Integrated boiler component wiring assembly and method

An integrated wiring assembly electrically connects components of a multi-zone boiler heating system. The integrated wiring assembly includes a plurality of connection terminals which are commonly connected to facilitate connecting thermostats and zone valves for each zone, end switches of each zone valve to a start switch of the boiler, and a transformer to supply electrical power to the components, in such a way that the complexity of the electrical connections is simplified.

This invention relates to electrically connecting together various components of a boiler heating system. More particularly, the present invention relates to a new and improved integrated wiring assembly and method which greatly facilitates electrically connecting the components of the boiler heating system and which aids in more quickly diagnosing problems associated with the components of the boiler heating system.

BACKGROUND OF THE INVENTION

Boiler heating systems are widely used to heat residential and commercial buildings. A typical boiler heating system includes a boiler, pipes, radiators and water or similar heat transfer fluid. The boiler generates heat from a heat source, such as a resistive heating element or a combustion chamber in which fuel is burned. The heat is transferred to the water, and the heated water is then pumped through supply pipes to radiators located within the interior of a building. Heat from the heated water flowing through the radiators is transferred to the cooler air. The relatively cooler water from the radiator is then returned to the boiler through return pipes to be heated and circulated again through the radiator.

Particular areas of the building, referred to as zones, are heated independently of other zones in the building. Each zone is heated by at least one radiator. A zone valve controls the flow of heated water from the boiler to each radiator in that zone. A thermostat is located in each zone, and the thermostat controls the zone valve for that zone. In this way, each zone valve is controlled independently of the others to allow independent control of the heat within each different zone in the building.

The thermostat and the zone valve for each zone are connected in series with a transformer which provides electrical power to operate those components. The thermostat functions as a temperature responsive switch which closes when the measured temperature of the air falls below a selected temperature and which opens when the temperature is at or greater than the selected temperature. When the thermostat switch closes, electrical power is delivered to the zone valve, causing the zone valve to open, and the open zone valve conducts heated water through the supply pipes to the radiator within the zone. The flow of heated water through the radiator eventually heats up the air within the zone until the temperature of the air within the zone reaches or exceeds the selected temperature. At that point the switch of the thermostat opens, causing the zone valve to close. The closed zone valve terminates the flow of heated water through the radiator. Thus, the thermostat is closed and the zone valve for a particular zone is opened when the temperature within that zone is less than the selected temperature, and the thermostat is open and the zone valve for the particular zone is closed when the temperature within the zone is at or greater than the selected temperature. In this manner, the temperature in each particular zone is regulated and maintained at approximately the selected temperature.

The boiler may include a hot water storage tank in which a supply of hot water is always maintained. The boiler may also heat the hot water for delivery to the radiators whenever hot water is requested by a thermostat. The boiler includes a start switch which activates both the heat source and an internal pump to circulate the heated water. In a situation where the boiler includes a hot water storage tank, the start switch activates the internal pump to circulate the heated water through the zone valves to the radiators, and a separate thermostatic switch associated with the hot water storage tank may control the heat source of the boiler. In the situation where the boiler heats the hot water when the thermostat requests heat, the heat source of the boiler and the internal pump are activated simultaneously by the start switch. An end switch is connected to each zone valve, and the end switch closes when the zone valve is opened. The boiler start switch is connected in parallel with all of the end switches of the all of the zone valves. Connected in this manner, the start switch is closed and the internal pump (and possibly the heat source) are operated when any one of the zone valves is opened by the thermostat.

Properly connecting the end switches, the boiler start switch, the thermostats in each zone and the zone valves is typically one of the most difficult wiring tasks for a technician to learn. Many hours are typically expended in training technicians to properly wire the different components of the boiler heating system. One of the factors that contributes to the difficulty in learning to correctly connect the components of the boiler heating system is a lack of organization of the wires connecting the components. Usually, these wires are not labeled and often must be traced to the boiler start switch, the transformer, the thermostats and the zone valves, in order to determine which wires are connected to what components. Even experienced technicians can spend a significant amount of time determining the wiring configuration. The time spent trying to determine which roles the connecting wires in a boiler heating system play adds extra cost to service calls. The cost to install a typical boiler heating system is also more expensive due to the lack of organization and clear identification of the electrical conductors which connect the boiler heating system components.

