System and method for heat pump oriented zone control

• US 7,789,317 B2
• Filed: 09/05/2006
• Issued: 09/07/2010
• Est. Priority Date: 09/14/2005
• Status: Active Grant

• Current Assignee: Arzel Zoning Technology, Inc.
• Original Assignee: Arzel Zoning Technology, Inc.
• Inventors: Ramunni, Joseph, Votaw, Mark, Laughlin, Dennis, Delp, Thomas, Roth, Leonard, Sipershteyn, Vladimir, Zelczer, Al
• Primary Examiner(s): Norman; Marc E
• Application Number:
  US11/469,971
• Publication Number:
  US 20070063059A1
• Time in Patent Office: 1,463 Days
• Field of Search: 236/1.B, 236/49.3, 165/213, 165/217
• US Class Current: 236/1.00B
• 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 11/52 Indication arrangements, e.g. displays
• CPC Class Codes: F24F 11/63 Electronic processing
• CPC Class Codes: F24F 11/64 using pre-stored data
• CPC Class Codes: F24F 11/65 for selecting an operating mode
• CPC Class Codes: F24F 11/67 Switching between heating and cooling modes
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 11/86 by controlling compressors within refrigeration or heat pump circuits
• CPC Class Codes: F24F 2110/10 Temperature
• CPC Class Codes: F24F 2110/12 of the outside air
• CPC Class Codes: F24F 2110/20 Humidity
• CPC Class Codes: F24F 3/001 in which the air treatment in the central station takes place by means of a heat-pump or by means of a reversible cycle reversible cycle for humidifying and drying air F24F3/147

Abstract

A system and method to control environmental parameters of pre-defined zones within an environment using an electronic controller are disclosed. The system includes a non-proprietary electronic controller which enables a weighting value to be assigned to each zone within the environment. The electronic controller also detects any zone service calls from sensor devices associated with each of the zones and determines a cumulative weighting value in response to the detected zone service calls. The electronic controller selects an equipment staging combination from at least two possible equipment staging combinations in response to thermal capacity, and an air handler stage is selected in response to at least the cumulative zone weighting value.

Claims

1. A method to control environmental parameters of pre-defined zones within a first environment using a non-proprietary electronic controller, where each of said pre-defined zones has an associated duct work capacity, and where said non-proprietary electronic controller stores a weighting value for each of said pre-defined zones representative of said associated duct work capacity of each of said pre-defined zones, said method comprising:

said non-proprietary electronic controller detecting any zone service calls from sensor devices associated with each of said pre-defined zones;

said non-proprietary electronic controller transforming said detected zone service calls and said weighting value of each of said pre-defined zones associated with said detected zone service calls into a cumulative zone weighting value representative of a cumulative duct work capacity of said pre-defined zones associated with said detected zone service calls;

said non-proprietary electronic controller selecting an air handler stage from at least two possible air handler stages in response to at least said cumulative zone weighting value; and

said non-proprietary electronic controller activating said selected air handler stage.

2. The method of claim 1 further comprising said non-proprietary electronic controller selecting an equipment staging combination from at least two possible equipment staging combinations in response to at least one of a leaving air temperature (LAT) from said air handler and an outside air temperature (OAT) of a second environment which is external to said first environment.

3. The method of claim 2 wherein each of said at least two possible equipment staging combinations includes a unique, pre-defined combination of heat pump and/or auxiliary equipment stages that may be activated by said electronic controller for servicing said zones.

4. The method of claim 3 further comprising said non-proprietary electronic controller activating said equipment stages defined by said selected staging combination.

5. The method of claim 3 wherein said selected equipment staging combination includes a first stage of a heat pump, and said selected air handler stage includes a first lower speed stage of an air handler.

6. The method of claim 3 wherein said selected equipment staging combination includes a first and a second stage of a heat pump.

7. The method of claim 3 wherein said selected equipment staging combination includes a first and a second stage of a heat pump, and said selected air handler stage includes a second higher speed stage of an air handler.

8. The method of claim 3 wherein said selected equipment staging combination includes a first and a second stage of a heat pump and a first stage of an auxiliary heat source, and said selected air handler stage includes a second higher speed stage of an air handler.

9. The method of claim 3 wherein said selected equipment staging combination includes a first and a second stage of a heat pump and a first and a second stage of an auxiliary heat source, and said selected air handler stage includes a second higher speed stage of an air handler.

10. The method of claim 2 wherein said selected equipment staging combination is selected also in response to types of said zone service calls.

