HVAC SYSTEM AND ZONE CONTROL UNIT

• US 20100307733A1
• Filed: 06/02/2010
• Published: 12/09/2010
• Est. Priority Date: 05/06/2005
• Status: Active Grant

• Current Assignee: HVAC Mfg
• Original Assignee: HVAC Mfg
• Inventors: KARAMANOS, John Chris, STUCK, Douglas Edward
• Granted Patent: US 9,677,777 B2
• Time in Patent Office: Days
• US Class Current: 165/254
• CPC Class Codes: F24F 11/30 for purposes related to the operation of the system, e.g. for safety or monitoring
• CPC Class Codes: F24F 11/46 Improving electric energy efficiency or saving
• CPC Class Codes: F24F 11/54 using one central controller connected to several sub-controllers
• CPC Class Codes: F24F 11/58 using Internet communication
• CPC Class Codes: F24F 11/62 characterised by the type of control or by internal processing, e.g. using fuzzy logic, adaptive control or estimation of values
• CPC Class Codes: F24F 11/63 Electronic processing
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 11/84 using valves
• CPC Class Codes: F24F 12/00 Use of energy recovery systems in air conditioning, ventilation or screening with both heat and humidity transfer between supplied and exhausted air F24F3/147
• CPC Class Codes: F24F 13/0272 Modules for easy installation or transport
• CPC Class Codes: F24F 13/04 Air-mixing units F24F13/06 takes precedence
• CPC Class Codes: F24F 3/044 Systems in which all treatment is given in the central station, i.e. all-air systems
• CPC Class Codes: F24F 3/08 with separate supply and return lines for hot and cold heat-exchange fluids i.e. so-called "4-conduit" system
• CPC Class Codes: F28D 1/05383 with multiple rows of conduits or with multi-channel conduits F28D1/05391 takes precedence
• CPC Class Codes: F28F 1/126 consisting of zig-zag shaped fins F28F1/105 takes precedence
• CPC Class Codes: F28F 2260/02 having microchannels

Abstract

HVAC systems, zone control units, and control systems are provided. An HVAC system employs distributed zone control units that provides for localized air recirculation. A zone control unit can include a return air section that receives return air from serviced building zones and can mix the return air with a supply of outside air. The mixed air can be heated and/or cooled by the zone control unit and discharged to serviced building zones in a controlled manner. An exhaust air system can be used to extract air from serviced building zones. An HVAC zone control unit can include a local control unit with an Internet protocol address. The local control unit can include a memory and a processor for storing and executing a control program for the zone control unit. The control program can control of the zone control unit in response to commands received via the Internet.

Claims

1. A method for providing heating, ventilation, and air conditioning (HVAC) to zones of a building, the method comprising:

providing a flow of supply air from outside the zones;

extracting first and second flows of return air from a first subset of the zones and a second subset of the zones, respectively;

mixing the first and second return airflows with first and second portions of the supply airflow to form first and second mixed airflows, respectively;

at least one of adding heat to or removing heat from at least one of the first return airflow, the first supply airflow, or the first mixed airflow;

at least one of adding heat to or removing heat from at least one of the second return airflow, the second supply airflow, or the second mixed airflow;

distributing the first mixed airflow to the first subset of zones; and

distributing the second mixed airflow to the second subset of zones.

2. The method of claim 1, wherein the steps of adding or removing heat comprise routing each of the first and second mixed airflows through a respective heat exchanging coil.

3. The method of claim 2, wherein the steps of adding or removing heat each comprises routing water having a temperature higher or lower than a temperature of the respective mixed airflow within the respective heat exchanging coil.

4. The method of claim 3, wherein:

each of the respective heat exchanging coils comprises a heating coil and a cooling coil; and

the steps of adding or removing heat each comprises at least one of routing water having a temperature higher than the temperature of the respective mixed airflow within the respective heating coil or routing water having a temperature lower than the temperature of the respective mixed airflow within the respective cooling coil.

5. The method of claim 4, wherein the steps of routing water each comprises using a variable rate pump to control a flow rate of water routed through the respective heat exchanging coil.

6. The method of claim 2, wherein the steps of routing each of the first and second mixed airflows through a respective heat exchanging coil each comprises drawing the respective mixed airflow through the respective heat exchanging coil by using a variable speed fan to control a flow rate of the respective mixed airflow.

