The present invention relates to apparatus and method for installing a macerator and, in particular, to a docking station for accurately positioning a macerator and facilitating the connection of services to the macerator.

The installation of a macerator into a building is a complex process, requiring not only suitably securing the macerator unit itself into position but also the connection of an inlet water supply, a drain outlet and electrical power.

In a conventional macerator installation process, a paper template is placed on the floor or wall where the macerator is to be installed and fixing holes are drilled as indicated by the template. The template is then removed, a mounting bracket is fixed in position and the macerator unit is placed in position. Fixing bolts are then placed through designated attachment points in the chassis, floor or walls of the macerator into fixings to mount the macerator unit in place.

In a conventional macerator unit, the water supply and drain connections are at fixed positions, generally on the rear of the unit and once installed, the unit itself therefore obstructs the connections for these services. This complicates both the installation and subsequent servicing of the macerator unit. Further, advanced plumbing skills are often required to route these services from the walls or floor of the building to the appropriate positions on the unit and thus a macerator installation operative needs to be highly skilled.

The present invention seeks to facilitate the installation, servicing and replacement of macerator units.

According to a first aspect, there is provided apparatus for docking a macerator comprising: a base plate with a front edge and a back edge; a back plate extending upwards from the back edge of the base plate; a drain pipe extending from the backplate to a drain connector for engaging with a drain outlet of a macerator; and a water pipe extending from the back plate to a water connector for engaging with a water supply inlet of the macerator, wherein the drain connector and the water connector are positioned nearer to the front edge of the base plate than the back edge of the base plate.

In one embodiment, the drain connector and the water connector provide vertical connections to the macerator.

The apparatus may further comprise a P-trap between the drain connector and the back plate. The apparatus may further comprise an isolator between the water connector and the back plate.

In one embodiment, the back plate may further comprises a guide configured to engage with a macerator unit and guide it to the correct position relative to the base plate. The guide may comprise one or more V-shaped guide bars adapted to engage with roller pins or vertical bars on the macerator unit.

The apparatus may further comprise an attachment bracket for fixing the macerator to the base plate.

The back plate may be removably attached to the base plate. The back edge of the base plate may be angled to the plane of the base plate.

According to a second aspect, there is provided a method for installing a macerator unit comprising: lifting a macerator unit using a wheeled trolley supporting a jack; positioning the macerator unit over apparatus according to any previous claim; and lowering the macerator unit to connect it to the water supply and the drain.

Various embodiments of the invention will now be described by way of examples and with reference to the accompanying drawings in which:

Figure 1 shows a perspective view of one embodiment of a docking station from the front left;

Figure 2 shows a perspective view of one embodiment of a docking station from the back right; Figure 3 shows a close-up view of locating guides in one embodiment of a docking station;

Figures 4A and 4B show a front view of the water supply and drain connections during installation of the macerator unit.

Figure 5 shows a view of a typical macerator unit for use with the present invention from the back right. A front cover has been removed.

Figure 6 shows the macerator of Figure 4 positioned on a docking station. Figure 7 shows a front view of the macerator of Figure 6 from the front right.

Figures 1 and 2 show a base plate 1 with a front edge and a back edge. The base plate is designed to sit horizontally on a floor of a room in which the macerator 20 is to be installed, with the back edge 2 closer to a wall of the room than the front edge 3. The base plate 1 may comprise a metal sheet. The base plate 1 may be 383mm from front 2 to back 3 and 416mm from side to side. The base plate 1 includes one or more fixing points 4 for firmly attaching the base plate 1 to the floor. The fixing points 4 may comprise predrilled holes and the base plate 1 may therefore act as a template for positioning fixing holes to be drilled in the floor, thereby avoiding the need for a separate template. The base plate 1 may be fixed to the floor using screws or bolts (shown) inserted through the base plate 1 and into the floor. In some situations, such as rooms with under floor heating, it may not be appropriate to drill fixing holes into the floor. In such circumstances, the base plate 1 may be fixed using alternative means, such as by gluing it to the floor.

The base plate 1 is preferably installed with its back edge between 80mm and 135mm from the wall to ensure correct positioning of the macerator unit 20. It is recommended that when installed the macerator unit 20 is positioned 100mm from the wall to facilitate cleaning and maintenance of the macerator unit 20.