SUMMARY OF THE INVENTION

The present invention pertains to an integrated boiler component wiring assembly which facilitates electrically connecting the components of a boiler heating system. The integrated wiring assembly reduces the amount of time required to electrically wire or connect the components of the boiler heating system. Diagnosing problems with the components of the boiler heating system is facilitated due to the organization of the wires and the ease with which electrical wires connected to the integrated wiring assembly can be identified. The costs of training technicians to wire the electrical connections of the boiler heating system components is also substantially reduced, due to the clarity and understanding of the electrical connections of the integrated wiring assembly. The costs of service calls involving malfunctioning components of the boiler heating system should also be reduced as a consequence of not having to trace the electrical conductors connecting the boiler components.

In accordance with these and other considerations, one aspect of the invention involves an integrated wiring assembly for connecting the components of a boiler heating system. The housing includes a elongated body, two opposite end connection sections and a plurality of intermediate zone connection sections between the end connection sections. Each end connection section includes a plurality of end connection terminals, and each zone connection section includes a plurality of zone connection terminals. Internal conductors connect the end connection terminals to the zone connection terminals, with each internal conductor connecting one end connection terminal with one zone connection terminal of each zone connection section. The zone valves and thermostats of one zone are connected to the zone connection terminals associated with each zone. The transformer and the boiler start switch are respectively connected to the end connection terminals to deliver electrical power to the components of each of the zones and to assure control of the boiler from each of the zones.

Another aspect of the invention involves a method of electrically connecting components of a boiler heating system using an integrated wiring assembly having four internal conductors. The method involves using the integrated wiring assembly to connect two leads of a transformer to a first two of the four internal conductors, connecting two leads of a boiler start switch to a second two of the four internal conductors, connecting a thermostat in series with a zone valve, connecting the remaining one lead of each of the thermostat and the zone valve between the first two of the four internal conductors, and connecting an end switch of the zone valve between the second two of the four internal conductors.

A more complete appreciation of the present invention and its scope may be obtained from the accompanying drawings, which are briefly summarized below, from the following detailed description of a presently preferred embodiment of the invention, and from the appended claims.

DETAILED DESCRIPTION

An integrated wiring assembly10which embodies the present invention is shown inFIG. 1. The integrated wiring assembly10electrically connects various components of a boiler heating system12within a plurality of different zones14a-14nof a residential or commercial building (not shown). The boiler components of the heating system12include zone valves16a-16nand thermostats18a-18n, one of each of which is associated with each zone14a-14n, and a start switch20of a boiler22and a transformer24. The integrated wiring assembly10connects these components within each of the zones14a-14nand in the boiler system12as a whole. The transformer24supplies electrical power from commercially available electrical power26to the integrated wiring assembly10. The integrated wiring assembly10distributes the electrical power to the zone valves16a-16nand thermostats18a-18nto cause those components to function independently with respect to each zone14a-14n, respectively, and to operate the boiler22with the start switch20, all in a precise, easy-to-understand and organized manner.

At least one radiator28a-28nis present in each of the zones14a-14n, respectively. The radiators28a-28nheat the zones14a-14n. The boiler22heats the water which is supplied to a hot water supply manifold30to each of the zone valves16a-16n. The zone valves16a-16nopen and close to control the supply of hot water to the radiators28a-28nthrough hot water supply pipes32a-32n. The thermostats18a-18ncontrol the opening and closing of the zone valves16a-16n. Heat is extracted from the hot water in the radiators28a-28nto heat the air within the zones14a-14n. The relatively cooler water leaving the radiators28a-28nflows back to the boiler22through cold water return pipes34a-34nwhich connect to a cold water return manifold36.