7. The method of claim 1, wherein:

the first subset of zones comprises a plurality of the zones; and

the step of extracting the first and second return airflows comprises controlling a flow rate of return air originating from one or more zones of the first subset of zones by using one or more automated controllable dampers.

8. The method of claim 7, wherein:

the first subset of zones comprises a plurality of the zones; and

the step of distributing the first mixed airflow comprises controlling a flow rate of a portion of the first mixed airflow distributed to one or more zone of the first subset of zones by using one or more automated controllable dampers.

9. A heating, ventilation, and air conditioning (HVAC) zone control unit (ZCU) configured to provide HVAC to a building in conjunction with at least one additional of said ZCU, the building have zones comprising first and second subsets of the zones, the ZCU providing HVAC to the first subset of the zones and the at least one additional of said ZCU providing HVAC to the second subset of the zones, the ZCU comprising:

a housing configured to mount to the building local to the first subset of zones;

a return air plenum disposed within the housing;

a first return air inlet configured to input a first return airflow originating from at least one of the first subset of zones into the return air plenum;

a supply air inlet configured to input a supply airflow into the plenum from a supply air duct transporting the supply airflow from outside the zones of the building, the supply airflow and the return airflow combining to form a mixed airflow;

at least one heat exchanging coil disposed within the housing;

a discharge air plenum disposed within the housing;

a fan motivating the mixed airflow to pass through the heat exchanging coil and discharges into the discharge air plenum; and

a first discharge outlet configured to discharge air from the discharge air plenum for distribution to at least one zone of the first subset of zones.

10. The HVAC ZCU of claim 9, further comprising an automated controllable damper to control a flow rate of the first return airflow input through the first return air inlet.

11. The HVAC ZCU of claim 9, further comprising a second return air inlet configured to input a second return airflow originating from at least one of the first subset of zones into the return air plenum.

12. The HVAC ZCU of claim 11, further comprising an automated controllable damper to control a flow rate of the second return airflow input through the second return air inlet.

13. The HVAC ZCU of claim 9, further comprising an automated controllable damper to control a flow rate of the supply airflow input through the supply air inlet.

14. The HVAC ZCU of claim 9, wherein the at least one heat exchanging coil comprises a heating coil and a cooling coil.

15. The HVAC ZCU of claim 14, further comprising:

a first variable rate pump to route water having a temperature higher than the mixed airflow through the heating coil at a controlled rate; and

a second variable rate pump to route water having a temperature lower than the mixed airflow through the cooling coil at a controlled rate.

16. The HVAC ZCU of claim 9, further comprising a second discharge outlet configured to discharge air from the discharge air plenum for distribution to at least one zone of the first subset of zones.

17. The HVAC ZCU of claim 16, further comprising an automated controllable damper to control a flow rate of at least one of the air discharged through the first discharge outlet or the air discharged through the second discharge outlet.

18. The HVAC ZCU of claim 9, further comprising a local control unit to control the ZCU.

19. The HVAC ZCU of claim 18, wherein the local control unit comprises an Internet Protocol (IP) address and is connectable to the Internet via a communication link comprising at least one of a hard-wired communication link or a wireless communication link.

20. The HVAC ZCU of claim 18, wherein the local control unit is configured to control lighting in the first subset of zones.

21. The HVAC ZCU of claim 18, further comprising a sensor coupled with the local control unit to measure a compound concentration level, wherein the local control unit controls a flow rate of the supply airflow input into the zone control unit to control a resulting concentration level of the measured compound.

22. The HVAC ZCU of claim 21, wherein the sensor comprises at least one of a carbon-dioxide (CO₂) sensor or a total organic volatile (TOV) sensor.

23. The HVAC ZCU of claim 21, wherein the local control unit transmits the measured compound concentration level to an external device.

24. An HVAC system for providing HVAC to a zones of a building, the system comprising:

a first HVAC ZCU according to claim 9;

the first ZCU providing HVAC to a first subset of the zones of the building;

a second HVAC ZCU according to claim 9, the second ZCU providing HVAC to a second subset of the zones of the building, the second subset being different from the first subset;

a supply airflow duct transporting a flow of supply air, a first portion of the supply airflow provided to the first ZCU and a second portion of the supply airflow provided to the second ZCU; and

an air-handling unit that intakes the supply airflow from external to the zones of the building and discharges the supply airflow into the supply airflow duct.

25. The HVAC system of claim 24, further comprising:

at least one supply line providing a heat transfer fluid to the at least one heat exchanging coil; and

at least one return line for transporting the heat transfer fluid discharged from the at least one heat exchanging coil.

