Abstract:
An air elimination device with a hydraulic separator in a compact format that eliminates numerous separate field installed components and connections and can be cost effectively made by means of spun, bent, bored, milled sheet copper or brass sheet, copper or brass tube or rod utilizing brazing, soldering and threading of parts. The device can be made to include a manifold, particularly with compact end suction pumps and can serve as a transition adaptor to other modular mechanical components.

Description:
BACKGROUND 
     Hydronic heating systems require a “mechanical space” for the central equipment. Mechanical spaces in the past were large spaces since the boilers they contained were large and needed to be accommodated. As a result, a considerable amount of wall space was typically available to mount mechanical components in a linear sequence. New, very small, condensing boilers have entered the market and created a need to make smaller, space saving hydronic mechanical modules to fit in small mechanical spaces. 
     The new boilers work best with hydraulic separation of flow between a primary piping loop and secondary loops that go to heating zones so that the primary loop can be predictably designed to provide the necessary flow for the boiler heat exchanger and to overcome the often high resistance to flow of such specialized heat exchangers. 
     If the components are piped conventionally and mounted on the wall, this takes up a great deal more space than the boiler which if installed alone would only require a very small space. The wasteful use of a large space in conventional hydronic mechanical rooms is costly in that the components themselves are costly, as is the cost per square foot to construct the large mechanical space to accommodate it. Thus a need has arisen for much more compact and cost effective components and modules for use in hydronic heating systems. 
     Hydraulic separation components have been constructed largely in the field with the use of closely spaced “Tees”. Hydraulic separators with a hydraulic separation chamber have been available in the past but they have not been made from inexpensive piping materials and methods or included a quality air elimination device or with specific thought in how to port them with space saving end suction pumps to save space for use with the new very small condensing boilers. 
     Previous air eliminators have been designed separately to be mounted in line with a single ingoing and outgoing pipe and have been predominantly made from cast parts. The use of closely spaced Tees to hydraulically separate the primary and secondary loops of a hydronic system have been employed before, and hydraulic separators have taken various forms but have not been integrated with a high quality air elimination system using the principles of change of volume, direction, rotation, and/or change in pressure to precipitate air from the hydronic fluid. 
     SUMMARY OF THE INVENTION 
     This invention is an improvement in that the components can be made from cost effective piping materials. Several components are combined into one compact unit. In one embodiment, this unit replaces numerous components that are normally installed separately on a wall with one centralized, module that serves multiple functions, combines a high quality air separation device with a hydraulic separator, pumps, supply and return ports in a compact format that eliminates numerous separate field installed components and connections. 
     In various embodiments, the invention can be cost effectively made predominantly by means of spun, bent, pressed, bored, milled sheet copper or brass sheet, copper or brass tube or rod utilizing brazing, soldering and threading of parts. Additionally, these embodiments can serve as a transition adaptor to other modular mechanical components by means of a shared commonality of pipe sizes, spacing and fitting systems. 
     The invention will significantly improve hydronic practice by making for more compact installations with fewer chances for installer error. The invention can be combined with other normal hydronic items to form a larger and very compact module. Furthermore it can be made from readily available materials and will be easy to clean and maintain. Additionally many of the parts can be used interchangeably to manufacture a wide range of variants with significant resulting cost savings. 
     In one aspect, the invention is a hydronic manifold with coupled secondary loop pumps that takes advantage of the compactness of end suction pumps. The assemblage comprises a manifold having a primary inlet, a primary outlet, a plurality of secondary loop outlets, and a plurality of secondary loop inlets, wherein at least two of the secondary loop outlets are respectively coupled to at least two inlets of centrifugal pumps, and each secondary loop outlet and coupled pump inlet are oriented along an axis of a rotational impeller in the pump. 
     Installation instructions instructing that the assembly should be installed with the axis of each rotational impeller oriented horizontally with respect to gravity may be included. Each centrifugal pump has an outlet that is oriented within a plane and this plane may be perpendicular to the axis of the impeller of the pump. Each centrifugal pump may be coupled to the manifold via its inlet with an inlet coupling that can be secured in a plurality of orientations by rotating the pump with respect to the manifold. 
