Apparatuses and methods for balancing combustion air and exhaust gas for use with a direct-vent heater appliance

Abstract

A combustion air and exhaust gas balancing system for use with a direct-vent heater appliance. The balancing system includes a combustion air valve in fluid communication with a combustion air duct and an exhaust gas valve in fluid communication with an exhaust gas duct. The combustion air valve is operatively coupled to the exhaust gas valve with an actuator. The combustion air and exhaust gas valves are shaped and sized so that a single operation of the actuator simultaneously adjusts the flow of combustion air into the firebox and the flow of exhaust gas out of the firebox and provide selected flame characteristics in the firebox. In one aspect of this embodiment, a movement of the actuator in a first direction simultaneously increases the flow of combustion air and exhaust gas, and a movement of the actuator shaft in a second direction simultaneously restricts the flow of combustion air and exhaust gas. The actuator shaft is securable after final adjustment of the combustion air and exhaust gas flows to maintain the selected adjustment. In another embodiment, the exhaust gas duct includes a dilution air inlet aperture that permits combustion air to pass from the combustion air duct into the exhaust gas duct without first passing through the firebox.

1 - 36 . (canceled)  
   
   
       37 . A direct-vent fireplace assembly, comprising: 
 a firebox;    a combustion air duct in communication with the firebox and configured to contain a flow of combustion air;    an exhaust gas duct in communication with the firebox and configured to contain a flow of exhaust gas;    a first valve in fluid communication with the combustion air duct, and being moveably adjustable to affect the flow of combustion air in the combustion air duct, the first valve being movable between a first open position and a first restricted position, and configured to be releasably retained in one or more first intermediate positions between the open and restricted positions; and    a second valve in fluid communication with the exhaust duct and being movably adjustable to affect the flow of exhaust gas in the exhaust duct, the second valve being movable between a second open position and a second restricted position, and configured to be releasably retained in one or more second intermediate positions, the second valve being operatively coupled to the first valve, the first and second valves being movable in unison toward or away from the first and second open positions, respectively.    
   
   
       38 . The direct-vent fireplace assembly of  claim 37 , further comprising a manifold assembly having a combustion air chamber and an exhaust gas chamber, wherein the combustion air duct communicates with the firebox via the combustion air chamber and the exhaust gas duct communicates with the firebox via the exhaust gas chamber.  
   
   
       39 . The direct-vent fireplace assembly of  claim 37  wherein the combustion air duct and the exhaust gas duct are generally concentrically disposed.  
   
   
       40 . The direct-vent fireplace assembly of  claim 37 , further comprising an actuator with first and second portions, wherein the first valve is movably coupled to the first portion of the actuator and the second valve is movably coupled to the second portion of the actuator.  
   
   
       41 . The direct-vent fireplace assembly of  claim 37  wherein the exhaust gas duct has a dilution air inlet aperture exterior of the firebox and in fluid communication with the combustion air duct, the dilution air inlet aperture being configured to permit a portion of the flow of combustion air that has not passed through the firebox to pass from the combustion air duct into the flow of exhaust gas moving away from the firebox in the exhaust gas duct.  
   
   
       42 . The direct-vent fireplace assembly of  claim 37  wherein the exhaust gas duct has a dilution air inlet aperture exterior of the firebox and in fluid communication with the combustion air duct, the dilution air inlet aperture being configured to permit a portion of the flow of combustion air that has not passed through the firebox to pass from the combustion air duct into the flow of exhaust gas moving away from the firebox in the exhaust gas duct, and wherein the flow of combustion air in the combustion air duct is a first temperature and the flow of exhaust gas in the exhaust gas duct is a second temperature higher than the first temperature, and the portion of flow of combustion air that passes into the exhaust gas flow via the dilution air inlet aperture cools the flow of exhaust gas from the second temperature as the exhaust gas moves away from the firebox.  
   