11. The method of claim 10 wherein said types of said zone service calls may include any of a heating call, a cooling call, a humidification call, a de-humidification call, and a fan-only call.

12. The method of claim 2 further comprising said non-proprietary electronic controller selecting a new equipment staging combination from said at least two possible equipment staging combinations in response to at least one of a new zone service call, a change in said outside air temperature (OAT), and a change in said leaving air temperature (LAT).

13. The method of claim 12 further comprising said non-proprietary electronic controller activating equipment stages defined by said selected new equipment staging combination.

14. The method of claim 13 further comprising said non-proprietary electronic controller activating the opening of dampers associated with said new zone service call.

15. The method of claim 1 further comprising said non-proprietary electronic controller opening air dampers associated with said zone service calls.

16. The method of claim 1 wherein said environmental parameters include at least one of temperature, humidity, and air flow.

17. The method of claim 1 wherein said sensor devices associated with each of said pre-defined zones includes at least one of a thermostat, a humidistat, and a de-humidistat.

18. The method of claim 1 wherein said weighting value for each of said pre-defined zones is assigned also based on a floor-space area associated with each of said zones.

19. The method of claim 1 wherein said weighting value for each of said pre-defined zones is assigned also based on a spatial volume associated with each of said zones.

20. The method of claim 1 wherein said zone service calls may include any of a heating call, a cooling call, a humidification call, a de-humidification call, and a fan-only call for any number of said pre-defined zones.

21. The method of claim 1 wherein said pre-defined zones are pre-defined also based on separate spatial volumes within said environment.

22. The method of claim 1 wherein said pre-defined zones are pre-defined also based on a time of day.

23. The method of claim 1 further comprising said non-proprietary electronic controller selecting a different air handler stage in response to at least one of a new zone service call and a completion of service to a previous zone service call.

24. The method of claim 23 further comprising said non-proprietary electronic controller activating said selected different air handler stage.

25. The method of claim 24 further comprising said non-proprietary electronic controller activating the opening and/or closing of dampers associated with said new zone service call and/or said completion of service.

26. The method of claim 1 wherein said non-proprietary electronic controller supports a set of functions including all of resistance heat lock-out, outdoor reset, outdoor temperature balance point, selectable O/B outputs, and discharge temperature controls.

27. The method of claim 1 further comprising:

manually selecting an emergency heat mode using one of said sensor devices associated with a first zone of said pre-defined zones; and

said non-proprietary electronic controller responding to said selecting of emergency heat by allowing emergency heat to be provided to all said zones.

28. The method of claim 1 further comprising said non-proprietary electronic controller automatically opening a humidifier damper, located between a humidifier on a forced air system and ductwork to the forced air system, in response to a humidification zone service call.

29. The method of claim 28 further comprising said non-proprietary electronic controller automatically closing said humidifier damper when servicing of said zone associated with said humidification zone service call is complete.

30. The method of claim 1 wherein one of said sensor devices associated with a first zone of said pre-defined zones comprises a complex heat pump thermostat.

31. The method of claim 1 wherein three of said sensor devices respectively associated with three zones of said pre-defined zones each comprise a simple heating/cooling thermostat.

32. A forced air system to control environmental parameters of pre-defined zones within a first environment, said system comprising:

an air handler providing at least two air handler stages; and

a non-proprietary electronic controller, wherein said non-proprietary electronic controller is capable of

(1) being used to assign a weighting value to each of said pre-defined zones within said environment based on at least duct work capacity for each said predefined zone;

(2) detecting any zone service calls originating from any of said pre-defined zones;

(3) determining a cumulative zone weighting value in response to said detected zone service calls; and

(4) selecting an air handler stage from said at least two air handler stages in response to at least said cumulative zone weighting value.

33. The system of claim 32 wherein said air handler is operationally connected to said non-proprietary electronic controller such that said non-proprietary electronic controller is capable of activating said selected air handler stage in response to said selecting an air handler stage.

34. The system of claim 33 wherein said non-proprietary electronic controller is capable of selecting an equipment staging combination from at least two possible equipment staging combinations in response to at least one of a leaving air temperature (LAT) from said air handler and an outside air temperature (OAT) of a second environment which is external to said first environment.

35. The system of claim 34 further comprising a heat pump operationally connected to said non-proprietary electronic controller such that said non-proprietary electronic controller may activate at least one stage of said heat pump in response to said selected equipment staging combination.

