with respect to exhaust system 145 are numbered with the same reference numeral plus one-hundred. The exhaust system 245 uses a pressure-based condensate drainage system that overcomes the drawbacks of a gravity-based drainage system as shown in FIGS. 2-3.

The exhaust conduit 255 includes an adaptor 320 positioned near the top of the water heater 100. The adaptor 320 includes multiple drain fittings 325. At a minimum, the adaptor 320 includes one drain fitting 325. The adaptor 320 and the drain fittings 325 are located on a vertical portion 327 of the exhaust conduit 255. The drain fittings 325 are located adjacent to the top of the water heater 100 and the top of the storage tank 110. The drain fittings 325 can be poka-yoke or error-proofed fittings which require the installer to remove a plug or other component for each fitting before attaching a drain conduit 285. This prevents a drain fitting 325 from being left open if the installer does not install the same number of drain conduits 285 as the number of drain fittings 325 provided by the adaptor 320. In the event a drain fitting 325 is left open and the water heater 100 and the blower 250 are operating, the adaptor 320 will be at a negative pressure relative to atmosphere such that products of combustion will not escape through the open drain fitting 325. Preferably, the drain fittings 325 are barb fittings.

Drain fittings 270, 275, and 280 are located downstream of the adaptor 320. More or fewer drain fittings downstream of the adaptor 320 can be included in the exhaust system 245. For example, as shown in FIG. 4, the blower 250 includes a third drain fitting 330. Drain conduits 285 are connected between the each of the drain fittings 270, 275, 280, and 330 and a drain fitting 325 of the adaptor 320. The adaptor 320 is positioned below all of the downstream drain fittings 270, 275, 280, and 330.

As shown in FIG. 5, when the blower 250 is operating, the exhaust conduit 255 including drain fittings 325 is at a first pressure P1, the inlet of blower 250 including drain fitting 270 is at a second pressure P2, the outlet of the blower 250 including drain fitting 275 is at a third pressure P3, and the vent attenuation assembly 265 including drain fitting 280 is at a fourth pressure P4. The blower 250 runs when the water heater 100 is operating to create products of combustion. The blower 250 may also run before and/or after the water heater 100 is operating to produce products of combustion. The second pressure P2, the third pressure P3, and the fourth pressure P4 are all greater than the first pressure P1. For example, the second pressure P2 and the first pressure P1 are both negative relative to atmosphere with the first pressure P1 being more negative than the second pressure P2, so the second pressure P2 is considered greater than or higher than the first pressure P1 relative to atmosphere.

Each of the drain fittings 270, 275, 280, and 330 is located in a relatively high pressure zone when compared to a relatively low pressure zone in which the drain fittings 325 are located. The relatively high pressure zones are located downstream of the relatively low pressure zone in which the drain fittings 325 are located. The pressure differentials between the second pressure P2 and the first pressure P1, the third pressure P3 and the first pressure P1, and the fourth pressure P4 and the first pressure P1 drive the condensate from the relatively high pressure zones through a corresponding drain conduit 285 to the relatively low pressure zone in the exhaust conduit 255. Gravity functions as a subsidiary method of drainage through the drain conduits 285 because the drain fittings 325 of the adaptor 320 are positioned lower than all of the drain fittings 270, 275, 280, and 330.

Gravity causes the condensate to travel downward through the exhaust conduit 255 from the drain fittings 325 to the trap 290. Condensate collects in the trap 290 until the collected condensate reaches the elevation of the main drainage conduit 295, which delivers the condensate to the drain 200.

The pressure-based condensate drainage system shown in FIGS. 4-5 improves on the installation, appearance, setup, and function of the gravity-based condensate drainage system shown in FIGS. 2-3. The pressure-based condensate drainage system is easier to install, neater looking, and requires less time to set up than the gravity-based condensate drainage system. For example, there is no need to prime the drain conduits 285 of the pressure-based condensate drainage system, only the main drain conduit 295 needs priming. Additionally, the condensate-based drainage system drains condensate more reliably and functions better than the gravity-based condensate drainage system.

Various features of the invention are set forth in the following claims.