   
       43 . The direct-vent fireplace assembly of  claim 37  wherein the exhaust gas duct has a dilution air inlet aperture exterior of the firebox and in fluid communication with the combustion air duct, the dilution air inlet aperture being configured to permit a portion of the flow of combustion air that has not passed through the firebox to pass from the combustion air duct into the flow of exhaust gas moving away from the firebox in the exhaust gas duct, and wherein the appliance further comprises a separator flue positioned adjacent to the dilution air inlet aperture, the separator flue being configured to form a dilution air passage having an inlet that receives a portion of the combustion air from the combustion air duct and an outlet that directs the portion of the combustion air into the exhaust gas duct.  
   
   
       44 . The direct-vent fireplace assembly of  claim 43  wherein the separator flue is concentrically disposed within the exhaust gas duct.  
   
   
       45 . The direct-vent fireplace assembly of  claim 37  wherein the exhaust gas duct has a dilution air inlet aperture exterior of the firebox and in fluid communication with the combustion air duct, the dilution air inlet aperture being configured to permit a portion of the combustion air flow that has not passed through the firebox to pass from the combustion air duct into the exhaust gas flow moving away from the firebox in the exhaust gas duct, and wherein the appliance further comprises a separator flue positioned adjacent to the dilution air inlet aperture, the separator flue being configured to form a dilution air passage having an inlet that receives a portion of the combustion air from the combustion air duct and an outlet that directs the portion of the combustion air into the exhaust gas duct, the outlet of the dilution air passage being at a higher elevation than the inlet.  
   
   
       46 . A direct-vent fireplace assembly, comprising: 
 a firebox configured to contain a fire;    a combustion air duct in communication with the firebox and configured to contain a flow of combustion air;    an exhaust gas duct in communication with the firebox and configured to contain a flow of exhaust gas;    a first valve located proximate to the combustion air duct and being movably positionable relative to the combustion air duct among at least three first stationary positions to affect the flow of combustion air in the combustion air duct, the at least three stationary positions including a first open position, a first fully restricted position, and a first intermediate position therebetween;    a second valve located proximate to the exhaust gas duct and being movably positionable relative to the exhaust gas duct among at least three second stationary positions to affect the flow of exhaust gas in the exhaust gas duct, the at least three second stationary positions including a second open position, a second fully restricted position, and a second intermediate position therebetween; and    an actuator operatively coupled to the first and second valves, the actuator mechanically coupling the first valve to the second valve so that movement of the actuator simultaneously moves the first valve relative to the combustion air duct and the second valve relative to the exhaust gas duct in the same direction relative to the first and second open positions to achieve a selected flame characteristic of the fire in the firebox.    
   
   
       47 . The direct-vent fireplace assembly of  claim 46 , further comprising a manifold assembly having a combustion air chamber and an exhaust gas chamber, wherein the combustion air duct communicates with the firebox via the combustion air chamber and the exhaust gas duct communicates with the firebox via the exhaust gas chamber.  
   
   
       48 . The direct-vent fireplace assembly of  claim 46  wherein the exhaust gas duct is concentrically disposed within the combustion air duct.  
   
   
       49 . A direct-vent fireplace assembly, comprising: 
 a firebox;    a combustion air duct in communication with the firebox;    an exhaust gas duct in communication with the firebox, the exhaust gas duct in combination with the firebox and the combustion air duct defining a flow path;    a first valve located in the flow path and being movably positionable among at least three first stationary positions to affect a flow of combustion air in the combustion air duct, the at least three stationary positions including a first open position, a first fully restricted position, and a first intermediate position therebetween; and    a second valve located in the flow path and being simultaneously moveable with the first valve in generally the same direction and being positionable among at least three second stationary positions to affect a flow of exhaust gas in the exhaust gas duct, the at least three second stationary positions including a second open position, a second fully restricted position, and a second intermediate position therebetween.    
   
