Modular header system

Abstract

The present invention provides a header module adapted for use with a retail store refrigeration system including a plurality of refrigerated merchandisers. The header module includes a first conduit defining at least a portion of a common suction header adapted to carry low-pressure gaseous refrigerant received from the plurality of refrigerated merchandisers and a second conduit defining at least a portion of a common liquid header adapted to carry compressed liquid refrigerant for discharge to the plurality of refrigerated merchandisers. The first and second conduits are integrally formed.

1 . A header module adapted for use with a retail store refrigeration system including a plurality of refrigerated merchandisers, the header module comprising: 
 a first conduit defining at least a portion of a common suction header adapted to carry low-pressure gaseous refrigerant received from the plurality of refrigerated merchandisers; and    a second conduit defining at least a portion of a common liquid header adapted to carry compressed liquid refrigerant for discharge to the plurality of refrigerated merchandisers, wherein the first and second conduits are integrally formed.    
   
   
       2 . The header module of  claim 1 , further comprising: 
 a first end plate coupling the first conduit and second conduit; and    a second end plate coupling the first conduit and second conduit, the second end plate positioned on the header module opposite the first end plate.    
   
   
       3 . The header module of  claim 2 , wherein the first and second end plates are configured with grooves, and wherein the header module includes a key configured to be selectively received within at least one of the grooves of the first and second end plates.  
   
   
       4 . The header module of  claim 3 , wherein the key is configured with a dovetail shape.  
   
   
       5 . The header module of  claim 1 , further comprising a suction inlet passageway through the header module and in communication with the first conduit.  
   
   
       6 . The header module of  claim 5 , further comprising a suction coupling positioned in the suction inlet passageway, wherein the suction coupling is configured to receive a refrigeration line carrying low-pressure gaseous refrigerant from at least one of the plurality of refrigerated merchandisers.  
   
   
       7 . The header module of  claim 5 , further comprising: 
 a suction valve positioned in the suction inlet passageway, the suction valve being controllable to regulate flow of low-pressure gaseous refrigerant through the suction inlet passageway; and    a suction isolation valve positioned in the suction inlet passageway to selectively block flow of low-pressure gaseous refrigerant through the suction inlet passageway.    
   
   
       8 . The header module of  claim 1 , further comprising a liquid outlet passageway through the header module and in communication with the second conduit.  
   
   
       9 . The header module of  claim 8 , further comprising a liquid coupling positioned in the liquid outlet passageway, wherein the liquid coupling is configured to receive a refrigeration line for carrying compressed liquid refrigerant to at least one of the plurality of refrigerated merchandisers.  
   
   
       10 . The header module of  claim 8 , further comprising: 
 a liquid valve positioned in the liquid outlet passageway, the liquid valve being controllable to regulate flow of compressed liquid refrigerant through the liquid outlet passageway; and    a liquid isolation valve positioned in the liquid outlet passageway to selectively block flow of compressed liquid refrigerant through the liquid outlet passageway.    
   
   
       11 . The header module of  claim 1 , further comprising: 
 a third conduit defining at least a portion of a common gas defrost header adapted to carry superheated, compressed gaseous refrigerant for selective discharge to the plurality of refrigerated merchandisers, wherein the first, second, and third conduits are integrally formed.    
   
   
       12 . The header module of  claim 11 , further comprising a gas defrost passageway through the header module and in communication with the third conduit.  
   
   
       13 . The header module of  claim 12 , further comprising: 
 a gas defrost valve positioned in the gas defrost passageway, the gas defrost valve being controllable to regulate flow of superheated, compressed gaseous refrigerant through the gas defrost passageway; and    a gas defrost isolation valve positioned in the gas defrost passageway to selectively block flow of superheated, compressed gaseous refrigerant through the gas defrost passageway.    
   
   
       14 . The header module of  claim 12 , further comprising a suction inlet passageway through the header module and in communication with an evaporator in one of the plurality of refrigerated merchandisers, wherein the gas defrost passageway is selectively fluidly connected with the suction inlet passageway to deliver superheated, compressed gaseous refrigerant to the evaporator.  
   