     In another aspect, the invention is a hydronic manifold adapted for compact installations. The manifold includes a primary loop inlet, a primary loop outlet, a plurality of secondary loop outlets, and a plurality of secondary loop inlets. At least two secondary loop outlets are on a first side of the manifold and at least two secondary loop outlets are on a second side of the manifold, and these at least four secondary loop outlets define a plane. At least two secondary inlets are directed parallel to each other and at 90 degrees to the plane, which allows for compactness. 
     The hydronic manifold may further comprise a hydraulic separation chamber that directly couples the primary loop inlet to the primary loop outlet such that water can flow from one to the other without inducing a flow through a secondary loop. An outer wall of the manifold may extend to form an outer wall of the hydraulic separation chamber. In addition, an air eliminator may be coupled to the manifold wherein an outer wall of the manifold extends into an outer wall of the air eliminator. 
     In another aspect, the invention is a hydraulic separator made of a section of pipe by cutting a section of pipe; coupling end fittings to ends of the pipe section and cutting holes in the pipe section and/or end fittings such that the pipe section with end fittings has a primary loop inlet, a primary loop outlet, and a plurality of secondary loop ports and forms a hydraulic separation chamber that directly couples the primary loop inlet to the primary loop outlet such that water can flow from the primary loop inlet to the primary loop outlet without inducing a flow through an open secondary loop port. The primary loop inlet and the primary loop outlet may be oriented parallel to each other at a standard distance and with standard fittings such that the inlet and outlet will mate with other hydronic components having a mating inlet and a mating outlet conforming to the standard. 
     In another aspect, the invention is a manifold with hydraulic separation made of a section of pipe by cutting a section of pipe; cutting holes in the pipe section and coupling fittings to ends of the pipe section such that the pipe section has a primary loop inlet, a primary loop outlet, and a plurality of secondary loop ports. The pipe section includes a hydraulic separation chamber that directly couples the primary loop inlet to the primary loop outlet such that water can flow from the primary loop inlet to the primary loop outlet without inducing a flow through an open secondary loop port. An outer wall of the manifold may extend to also form an outer wall of an air eliminator. A smaller diameter pipe may be installed inside the pipe section to carry water between the hydraulic separation chamber and an end of the pipe section. 
     In another aspect, the invention is a manifold with air eliminator made of a section of pipe by cutting a section of pipe; cutting holes in the pipe section or coupling fittings to ends of the pipe section such that the pipe section has a primary loop inlet, a primary loop outlet, and a plurality of secondary loop ports; with an outer wall of the manifold extending to also form an outer wall of an air eliminator coupled to the manifold such that water flows between the manifold and the air eliminator. A smaller diameter pipe may be installed inside the pipe section to carry water between the air eliminator and an end of the pipe section. 
     In another aspect, the invention is an air eliminator with hydraulic separation made of pipe section by cutting a section of pipe; cutting holes in the pipe section and coupling fittings to ends of the pipe section such that the pipe section has a primary loop inlet, a primary loop outlet, a secondary loop inlet, and a secondary loop outlet all coupled to a hydraulic separation chamber within the pipe section; wherein the pipe section extends to also form an outer wall of an air eliminator which is coupled to the hydraulic separation chamber. A smaller diameter pipe may be installed inside the pipe to carry water between the hydraulic separation chamber and the air eliminator. 
     In another aspect, the invention is a method of making an air eliminator or an air eliminator plus hydraulic separator by making a hydronic air eliminator upper portion that is complete except for lower components and, for completion of lower components, selecting one of: (i) coupling the upper portion to a hydraulic separation chamber with a primary loop inlet, a primary loop outlet, a secondary loop inlet, and a secondary loop outlet; or (ii) coupling the upper portion to one and only one inlet and to one and only one outlet. The air eliminator plus a hydraulic separator may be formed within a single pipe section cut from a length of pipe. 
     In another aspect, the invention is a swirling air eliminator (air and water separator). It is formed with an inlet passage directed tangentially into an inner swirl chamber which has a cylindrical wall, an enclosed bottom, and an open circular top. An outer cylindrical swirl chamber surrounds the circular top with an annulus gap between it and the circular top. A water outlet passage is coupled to the outer swirl chamber. An air outlet venting a space sits above the inner chamber and its circular top. 
