Patent Description:
When conventional two-way valves in multi-zone, heating and/or cooling systems open or close, a pressure flow characteristic of a pump in the system causes an immediate head pressure change to all other valves in the system resulting in overflow or underflow. As a result, pressure independent control valves have been developed to maintain the required flow rate independent of the pressure. An example of such a Pressure Independent Control Valve (PICV) is disclosed in <CIT>.

Such PICVs typically comprise an actuator adjuster for an actuator to vary the flow rate through the valve, e.g. when instructed by a controller in communication with the actuator. In addition, PICVs may comprise a manual adjuster that allows a technician during installation (or subsequently) to pre-set a maximum flow rate through the valve. However, adjustment of the manual adjuster after installation by an unqualified user is undesirable, because it interferes with the desired maximum flow rate through the valve which can affect the heating or cooling provided by one or more branches of the heating or cooling system. Nonetheless, it may be desirable for a qualified technician to be able to make adjustments to the maximum flow rate through the valve after installation and without necessarily having to remove the actuator.

<CIT> discloses a reversible valve that can be adjusted in terms of flow through the valve and the valve comprises a pre-setting element that can be adjusted to change the maximum flow through the valve. <CIT> discloses a fluid flow valve having a pre-setting member and means inhibiting rotation of a rotatable adjustment member for setting the angular position of the flow pre-setting member.

According to a first specific aspect, there is provided a control valve assembly comprising:.

wherein the control valve assembly further comprises:.

The locking member may selectively cover the manual adjuster. The manual adjuster may comprise a dial, e.g. which may rotate to pre-set the flow value limit. The locking member may comprise a ring that selectively covers the dial.

The locking member may lock the manual adjuster by restricting user access to the manual adjuster. The locking member may additionally lock the manual adjuster as well as restricting access. By way of example, the manual adjuster may comprise a plurality of teeth and the locking member may comprise a corresponding plurality of teeth configured to lockingly engage the plurality of teeth of the manual adjuster.

The locking member may be located between the manual adjuster and the actuator adjuster. The locking member may be configured such that the locking member may not be removed when the actuator is in place. The at least one tab may extend radially inward from a ring of the locking member. The at least one tab may be configured, e.g. sized, to prevent the locking member from being removed when the actuator is installed.

Adjustment of the manual adjuster may be permitted in the unlocked position. The locking member may be slidable between the unlocked position and the locked position when the actuator is connected to the control valve.

The locking member may be rotatably coupleable to the control valve by virtue of a hinge assembly. The hinge assembly may permit the locking member to rotate between first and second orientations, e.g. angles, relative to the control valve. The hinge assembly may be configured to permit the locking member to slide, e.g. linearly, between the unlocked position and the locked position, e.g. when the locking member is in the first orientation.

The locking member may be in a further unlocked position when the locking member is in the second orientation. The locking member may only move from the unlocked position to the further unlocked position when the actuator is disconnected from the control valve.

The locking member may be detachable from the control valve. The hinge assembly may be configured such that disassembly of the hinge assembly may be permitted. Disassembly of the hinge assembly may be permitted when the locking member is in the second orientation.

The locking member may comprise a first hinge portion and the control valve may comprise a second hinge portion. The first and second hinge portions may together form the hinge assembly. The first and second hinge portions may form an interference fit.

One of the first and second hinge portions may comprise a slot. The other of the first and second hinge portions may comprise at least one pin configured to linearly slide and rotate in the slot. The slot and pin may each comprise abutment surfaces that limit the travel (e.g. linear movement) of the pin in the slot.

At least one of the first and second hinge portions may comprise a resiliently deformable portion such that the first and second hinge portions may form a snap fit assembly. Both of the first and second hinge portions may comprise such a resiliently deformable portion. For example, a resiliently deformable portion may be provided at each end of the slot. At least one of the first and second hinge portions may comprise a pair of such resiliently deformable portions.

At least one of the first and second hinge portions may comprise at least one angled surface. The angled surface may act on and cause the resiliently deformable portion to deform as the first and second hinge portions are snapped together.

