Patent Application
20120118246
None
One aspect of the invention relates to a sediment or scale flushing system for removal of deposits, such as scale or sediment, from a tankless water heater, which system can also be used with other equipment, such as heat exchangers, boilers, condensers, and other equipment, wherein scale and sediment build-up is a problem.
This section is intended to introduce the reader to various aspects of art that may be related to various aspects or embodiments of the present invention, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects and embodiments of the present invention. Accordingly, it should be understood that these statements are to be read in light of, and not as admissions of prior art.
Tankless water heaters, also called instantaneous or demand water heaters, provide hot water, as needed. Traditional storage water heaters experience standby energy losses that can be both expensive and time consuming because they are required to maintain a predetermined volume of hot water. Tankless water heaters only produce hot water when there is a demand. In operation, when a hot water tap of such heaters is turned on, cold water travels through a pipe into the tankless water heater. In an electric tankless water heater, an electric element heats the water directly. In a gas-fired tankless water heater, a gas burner is lit which heats the water. Tankless water heaters deliver a constant supply of hot water and do not require a storage tank for previously heated water. Tankless water heaters can be used in a number of situations that demand an instantaneous supply of hot water, including use with certain appliances, such as clothes washers or dish washers, and in other situations such as in kitchens, outdoor sinks, remote bathrooms or hot tubs.
One problem that has occurred with these tankless water heaters, especially in areas with hard water, is that minerals present within the water solidify and adhere to the sides of the piping, particularly copper piping, that is utilized within these tankless water heaters. These minerals, commonly calcium carbonate, condense within the piping of the tankless water heater, gradually reducing the flow of the water through the piping and thereby interfere with the normal operation of the tankless water heater. The result is an inefficient tankless water heating system and, if a large amount of buildup occurs, permanent damage to the tankless water heater system.
Currently, the piping of tankless water heater systems is cleaned utilizing open, flushing systems, wherein a solution of an acid, such as vinegar in water, is poured into an open bucket and is then pumped through the tankless water heater system for a sufficient period of time to remove the scale or other deposits from the piping. Unfortunately, many of these scale removal systems are cumbersome, difficult to use, subject to spills and create significant odor and irritation when used, especially indoors, because of the vapors generated by the acidic material. Further, these open scale removal systems can be troublesome and time consuming to use and require repeated use to remove substantially all of the sediment or scale.
These open scale removal systems also create significant risks to users, bystanders, and to the environment in which they are used. The system design of these prior art systems offers no protection against spills, splashing, or vapors given off by the acidic material. In addition, this acidic material can cause injury to the operator or bystanders, such as chemical burns to the skin, eyes, or lungs through inhalation. Also, spilled material poses a slip-and-fall hazard and can damage property, such as carpet, wood or vinyl flooring.
Prior art open scale removal systems also create a difficult storage challenge for end users. When not in use, the discharge hose of such system is often left secured to the pump to reduce the time required to hook up or unhook the system. The return hose is often placed loosely with the pump, usually in a bucket. The power cord is often wrapped around the pump and also placed in the bucket with the other hose. These systems give the end user few options for safe system storage without risking damage to the hoses, power cord, pump or the surrounding environment.
It is therefore one object to produce a sealed, preassembled, and self-contained recirculating system to remove scale and other sediment from tankless water heater systems without the problems of previous open systems.
It is a further object to produce a sealed, preassembled self-contained recirculating system for cleaning tankless water heater systems, which reduces the presence of unpleasant odors and the opportunity for the acidic liquid to spill during use.
It is a further object to provide a sealed, preassembled self-contained recirculating system for cleaning tankless water heater systems which can be monitored visually while in operation without opening the system.
It is a further object to provide a sealed, preassembled self-contained recirculating system for cleaning a tankless water heater system which can be reused, regardless of the quantity of scale and other sediments that are present in the tankless water heater system being cleaned.
It is a further object to provide a sealed, preassembled self-contained system for cleaning a tankless water heater system utilizing a filter to remove the scale and other sediment, which filter can be removed, cleaned and reused.
It is a further object to provide a sealed, preassembled self-contained system for cleaning a tankless water heater system with serviceable access connections in a holding basin and a cover lid for the purpose of filling and emptying an acidic solution without having to disassemble the tankless water heater flushing system.
It is a further object to provide a sealed, preassembled self-contained system for cleaning a tankless water heater system that is easy and safe for the end user to store and secure the hoses and power cord when not in use.
To accomplish these and other objects, a sealed and self-contained tankless water heater flushing system is provided comprising a holding basin, a cover lid for the holding basin secured to the holding basin, a submersible pump contained within the holding basin, a submersible pump hose system secured from the submersible pump to a discharge opening in the cover lid of the holding basin, a filter system secured within the holding basin to a filter opening in the cover of the holding basin, which filter system is an integral component of the flushing system, wherein the filter system includes a filter for filtering solid substances, such as scale or sediment, from the tankless water heater during a flushing procedure, a discharge hose for connecting the discharge opening to the tankless water heater, a filter hose for connecting the filter opening to the tankless water heater, serviceable access connections in the holding basin and cover lid for filling and emptying the system, and handles that can be used to conveniently store and secure the discharge hose, filter hose, and power cord when not in use.