The back edge 2 of the base plate 1 may be bent upwards, so that it is angled to the plane of the floor on which the base plate 1 is sitting. This provides additional space for features in the room such as skirting, piping or cabling to run along the floor between the base plate 1 and the wall. A back plate 5 rises substantially vertically from the back edge 2 of the base plate 1. The back plate 5 is preferably at least 75mm from the wall to allow access to facilitate the connection and tightening of pipes, hoses or cables protruding from the wall.

The back plate 5 is rigidly joined to the base plate 1 and the two may be formed from a single folded steel sheet. However, preferably, the two plates may be separable from each other to allow easy replacement of the back plate 5 should it be damaged during installation. The back plate 5 may be bolted to the base plate to allow easy replacement.

In one embodiment, the back plate 5 extends 272mm upwards. The back plate 5 includes a hole through which a drain pipe 6 passes for connection to a drain pipe protruding from the wall and a hole through which a water supply pipe 7 passes for connection to a water supply pipe protruding from the wall.

The drain pipe 6 extends from the back plate 5 over the base plate 1 to a drain connector 8 for engaging with a drain outlet of the macerator unit 20. The drain pipe 6 is preferably supported above the base plate 1 by the back plate 5. Preferably, a P-shaped trap is positioned between the connector 8 and the backplate 5. A trap prevents sewer gases venting to the air, improving odour and reducing infection risk. A trap is conventionally part of a macerator unit but by moving it to a docking station, the trap will still function even when the macerator unit 20 is not docked. A blanking cap 9 may also be placed on the open end of the drain pipe 6 when the macerator unit 20 is removed from the docking station for an extended period.

The drain connector 8 comprises a short length of piping rising vertically from the P-shaped trap so as to engage with a vertical drain outlet on the macerator unit 20. The connector 8 may be held tightly on the P-shaped trap by a hose clamp. The connector pipe 8 may be transparent or translucent to allow blockages in the drain to be easily seen and to allow visual confirmation that the macerator drain outlet is properly seated in the connector 8. The internal diameter of the connector piping approximately matches the external diameter of the macerator unit drain outlet. The macerator drain outlet pipe preferably has a circumferential ridge around the outside which may be approximately 8mm from the end to act as a stop for the drain connector. A second hose clamp may be used to tighten the connector 8 around the drain outlet of the macerator unit 20 to ensure a watertight seal.

The top of the connector pipe 8 is positioned above the level of the trap to reduce the risk of spills during connection and disconnection. In one embodiment, the top of the connector pipe 8 is more than 40mm above the level of the trap (i.e. the bottom of the drain pipe 6, which dictates the level of fluid in the trap.

Importantly, the drain connector 8 is positioned towards the front edge 3 of the base plate 1. This means that when the macerator unit 20 is in position on the base plate 1, the drain connector 8 is easily accessible. In one embodiment, the macerator unit 20 may have a removable front cover. When such a front cover is removed, the drain connector 8 is even more easily accessible.

The water supply pipe 7 extends from the back plate 5 to a water connector 10 for engaging with a water supply inlet of the macerator unit 20. In the embodiment shown, the water supply pipe 7 is substantially parallel to the drain pipe 6. The water supply pipe 7 is preferably supported above the base plate 1 by the back plate 5.

The connector 10 for engaging with the macerator unit 20 is in the form of a bend (shown as right-angled isolator) so as to connect with a vertical water supply inlet of the macerator unit 20. It may include a tap or valve to act as a supply isolator. The isolator control (e.g. tap handle) is accessible from the front edge 3 of the base plate 1 when the macerator unit 20 is in position on the base plate 1. As with the drain connector 8, the water connector 10 is positioned towards the front edge 3 of the base plate 1 so that when the macerator unit 20 is in position on the base plate 1, the water connector 10 is easily accessible. In one embodiment, a front cover of the macerator unit 20 may be opened to facilitate access to the isolator and connectors 8, 10.

The position of the drain connector 8 and the water connector 10 nearer to the front edge 3 of the base plate 1 than the back edge 2 of the base plate 1 is important in making the two connectors and particularly the water supply isolator easily accessible through the front of the macerator unit 20, when the macerator unit 20 is in position.

Both the drain connector 8 and the water connector 10 are preferably oriented vertically, so that the final movement to connect the macerator unit 20 to the pipes is a downward motion.