The locking member may comprise a first engaging portion. The control valve may comprise a second engaging portion. The first and second engaging portions may be configured to selectively engage one another, e.g. in the unlocked and locked positions. The first and second engaging portions may be provided away from the hinge assembly, e.g. opposite the hinge assembly.

The first and second engaging portions may slide with respect to each other as the locking member moves between the unlocked position and the locked position, e.g. when the locking member is in the first orientation. The first and second engaging portions may form an interference fit.

At least one of the first and second engaging portions may comprise at least one stop that may limit relative movement of the first and second engaging portions. For example, the second engaging portion may comprise at least one such stop and the first engaging portion may ride over the at least one stop as the locking member moves between the unlocked and locked positions.

The first engaging portion may comprises a locking feature that allows the locking member to be locked to the control valve. The second engaging portion may comprise a corresponding locking feature that may permit the first and second engaging portions to be locked together.

The locking member may comprise at least one finger hold to assist in rotating the locking member relative to the control valve. The first hinge portion of the locking member may provide a finger hold. The first engaging portion of the locking member may provide a finger hold.

The control valve may be a pressure independent control valve. The control valve assembly may further comprise the actuator.

According to a second specific aspect, there is provided a use of a locking member for a control valve to selectively restrict user access and as a tool for adjusting a manual adjuster of the control valve, the control valve further comprising an actuator flow adjuster,.

Features described above in respect of the first aspect may also apply to the second aspect.

According to a third specific aspect, there is provided a method of installing or commissioning a control valve assembly, the control valve assembly comprising:.

Features described above in respect of the first aspect may also apply to the third aspect.

With reference to <FIG>, the present disclosure relates to a control valve assembly <NUM> comprising a control valve <NUM> and a locking member <NUM>. The control valve <NUM> may be a pressure independent control valve, which as described above, may maintain a required flow rate through the valve independent of the upstream pressure. The details of such a control valve are disclosed for example in <CIT>. In particular, as shown in <FIG> and <FIG>, the control valve <NUM> may comprise inlet and outlet flow ports <NUM>, 20b with a valve provided therebetween. The control valve <NUM> may also comprise pressure testing ports 21a, 21b, which may be selectively opened and which may enable the pressure either side of the valve to be tested.

With particular reference to <FIG>, the control valve assembly <NUM> may further comprise an actuator <NUM>, although it will be appreciated that the actuator may be provided separately from the control valve. The actuator <NUM> and control valve <NUM> may be coupled together, e.g. by virtue of threaded portions or a push fit. The control valve <NUM> may comprise an actuator adjuster <NUM> configured to allow the actuator <NUM> to interface with the control valve and adjust a flow rate through the control valve. The actuator adjuster <NUM> may be in the form of a pin or shaft that the actuator <NUM> may move linearly and/or rotatably to vary the flow rate through the control valve. The actuator <NUM> may receive instructions from a controller (not shown) in communication with the actuator.

As best depicted in <FIG>, the control valve <NUM> further comprises a manual adjuster <NUM> configured to allow a user to pre-set a maximum flow value, such as the flow rate through the control valve. The manual adjuster <NUM> may comprise a dial <NUM>, which may rotate to pre-set the flow value limit. The manual adjuster may extend around the actuator adjustor <NUM>. The manual adjuster <NUM> is connected to valve components (not shown) within the control valve which adjust the maximum flow rate through the control valve. The actuator <NUM> may then control the flow rate through the control valve <NUM> up to the set maximum value.

The manual adjuster <NUM> may be rotated by hand or by using a tool. For example, a tool may engage one or more flat surfaces <NUM> of the manual adjuster <NUM>. The flat surfaces <NUM> may be provided on a shaft portion <NUM> that is coupled to and spaced apart from (e.g. proud of) the dial <NUM>. The shaft portion <NUM> may rotate with the dial <NUM>. The manual adjustor <NUM> may also be rotated by using the locking member <NUM> as a tool as will be described in more detail below.

The manual adjuster <NUM> may comprise an indicator <NUM> that may move with the manual adjuster <NUM>. The control valve <NUM> may comprise a surface <NUM> that is fixed and does not move with the manual adjustor <NUM>. The surface <NUM> may comprise a scale of flow values and the indicator <NUM> may point to a value on the scale so that a user can determine the setting.