26. A prefabricated assembly configured for use in an HVAC system providing HVAC to zones of a building, the HVAC system having a plurality of distributed ZCUs, each of the ZCUs locally providing HVAC to a respective subset of the zones, the prefabricated assembly having a length and comprising:

a length of duct having first and second ends, the duct configured to transport a flow of supply air from the first end to the second end;

the duct adaptable to include a discharge port to discharge a portion of the supply airflow to one of the distributed ZCUs;

a plurality of brackets coupled with the duct along the length of duct, the brackets comprising mounting features; and

a supply line to supply water to and a return line to return water from a heat exchanging coil of one or more of the distributed ZCUs, the supply and return lines supported by at least one of the mounting features,

wherein corresponding components of a plurality of the prefabricated assemblies can be coupled to provide for the transport of the flow of supply air along a combined length of the coupled assemblies and for the transport of the supply and return water along the combined length, and

wherein the prefabricating assembly comprises mounting surfaces to mount the assembly to the building.

27. The assembly of claim 26, further comprising at least one electrical conduit supported by at least one of the mounting features.

28. The assembly of claim 26, further comprising at least one cable tray supported by at least one of the mounting features.

29. The assembly of claim 26, further comprising at least one of a wireless transmitter or a wireless repeater coupled with at least one of the brackets.

30. The assembly of claim 26, further comprising control wires connectable to the distributed ZCUs to transmit at least one of control signals or data at least to or from the distributed ZCUs.

31. A method for providing heating, ventilation, and air conditioning (HVAC) to first and second zones of a building, the method comprising:

providing first and second flows of supply air from outside the zones via an air duct;

extracting a first flow of return air from the first zone and a second flow of return air from a second zone;

mixing the first flow of return airflow with the first flow of supply air in a first zone control unit so as to form a first mixed flow;

mixing the second flow of return air with the second flow of supply air in a second zone control unit;

directing heated water to the first and second zone control units from a hot water source;

directing cooled water to the first and second zone control units from a cold water source;

in response to a low temperature in the first zone, increasing heat transfer within the first zone control unit from the heated water to the first mixed airflow;

in response to a high temperature in the first zone, increasing heat transfer within the first zone control unit from the cooled water to the first mixed airflow;

in response to a low temperature in the second zone, increasing heat transfer within the second zone control unit from the heated water to the second mixed airflow;

in response to a high temperature in the second zone, increasing heat transfer within the second zone control unit from the cooled water to the first mixed airflow;

distributing the first mixed airflow to the first zone; and

distributing the second mixed airflow to the second zone.

32. The method of claim 31, wherein increasing heat transfer comprises varying the return airflows by altering a fan speed within each zone control unit.

33. The method of claim 32, wherein increasing heat transfer comprises varying flow of the heated water or the cooled water within each zone control unit.

34. The method of claim 31, wherein the first zone control unit is interchangeable with the second zone control unit, and wherein the first zone has significantly different heating and cooling load characteristics than the second zone.

35. The method of claim 31, further comprising installing the HVAC system in the building by coupling the first zone control unit to the duct, the hot water source, and the cold water source using a first assembly and coupling the second zone control unit to the duct, the hot water source, and the cold water source using a second assembly, wherein the each assembly includes a supply air duct, a hot water line, and a cold water line supported by a bracket.

36. A set of prefabricated assemblies configured for use in an Heating, Ventilation, and Air Conditioning (“

HVAC”

) system providing HVAC to zones of a building, the HVAC system having a plurality of distributed Zone Control Units (“

ZCUs”

), each of the ZCUs locally providing HVAC to a respective subset of the zones, each prefabricated assembly having a length and comprising;

a length of duct having first and second ends, the duct configured to transport a flow of supply air from the first end to the second end;

the duct adaptable to include a discharge port to discharge a portion of the supply airflow to an associated one of the distributed ZCUs;

a plurality of brackets coupled with the length of duct, the brackets comprising mounting features; and

a supply line to supply water to and a return line to return water from a heat exchanging coil of one or more of the distributed ZCUs, the supply and return lines supported by at least one of the mounting features,

wherein corresponding components of a plurality of the prefabricated assemblies can be coupled to provide for the transport of the flow of supply air along a combined length to the coupled assemblies and for the transport of the supply and return water along the combined length, and

wherein the prefabricated assemblies comprise mounting surfaces to mount the assemblies to the building.