     The swirling air eliminator may be combined with a hydronic manifold coupled to the air eliminator wherein the second cylindrical wall of the air eliminator extends to also form a cylindrical outer wall of a manifold. In addition, a hydraulic separation chamber may be added such that the second cylindrical wall of the air eliminator extends into the cylindrical outer wall of the manifold and into a cylindrical outer wall of the hydraulic separation chamber. 
     Each of the aspects of the invention described above may be adapted to work with modular hydronic components that have a standard mating system. In this case, the primary loop inlet and primary loop outlet will be parallel to each other at a standard distance and with standard fittings such that the inlet and outlet will mate with other hydronic components having a mating inlet and a mating outlet conforming to the standard. Secondary loop inlets and outlets may also conform to the standard. 
     Each aspect of the invention may be made from formed, bent, brazed, induction welded, soldered or milled copper brass or other metal sheet or tube that lends itself to easy manufacture without cast parts, preferably materials normally approved for potable water use such as copper tube and sheet, lead free solder and brazing compounds, low lead or treated brass or stainless steel, and rubber gaskets approved for potable water use. 
    
    
     
       BRIEF DESCRIPTION OF THE ILLUSTRATIONS 
       Illustrations  1  and  2  shows a vertically piped air eliminator (air separator). 
       Illustrations  3 ,  4  and  5  show an air eliminator combined with a hydraulic separator. 
       Illustrations  6 ,  7 , and  8  show a multi zone secondary loop. 
       Illustrations  9  and  10  show a variation of the module shown in Illustrations  6  and  7 . 
       Illustrations  11 ,  12  and  13  show an embodiment similar to Illustrations  6 ,  7 , and  8 . 
       Illustrations  14 ,  15 ,  16  and  17  show an embodiment similar in construction to Illustration  6 , while Illustrations  18 ,  19 , and  20  show the same components but with a horizontal orientation of the primary chamber. 
       Illustration  21  shows a simple hydraulic separator. 
       Illustrations  22 ,  23  and  24  show a simple horizontally ported air eliminator  68 . 
       Illustration  25  shows a simple way of pressing plates into a cylindrical canister, and Illustration  26  shows the convenience of being able to rotate end suction pumps upward. 
     
    
    
     DETAILED DESCRIPTION 
     In the following detailed description of exemplary embodiments of the invention, reference is made to the accompanying drawings. The detailed description and the drawings illustrate specific exemplary embodiments by which the invention may be practiced. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the present invention. The following detailed description is therefore not to be taken in a limiting sense, and the scope of the present invention is defined by the stated claims. 
     Illustrations  1  and  2  show a vertically piped air eliminator  1  made from cylindrical materials and plates or caps. It may be incorporated also into other embodiments integrated into a bigger multifunctional canister. Fluid goes up the supply pipe  4 , until it reaches the supply pipe orifice  14  where the fluid is redirected to the outside wall of the swirl chamber  9 . The swirl chamber wall  9  is attached to the swirl chamber bottom  8  and the supply pipe by brazing, soldering, threading or other conventional means. The fluid is directed to rotate in the swirl chamber. The principles of change of volume, direction, rotation, and/or change in pressure precipitate and direct air from the hydronic fluid at the top to the air vent  2 . From there the fluid rotates downward between the outside of the swirl chamber wall  9  and the inside of the canister wall  6  to reach the return chamber. From there it exits down the return pipe  5 . 
     In assembling the unit  1  shown in Illustrations  1  and  2 , the supply pipe  4  is brazed, soldered, threaded or otherwise attached to the swirl chamber bottom  8  and then the swirl chamber wall  9  is brazed, soldered, threaded or otherwise attached to the swirl chamber wall  9  forming an assembly  21  which is then similarly attached to the bottom two holed plate  7  and the return pipe  5  is brazed, soldered, threaded or otherwise attached to the bottom two holed plate  7 . This assembly is then placed up inside the canister (made from a cut section of pipe) and the bottom two holed plate is brazed, soldered, threaded or otherwise attached to the canister wall  6 . A lid  3  is fitted to the top either as a soldered, brazed, or otherwise joined with a flange  11  or as threaded or insert cap with O-ring  10 . The lid  3  provides attachment for a float or other style air vent  2 . 