With particular reference to <FIG>, <FIG> and <FIG>, the locking member <NUM> is configured to selectively limit or restrict user access to the manual adjuster <NUM> when the locking member <NUM> is in a locked position. The locking member <NUM> may substantially cover the manual adjuster <NUM> such that a user has limited access to the manual adjuster <NUM> and is therefore unable to adjust the manual adjuster <NUM>. In particular, the locking member <NUM> may comprise a ring <NUM> that extends around the dial <NUM> of the manual adjuster <NUM>.

In addition to restricting access to the manual adjuster <NUM>, the locking member <NUM> may lock the manual adjuster in place by virtue of a locking feature. In particular, as best shown in <FIG> and <FIG>, the locking member <NUM> may comprise a plurality of teeth <NUM> and the manual adjuster <NUM> may comprise a corresponding plurality of teeth <NUM>. The manual adjuster teeth <NUM> may be circumferentially distributed about a radially outer edge of the dial <NUM>. The locking member teeth <NUM> may be circumferentially distributed about a radially inner surface of ring <NUM>. When the locking member <NUM> is in the locked position (e.g. as shown in <FIG>, <FIG> and <FIG>), the locking member teeth <NUM> may lockingly engage the manual adjuster teeth <NUM>, e.g. such that movement of the manual adjuster <NUM> is prevented.

As shown in <FIG> and <FIG>, the locking member <NUM> may be located between (e.g. axially between) the manual adjuster <NUM> and the actuator adjuster <NUM>. Furthermore, as shown in <FIG>, the locking member <NUM> may be configured such that the locking member may not be removed when the actuator <NUM> is in place. For example, in the case of the locking member <NUM> comprising ring <NUM>, it may not be possible for the ring to pass over a standard actuator used with the control valve <NUM>.

In addition, the locking member <NUM> comprises at least one tab <NUM> and, in the particular example shown, the locking member comprises three such tabs. The tabs <NUM> are distributed, e.g. equiangularly, about the circumference of the ring <NUM>. The tabs <NUM> extend in a radially inward direction from the locking member ring <NUM>. The tabs <NUM> are sized, e.g. have a radial length, so as to define an opening <NUM> that receives (and may be similar in size to) the shaft portion <NUM>. The shaft portion <NUM> (and dial <NUM>) may thus be free to rotate in opening <NUM> (e.g. when the locking member <NUM> is in the unlocked position as will be described below). However, the actuator <NUM> may engage the shaft portion <NUM> (or other portion of the control valve) and may thus be larger than the shaft portion <NUM>. The opening <NUM> defined by the tabs <NUM> may therefore be smaller than a corresponding dimensions of the actuator <NUM>. Accordingly, the locking member <NUM> may not be moved beyond a certain range when the actuator <NUM> is installed.

With particular reference to <FIG> and <FIG>, the locking member <NUM> is slidable, e.g. linearly, between an unlocked position (e.g. depicted in <FIG>) and the locked position (e.g. depicted in <FIG>). Such movement between the unlocked and locked positions may occur regardless of whether the actuator <NUM> is connected to the control valve <NUM>. The manual adjuster teeth <NUM> may be engaged with the locking member teeth <NUM> when the locking member <NUM> is in the locked position. By contrast, the manual adjuster teeth <NUM> may be disengaged from the locking member teeth <NUM> when the locking member <NUM> is in the unlocked position. The locking member <NUM> and manual adjuster <NUM> are configured so that the manual adjuster <NUM> is adjustable in the unlocked position. In particular, the flat surfaces <NUM> of the manual adjustor may still be accessible to a tool when the locking member <NUM> is in the unlocked position.

With particular reference to <FIG>, the locking member <NUM> may be rotatably coupled to the control valve <NUM> by virtue of a hinge assembly <NUM>. The hinge assembly <NUM> may permit the locking member <NUM> to rotate between a first orientation, e.g. angle, (as depicted in <FIG>, <FIG> and <FIG>) and a second orientation (as depicted in <FIG> and <FIG>) relative to the control valve <NUM>. The locking member <NUM> may rotate through approximately <NUM> degrees between the first and second orientations.