   
       15 . A modular header system adapted for use with a retail store refrigeration system, the modular header system comprising: 
 a first header module including 
 a first conduit defining at least a portion of a common suction header adapted to carry low-pressure gaseous refrigerant; and  
 a second conduit defining at least a portion of a common liquid header adapted to carry compressed liquid refrigerant;  
 wherein the first conduit and second conduit of the first header module are integrally formed; and  
   a second header module including 
 a first conduit defining at least a portion of the common suction header;  
 a second conduit defining at least a portion of the common liquid header;  
 wherein the first conduit and second conduit of the second header module are integrally formed, and wherein the second header module is coupled to the first header module to fluidly couple the first conduits of the common suction header and the second conduits of the common liquid header.  
   
   
   
       16 . The modular header system of  claim 15 , wherein the first header module includes a plate positioned toward respective ends of the first conduit and second conduit of the first header module, and wherein the second header module includes a plate positioned toward respective ends of the first conduit and second conduit of the second header module.  
   
   
       17 . The modular header system of  claim 16 , wherein the first and second plates are configured with grooves, wherein the modular header system further comprises a key, and wherein the grooves are configured to receive the key.  
   
   
       18 . The modular header system of  claim 17 , wherein the key is configured with a dovetail shape.  
   
   
       19 . The modular header system of  claim 15 , further comprising a suction inlet passageway through each of the first and second header modules, the suction inlet passageways communicating with the respective first conduits of the common suction header.  
   
   
       20 . The modular header system of  claim 19 , further comprising a suction coupling positioned in each suction inlet passageway, wherein the suction couplings are each configured to receive a refrigeration line carrying low-pressure gaseous refrigerant from a respective refrigerated merchandiser.  
   
   
       21 . The modular header system of  claim 19 , further comprising: 
 a suction valve positioned in each of the suction inlet passageways of the first and second header modules, the suction valves being controllable to regulate flow of low-pressure gaseous refrigerant through the respective suction inlet passageways; and    a suction isolation valve positioned in each of the suction inlet passageways to selectively block flow of low-pressure gaseous refrigerant through the respective suction inlet passageways.    
   
   
       22 . The modular header system of  claim 15 , further comprising a liquid outlet passageway through each of the first and second header modules, the liquid outlet passageways communicating with the respective second conduits of the common liquid header.  
   
   
       23 . The modular header system of  claim 22 , further comprising a liquid coupling positioned in each liquid outlet passageway, wherein the liquid couplings are each configured to receive a refrigeration line carrying compressed liquid refrigerant to a respective refrigerated merchandiser.  
   
   
       24 . The modular header system of  claim 22 , further comprising: 
 a liquid valve positioned in each of the liquid outlet passageways of the first and second header modules, the liquid valves being controllable to regulate flow of compressed liquid refrigerant through the respective liquid outlet passageways; and    a liquid isolation valve positioned in each of the liquid outlet passageways to selectively block flow of compressed liquid refrigerant through the respective liquid outlet passageways.    
   
   
       25 . The modular header system of  claim 15 , wherein the first header module includes a third conduit defining at least a portion of a common gas defrost header adapted to carry superheated, compressed gaseous refrigerant, wherein the first, second, and third conduits of the first header module are integrally formed, wherein the second header module includes a third conduit defining at least a portion of the common gas defrost header, wherein the first conduit, second conduit, and the third conduit of the second header module are integrally formed, and wherein the second header module is coupled to the first header module to fluidly couple the third conduits of the common gas defrost header.  
   
   
       26 . The modular header system of  claim 25 , further comprising a gas defrost passageway through each of the first and second header modules, the gas defrost passageways communicating with the respective third conduits of the common gas defrost header.  
   
   
       27 . The modular header system of  claim 26 , further comprising: 
 a gas defrost valve positioned in each of the gas defrost passageways of the first and second header modules, the gas defrost valves being controllable to regulate flow of superheated, compressed gaseous refrigerant through the respective gas defrost passageways; and    a gas defrost isolation valve positioned in each of the gas defrost passageways to selectively block flow of superheated, compressed gaseous refrigerant through the respective gas defrost passageways.    
   
   
       28 . The modular header system of  claim 26 , further comprising a suction inlet passageway through each of the first and second header modules, the respective suction inlet passageways communicating with an evaporator in a refrigerated merchandiser, wherein the gas defrost passageways are selectively fluidly connected with the respective suction inlet passageways of the first and second header modules to deliver superheated, compressed gaseous refrigerant to the respective evaporators.  
   