   
       50 . The direct-vent fireplace assembly of  claim 49 , further comprising an actuator mechanically and synchronously coupling the first valve to the second valve for simultaneous movement of the first valve relative to the flow of combustion air and the second valve relative to the flow of exhaust gas.  
   
   
       51 . The direct-vent fireplace assembly of  claim 49  wherein the exhaust gas duct has at least one dilution air inlet aperture exterior of the firebox and in fluid communication with the combustion air duct, the dilution air inlet aperture being configured to permit a portion of the combustion air flow from the combustion air duct that has not passed through the firebox to pass from the combustion air duct into the exhaust gas flow moving away from the firebox in the exhaust gas duct.  
   
   
       52 . A direct-vent fireplace assembly, comprising: 
 a firebox configured to contain a fire having a flame characteristic;    a combustion air duct in communication with the firebox and configured to contain a flow of combustion air;    an exhaust gas duct in communication with the firebox and configured to contain a flow of exhaust gas, one of the exhaust gas duct and the combustion air duct being disposed at least partially in the other of the exhaust gas duct and the combustion air duct;    a first valve in fluid communication with the combustion air duct and being moveably adjustable to affect the flow of combustion air in the combustion air duct; and    a second valve in fluid communication with the exhaust duct and being movably adjustable to affect the flow of exhaust gas in the exhaust duct, the second valve being operatively coupled to the first valve, the first and second valves being movable in unison generally in the same direction relative to the combustion air duct and the exhaust duct, respectively to adjust the flame characteristic of the fire in the firebox.    
   
   
       53 . The direct-vent fireplace assembly of  claim 52  wherein the combustion air duct and the exhaust gas duct are generally concentrically disposed.  
   
   
       54 . The direct-vent fireplace assembly of  claim 52 , further comprising an actuator, wherein the first valve is movably coupled to a first portion of the actuator and the second valve is coupled to a second portion of the actuator spaced apart from the first portion.  
   
   
       55 . The direct-vent fireplace assembly of  claim 52  wherein the exhaust gas duct has a dilution air inlet aperture exterior of the firebox and in fluid communication with the combustion air duct, the dilution air inlet aperture being configured to permit a portion of the flow of combustion air that has not passed through the firebox to pass from the combustion air duct into the flow of exhaust gas moving away from the firebox in the exhaust gas duct.  
   
   
       56 . The direct-vent fireplace assembly of  claim 52  wherein the exhaust gas duct has a dilution air inlet aperture exterior of the firebox and in fluid communication with the combustion air duct, the dilution air inlet aperture being configured to permit a portion of the flow of combustion air that has not passed through the firebox to pass from the combustion air duct into the flow of exhaust gas moving away from the firebox in the exhaust gas duct, and wherein the flow of combustion air in the combustion air duct is a first temperature and the flow of exhaust gas in the exhaust gas duct is a second temperature higher than the first temperature, and the portion of combustion air flow that passes into the flow of exhaust gas via the dilution air inlet aperture cools the exhaust gas flow from the second temperature as the exhaust gas moves away from the firebox.  
   
   
       57 . The direct-vent fireplace assembly of  claim 52  wherein the exhaust gas duct has a dilution air inlet aperture exterior of the firebox and in fluid communication with the combustion air duct, the dilution air inlet aperture being configured to permit a portion of the flow of combustion air that has not passed through the firebox to pass from the combustion air duct into the flow of exhaust gas moving away from the firebox in the exhaust gas duct, and wherein the appliance further comprises a separator flue positioned adjacent to the dilution air inlet aperture and configured to form a dilution air passage having an inlet that receives a portion of the combustion air from the combustion air duct and an outlet that directs the portion of the combustion air into the exhaust gas duct.  
   
   
       58 . The direct-vent fireplace assembly of  claim 57  wherein the separator flue is disposed within the exhaust gas duct.  
   