Claims

1. A method of conveying condensate from an exhaust system of a gas water heater to a drain, the method comprising:

operating the gas water heater to produce products of combustion;

connecting an exhaust outlet of the gas water heater to the exhaust system such that the exhaust system receives the products of combustion;

operating a blower to cause the products of combustion to flow through the exhaust system to atmosphere;

allowing condensate from the products of combustion to form within the exhaust system;

using a drain conduit to connect a relatively high pressure zone of the exhaust system to a relatively low pressure zone of the exhaust system, the relatively low pressure zone between the exhaust outlet and the blower and the relatively high pressure zone downstream of the relatively low pressure zone;

using a pressure differential between the relatively high pressure zone and the relatively low pressure zone to convey condensate through the drain conduit from the relatively high pressure zone to the relatively low pressure zone; and

conveying condensate from the relatively low pressure zone to the drain.

2. The method of claim 1, wherein the relatively high pressure zone is located at the blower.

3. The method of claim 1, wherein the relatively high pressure zone is located downstream of the blower.

4. The method of claim 1, further comprising:

conveying condensate from the relatively low pressure zone to the drain at least in part due to gravity.

5. The method of claim 1, further comprising:

using a second drain conduit to connected a second relatively high pressure zone of the exhaust system to the relatively low pressure zone; and

using a second pressure differential between the second relatively high pressure zone and the relatively low pressure zone to convey condensate through the second drain conduit from the second relatively high pressure zone to the relatively low pressure zone.

6. A gas water heater comprising:

a storage tank for storing water;

a combustion chamber;

a burner positioned in the combustion chamber, the burner for producing products of combustion;

a heat exchanger positioned in the storage tank for receiving the products of combustion from the combustion chamber and for transferring heat from the products of combustion to the water stored in the storage tank, the heat exchanger including an outlet that extends from the storage tank; and

an exhaust system including a first exhaust conduit connected to the outlet to receive the products of combustion from the heat exchanger, a second exhaust conduit fluidly connected to atmosphere, a blower connected between the first exhaust conduit and the second exhaust conduit with the first exhaust conduit upstream of the blower and the second exhaust conduit downstream of the blower, a first drain fitting in the first exhaust conduit between the outlet and the blower and a second drain fitting downstream of the first drain fitting such that the first drain fitting is at a first pressure and the second drain fitting is at second pressure, the second pressure greater than the first pressure, and a drain conduit connected between the first drain fitting and the second drain fitting such that the difference between the second pressure and the first pressure causes condensate from the products of combustion to flow through the drain conduit from the second drain fitting to the first drain fitting.

7. The gas water heater of claim 6 wherein the first exhaust conduit further includes a vertical portion and the first drain fitting is located on the vertical portion.

8. The gas water heater of claim 7 wherein the first drain fitting is located adjacent to the top of the storage tank.

9. The gas water heater of claim 8 wherein the blower includes the second drain fitting.

10. The gas water heater of claim 9, wherein the blower is located above the storage tank.

11. The gas water heater of claim 10, further comprising:

a trap connected to the first exhaust conduit and positioned below the outlet of the heat exchanger; and

a second drain conduit connected to the trap, the second drain conduit for conveying condensate to a drain.

12. The gas water heater of claim 8 wherein the second drain fitting is located downstream of the blower.

13. The gas water heater of claim 12, wherein the blower is located above the storage tank.

14. The gas water heater of claim 13, further comprising:

a trap connected to the first exhaust conduit and positioned below the outlet of the heat exchanger; and

a second drain conduit connected to the trap, the second drain conduit for conveying condensate to a drain.

15. The gas water heater of claim 6 wherein the blower includes the second drain fitting.

16. The gas water heater of claim 15, wherein the blower is located above the storage tank.

17. The gas water heater of claim 6 wherein the second drain fitting is located downstream of the blower.

18. The gas water heater of claim 17, wherein the blower is located above the storage tank.

19. The gas water heater of claim 7, wherein the blower is located above the storage tank.

20. The gas water heater of claim 7, further comprising:

a trap connected to the first exhaust conduit and positioned below the outlet of the heat exchanger; and

a second drain conduit connected to the trap, the second drain conduit for conveying condensate to a drain.