The locking member <NUM> may be in either of the locked or unlocked positions when in the first orientation (e.g. as shown in <FIG> and <FIG> respectively). The locking member <NUM> may be in a further unlocked position when the locking member is in the second orientation as the locking member <NUM> has rotated away from the manual adjuster <NUM>. The locking member <NUM> may only move from the unlocked position to the further unlocked position when the actuator <NUM> is disconnected from the control valve <NUM> because as mentioned above, the locking member <NUM> may not pass over the actuator <NUM>.

As shown in <FIG>, the locking member <NUM> may comprise a first hinge portion <NUM>. As shown in <FIG>, the control valve <NUM> may comprise a second hinge portion <NUM>. The first and second hinge portions <NUM>, <NUM> may be rotatably coupled together so as to form the hinge assembly <NUM>. In particular, the second hinge portion <NUM> may comprise at least one slot <NUM> and the first hinge portion <NUM> may comprise at least one pin <NUM> configured to rotate in a corresponding slot <NUM>. The hinge assembly <NUM> may also be configured to permit the locking member <NUM> to slide, e.g. linearly, between the unlocked position and the locked position. To achieve this, the at least one pin <NUM> may also be configured to linearly slide in the corresponding slot <NUM>.

The first hinge portion <NUM> may comprise a pair of pins 64a, 64b. The pins 64a, 64b may project in opposite directions and approximately tangentially with respect to the ring <NUM>. The pins 64a, 64b may rotate and slide in a corresponding pair of slots 63a, 63b. The slots 63a, 63b may be provided either side of a channel formed from a pair of spaced apart walls 65a, 65b extending from the control valve <NUM> in the vicinity of the dial <NUM>.

With reference to <FIG>, during assembly, the first and second hinge portions <NUM>, <NUM> may be coupled together, e.g. by virtue of a snap fit. <FIG> depicts the first and second hinge portions <NUM>, <NUM> prior to being coupled together and <FIG> depicts the first and second hinge portions <NUM>, <NUM> after the snap fit has occurred. The first and second hinge portions <NUM>, <NUM> may be coupled, e.g. snapped, together when the locking member <NUM> is in the first orientation.

To facilitate such a snap fit, the pins 64a, 64b may be resiliently deformable relative to one another. For example, first and second pins 64a, 64b may project from respective first and second fingers 66a, 66b, which are in turn connected to the ring <NUM>. The first and second fingers 66a, 66b may be spaced apart such that there is a gap therebetween. The first and second fingers 66a, 66b may resiliently deform, e.g. bend, when a sufficient force is applied as the first and second hinge portions <NUM>, <NUM> are brought together. The first and second pins 64a, 64b may comprise respective angled surfaces 67a, 67b, which may assist in causing the first and second fingers 66a, 66b to deform as the first and second hinge portions <NUM>, <NUM> are snapped together. Additionally or alternatively, the walls 65a, 65b may comprise further angled surfaces 68a, 68b at one end (e.g. a top end) of respective slots 63a, 63b. The further angled surfaces 68a, 68b may also assist in causing the first and second fingers 66a, 66b to deform as the first and second hinge portions <NUM>, <NUM> are snapped together.

As depicted in <FIG>, the locking member <NUM> may be in the first orientation prior to engagement of the first and second hinge portions <NUM>, <NUM>. The locking member <NUM> may move towards the control valve <NUM>, e.g. linearly, into the position depicted in <FIG> as the first and second hinge portions <NUM>, <NUM> are coupled together. Immediately after the first and second hinge portions are coupled together (as depicted in <FIG>), the locking member <NUM> may be in the unlocked position. The locking member <NUM> may move further towards the control valve <NUM> and into the locked position depicted in <FIG>.

A resiliently deformable portion, e.g. in the form of a tongue <NUM>, may be provided at one end of the channel formed from the pair of spaced apart walls 65a, 65b. The tongue <NUM> may be provided at the end of the channel that receives the first and second pins 64a, 64b when the locking member <NUM> is in the locked position (e.g. at a bottom end or end opposite to that of the further angled surfaces 68a, 68b). The first and second pins 64a, 64b may not move further in the channel when the locking member <NUM> is in the first orientation and the locked position, e.g. because the control valve <NUM> blocks further movement. However, if the locking member <NUM> is in the second orientation, the first and second pins 64a, 64b with sufficient force may ride over a distal (e.g. enlarged or bulbous) end of the tongue <NUM> causing it to bend and permit the first and second pins 64a, 64b to leave the channel. In this way, the first and second hinge portions <NUM>, <NUM> may be decoupled and the locking member <NUM> may be separated from the control valve <NUM>. <FIG> depicts the locking member <NUM> in the second orientation and prior to decoupling of the first and second hinge portions <NUM>, <NUM>.

