CONDENSATE PAN WITH CONDENSATE TRAP

• US 20120055465A1
• Filed: 11/14/2011
• Published: 03/08/2012
• 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
• Granted Patent: US 10,145,581 B2
• Time in Patent Office: Days
• US Class Current: 126/99.R
• 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 chamber to receive exhaust gases and condensate from a furnace; and

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

2. The condensate pan of claim 1 wherein the plurality of traps and the 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 baffles positioned between the chamber and the plurality of traps to separate the chamber and the plurality of traps, each trap of the plurality of traps having a corresponding baffle of the plurality of baffles to separate the trap from the chamber.

5. The condensate pan of claim 1 further comprising a plurality of channels fluidly connecting the chamber and the plurality of traps, each trap of the plurality of traps being connected to the chamber by a corresponding channel of the plurality of channels to provide a flow path for condensate from the chamber to the trap.

6. 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 chamber.

7. A condensate pan for a furnace comprising:

a body, the body comprising first wall and a second wall projecting from the first wall, the first wall comprising an aperture configured to receive a connection to an inducer;

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

the body and cover being configured and positioned to form a chamber and a plurality of traps in fluid communication with the chamber in response to the cover being connected to the body;

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

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

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

8. The condensate pan of claim 7 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 corresponds to a trap of the plurality of traps.

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

10. The condensate pan of claim 7 wherein the body comprises a plurality of baffles extending from the second wall between the first wall and the cover, the plurality of baffles being positioned to separate the chamber and the plurality of traps, each baffle of the plurality of baffles being positioned to partially define a corresponding trap of the plurality of traps.

11. The condensate pan of claim 10 wherein the plurality of 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 chamber and the plurality of traps, each trap of the plurality of traps being connected to the chamber by a corresponding channel of the plurality of channels to provide a flow path for condensate from the chamber to the trap.

12. The condensate pan of claim 10 wherein the first wall, the second wall and the plurality of baffles form an integral piece.

13. The condensate pan of claim 7 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 chamber.

14. The condensate pan of claim 7 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 corresponds to a trap of the plurality of traps.

15. 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 comprises;

a chamber to receive combustion air and condensate from the heat exchanger; and

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

16. The furnace of claim 15 wherein each trap of the plurality of traps comprises a drain to remove condensate from the corresponding trap.

17. The furnace of claim 15 wherein the condensate pan comprises a plurality of baffles positioned between the chamber and the plurality of traps to separate the chamber and the plurality of traps, each trap of the plurality of traps having a corresponding baffle of the plurality of baffles to separate the trap from the chamber.

18. The furnace of claim 17 wherein each baffle of the plurality of baffles has an L-shape.

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

20. The furnace of claim 15 wherein the chamber comprises at least one blocked condensate tab connected to a pressure switch to measure liquid level.