As shown in Figures 1 and 2 and in close up in Figure 3, the back plate 5 further comprises one or more guides 11 configured to engage with a macerator unit 20 and guide it to the correct position relative to the base plate 1. In one embodiment, the guides may be guide bars formed in the shape of a "V" oriented horizontally with the apex of the "V" pointing towards the back of the apparatus. The bars engage with one or more vertical pegs or pins on the macerator unit 20. The pins may be roller pins and/or the guide bars may be covered in or formed from acetal plastic or another low friction material to facilitate sliding of the pin along the guide bar. As the macerator unit 20 is pushed towards the back of the base plate, the pin on the macerator unit 20 press against either the left or right side of the "V" and the macerator unit 20 is therefore forced to move sideways so that the pin ultimately locates in the apex of the "V" and the macerator unit 20 is in the correct position. In a preferred embodiment, two spaced apart "V"s engage with two similarly spaced pins on the macerator unit 20 in order to ensure that rotation of the macerator unit 20 about a vertical axis is also controlled.

In one embodiment the "V" is preferably 40mm wide allowing an initial positioning error of 20mm left or right to be corrected. Preferably, the tolerance of the final positioning relative to the base plate 1 is 0.5mm. The guides 11 may be formed as a separate section of the back plate 5 that can be bolted onto the remainder of the back plate 5. However, the whole back plate 5, including the guide bars 11, is preferably formed from a single metal sheet to ensure manufacturing accuracy in the relative positions of the guide bars 11, the drain pipe 6 hole and the water supply pipe 7 hole.

A macerator fixing point 12 is positioned on the base plate 1 for securing the macerator unit 20 to the base plate 1. In one embodiment, the fixing 12 comprises a bracket supported above the base plate 1 at the same height as the floor panel of a properly positioned macerator unit 20. A bolt through the floor panel of the macerator unit 20 engages with the bracket to secure the macerator unit 20. The guides 11 ensure that the macerator is accurately positioned, so minimal tolerance is required in the bolt holes. In one embodiment, the bolt may comprise a custom made fixing (as shown) that enables the bolt to be tightened by hand.

A typical macerator unit 20 (such as shown in Figure 5) weights 50 - 70kg but some are heavier. Preferably, the weight of the unit is supported on the base plate 1, which can help distribute the weight across the floor. An additional wall mount is not considered necessary or desirable.

It is to be noted that there is preferably no plate or other feature extending upwards from the front of the base plate 1. This clear area at the front of the base plate 1 ensures that a macerator 20 can be easily moved on or off the base plate 1 from the front. Further, it facilitates access to internal components of the docking station, especially the pipe connections 8, 10 and/or the supply isolator, through the front of the macerator 20 when the macerator 20 is in position on the docking station. Similarly, there are preferably no plates or other features rising from the left or right side of the base plate 1. This may facilitate access to internal components of the docking station when used with a macerator 20 that has removable panels or doors to the side.

In order to install a macerator unit 20 using the docking station described, the macerator unit 20 is preferably positioned on a platform (or other macerator support) on a trolley. The platform is then lifted, lifting the unit so that the drain outlet and water inlet of the macerator unit 20 are above the drain connector 8 and water connector 7 of the docking station. The macerator unit 20 may be lifted 40mm from the floor. The trolley preferably incorporates a jack to raise and lower the platform.

Once lifted, the macerator unit 20 can be pushed on the trolley over the base plate without being obstructed by the docking station. A large hole 21 in the back of the macerator unit 20 allows the P-Trap and water isolator to pass inside the macerator unit 20. If use of the docking station with the particular model of macerator unit 20 is optional, the hole may be covered with a removable panel 21 when the macerator unit 20 is used without the docking station.

As the macerator unit 20 is pushed back the guides 11 position it accurately above the docking station by causing sideways and rotational movement. The unit then reaches the position shown in Figure 4A. The trolley platform can then be lowered moving the macerator unit 20 into the position shown in Figure 4B. This downward motion causes the macerator unit 20 to move down and engages the drain connector 8 and the water supply connector 10 with the drain outlet and water inlet of the macerator unit 20.

Trolley is then removed and the installer can easily access the pipe to tighten the pipe clamp on the drain connector 8 through the front of the macerator unit 20. Connection of both the drain and water supply in one movement greatly facilitates installation of the of the macerator unit 20. The docking station ensures that the drain connector 8 and water supply connector 10 are always in the same position and that the macerator unit 20 is always accurately positioned to engage correctly with the macerator unit 20.

It is to be understood that any feature described in relation to one embodiment may be used alone or in combination with other features described and may also be used in combination with one or more features of one or more other embodiments, so long as technically feasible. Furthermore, equivalents and modifications not described may also be employed without departing from the scope of the invention, which is defined by the following claims.