Condensate Pump

Abstract

A condensate pump for an HVAC system includes a reservoir, a unitary top support plate, and a cover. A pump motor, an impeller pump, a float, and control electronics are mounted on the unitary top support plate. The transition from the cylindrical volute chamber to the tangential output port of the impeller pump has a swept diagonal surface that creates a gradual transition from the cylindrical volute chamber to the tangential output port. The gradual transition minimizes the pulsing. An intake profile with a concave surface extends from the center of the impeller and matches a complementary intake profile extending from the bottom of the reservoir. Vortex inhibiting vanes are molded into the bottom of the reservoir adjacent the central intake port of the impeller pump to break up any induced vortex within the reservoir.

1 . A condensate pump for collecting condensate water and pumping the condensate water to a remote location comprising:
 a. a reservoir having an open top and a bottom panel;   b. a unitary top support plate fixed on the open top of the reservoir and comprising:
 i. an impeller pump support structure extending into the reservoir; 
 ii. a motor support structure on the unitary top support plate outside of the reservoir; 
 iii. cover support structure on the unitary top support plate outside of the reservoir; 
 iv. a control circuitry support structure on the unitary top support plate outside of the reservoir; and 
 v. a float assembly support structure on the unitary top support plate; 
   c. an impeller pump mounted to the impeller pump support structure of the unitary top support plate and having a cylindrical volute chamber, with an intake port, an output port, and an impeller mounted for rotation within the volute chamber;   d. a motor mounted to the motor support structure of the unitary top support plate and connected to the impeller pump for driving the impeller of the impeller pump;   e. a float assembly mounted to the float assembly support structure of the unitary top support plate for determining the level of water in the reservoir;   f. control circuitry mounted to the control circuitry support structure of the unitary top support plate and operatively connected to the float assembly for controlling the operation of the motor based on the level of the water in the reservoir; and   g. a cover mounted to the cover support structure of the unitary top support plate for covering the motor and the control circuit.   
   
   
       2 . The condensate pump of  claim 1 , wherein the unitary top support plate is fastened to the top of the reservoir by a snap connection so that the unitary top support plate snaps onto the top of the reservoir. 
   
   
       3 . The condensate pump of  claim 1 , wherein the output port of the volute chamber is oriented tangentially to the cylindrical volute chamber and wherein a transition region between the cylindrical volute chamber and the output port has a swept diagonal surface for extending the transition region. 
   
   
       4 . The condensate pump of  claim 1 , wherein the impeller has an intake profile with a concave surface extending from the center of the impeller toward the intake port of the volute chamber, the reservoir has an intake profile with a concave surface that extends from the bottom panel of the reservoir toward the intake port of the volute chamber and that aligns with the impeller intake profile, and a set of vortex inhibiting vanes extending upward from the bottom panel of the reservoir to break up any induced vortex within the condensate water in the reservoir. 
   
   
       5 . A condensate pump for collecting condensate water and pumping the condensate water to a remote location comprising:
 a. a reservoir having an open top;   b. a unitary top support plate fixed on the open top of the reservoir and comprising:
 i. an impeller pump support structure extending into the reservoir; 
 ii. a motor support structure on the unitary top support plate outside of the reservoir; 
   c. an impeller pump mounted to the impeller pump support structure of the unitary top support plate and having a cylindrical volute chamber, with an intake port, an output port, and an impeller mounted for rotation within the volute chamber; and   d. a motor mounted to the motor support structure of the unitary top support plate and connected to the impeller pump for driving the impeller of the impeller pump.   
   
   
       6 . The condensate pump of  claim 5 , wherein the unitary top support plate is fastened to the top of the reservoir by a snap connection so that the unitary top support plate snaps onto the top of the reservoir. 
   
   
       7 . A condensate pump for collecting condensate water and pumping the condensate water to a remote location comprising:
 a. a reservoir for collecting condensate water and having a bottom panel;   b. a motor driven impeller pump disposed within the reservoir and having a cylindrical volute chamber, with an intake port, an output port, and an impeller mounted for rotation within the volute chamber, wherein the impeller has an intake profile with a concave surface extending from the center of the impeller toward the intake port of the volute chamber, the reservoir has an intake profile with a concave surface that extends from the bottom panel of the reservoir toward the intake port of the volute chamber and that aligns with the impeller intake profile, and a set of vortex inhibiting vanes extending upward from the bottom panel of the reservoir to break up any induced vortex within the condensate water in the reservoir.   
   
   
       8 . The condensate pump of  claim 7 , wherein the output port of the volute chamber is oriented tangentially to the cylindrical volute chamber and wherein a transition region between the cylindrical volute chamber and the output port has a swept diagonal surface for extending the transition region. 
   
   
       9 . An impeller pump for a condensate pump comprising a cylindrical volute chamber, with an intake port, an output port, and an impeller mounted for rotation within the volute chamber, wherein the output port of the volute chamber is oriented tangentially to the cylindrical volute chamber and wherein a transition region between the cylindrical volute chamber and the output port has a swept diagonal surface for extending the transition region.