     Illustrations  3 ,  4  and  5  show incorporating an air eliminator working on similar principles such as described above but additionally incorporating a hydraulic separator and secondary loop supply and return lines. In this embodiment, a primary loop supply pipe  27  and a primary loop return pipe  28  are brazed, soldered threaded or otherwise joined to the separator outer plate  74 . The inner separator divider  16  is similarly joined to the canister wall  6 . The secondary return manifold  25  is inserted and joined to the canister wall  6  before the other parts. The inner separator divider  16  is joined to the inner wall of the canister  6 , which is joined to the air eliminator supply pipe  4 . The air chamber supply pipe  4  is joined to the swirl chamber bottom  8 . Note that the swirl chamber bottom may have alignment tabs as shown. The secondary loop supply pipe  26  is joined to the canister wall  6 . The unit is fitted with a lid  3  and an air vent  13  usually with a float mechanism  12  for releasing air. 
     Fluid enters from the primary loop supply pipe  27  and may either return by the primary loop return pipe  28  or be drawn up the swirl chamber supply pipe  4  and then it is redirected by the swirl chamber supply pipe orifice against the swirl chamber wall  9 . The fluid is directed to rotate in the swirl chamber. The principles of change of volume, direction, rotation, and/or change in pressure precipitate and direct air from the hydronic fluid at the top to the air vent  2 . From there the fluid rotates downward between the outside of the swirl chamber wall  15  and the inside of the canister wall  6  to reach the return chamber. From there it will flow out the secondary loop supply pipe  26  and return by means of the secondary loop return pipe  25  to the hydraulic separation chamber  124 . From there, when there is a higher flow rate in the primary loop, the fluid will be directed down the primary loop return pipe  28 . If there is a higher flow rate in the secondary loop, then some of the fluid from the secondary loop return pipe  25  will be directed up the swirl chamber supply pipe  4  and some back to the primary loop return pipe  28 . This feature can be used to control water temperature in the secondary loops by controlling the amount of cooled secondary loop return water that is mixed with primary loop supply water. The hydraulic separation chamber allows the pressure differences between the supply and returns to equalize and prevents the inducing of ghost flows. 
     Illustration  5  shows the embodiment of Illustration  3  and  4  but with an end suction centrifugal pump  33  attached to the canister  6  instead of the secondary loop supply pipe  26  and with the addition of pump and shut off valves on the primary loop return  34  and a longer pipe and shut off valve on the primary loop supply  35 . This embodiment shows how primary and secondary loop pumps, a hydraulic separator and a quality air eliminator may be made in a space saving, compact format. 
     Since the impeller shafts of wet rotor pumps must be kept horizontal, the end suction pump offers a significant advantage over conventional pumps in combination with a cylindrical vertical canister. The pumps may be easily swiveled to face straight out as shown or up, down or in between and the ports for such pumps may be located anywhere on the circumference of the canister. Conventional straight through pump flanges and pumps may be used with this invention but they will take up a great deal more space and may not be swiveled to alternate orientations and do not lend themselves to flexible on the job alterations of pump orientation. Being able to alter the pump orientation easily on the job site, where heating zones may be located in different directions, is a huge time saving benefit and reduces piping and installation costs. 
     Illustrations  6 ,  7  and  8  show a multi zone secondary loop module similar to the one described immediately above but with differences that the secondary loop return pipe  81  is now a multi ported manifold that is inserted from inside the unit through holes  80  and joined to the canister wall  6 , the canister  6  has been lengthened, the swirl chamber supply pipe  4  has been lengthened, and multiple secondary loop supply pipes  79  have been added, as well as hanging bracket  39 , expansion tank  38 , fill valve  37 , fill pipe  75 , and a fill water port  78  on the canister  6 . Fill water pipes would be field connected to the fill water connection end  77  of the fill valve. The entire fill water assembly  76 , which includes the fill pipe, expansion tank and pressure reducing fill valve are joined to the canister  6  at the fill port  78 . In Illustrations  6  and  7 , end suction pumps  33  are shown joined to the canister instead of the secondary loop supply pipe  26  shown in Illustration  8  of the same embodiment. 