   
       59 . The direct-vent fireplace assembly of  claim 52  wherein the exhaust gas duct has a dilution air inlet aperture exterior of the firebox and in fluid communication with the combustion air duct, the dilution air inlet aperture being configured to permit a portion of the flow of combustion air that has not passed through the firebox to pass from the combustion air duct into the flow of exhaust gas moving away from the firebox in the exhaust gas duct, and further comprises a separator flue positioned adjacent to the dilution air inlet aperture, the separator flue being configured to form a dilution air passage having an inlet that receives a portion of the combustion air from the combustion air duct and an outlet that directs the portion of the combustion air into the exhaust gas duct, the outlet of the dilution air passage being at a higher elevation than the inlet.  
   
   
       60 . A direct-vent fireplace assembly, comprising: 
 a firebox having an opening for viewing a decorative fire having a flame characteristic;    a combustion air duct in communication with the firebox and configured to contain a flow of combustion air;    an exhaust gas duct in communication with the firebox and configured to contain a flow of exhaust gas;    a first valve in fluid communication with the combustion air duct, and being moveably adjustable to affect the flow of combustion air in the combustion air duct; and    a second valve in fluid communication with the exhaust duct and being movably adjustable to affect the flow of exhaust gas in the exhaust duct, the second valve being operatively coupled to the first valve, the first and second valves being movable in unison in the same direction relative to the combustion air duct and the exhaust duct, respectively to adjust the flame characteristic of the decorative fire in the firebox.    
   
   
       61 . The direct-vent fireplace assembly of  claim 60 , further comprising a manifold assembly having a combustion air chamber and an exhaust gas chamber, wherein the combustion air duct communicates with the firebox via the combustion air chamber and the exhaust gas duct communicates with the firebox via the exhaust gas chamber.  
   
   
       62 . The direct-vent fireplace assembly of  claim 60  wherein the combustion air duct and the exhaust gas duct are generally concentrically disposed.  
   
   
       63 . The direct-vent fireplace assembly of  claim 60 , further comprising an actuator coupled to the first and second valves and moveable to simultaneously adjust the first and second valves.  
   
   
       64 . The direct-vent fireplace assembly of  claim 60  wherein the exhaust gas duct has a dilution air inlet aperture exterior of the firebox and in fluid communication with the combustion air duct, the dilution air inlet aperture being configured to permit a portion of the flow of combustion air that has not passed through the firebox to pass from the combustion air duct into the flow of exhaust gas moving away from the firebox in the exhaust gas duct.  
   
   
       65 . The direct-vent fireplace assembly of  claim 60  wherein the exhaust gas duct has a dilution air inlet aperture configured to permit a portion of the flow of combustion air that has not passed through the firebox to pass into the exhaust gas duct, and wherein the flow of combustion air in the combustion air duct is a first temperature and the flow of exhaust gas in the exhaust gas duct is a second temperature higher than the first temperature, and the portion of combustion air flow that passes into the exhaust gas duct via the dilution air inlet aperture cools the flow of exhaust gas from the second temperature as the exhaust gas moves away from the firebox.  
   
   
       66 . The direct-vent fireplace assembly of  claim 60  wherein the exhaust gas duct has a dilution air inlet aperture configured to permit a portion of the flow of combustion air that has not passed through the firebox to pass from the combustion air duct into the flow of exhaust gas moving away from the firebox in the exhaust gas duct, and wherein the direct-vent fireplace further comprises a separator flue positioned adjacent to the dilution air inlet aperture, the separator flue being configured to form a dilution air passage having an inlet that receives a portion of the combustion air from the combustion air duct and an outlet that directs the portion of the combustion air into the exhaust gas duct.  
   
   
       67 . The direct-vent fireplace assembly of  claim 66  wherein the separator flue is concentrically disposed within the exhaust gas duct.  
   
   
       68 . The direct-vent fireplace assembly of  claim 66  wherein the outlet of the dilution air passage is at a higher elevation than the inlet.