36. The system of claim 34 further comprising at least one auxiliary heating source operationally connected to said non-proprietary electronic controller such that said non-proprietary electronic controller may activate at least one stage of said at least one auxiliary heating source in response to said selected equipment staging combination.

37. The system of claim 34 wherein each of said at least two possible equipment staging combinations includes a unique, pre-defined combination of heat pump and/or auxiliary equipment stages that may be activated by said non-proprietary electronic controller.

38. The system of claim 34 wherein said non-proprietary electronic controller is capable of activating said stages defined by said selected equipment staging combination.

39. The system of claim 34 wherein one of said at least two possible equipment staging combinations includes a first stage of a heat pump, a first stage of an air handler.

40. The system of claim 34 wherein one of said at least two possible equipment staging combinations includes a first and a second stage of a heat pump, and one of said at least two possible air handler stages includes a first stage of an air handler.

41. The system of claim 34 wherein one of said at least two possible equipment staging combinations includes a first and a second stage of a heat pump, and one of said at least two possible air handler stages includes a second stage of an air handler.

42. The system of claim 34 wherein one of said at least two possible equipment staging combinations includes a first and a second stage of a heat pump and a first stage of an auxiliary heat source, and one of said at least two possible air handler stages includes a second stage of an air handler.

43. The system of claim 34 wherein one of said at least two possible equipment staging combinations includes a first and a second stage of a heat pump and a first and a second stage of an auxiliary heat source, and one of said at least two possible air handler stages includes a second stage of an air handler.

44. The system of claim 34 wherein said selected equipment staging combination is selected by said electronic controller also in response to types of said zone service calls.

45. The system of claim 44 wherein said types of said zone service calls may include any of a heating call, a cooling call, a humidification call, a de-humidification call, and a fan-only call.

46. The system of claim 34 wherein said non-proprietary electronic controller is capable of selecting a new equipment staging combination from said at least two possible equipment staging combinations in response to at least one of a new zone service call, a change in said outside air temperature (OAT), and a change in said leaving air temperature (LAT).

47. The system of claim 46 wherein said non-proprietary electronic controller is capable of activating corresponding stages defined by said selected new equipment staging combination.

48. The system of claim 47 wherein said non-proprietary electronic controller is capable of activating dampers to be opened which are associated with said new zone service call.

49. The system of claim 34 further comprising an outside air temperature (OAT) sensor operationally connected to said non-proprietary electronic controller.

50. The system of claim 34 further comprising a leaving air temperature (LAT) sensor operationally connected to said non-proprietary electronic controller.

51. The system of claim 32 further comprising sensor devices being associated with each of said pre-defined zones and being operationally connected to said non-proprietary electronic controller such that there is at least one of said sensor devices for each pre-defined zone to sense a present status of at least one of said environmental parameters and to make said zone service calls to said non-proprietary electronic controller.

52. The system of claim 51 wherein said sensor devices associated with each of said pre-defined zones includes at least one of a thermostat, a humidistat, and a de-humidistat.

53. The system of claim 51 wherein one of said sensor devices is associated with a first zone of said pre-defined zones and comprises a complex heat pump thermostat.

54. The system of claim 51 wherein three of said sensor devices is respectively associated with three zones of said pre-defined zones and each comprise a simple heating/cooling thermostat.

55. The system of claim 32 further comprising at least one air pump device operationally connected to said non-proprietary electronic controller such that said non-proprietary electronic controller may activate said air pump device to service at least one of said zones in response to any said detected zone service calls.

56. The system of claim 55 further comprising at least one air damper operationally connected to said air pump device such that said air pump device may pump air to open said at least one air damper in response to an activation signal from said non-proprietary electronic controller.

57. The system of claim 56 wherein said non-proprietary electronic controller is capable of activating the opening of air dampers associated with said zone service calls.

58. The system of claim 55 further comprising a humidifier operationally connected to said forced air system and a humidifier damper located between said humidifier and ductwork of said forced air system.

59. The system of claim 58 wherein said humidifier damper is operationally connected to said air pump device and wherein said non-proprietary electronic controller is capable of automatically opening said humidifier damper in response to a humidification zone service call.

60. The system of claim 32 wherein said environmental parameters include at least one of temperature, humidity, and air flow.

61. The system of claim 32 wherein said weighting value for each of said pre-defined zones is assigned also based on at least a floor-space area associated with each of said zones.