Electrical power is supplied from the transformer24to each of the thermostats18a-18nby two internal conductors56aand56b(FIGS. 3,4and6) of the integrated wiring assembly10. When the temperature responsive switch of each thermostat18a-18ncloses, electrical power is supplied from the thermostat to open the zone valves16a-16nto which each thermostat is connected. Each zone valve16a-16nincludes an end switch38a-38n, respectively. The end switches38a-38nare electrically connected in parallel to the boiler start switch20by two other internal conductors56cand56d(FIGS. 3,4and6) of the integrated wiring assembly10. When the thermostat18a-18nopens a zone valve16a-16n, the end switch38a-38nassociated with the open zone valve closes to activate the boiler start switch20. The activated boiler start switch20causes the boiler22to commence heating water and causes a circulation pump (not shown) to start circulating the hot water through the open zone valve to the radiator and heat the air within the zone. If the boiler22includes a hot water storage tank (not shown) the activated boiler start switch20causes the circulation pump (not shown) to start circulating the hot water from the storage tank through the open zone valve to the radiator and heat the air within the zone. In the latter circumstance, the boiler22commences heating water in the storage tank when the temperature of the water in the storage tank drops below a desired level.

The integrated wiring assembly10facilitates creating the aforementioned electrical connections and thereby establishes the functionality between the various components of the boiler heating system12. The manner in which the integrated wiring assembly accomplishes these functions is explained in connection with the details of the integrated wiring assembly10described below.

The integrated wiring assembly10, shown inFIG. 2, is formed as an elongated housing40which is preferably made of plastic or other non-electrically conducting material. The integrated wiring assembly10is generally divided along its length into multiple (five are shown) intermediate zone connection sections42a-42elocated in the middle of the elongated housing40, and two end connection sections44aand44blocated at opposite ends of the elongated housing40. The integrated wiring assembly10may include more or less than the five zone connection sections42a-42eshown inFIG. 2, depending upon the length of the housing40and the number of zones to be connected.

Each of the zone connection sections42a-42eincludes five component zone connection terminals46a-46e, as shown inFIGS. 2 and 3. Each of the zone connection terminals46a-46eelectrically connects to electrical conductors extending from the thermostat, the zone valve and the end switch associated with each zone. The two end connection sections44aand44beach include four end connection terminals48a-48d. Only the end connection terminals48a-48dof one end section, such as end section44a, is needed to connect the integrated wiring assembly10to the transformer24and to the boiler start switch20. The end connection terminals48a-48dof the other end connection section, end connection section44bfor example, can be wired to the end connection terminals48a-48dof an end connection section, such as end connection section44a, of a second integrated wiring assembly10. Proceeding in this manner, multiple integrated wiring assemblies10can be daisy chain connected together to accommodate a boiler heating system having more zones than a single integrated wiring assembly10can accommodate. Conversely, if only a single integrated wiring assembly10is required for a particular boiler heating system, that single integrated wiring assembly10need only include one end connection section44aor44bin order to connect to the transformer and boiler start switch.

Mounting tabs50a-50eare formed onto the housing40of the integrated wiring assembly and facilitate hanging or mounting the integrated housing10on the hot water supply manifold30and the hot water supply pipes32a-32n, as shown inFIG. 2. Each of the mounting tabs50a-50edefines openings52through which a retaining tie or strap53is extended around the supply manifold30and the hot water supply pipe32n(FIG. 2) to hold the integrated housing in a desired position at a height that makes working with the integrated housing10convenient.

The housing40defines an interior space54in which four internal conductors56a-56dare located, as shown inFIG. 3. The internal conductors56a-56dextend from and electrically connect the end connection terminals48a-48dof the end connection section44a(FIGS. 2 and 5) to the corresponding end connection terminals48a-48dof the end connection section44b(FIGS. 2 and 5). The internal conductors56a-56dare also electrically connected to the zone connection terminals46a-46dof each zone connection section42a-42e. Specifically, the internal conductor56aelectrically connects the end connection terminals48aof both end connection sections44aand44bto the zone connection terminals46aof the intermediate zone connection sections42a-42e, the internal conductor56belectrically connects the end connection terminals48bof both end connection sections44aand44bto the zone connection terminals46bof the zone connection sections42a-42e, and so on. Indicia58which identifies the boiler component leads which attach to the particular zone and end connection terminals46a-46eand48a-48dare printed, embossed or otherwise attached to the housing40adjacent to each of the connection terminals, to thereby facilitate connecting the correct conductors to the terminals.