A sealed and self-contained tankless water heater flushing system comprising
a holding basin,
a cover lid for the holding basin, firmly securable to the holding basin,
serviceable access connections in the holding basin and cover lid,
a submersible pump, contained or secured within the holding basin,
a system securable from the submersible pump to a discharge opening in the cover lid of the holding basin,
a filter system, secured within the holding basin to a filter opening in the cover lid of the holding basin, which filter system is an integral component of the flushing system, wherein the filter system comprises a filter for filtering solid substances from the tankless water heater during the flushing process, wherein the filter is removable for cleaning,
a discharge hose for connecting the discharge opening to the tankless water heater,
a filter hose for connecting the filter opening to the tankless water heater, and
carry handles for providing a means for hose and power cord storage.
The sealed and self-contained tankless water heater flushing system (1), disclosed in
In one embodiment, the holding basin (10) of the flushing system (1) is a generally bucket-shaped container, which has a capacity to hold a substantial quantity of liquids, preferably from about at least 1 gallon up to about 10 gallons or so. The holding basin is preferably made of a pliable product that is resistant to acids, particularly mild acids, such as vinegar or other mild acidic solutions. In one preferred embodiment the holding basin is made of an HDPE polymer, which is resistant to acids and can withstand intermittent temperatures of those acidic solutions up to at least 110° F. (43° C.) or so.
In one preferred embodiment, the holding basin and/or cover lid further contains access connection with a removable sealing cover (17). This access connection can be used to empty the basin after use or to fill the basin before use.
In one embodiment, there is incorporated into at least one portion of a side of the holding basin a transparent or generally transparent viewing window (12). In a preferred embodiment, an individual looking through the viewing window (12) of the holding basin can see the interior of the holding basin and the equipment, filter, piping and liquids that are present therein. The size or shape of this viewing window is not critical but should be at least about 6 inches square or so. In addition, the composition of this viewing window should also be resistant to acids and heat in a manner similar to the holding basin. If desired, this viewing window can be removable from the holding basin for cleaning. As an alternative, the entire holding basin can be transparent, if desired.
In another embodiment, a generally transparent polymeric return fitting (50) can be used to view the condition of the returned liquid mixture and monitor for excessive scale and sediment before the filter element (52) becomes clogged. (See
Securable to a top lip (14) of the holding basin (10) is the cover lid (20). Said cover lid should be firmly securable to the holding basin, although it should also be capable of removal to access the interior of the holding basin. The cover lid can be firmly secured to the holding basin by conventional means, such as screws (16) or bolts passing through the cover lid and into the holding basin, or by clips which secure the cover lid to the holding basin. Preferably, the cover lid (20) and/or top lip (14) design should also include sealing agents, such as o-rings, gaskets, or other mechanical seals, to prevent vapors from escaping the holding basin (10). The cover lid (20) should be made of the same or similar acid and heat resistant material as is the holding basin, for example an HDPE polymer.
There is preferably secured to the cover lid (20) or the top lip (14) of the holding basin (10) carry handles (18) for lifting the flushing system (1). In one embodiment, the handles are three sided with perpendicular corners in a “C” shape, secured to the cover lid (20), and located on opposite sides of the holding basin when the cover lid is installed, as shown in
Contained within the holding basin is a removable, submersible pump (30). The submersible pump can be a conventional, submersible pump with a capacity of flow of approximately 1 to 3 gallons or so per minute and should be able to draw down to about one-fourth of an inch or less of depth within the holding basin (10). In one embodiment, the pump is air filled with no oil present within the motor housing and the motor is a 115/230 volt, 50/60 Hz and thermally overload protected and approved. The pump should be tested to 130° F. for three hours of continuous operation. One example of such a pump is a 42-0009 pump, manufactured by Zoeller Co. The submersible pump is preferably seated in a bottom portion (19) in the holding basin and held in position by gravity. Alternatively, it may be permanently secured to the bottom portion of the holding basin by conventional securing means. In a further alternative embodiment, legs of the submersible pump fit within open receptacles formed as a component of the bottom portion of the holding basin (not shown). Alternatively, the pump can be held in place within the holding basin (10) by the interaction of components of the system secured to the cover lid, such as the pump hose system (40), and the pump itself.
Securable to the submersible pump (30), is the submersible pump hose system (40). (See
An electrical line cord seal (26) is also provided in the cover lid (20) to permit the power cord (27) from the submersible pump (30) to pass from the submersible pump through the cover lid (20) for attachment into a conventional electrical outlet (See
A third opening in the cover lid is the filter opening (24). (See
The filter system (50) includes at least the filter (52) for filtering solid substances, such as scale or sediment, from the tankless water heater (90) during a flushing process. The filter system is secured to the filter opening (24) in the cover lid (20), as previously discussed, and includes hose adaptors, piping and other elements as shown in
An integral component of the filter system (50) is the filter (52), which is preferably secured on or near the end of the filter system (50) within the holding basin (10), as shown in
In one preferred embodiment, if the filter (52) becomes full, or substantially full, of sediment or scale, the filter (52) construction and design allows for the acidic liquid to pass through the packed filter without failing the filter or causing damage to the submersible pump (30).
Securable to the discharge opening (22) is the discharge hose (60) and to the filter opening (24) is the filter hose (70). (See
In operation, one end of each of the discharge hose (60) and the filter hose (70) is connected to the tankless water heater inlet and outlet openings. (91, 92) (See
While the present disclosure has been described by references to specific embodiments, it will be apparent that other alternative embodiments and methods of implementation or modification may be employed without departing from the scope of the disclosure.