In a reverse action, the first and second hinge portions <NUM>, <NUM> may be coupled together when the locking member <NUM> is in the second orientation. The first and second hinge portions <NUM>, <NUM> may snap fit together, for example by virtue of the first and second pins 64a, 64b riding over the distal (e.g. bulbous) end of the tongue <NUM> causing it to bend and permit the first and second pins 64a, 64b to enter the channel.

The slots 63a, 63b and pins 64a, 64b may comprise respective abutment surfaces that limit the travel (e.g. linear movement) of the pins in the slots. For example, the walls 65a, 65b may comprise an overhang that engages a corresponding overhang of the pins 64a, 64b, e.g. to limit travel of the locking member <NUM> away from the control valve <NUM>. The bulbous end of the tongue <NUM> may form an abutment surface at the opposite end of the channel, which the pins 64a, 64b may engage. This engagement may limit travel of the locking member <NUM> towards the control valve <NUM>, particularly when the locking member is in the second orientation (although the locking member may ride over the end of the tongue with enough force as described above).

The first and second hinge portions <NUM>, <NUM> may form an interference fit such that a certain force is required to move the locking member <NUM> relative to the control valve <NUM>. In particular, a further pair of locking member walls 70a, 70b may extend either side of the walls 65a, 65b of the control valve <NUM>. The further pair of locking member walls 70a, 70b may contact and thus form an interference fit with respective walls 65a, 65b. This arrangement may help prevent unwanted movement of the locking ring <NUM> relative to the control valve <NUM>, e.g. when in the unlocked position.

With reference to <FIG> and <FIG>, the locking member <NUM> may comprise a first engaging portion <NUM> that may selectively engage a second engaging portion <NUM> of the control valve <NUM>. The first and second engaging portions <NUM>, <NUM> may be provided opposite respective first and second hinge portions <NUM>, <NUM>. The first engaging portion <NUM> may comprise a pair of spaced apart engaging walls 73a, 73b, which may extend from the locking member ring <NUM>. The second engaging portion <NUM> may comprise a projection <NUM>, which may extend from the control valve <NUM> and may be straddled by engaging walls 73a, 73b. The projection <NUM> may fit between the engaging walls 73a, 73b, e.g. with an interference fit.

The first and second engaging portions <NUM>, <NUM> may slide with respect to each other as the locking member moves between the unlocked position (depicted in <FIG>) and the locked position (depicted in <FIG>). However, the engaging walls 73a, 73b may comprise bump stops to resist relative movement of the first and second engaging portions <NUM>, <NUM>. For example, the engaging walls 73a, 73b may comprises respective first stops 75a, 75b, which the projection <NUM> may ride over as the locking member <NUM> moves between the locked and unlocked positions. The engaging walls 73a, 73b may also comprise respective second stops 76a, 76b, which the projection <NUM> may ride over as the locking member <NUM> moves away from the control valve <NUM> when in the unlocked position.

Referring in particular to <FIG> and <FIG>, the projection <NUM> may comprise an opening <NUM> and a projection <NUM> projecting from the locking member ring <NUM> may comprise a corresponding opening <NUM>. The openings <NUM>, <NUM> may align with one another when the hinge assembly <NUM> is coupled together and the locking ring <NUM> is in the locked position. A lock, e.g. fastener, cable tie or other locking device, may pass through the openings <NUM>, <NUM> to maintain the locking ring <NUM> in the locked position and prevent access to the manual adjuster <NUM>.