62. The system of claim 32 wherein said weighting value for each of said pre-defined zones is assigned also based on at least a spatial volume associated with each of said zones.

63. The system of claim 32 wherein said zone service calls may include any of a heating call, a cooling call, a humidification call, a de-humidification call, and a fan-only call for any number of said pre-defined zones.

64. The system of claim 32 wherein said pre-defined zones are pre-defined based on at least separate spatial volumes within said first environment.

65. The system of claim 32 wherein said pre-defined zones are pre-defined based on at least a time of day.

66. The system of claim 32 wherein said non-proprietary electronic controller includes a display device to aid an operator in manually selecting setting options which are pre-programmed into said non-proprietary electronic controller.

67. The system of claim 66 wherein said manual selecting includes the steps of:

powering up said electronic controller;

displaying a first set of options on said display device;

selecting at least one of said options from said first set of options using at least one switching device on said non-proprietary electronic controller;

displaying a second set of options on said display device; and

selecting at least one of said options from said second set of options using at least one switching device on said non-proprietary electronic controller.

68. The system of claim 67 wherein said manual selecting further includes the steps of:

displaying a third set of options on said display device; and

selecting at least one of said options from said third set of options using at least one switching device on said non-proprietary electronic controller.

69. The system of claim 32 wherein said non-proprietary electronic controller includes a USB port for interfacing to a personal computer (PC) or a home automation device.

70. The system of claim 69 wherein said electronic controller is capable of storing a history of operational data which may be read out of said electronic controller to said personal computer (PC) via said USB port.

71. The system of claim 69 wherein said non-proprietary electronic controller is capable of having a set of default setting options reloaded from said personal computer (PC) into said non-proprietary electronic controller via said USB port.

72. The system of claim 32 wherein said non-proprietary electronic controller is capable of supporting a set of functions including all of resistance heat lock-out, outdoor reset, outdoor temperature balance point, selectable O/B outputs, and discharge temperature controls.

73. A non-proprietary electronic controller for use in a forced air system to control environmental parameters of pre-defined zones within a first environment, where each of said pre-defined zones has an associated duct work capacity, and where said non-proprietary electronic controller stores a weighting value for each of said pre-defined zones representative of said associated duct work capacity of each of said pre-defined zones, wherein said non-proprietary electronic controller is capable of:

(1) detecting any zone service calls originating from any of said pre-defined zones;

(2) transforming said detected zone service calls and said weighting value of each of said pre-defined zones associated with said detected zone service calls into a cumulative zone weighting value representative of a cumulative duct work capacity of said pre-defined zones associated with said detected zone service calls;

(3) selecting an air handler stage from at least two possible air handler stages in response to at least said cumulative zone weighting value; and

(4) activating said selected air handler stage.

74. The non-proprietary electronic controller of claim 73 wherein said non-proprietary electronic controller is capable of selecting and activating an equipment staging combination from at least two possible equipment staging combinations in response to at least one of a leaving air temperature (LAT) from an air handler of said forced air system and an outside air temperature (OAT) of a second environment which is external to said first environment.

75. The non-proprietary electronic controller of claim 73 wherein said non-proprietary electronic controller is capable of supporting a set of functions including all of resistance heat lock-out, outdoor reset, outdoor temperature balance point, selectable O/B outputs, and discharge temperature controls.

76. The non-proprietary electronic controller of claim 73 wherein said non-proprietary electronic controller is capable of activating dampers of said forced air system in response to said zone service calls.

77. The non-proprietary electronic controller of claim 73 wherein said non-proprietary electronic controller is capable of staging heating and/or cooling equipment of said forced air system based on thermal capacity alone, and not just calls from said pre-defined zones.

78. The non-proprietary electronic controller of claim 73 wherein said non-proprietary electronic controller is capable of staging cooling and/or heating equipment of said forced air system on thermal capacity, based on at least a discharge temperature of air leaving an air handler of said forced air system.

79. The non-proprietary electronic controller of claim 77 wherein said non-proprietary electronic controller is capable of staging an air handler based on said cumulative zone weighting value, independent of said staging of said heating and/or cooling equipment of said forced air system.

80. The non-proprietary electronic controller of claim 73 wherein said non-proprietary electronic controller is capable of allowing emergency heat to be provided to all said zones when an emergency heat mode is selected.

81. The non-proprietary electronic controller of claim 73 wherein said zone service calls may include any of a heating call, a cooling call, a humidification call, a de-humidification call, and a fan-only call for any number of said pre-defined zones.