Two zone connection terminals46aand46c, which are representative of all of the zone connection terminals46a-46eof each of the zone connection sections42a-42e, are shown in detail inFIG. 4. Each of the zone connection terminals46aand46cincludes an electrically conductive terminal body60aand60cwhich is located and retained within the interior space54of the housing40. Terminal set screws62aand62cextend from of the terminal bodies60aand60c, respectively, and extend through access openings63formed in the housing40. The terminal bodies60aand60ceach define a clamping cavity64aand64c, respectively, which receives at least one exposed end66of a wire lead68or other conductor extending from the components of the boiler heating system12which are to be connected by use of the integrated wiring assembly10. The end66of a wire lead68is inserted into the clamping cavity64aof the terminal body60athrough an access hole69formed through the housing40in a position which aligns with each clamping cavity64aand64c.

Each of the terminal bodies60aand60calso defines threaded passageways70aand70cwhich receive the terminal screws62aand62c. Rotation of the set screws62aand62ccauses them to move in or out of the threaded passageways70aand70c. The clamping cavities64aand64cintersect the threaded passageways70aand70cin the terminal bodies60aand60b, and allow the ends72aand72cof the terminal screws62aand62cto enter the clamping cavities64aand64c, respectively, when the set screws62aand62care fully inserted into the threaded passageways70aand70c. Fully inserting the set screws62aand62ccauses the ends72aand72cto clamp the exposed ends66of the wire leads68within the clamping cavities64aand64c, as shown by the end72aof the terminal screw62aclamping the exposed end66of wire lead68. Clamping the exposed end of a wire lead within the clamping cavities64aor64ccreates an electrical connection between those wire leads and the respective zone connection terminals46aor46cand also creates a mechanical connection to retain those wire leads in position.

The internal conductors56aand56cwithin the housing40are also electrically connected to the terminal bodies60aand60c, respectively. The internal conductors56aand56care electrically connected to the terminal bodies60aand60cthrough conventional splicing mechanisms74aand74cwhich penetrate through exterior electrical insulation to reach the internal leads of the conductors56aand56c. The Internal conductors56a,56b,56cand56d(FIG. 2) are connected to only one of the terminal bodies at each of the intermediate zone connection sections. As shown inFIG. 4, the internal conductors56band56dare not electrically connected to the terminal bodies60aor60c, but instead are connected to the terminal bodies corresponding to the zone connection terminals46band46d.

The zone connection terminal46edoes not connect to any of the internal conductors56a-56d. Instead, the zone connection terminal46eserves as a junction terminal for connecting a wire lead from the thermostat in series with a wire lead from the zone valve in each zone, as is shown inFIG. 1. To make the junction connection, the exposed ends of the two lead wires from the thermostat in the zone valve are inserted into the single clamping cavity and the terminal set screw is tightened to make the electrical series connection at the zone connection terminal46e.

Two end connection terminals48aand48c, which are representative of all of the end connection terminals48a-48dof both end connection sections44aand44b, are shown in detail inFIG. 5. The structural details and operation of each end connection terminal is similar to that of the zone connection terminals46a-46e(FIG. 4) previously described. For that reason, the two end connection terminals48aand48cutilize the same electrically conductive terminal bodies60aand60c, terminal set screws62aand62c, access openings63, clamping cavities64aand64c, access holes69, threaded passageways70aand70b, set screw ends72aand72band splicing mechanisms74aand74b. The access hole69for the end connection terminals48a-48dare formed in an end75attached to the end of the housing40, rather than in the housing40itself which is the case for the access holes69for the zone connection terminals46a-46e.

The end connection terminals48a-48dat one end connection section, for example end connection section44aconnects to the wire leads or conductors from the boiler start switch20and the transformer24. Consequently, the wire leads68shown inFIG. 5extend from either the start switch20or the transformer24. Also, the internal conductors56a-56dwithin the housing40begin and end with the connections to the terminal bodies of the end connection terminals48a-48d, respectively. Conventional splicing mechanisms74aand74cmake those connections to the ends of the conductors56a-56d.

