Condensate pan with condensate trap

• US 10,145,581 B2
• Filed: 11/14/2011
• Issued: 12/04/2018
• Est. Priority Date: 06/25/2007
• Status: Active Grant

• Current Assignee: Johnson Controls Tyco IP Holdings LLP (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Khan, Tabraiz Ali
• Primary Examiner(s): McAllister, Steven B
• Assistant Examiner(s): Peyton, Desmond C
• Application Number:
  US13/295,556
• Publication Number:
  US 20120055465A1
• Time in Patent Office: 2,577 Days
• Field of Search: 126110 R, 126116 R, 126 20, 4351, 62285, 62291, 137247, 137 33, 137312, 137574
• CPC Class Codes: F24H 3/087 using fluid fuel
• CPC Class Codes: F24H 8/006 Means for removing condensate from the heater
• CPC Class Codes: Y02B 30/00 Energy efficient heating, ventilation or air conditioning [HVAC]
• CPC Class Codes: Y10T 137/5762 With leakage or drip collecting
• CPC Class Codes: Y10T 137/5907 Collector for waste liquid derived from solid, gas or vapor

Abstract

A condensate pan for a condensing furnace includes a main chamber to receive exhaust gases, a condensate trap separate from the main chamber and internal the condensate pan and a main drain.

Claims

1. A condensate pan for a furnace comprising:

a single chamber defined partially by an external wall of the condensate pan extending along an outermost perimeter of the condensate pan, wherein the single chamber is configured to receive exhaust gases and condensate from a furnace;

a plurality of traps in fluid communication with the single chamber, the plurality of traps being positioned on a periphery of the single chamber, and at least one trap of the plurality of traps having a position on the periphery of the single chamber that results in the at least one trap not receiving condensate from the single chamber during operation of the furnace; and

a plurality of L-shaped baffles positioned between the single chamber and the plurality of traps to separate the single chamber from the plurality of traps, wherein a portion of each L-shaped baffle of the plurality of L-shaped baffles extends from the external wall to partially define the single chamber and wherein the exhaust gases are capable of flowing directly from the single chamber to an inducer.

2. The condensate pan of claim 1 wherein the plurality of traps and the single chamber are defined by a single body and enclosed by a cover.

3. The condensate pan of claim 1 wherein each trap of the plurality of traps comprises a drain connection to remove condensate from the corresponding trap.

4. The condensate pan of claim 1 further comprising a plurality of channels fluidly connecting the single chamber and the plurality of traps between an additional portion of each L-shaped baffle of the plurality of L-shaped baffles and the external wall, each trap of the plurality of traps being connected to the single chamber by a corresponding channel of the plurality of channels to provide a flow path for condensate from the single chamber to the trap.

5. The condensate pan of claim 1 wherein the plurality of traps comprises at least one pair of traps and the at least one pair of traps being positioned opposite each other on the periphery of the single chamber.

17. The condensate pan of claim 1 wherein the condensate pan comprises a cruciform shape.

6. A condensate pan for a furnace comprising:

a body comprising a first wall and a second wall projecting from the first wall, the first wall comprising a first aperture configured to receive a connection to an inducer, and wherein the second wall at least partially defines an outermost perimeter of the condensate pan;

a cover configured to be connected to the body, the cover comprising a second aperture configured to receive a plurality of tubes from a heat exchanger;

the body and cover being configured and positioned to form a single chamber and a plurality of traps in fluid communication with the single chamber in response to the cover being connected to the body, wherein the single chamber is defined partially by the second wall of the body and partially by a plurality of L-shaped baffles projecting from the first wall between the single chamber and the plurality of traps;

at least one of the body or cover having one or more connection points to connect the body and cover to a vestibule of a furnace;

the single chamber being in direct fluid communication with the second aperture in the cover to receive exhaust gases and condensate from the plurality of tubes and in fluid communication with the first aperture in the body to provide exhaust gases to the inducer; and

the plurality of traps being positioned on a periphery of the single chamber, at least one trap of the plurality of traps having a position on the periphery of the single chamber that results in the at least one trap not receiving condensate from the single chamber during operation of the furnace.

7. The condensate pan of claim 6 wherein the body comprises a plurality of drain apertures configured to remove condensate from the plurality of traps, each drain aperture of the plurality of drain apertures corresponding to a trap of the plurality of traps.

8. The condensate pan of claim 7 further comprising at least one cap configured to close a drain aperture of the plurality of drain apertures, the at least one cap being used with the corresponding drain aperture of the at least one trap not receiving condensate from the single chamber during operation of the furnace.

9. The condensate pan of claim 6 wherein a portion of each L-shaped baffle of the plurality of L-shaped baffles extends from the second wall between the first wall and the cover, the plurality of L-shaped baffles being positioned to separate the single chamber from the plurality of traps, each L-shaped baffle of the plurality of L-shaped baffles being positioned to partially define a corresponding trap of the plurality of traps, and wherein the first wall, the second wall, and the plurality of L-shaped baffles form an integral piece.

10. The condensate pan of claim 9 wherein an additional portion of each L-shaped baffle of the plurality of L-shaped baffles and at least a portion of the second wall of the body are configured and positioned to form a plurality of channels fluidly connecting the single chamber and the plurality of traps, each trap of the plurality of traps being connected to the single chamber by a corresponding channel of the plurality of channels to provide a flow path for condensate from the single chamber to the trap.

11. The condensate pan of claim 6 wherein the plurality of traps comprises at least one pair of traps and the at least one pair of traps being positioned opposite each other on the periphery of the single chamber.

12. The condensate pan of claim 6 wherein the body comprises a plurality of flue drain apertures configured to permit condensate collected downstream of the inducer to enter the plurality of traps, each flue drain aperture of the plurality of flue drain apertures corresponding to a trap of the plurality of traps.

18. The condensate pan of claim 6 wherein the condensate pan comprises a cruciform shape.

13. A furnace comprising:

a housing, the housing having a plurality of mounting positions;

a heat exchanger;

a plate positioned in the housing and connected to the heat exchanger to support the heat exchanger; and

a condensate pan mounted to the plate, the condensate pan comprising;

a single chamber defined partially by an external wall of the condensate pan extending along an outermost perimeter of the condensate pan, wherein the single chamber is configured to receive combustion air and condensate from the heat exchanger;

a plurality of traps in fluid communication with the single chamber, the plurality of traps being positioned on a periphery of the single chamber, and at least one trap of the plurality of traps being positioned on the periphery of the single chamber to receive condensate from the single chamber for each mounting position of the plurality of mounting positions of the housing; and

a plurality of L-shaped baffles positioned between the single chamber and the plurality of traps to separate the single chamber from the plurality of traps, wherein a portion of each L-shaped baffle of the plurality of L-shaped baffles extends from the external wall to partially define the single chamber and wherein the exhaust gases are capable of flowing directly from the single chamber to an inducer.

14. The furnace of claim 13 wherein each trap of the plurality of traps comprises a drain to remove condensate from the corresponding trap.

15. The furnace of claim 13 wherein the condensate pan comprises a plurality of channels fluidly connecting the single chamber and the plurality of traps, each trap of the plurality of traps being connected to the single chamber by a corresponding channel of the plurality of channels to provide a flow path for condensate from the single chamber to the trap.

16. The furnace of claim 13 wherein the single chamber comprises at least one blocked condensate tab connected to a pressure switch to measure liquid level.

19. The furnace of claim 13 wherein the condensate pan comprises a cruciform shape.

20. The furnace of claim 15, wherein the plurality of channels is partially defined by the external wall and partially defined by an additional portion of each L-shaped baffle of the plurality of L-shaped baffles.