Energy reducing retrofit method and apparatus for a constant volume HVAC system

• US 9,043,034 B2
• Filed: 12/08/2014
• Issued: 05/26/2015
• Est. Priority Date: 08/20/2009
• Status: Active Grant

• Current Assignee: Pro Star Energy Solutions LLC
• Original Assignee: Transformative Wave Technologies LLC (Performance Mechanical Group)
• Inventors: Miller, Danny, Sipe, Justin
• Primary Examiner(s): Fennema, Robert
• Assistant Examiner(s): Norton, Jennifer L
• Application Number:
  US14/563,941
• Publication Number:
  US 20150094864A1
• Time in Patent Office: 169 Days
• Field of Search: 700/276, 621/86, 165/201, 236/44.C, 236/44.R, 236/49.3, 454/239, 454/256, 454/333
• US Class Current: 700/276
• 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 11/58 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 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 2011/0006 using low temperature external supply air to assist cooling
• CPC Class Codes: F24F 2110/20 Humidity
• CPC Class Codes: F24F 2110/50 Air quality properties
• CPC Class Codes: F24F 2110/70 Carbon dioxide
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: G05B 19/05 Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
• CPC Class Codes: G05B 2219/1133 Sensor actuator, asi, bus, network
• CPC Class Codes: G05B 2219/25289 Energy saving, brown out, standby, sleep, powerdown modus for microcomputer
• CPC Class Codes: G05B 2219/2614 HVAC, heating, ventillation, climate control
• CPC Class Codes: G05D 23/1919 characterised by the type of controller
• CPC Class Codes: G05D 7/0676 by action on flow sources G05D7/0688, G05D7/0694 take precedence
• CPC Class Codes: H04L 67/12 specially adapted for proprietary or special-purpose networking environments, e.g. medical networks, sensor networks, networks in vehicles or remote metering networks
• CPC Class Codes: H04L 67/125 involving control of end-device applications over a network
• CPC Class Codes: Y02B 30/54 Free-cooling systems
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating
• CPC Class Codes: Y02B 30/90 : Passive houses; Double facade technology

Abstract

An energy-reducing method and apparatus for retrofitting a single zone, constant volume HVAC system, with or without an economizer, that provides heating, cooling, and ventilation to occupants within a building space. The present invention includes the introduction of a programmable logic controller and variable frequency drive (VFD) that takes control of the existing fan, heating, cooling, and optional economizer operation. The reduction of the fan speed in the ventilation mode when the 100% operation is not needed saves significant energy of the existing constant volume HVAC system where the fan motor is designed to run 100% of the time.

Claims

1. A method for reducing energy consumption comprising retrofitting a preexisting single zone constant volume HVAC system that provides one or more of the following:

heating, cooling, or ventilation to an indoor space within a single zone of a building, wherein the indoor space has at least partial occupancy, and the heating, cooling, or ventilation is controlled and operable from a range of not operating to a maximum operation based on preset conditions or on occupancy command, and wherein the preexisting HVAC system comprises a fan, a fan motor associated with the fan, a thermostatic device that references temperature of the indoor space, heating or cooling equipment having equipment control terminations, the method further comprising;

providing a programmable logic controller to receive input from the preexisting thermostatic device and send heating, cooling, and ventilation instructions to the preexisting fan motor to actuate the preexisting fan to ventilate the indoor space within the single zone of the building, and the preexisting heating and/or cooling equipment to send heat or cooling to the indoor space;

operably connecting the programmable logic controller to the preexisting equipment control terminations;

providing a variable frequency drive (VFD), controlled by the programmable logic controller, and operably connecting the VFD to the preexisting fan motor;

operating the preexisting HVAC system in a ventilation mode and a heating or cooling mode, wherein all said modes are controlled by the programmable logic controller; and

operating the preexisting fan motor at a reduced speed during the ventilation mode when less than maximum operation in the ventilation mode is required.

2. The method according to claim 1 wherein the preexisting fan motor is operated at a reduced speed during the heating or cooling mode.

3. The method according to claim 2 wherein the preexisting fan speed is reduced in the range of 10% to 90% in the ventilation mode.

4. The method according to claim 2 wherein the preexisting fan speed is reduced in the range of 1%-30% in the heating and/or cooling mode.

5. The method according to claim 1 further comprising providing an occupancy sensor to determine occupancy levels within the indoor space and sending the sensed occupancy level to the programmable logic controller;

and operating the preexisting fan motor at a reduced speed during the ventilation mode when the occupancy level requires less than maximum operation in the ventilation mode.