     Illustrations  9  and  10  show a variation of the module shown in Illustrations  6  and  7 , where the primary loop supply and return have been adapted to fit under a small wall hung boiler. The primary loop supply pipe with shut off valve  35  and the primary loop return pipe with pump and shut off valves  34  are piped down from the canister  88  but then turn upward towards the boiler  82 . The primary loop supply line  35  shows a tap  85  for supply to an indirect water tank. The primary loop return pipe  34  shows an additional pump with shut off valves  84  joined into it for a return from an indirect water tank, as well as additional air purge bleeder valve  83 . The boiler supply pipe  86  connects to the module primary loop supply  35  and the boiler return pipe  87  connects to the primary loop return pipe  34 . 
     Since boilers come ported in many ways top, left side, right side, bottom or a combination, the primary loop supply pipe and shut off  35  and primary loop return with pump and shut off valves may be modified to many possible shapes and could include additional standard hydronic components such as gauges, strainers and low water cut off valves. The primary loop supply  35  and return  34  might reverse the location of the pump from supply to return and need not have shut off valves. In some cases the primary loop pump may be deleted, for example if the boiler already contains an integral pump. 
     Illustrations  11 ,  12  and  13  show an embodiment similar to that shown in Illustrations  6 ,  7 , and  8 , with the difference that the multiported secondary loop return manifold  81  shown in Illustration  7  has been replaced by using a return chamber  93  that is made by joining the supply/return divider  89  to the canister wall and the air swirl chamber supply pipe  4  with directional opening  13 . In this and other embodiments secondary loop supply pipes  91  are shown in three directions but may be in fact be located anywhere on the circumference of the canister  6  as long as they have access to the supply chamber  94 . Likewise the secondary loop return pipes  90  may be located anywhere around the circumference of the canister provided they have access to the return chamber  93 . End suction pumps  33  or conventional pumps may be attached anywhere in place of secondary loop pipes and, if end suction pumps, may be swiveled by means of a union flange in any direction to facilitate fast installation. 
     Illustrations  14 ,  15 ,  16  and  17  show an embodiment similar in construction to Illustration  6  but where the canister has been turned upside down, putting the hydraulic separator on top of the canister. The air eliminator has been moved and a horizontally piped air eliminator  95 , either conventional or as shown in Illustrations  1  and  2 , has been incorporated into the primary loop return assembly  96 . The primary loop return assembly consists of the following piped together parts: an air eliminator  95 , a pump with or with out shut offs  99  and a fill valve  37 . Other normal hydronic components might be added. The primary loop supply pipe  35  normally would have a shut off valve. Additional standard hydronic components such as gauges, strainers and low water cut off valves may be added to the primary loop return assembly  96  or the primary loop supply  35 . The primary loop supply  35  and return assembly  96  might reverse the location of the pump from supply to return and need not have shut off valves. In some cases the primary loop pump may be deleted, for example if the boiler already contains an integral pump. 
     Illustration  14  shows the embodiment with end suction pumps  33  and an expansion tank  38  attached to the bottom of the canister  98  which is joined to the canister wall  6 . The design includes a shortened secondary loop supply pipe  97  and a multiport secondary loop manifold  81 , both joined to the inner separator divider  16 . The inner separator divider  16  and the separator outer plate  74  are both joined to the canister wall  6 . The primary loop supply pipe assembly  35 , shown more simply as  28 , attaches to the separator outer plate  74  and to the supply from the boiler  44 . The primary loop return assembly  96  attaches to the outer plate assembly  74  and to the return of the boiler  44 . 
     Fluid moves from the boiler to the supply pipe  35  to the separation chamber  124  down the supply pipe  97 , is drawn out by the pumps  33 , returned to the secondary loop manifold  81  and back to the boiler through the separation chamber  124  to the return pipe  27  or return assembly  96  back to the boiler  44 . In this design and all embodiments using the hydraulic, separator, flow paths may vary to include mixing of primary and secondary loop water, dependent on flow rates as previously described above. Pumps  33  may be attached to where the secondary loop supply pipes  91  are shown. 
     Illustrations  18 ,  19  and  20  show a horizontal embodiment using a separate supply chamber  94  and return chamber  93 . Fluid flows through the primary loop supply pipe  35  enters the separation chamber  124  which is formed between the outer plate  74  and the separator inner divider plate  16 , then flows up the supply pipe  97  to the supply chamber  94 , is drawn out by any of the secondary loop supply pipes  91 , returns to the secondary loop return pipes  90 , to the return chamber  93 , to the return pipe  92 , back through the hydraulic separation chamber  124  to the primary loop return pump and assembly  34 . In this design and all embodiments using the hydraulic separator, flow paths may vary to include mixing of primary and secondary loop water, dependent on flow rates as previously described above. 
