Multi-purpose condensate shut-off switch with maintenance port accessory

Abstract

A float switch assembly and maintenance port accessory each made from plastic and impervious to corrosion that are connected in-line to a fluid discharge line, but which are also adaptable to auxiliary applications. Improvements over the prior art include a more responsive operation resulting from use of a wide float switch body and a closely fitting inner wall within the float housing that allow for rapid shut-off of the condensate producing system after collection of only a very small amount of fluid, a simple design, the ability to handle a large fluid flow, a small float housing dimension for easy installation, protection of its float switch body from routine fluid flow, a removable bottom cap for rapid maintenance and inspection of its float switch body, a fluid deflecting member and/or design that resists upstream movement of fluids, and an air-lock preventing configuration that permits operation without air vent holes.

1 . A multi-purpose float switch assembly for use in-line with a main fluid discharge line connected to a fluid-producing system, to shut off the system when blockage of the main fluid discharge line occurs so that fluid in the main fluid discharge line will be prevented from backing up and damaging the system producing it, said assembly comprising: 
 a tubular member with opposing ends and an interior fluid-diverting member;    a housing having a top surface and an open bottom end, said housing depending from said tubular member and in fluid communication therewith, with said open bottom end being positioned lower than said tubular member, said housing also being positioned relative to said tubular member so that said interior fluid-diverting member prevents said fluid communication between said tubular member and said housing during routine fluid flow in the associated main fluid discharge line when no blockage occurs;    watertight closure means adapted for sealing said open bottom end of said housing;    a shaft with an upper threaded portion;    fastening means adapted for removably securing said shaft in a fixed position centrally within said housing;    a float switch body concentric with said shaft and positioned for free movement along said shaft; and    stop means adapted for removable attachment to said shaft and maintaining said float switch body on said shaft prior to upward float switch body deployment whereby the amount of upward vertical movement of said float switch body needed to activate a signal for shutting off the fluid-producing system in fluid communication with said assembly is adjusted in advance of deployment via said fastening means and said stop means according to a threshold fluid level pre-determined to pose a risk of harm to the fluid-producing system so that when electrical wires are connected between said float switch body and the fluid-producing system, and an amount of fluid accumulates in said housing to exceed the pre-determined threshold fluid level, said float switch body is caused to rise sufficiently to activate a signal that is sent via the connected electrical wires to the fluid-producing system to shut it off before it suffers any harm.    
   
   
       2 . The assembly of  claim 1  wherein said closure means is selected from a group consisting of caps having female threads, closures having male threads, and closures having male threads and an upstanding wall.  
   
   
       3 . The assembly of  claim 1  wherein said watertight closure means comprises an o-ring.  
   
   
       4 . The assembly of  claim 1  wherein said tubular members and said housings are selected from a group consisting of tubular members centered above a depending housing and tubular members adjacent to a laterally depending housing.  
   
   
       5 . The assembly of  claim 4  wherein said laterally depending housing is substantially centered between said opposing ends of said tubular member.  
   
   
       6 . The assembly of  claim 1  wherein said tubular member is centered above said housing and said fastening means secures said upper threaded portion of said shaft to said tubular member.  
   
   
       7 . The assembly of  claim 1  wherein said housing is laterally depending from said tubular member and said fastening means secures said upper threaded portion of said shaft to said top surface of said housing.  
   
   
       8 . The assembly of  claim 1  wherein said fastening means comprises at least one lock-nut.  
   
   
       9 . The assembly of  claim 1  wherein said upper threaded portion of said shaft has a top opening configured for the passage of electrical wires.  
   
   
       10 . The assembly of  claim 1  further comprising a sealing means adapted for watertight closing of one of said opposing ends of said tubular member to adapt said assembly for auxiliary application.  
   
   
       11 . The assembly of  claim 1  wherein said interior fluid-diverting member is selected from a group consisting of upstanding walls connected to a cap and fluid-diverting members connected to said tubular member.  
   
   
       12 . The assembly of  claim 1  further comprising a maintenance port accessory configured for in-line connection with said assembly in a fluid discharge line, said accessory having an enlarged threaded opening configured for the addition of fluids therethrough without the need for a funnel to prevent airlock that otherwise would block fluid entry, said accessory also having an easily removable closure means adapted for watertight sealing of said enlarged threaded opening.  
   
   
       13 . The assembly of  claim 1  further comprising a maintenance port accessory configured for in-line connection with said assembly in a fluid discharge line, said accessory having a wider threaded end, a narrower non-threaded end, and a fluid-deflecting internal structure between said wider threaded end and said narrower non-threaded end.  
   
   
       14 . The assembly of  claim 1  further comprising a maintenance port accessory configured for in-line connection with said assembly in a fluid discharge line, said accessory having a wider threaded end, a narrower non-threaded end, and a fluid-deflecting internal structure between said wider threaded end and said narrower non-threaded end, said accessory also having an extension substantially perpendicular to said wider threaded end and depending therefrom in a position remote from said narrower non-threaded end, said extension also having an enlarged opening configured for the addition of fluids therethrough without the need for a funnel to prevent airlock that blocks fluid entry, said accessory also having an easily removable closure means adapted for watertight sealing of said enlarged opening.  
   
   
       15 . The assembly of  claim 14  wherein said easily removable closure means of said accessory has a threaded connection to said extension.  
   
   
       16 . The assembly of  claim 14  wherein said narrower non-threaded end of said accessory has a bonded connection to the associated discharge line.  
   
   
       17 . The assembly of  claim 14  wherein said fluid-deflecting internal structure of said accessory is configured for positioning of said wider threaded end downstream from said narrower non-threaded end in horizontally-extending applications and upstream from said narrower non-threaded end in vertically-extending applications.  
   
   
       18 . The assembly of  claim 7  wherein said fluid communication between said tubular member and said housing occurs immediately above said interior fluid-diverting member.  
   
   
       19 . The assembly of  claim 1  wherein said tubular member is centered above said housing, said tubular member further comprises a flattened top area, and said fastening means secures said upper threaded portion of said shaft to said flattened top area.  
   
   
       20 . The assembly of  claim 19  wherein said flattened top area has a central aperture, and said fastening means secures said upper threaded portion of said shaft to said flattened top area so that said upper threaded portion extends at least partially through said central aperture.