The first hinge potion <NUM> and/or first engaging portion <NUM> may extend from the ring <NUM> of the locking ring <NUM>. The first hinge portion <NUM> and/or first engaging portion <NUM> may thus be unitary with the locking member ring <NUM>. The locking member <NUM> may be formed from a plastics material and may for example be moulded. The second hinge portion <NUM> and/or second engaging portion <NUM> may extend from the control valve <NUM>, in particular a ring <NUM> of the control valve that may be provided beneath the dial <NUM>. The control valve ring <NUM> may provide the surface <NUM> with the scale of flow values. The second hinge portion <NUM> and/or second engaging portion <NUM> may thus be unitary with the control valve ring <NUM>. The control valve ring <NUM> may be formed from a plastics material and may for example be moulded.

With reference to <FIG> and <FIG>, the manual adjuster <NUM> comprises at least one recess <NUM> corresponding to the at least one tab <NUM> of the locking member <NUM>. In the example shown, the manual adjustor <NUM> comprises three recesses <NUM>. The recesses <NUM> are distributed, e.g. equiangularly, about the circumference of the dial <NUM> and extend radially inward from the outer edge of the dial. The recesses <NUM> may be shaped and sized so as to correspond to the tabs <NUM> such that the locking member tabs <NUM> may engage the corresponding manual adjuster recesses <NUM>. The tabs <NUM> may be spaced apart from (e.g. sit above) the dial <NUM> when the locking member <NUM> is in the locked or unlocked positions. However, the locking member <NUM> may be removed and inverted from the locking position such that the locking member tabs <NUM> may engage the recesses <NUM>. In this way, the locking member <NUM> may be used as a tool for adjusting the manual adjuster <NUM>.

Referring still to <FIG>, a further recess <NUM> may be provided in the dial <NUM>. The further recess <NUM> may not be intended to receive one of the locking member tabs <NUM>. Instead, the further recess <NUM> may comprise the indicator <NUM> and may reveal a portion of the surface <NUM> indicating the relevant flow values.

With particular reference to <FIG>, the locking member <NUM> may comprise at least one finger hold to assist in rotating the locking member <NUM> relative to the control valve <NUM>. In the particular example shown, the locking member <NUM> comprises first and second finger holds <NUM>, <NUM>, which may be provided on an outer edge of the ring <NUM>. The first and second finger holds <NUM>, <NUM> may be opposite one another. The first hinge portion <NUM>, which may protrude from the ring <NUM>, may provide the first finger hold <NUM>. The first engaging portion <NUM>, which may also protrude from the ring <NUM>, may provide the second finger hold <NUM>.

Referring now to <FIG>, the present disclosure also relates to a method <NUM> of installing or commissioning the control valve assembly <NUM> (e.g. after the control valve has been installed into surrounding pipework). The method comprises a first step <NUM> in which the manual adjuster <NUM> is adjusted to the appropriate setting for the desired maximum flow rate through the control valve. In a second step <NUM>, the locking member <NUM> is installed to restrict user access to the manual adjuster <NUM>. The locking member <NUM> may be moved into the locked position described above. In an optional third step <NUM>, the actuator <NUM> may be installed onto the control valve <NUM>.

Claim 1:
A control valve assembly (<NUM>) comprising:
a control valve (<NUM>), the control valve (<NUM>) comprising:
a manual adjuster (<NUM>) configured to allow a user to pre-set a flow value limit for the control valve (<NUM>); and
an actuator adjuster (<NUM>) configured to allow an actuator (<NUM>) to interface with the control valve (<NUM>) and adjust the flow value;
wherein the control valve assembly (<NUM>) further comprises:
a locking member (<NUM>) configured to selectively restrict user access to the manual adjuster (<NUM>) when in a locked position, wherein the locking member (<NUM>) is slidable between an unlocked position and the locked position, adjustment of the manual adjuster (<NUM>) being permitted in the unlocked position,
characterised in that
the locking member (<NUM>) comprises at least one tab (<NUM>) and the manual adjuster (<NUM>) comprises at least one recess (<NUM>) corresponding to the at least one tab (<NUM>) of the locking member (<NUM>), such that when the locking member (<NUM>) is inverted from the locked position the locking member (<NUM>) is useable as a tool for adjusting the manual adjuster (<NUM>) with the at least one tab (<NUM>) of the locking member (<NUM>) engaging the corresponding at least one recess (<NUM>) of the manual adjuster (<NUM>).