     Pumps, either end suction  33  or conventional  101  may be attached to where the secondary loop supply pipes  91  are shown. Illustration  19  shows a version with both end suction and conventional pumps. The assembled canister is built by joining the return pipe  92 , the supply pipe  97  to the separator inner plate  16  and the supply return chamber divider  89 . Once joined, these are inserted into the canister and joined to the canister wall  6 . Secondary loop return pipes  90  and secondary loop supply pipes  91  are joined to the canister wall  6 . Then the end cap  100  and the outer separator plate  74  are joined to the canister. The primary loop supply  35  and primary loop return  34  may then be joined to the outer separator plate  74 . 
     Illustration  21  shows a simple hydraulic separator-made from the same parts as the canisters and, that when combined with modular fittings, will serve as an efficient way to connect modular primary and secondary loop parts. Illustrations  21   a  and  21   b  show the simple separator made as shown in Illustration  21   d  from two separator outer plates  74  joined to primary loop supply pipe  101  and primary loop return pipe  102  on one side and to the secondary loop supply  103  and the secondary loop return pipe  104  with the two plates  74  joined to a short pipe section  56 . Illustration  21   c  shows an assembled separator  110  with male  114  and female  113  modular fittings joined to the simple separator  109 . 
     Illustration  21   e  shows how modular secondary and primary loop parts may be attached. A primary loop supply pumping module  59  pumps water to the separator and the primary loop return module  60  returns it. A multi pump secondary loop module  105  is comprised of in this case a simple pumping station plus a pumping station with a two way valve. Secondary loop supply water flows from the modular separator  110  through the modular fitting  114  to the secondary branch supply pipe  111 , in the case of the simple pumping station, out through the pump  99  via outlet  106  and back to the secondary loop return  107  to the secondary loop branch return pipe  112 , back to the modular separator  110 , and back to the primary loop return pipe  60 . In the case of the two way valve, fluid flows from the secondary loop supply branch  111  through the two way valve  61 , is blended with return water from the secondary loop return pipe  107  and is pumped out by the pump  99  via its outlet  106 , returns to the secondary loop return  107  where what is not blended to the two way valve returns to the return branch manifold  112 . 
     Illustrations  22 ,  23  and  24  show a simple horizontally ported air eliminator  68  made from simple parts. Fluid flows in through the supply pipe  72  and is directed against the swirl chamber wall  115 , swirls up and over the swirl chamber wall  115  and, due to change of direction volume and pressure, releases air upward towards the lid  3  and out the air vent  2 . Fluid then goes down between the swirl chamber wall  115  and the canister wall  69  and exits to the return pipe  73 . The unit is constructed by inserting the supply pipe  72  through the outer canister wall  69  and through the opening  117  in the swirl chamber wall  115 . The supply pipe  72  is then joined to the swirl chamber. The swirl chamber bottom  116  is then joined to the swirl chamber side  115 , then the supply pipe  72  is joined to the canister wall  69 , then the canister bottom  70  is joined to the canister wall  69 , and then the return pipe  73  is joined to the canister wall  69 . The unit is then fitted with a flange  11  and a lid  3  containing an air vent  2 . 
     This invention lends itself to many embodiments using the same cost effective parts such as the plate  119  shown in Illustration  25 . These parts may be joined by soldering, threading, brazing, spinning or pressing. Illustration  25  shows a simple way of pressing the plates into a cylindrical canister  120  using a pressing wheel  118  forming indentations  121 . The plate may be further joined in place by soldering or brazing. 
     Illustration  26   a  shows the convenience of being able to rotate end suction pumps upward. A five pump module ( 131 ) shows three of the five pumps rotated upward. A union connection ( 130 ) to accomplish this is shown in illustration  26   b.    
     Applicant reserves the right to copy into this document material contained in the provisional patent application from which this application claims priority. Although the present invention has been described in detail with reference to certain preferred embodiments, other embodiments are possible. Therefore, the spirit or scope of the appended claims should not be limited to the description of the embodiments contained herein. It is intended that the invention resides in the claims hereinafter appended.