Multi-pass header assembly for a heat exchanger

Abstract

The disclosed technology includes a header assembly for a water heating system heat exchanger. The header assembly can have an inlet, an outlet, a first compartment configured to receive a fluid from the inlet and direct the fluid to a first heat exchanger tube, a second compartment configured to receive the fluid from a second heat exchanger tube and direct the fluid to a third heat exchanger tube, and a third compartment configured to receive the fluid from a fourth heat exchanger tube and direct the fluid to the outlet.

What is claimed is: 
     
         1 . A header assembly for a water heating system heat exchanger, the header assembly comprising:
 a header body comprising:
 an inlet; 
 an outlet; 
 a first compartment configured to receive a fluid from the inlet and direct the fluid to a first heat exchanger tube; 
 a second compartment configured to receive the fluid from a second heat exchanger tube and direct the fluid to a third heat exchanger tube; 
 a third compartment configured to receive the fluid from a fourth heat exchanger tube and direct the fluid to the outlet; and 
 a removeable baffle configured to, at least partially separate the first compartment, the second compartment, and the third compartment. 
   
     
     
         2 . The header assembly of  claim 1 , wherein:
 the removeable baffle comprises a first removeable baffle and a second removeable baffle,   the first removeable baffle is configured to at least partially separate the first compartment and the third compartment, and   the second removeable baffle is configured to (i) at least partially separate the first compartment, the second compartment, and the third compartment, and (ii) direct the fluid from the inlet to the first heat exchanger tube.   
     
     
         3 . The header assembly of  claim 2 , wherein the second removeable baffle further comprises a curved planar surface configured to direct the fluid from the inlet to the first heat exchanger tube. 
     
     
         4 . The header assembly of  claim 2 , wherein the first removeable baffle further comprises a fluid bypass mechanism configured to direct an amount of the fluid proximate the inlet away from the first heat exchanger tube and toward the outlet. 
     
     
         5 . The header assembly of  claim 2 , wherein the first removeable baffle further comprises a channel configured to receive and provide support to the second removeable baffle. 
     
     
         6 . The header assembly of  claim 2 , wherein the second removeable baffle further comprises a channel configured to receive a sealing material configured to create a seal between the second removeable baffle and a tube sheet of the heat exchanger. 
     
     
         7 . The header assembly of  claim 1 , wherein:
 the first heat exchanger tube comprises a first number of heat exchanger tubes,   the second heat exchanger tube comprises a second number of heat exchanger tubes,   the third heat exchanger tube comprises a third number of heat exchanger tubes,   the fourth heat exchanger tube comprises a fourth number of heat exchanger tubes, and   the first number of heat exchanger tubes is at least one greater than each of the second, third, and fourth numbers of heat exchanger tubes.   
     
     
         8 . The header assembly of  claim 1 , wherein the header body further comprises one or more ports configured to receive at least one of a temperature sensor and a water chemistry sensor. 
     
     
         9 . The header assembly of  claim 1 , wherein the header assembly further comprises at least one of:
 an inlet temperature sensor configured to detect a temperature of the fluid proximate the inlet; and   an outlet temperature sensor configured to detect a temperature of the fluid proximate the outlet.   
     
     
         10 . The header assembly of  claim 1 , wherein the header assembly further comprises a governor assembly configured to control a flowrate of the fluid based on a temperature of the fluid. 
     
     
         11 . The header assembly of  claim 1 , wherein the header assembly further comprises a sealing material configured to create a seal between the header and a tube sheet of the heat exchanger. 
     
     
         12 . A header assembly for a water heating system heat exchanger, the header assembly comprising:
 a header body comprising:
 an inlet; 
 an outlet; 
 an inlet compartment configured to receive a fluid from the inlet and direct the fluid to flow in a first direction; 
 an outlet compartment configured to receive the fluid flowing from a second direction and direct the fluid to the outlet, the second direction being approximately opposite the first direction; and 
 one or more intermediate compartments, each of the one or more intermediate compartments configured to receive the fluid flowing from the second direction and direct the fluid to flow in the first direction. 
   
     
     
         13 . The header assembly of  claim 12  further comprising:
 a return header body comprising:
 two or more return compartments, each of the two or more return compartments configured to receive the fluid flowing from the first direction and direct the fluid to flow in the second direction. 
 
 
     
     
         14 . The header assembly of  claim 13  further comprising a plurality of heat exchanger tubes fluidly connecting each of the two or more return compartments to one or more of the inlet compartment, the outlet compartment, and the one or more intermediate compartments. 
     
     
         15 . A heat exchanger assembly for a water heating system, the heat exchanger assembly comprising:
 a plurality of heat exchanger tubes, the plurality of heat exchanger tubes configured to transfer heat from a first fluid to a second fluid;   a first header in fluid communication with the plurality of heat exchanger tubes, the first header comprising:
 an inlet; 
 an outlet; 
 a first header baffle configured to at least partially separate an interior of the first header into a first compartment, a second compartment, and a third compartment; and 
 a second header in fluid communication with the plurality of heat exchanger tubes, the second header comprising:
 a second header baffle configured to at least partially separate an interior of the second header into a first return compartment and a second return compartment, 
 
   wherein the heat exchanger assembly is configured to direct a flow of the second fluid from the inlet and sequentially through the first compartment, through a first heat exchanger tube of the plurality of heat exchanger tubes, through the first return compartment, through a second heat exchanger tube of the plurality of heat exchanger tubes, through the second compartment, through a third heat exchanger tube of the plurality of heat exchanger tubes, through the second return compartment, through a fourth heat exchanger tube of the plurality of heat exchanger tubes, and through the third compartment to the outlet.   
     
     
         16 . The heat exchanger assembly of  claim 15 , wherein the first header further comprises at least one of:
 an inlet temperature sensor configured to detect a temperature of the fluid proximate the inlet; and   an outlet temperature sensor configured to detect a temperature of the fluid proximate the outlet.   
     
     
         17 . The heat exchanger assembly of  claim 15 , wherein:
 the first header baffle comprises a first removeable baffle portion and a second removeable baffle portion,   the first removeable baffle portion is configured to at least partially separate the first compartment and the third compartment, and   the second removeable baffle portion is configured to at least partially separate the first compartment, the second compartment, and the third compartment.   
     
     
         18 . The heat exchanger assembly of  claim 17 , wherein the first removeable baffle portion further comprises a fluid bypass mechanism configured to direct an amount of the second fluid proximate the inlet toward the outlet. 
     
     
         19 . The heat exchanger assembly of  claim 17 , wherein the first header further comprises a plurality of support ribs configured to provide support to the first removeable baffle portion and the second removeable baffle portion. 
     
     
         20 . The heat exchanger assembly of  claim 17 , wherein the second header further comprises a protrusion on an inside surface of the second header configured to direct the second fluid toward the plurality of heat exchanger tubes.