   
       29 . The modular header system of  claim 25 , wherein one of the first and second header modules is coupled to a suction inlet of a compressor via a first refrigeration line, wherein the one of the first and second header modules is coupled to an outlet of a liquid receiver via a second refrigeration line, and wherein the one of the first and second header modules is coupled to a discharge outlet of the compressor via a third refrigeration line.  
   
   
       30 . The modular header system of  claim 25 , further comprising a valve positioned downstream of a discharge outlet of a compressor and upstream of the common liquid header defined by the first and second header modules, wherein the valve selectively causes a pressure differential between the common liquid header and the common gas defrost header defined by the first and second header modules.  
   
   
       31 . A method of assembling a retail store refrigeration system including a plurality of refrigerated merchandisers, the method comprising: 
 providing a first header module including 
 a first conduit defining at least a portion of a common suction header adapted to carry low-pressure gaseous refrigerant received from the plurality of refrigerated merchandisers;  
 a second conduit defining at least a portion of a common liquid header adapted to carry compressed liquid refrigerant for discharge to the plurality of refrigerated merchandisers, the first conduit and second conduit of the first header module being integrally formed;  
   providing a second header module including 
 a first conduit defining at least a portion of the common suction header;  
 a second conduit defining at least a portion of the common liquid header;  
 the first conduit and the second conduit of the second header module being integrally formed;  
   interconnecting the second header module with the first header module; and    fluidly coupling the first conduits of the common suction header and the second conduits of the common liquid header.    
   
   
       32 . The method of  claim 31 , wherein providing a first header module includes providing a first header module having a third conduit defining at least a portion of a common gas defrost header adapted to carry superheated, compressed gaseous refrigerant for selective discharge to the plurality of refrigerated merchandisers, the first conduit, second conduit, and the third conduit of the first header module being integrally formed, wherein providing a second header module includes providing a second header module having a third conduit defining at least a portion of the common gas defrost header, the first conduit, second conduit, and the third conduit of the second header module being integrally formed, wherein fluidly coupling includes fluidly coupling the third conduits of the common gas defrost header.  
   
   
       33 . The method of  claim 32 , wherein interconnecting the second header module with the first header module includes engaging a key with grooves located on the first and second header modules.  
   
   
       34 . The method of  claim 32 , further comprising controlling a suction valve positioned in a suction inlet passageway in at least one of the first and second header modules to regulate flow of low-pressure gaseous refrigerant through the suction inlet passageway of the at least one of the first and second header modules.  
   
   
       35 . The method of  claim 34 , further comprising: 
 controlling the suction valve to block flow of low-pressure gaseous refrigerant through the suction inlet passageway of at least one of the first and second header modules; and    controlling a gas defrost valve positioned in a gas defrost passageway in the at least one of the first and second header modules to regulate flow of superheated, compressed gaseous refrigerant through the gas defrost passageway and through the suction inlet passageway of the at least one of the first and second header modules.    
   
   
       36 . The method of  claim 32 , further comprising controlling a liquid valve positioned in a liquid outlet passageway in at least one of the first and second header modules to regulate flow of compressed liquid refrigerant through the liquid outlet passageway of the at least one of the first and second header modules.  
   
   
       37 . The method of  claim 32 , further comprising: 
 coupling one of the first and second header modules to a suction inlet of a compressor via a first refrigeration line;    coupling the one of the first and second header modules to an outlet of a liquid receiver via a second refrigeration line; and    coupling the one of the first and second header modules to a discharge outlet of the compressor via a third refrigeration line.    
   
   
       38 . The method of  claim 32 , further comprising: 
 mounting a suction coupling in a suction inlet passageway in at least one of the first and second header modules;    securing a refrigeration line to the suction coupling; and    fluidly connecting the refrigeration line to an outlet of an evaporator in one of the plurality of refrigerated merchandisers.    
   
   
       39 . The method of  claim 38 , wherein securing the refrigeration line to the suction coupling includes brazing the refrigeration line to the suction coupling.  
   
   
       40 . The method of  claim 32 , further comprising: 
 mounting a liquid coupling in a liquid outlet passageway in at least one of the first and second header modules;    securing a refrigeration line to the liquid coupling; and    fluidly connecting the refrigeration line to an inlet of an evaporator in one of the plurality of refrigerated merchandisers.    
   
   
       41 . The method of  claim 40 , wherein securing the refrigeration line to the liquid coupling includes brazing the refrigeration line to the liquid coupling.