6. The method according to claim 5 wherein the fan speed is reduced in the range of 10% to 90% in the ventilation mode in response to the sensed occupancy needs.

7. The method according to claim 1 wherein the programmable logic controller and VFD are incorporated into a single unit.

8. The method according to claim 1 further comprising providing a central processor and an interconnection in order to network the programmable logic controller with one or more additional controllers.

9. The method according to claim 8 wherein the interconnection is wireless.

10. The method according to claim 1 further comprising providing fault detection.

26. The method according to claim 10 wherein providing fault detection further includes detection of fan fault, heat/cool (temperature-based) fault, and energy consumption fault.

11. A method reducing energy consumption comprising retrofitting a preexisting single zone constant volume HVAC system that provides heating, cooling, or ventilation to an indoor space within a single zone of a building, wherein the indoor space has at least partial occupancy, and the heating, cooling, or ventilation is controlled and operable from a range of not operating to a maximum operation based on preset conditions or on occupancy command, and wherein the preexisting HVAC system comprises a fan, a fan motor associated with the fan, a thermostatic device that references temperature of the indoor space, heating or cooling equipment having equipment control terminations, and an economizer comprising at least one outside air damper and one return air damper with an associated damper actuator, the method comprising:

providing a programmable logic controller to receive input from the preexisting thermostatic device and send instructions to the preexisting fan motor to actuate the preexisting fan to ventilate the indoor space within the single zone of the building (ventilation mode), and the preexisting heating or cooling equipment to send heat (heating mode) or cooling (cooling mode) to the indoor space, and the preexisting economizer to actuate the preexisting damper actuator (economizer mode);

operably connecting the programmable logic controller to the preexisting equipment control terminations;

providing a variable frequency drive (VFD), controlled by the programmable logic controller, and operably connecting the VFD to the preexisting fan motor;

providing an input sensor and an output sensor to sense respective outside air condition and return economizer air and that the sensors communicate their sensed conditions to the programmable logic controller;

operating the preexisting fan motor at a reduced speed during the ventilation mode less than maximum operation in the ventilation mode is required;

operating the preexisting fan motor at a reduced speed during the heating and/or cooling mode; and

operating the preexisting HVAC system in the ventilation mode the heating and/or cooling mode and the economizer mode, wherein all said modes are controlled by the programmable logic controller.

12. The method according to claim 11 wherein further energy savings are gained by the operation of the preexisting economizer to bring in outside air through the preexisting outside air damper in response to the monitoring of outside air and return air for cooling operations when the outside air temperature is less than the temperature of the indoor space.

13. The method according to claim 11 further comprising:

providing an occupancy sensor to determine occupancy levels within the indoor space and sending the occupancy level to the programmable logic controller for at least the ventilation mode and the heating and/or cooling mode; and

operating the preexisting fan motor at a reduced speed during the ventilation mode when the occupancy level requires less than maximum operation in the ventilation mode.

14. The method according to claim 13 wherein further energy savings are gained by closing the at least one preexisting outside air damper during the heating mode if the occupancy sensor indicates that the indoor space in unoccupied.

15. The method according to claim 11 wherein further energy savings are gained by integrating operation of the preexisting economizer and preexisting cooling equipment.

16. The method according to claim 11 wherein the fan speed is reduced in the range of 10% to 90% in the ventilation mode.

17. The method according to claim 16 wherein the fan speed is reduced in the range of 1%-30% in the heating or cooling mode.

18. The method according to claim 11 wherein the programmable logic controller is responsive to one of the following:

temperature, enthalpy, or dew point in the economizer mode.

19. The method according to claim 11 wherein the programmable logic controller and VFD are incorporated into a single unit.

20. The method according to claim 11 further comprising providing a central processor and an interconnection in order to network the programmable logic controller with one or more additional controllers.

21. The method according to claim 20 wherein the interconnection is wireless.

22. The method according to claim 11 further comprising providing fault detection.

23. The method according to claim 22 wherein providing fault detection further includes detection of fan fault, heat/cool (temperature-based) fault, and energy consumption fault.

24. The method according to claim 23 wherein the fan fault and heat/cool (temperature-based) fault detection are interconnected and the fan fault detection is run first and then the heat/cool (temperature-based) fault detection is run, and wherein the energy consumption fault detection is independent of the fan fault and the heat/cool (temperature-based) fault detection.

25. The method according to claim 24 wherein the energy consumption fault detection is run continuously.