The internal connections of the integrated wiring assembly10to the thermostat, zone valves, and end switches is shown inFIG. 6. The transformer24is connected to end connection terminals48aand48bof end connection section44aby transformer leads76aand76b. The transformer24supplies a voltage potential across the transformer leads76aand76bwhich is conducted by the internal conductors56aand56b. Each of the thermostats18a-18nis connected to the zone connection terminals46aand46evia thermostat leads78aand78e. Each of the zone valves16a-16nis connected to the zone connection terminals46band46evia zone valve leads80band80e. The zone connection terminals46eelectrically connect the leads78efrom each of the thermostats18a-18nto the leads80efrom each of the corresponding zone valves16a-16nin each zone.

The end switches38a-38nare electrically connected to the zone connection terminals46cand46dvia end switch leads82cand82d. The boiler start switch20is connected to the end connection terminals48cand48dof end connection section44aby start switch leads84cand84d. Each of the end switches38a-38nis open when the corresponding one of the zone valves16a-16nis closed. Likewise, each of the end switches38a-38nis closed when the corresponding one of the zone valves16a-16nis opened. Thus, when any one of the zone valves16a-16nis open, an electrical connection is created between the internal conductors56cand56dthrough the end switch corresponding to that zone valve. The electrical connection between the internal conductors56cand56dwhen an end switch is closed completes a circuit through the start switch leads84cand84dand starts the boiler22and/or its circulation pump.

As an example of operation, the interaction between the various components of the boiler heating system12to heat the air within the exemplary zone14ais next described. Similar operation exists with respect to the other zones14b-14n. The thermostat18ais preset to a preselected temperature. When the temperature of the air within the zone14afalls beneath that preselected temperature, the internal temperature responsive switch within the thermostat18acloses. Closing the temperature responsive switch causes the voltage potential across the internal conductors56aand56bto be conducted to the zone valve16awhich causes the zone valve16ato open. As a result of the zone valve16aopening, the end switch38acloses. The closing of the end switch38acauses an electrical connection between the internal conductors56cand56d, which starts the boiler22and/or its circulation pump. The starting of the boiler22causes water within the boiler22to be heated and also causes the circulation pump to pump the heated water to the hot water supply manifold30. The heated water flows from the hot water supply manifold30, through the open zone valve16aand through the hot water supply pipe32ato the radiator28a. Heat is extracted from the heated water flowing through the radiator28athereby heating the air and cooling the water. The relatively cooler water from the radiator28aflows back to the boiler22through the cold water return pipe34aand the cold water return manifold36.

As more and more heated water flows through the radiator28a, the air within the zone14agets warmer and warmer until the temperature of the air within the zone14areaches the preselected temperature of the thermostat18a. When the temperature of the air within the zone14areaches that preselected temperature, the temperature responsive switch of the thermostat18aopens. Opening the temperature responsive switch of the thermostat18acauses the zone valve16ato close, which causes the end switch38ato open, which in turn causes the start switch20to open and the boiler22to turn off, provided that none of the other end switches38b-38nare still closed. In this manner, the boiler heating system12independently heats the various zones14a-14nwithin the building.

The integrated wiring assembly10can substantially reduce the amount of time taken by a technician to wire the components of a boiler heating system. The integrated wiring assembly10removes the guess-work and confusion often involved when a technician attempts to wire components of a boiler heating system. Time spent training technicians to be proficient at installing and servicing problems with boiler heating systems is a significant cost. Significantly less training time is required for new technicians when they are trained to wire the components of a boiler heating system using the integrated wire housing10. Use of the integrated wiring assembly10to connect the components of a boiler heating system also reduces the risk that a boiler heating system component will be damaged as a result of incorrectly connecting the component to the boiler heating system. The use of the integrated wiring assembly10results in a central location at which the electrical components of the boiler heating system are neatly wired. The neat and orderly wiring facilitates speedy problem determination and resolution concerning the boiler heating system. Many other advantages and improvements will become apparent upon fully comprehending the scope and significance of the present invention.

A presently preferred embodiment of the present invention and many of its improvements have been described with a degree of particularity. This description is a preferred example of implementing the invention, and is not necessarily intended to limit the scope of the invention. The scope of the invention is defined by the following claims.