HVAC system and zone control unit

• US 9,459,015 B2
• Filed: 11/30/2010
• Issued: 10/04/2016
• Est. Priority Date: 05/06/2005
• Status: Active Grant

• Current Assignee: John Chris Karamanos
• Original Assignee: John Chris Karamanos
• Inventors: Karamanos, John Chris, Stuck, Douglas Edward
• Primary Examiner(s): Ruby, Travis
• Application Number:
  US12/956,668
• Publication Number:
  US 20110155354A1
• Time in Patent Office: 2,135 Days
• Field of Search: 165/121, 165/47, 165/300, 165/67, 294/28, 298/900.3, 297/26
• US Class Current: 1/1
• CPC Class Codes: F24F 1/04 Arrangements for portability
• CPC Class Codes: F24F 13/02 Ducting arrangements
• CPC Class Codes: F24F 13/0245 Manufacturing or assembly of air ducts; Methods therefor
• CPC Class Codes: F24F 13/32 Supports for air-conditioning, air-humidification or ventilation units
• CPC Class Codes: F24F 3/052 Multiple duct systems, e.g. systems in which hot and cold air are supplied by separate circuits from the central station to mixing chambers in the spaces to be conditioned
• 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
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

Methods for installing one or more heating, ventilation, and air conditioning (HVAC) units in an HVAC system include the steps of securing inlet and outlet piping assemblies of the HVAC unit to a bracket, coupling a thermal transfer mechanism of the HVAC unit with the inlet piping assembly and the outlet piping assembly, fluidly coupling a water pump with the thermal transfer mechanism, the inlet piping assembly, or the outlet piping assembly, mounting the HVAC unit by mounting the bracket to the HVAC system, and maintaining alignment of the HVAC unit thermal transfer mechanism, the HVAC unit inlet piping assembly, and the HVAC unit outlet piping assembly while mounting the HVAC unit in the HVAC system. An HVAC unit can include a thermal transfer mechanism, inlet and outlet piping assemblies, a water pump, and a bracket.

Claims

1. A method of installing a heating, ventilation, and air conditioning (HVAC) unit in an HVAC system, the method comprising:

(a) obtaining an HVAC unit manufactured by providing a bracket with mounting features configured to support an inlet piping assembly and an outlet piping assembly;

securing an inlet piping assembly of the HVAC unit to the bracket at a mounting location of the inlet piping assembly;

securing an outlet piping assembly of the HVAC unit to the bracket at a mounting location of the outlet piping assembly;

coupling a thermal transfer mechanism of the HVAC unit with the inlet piping assembly and the outlet piping assembly, wherein at least a portion of the thermal transfer mechanism is positioned along an air flow path disposed within a casing of the HVAC unit and wherein at least a portion of the inlet piping assembly and at least a portion of the outlet piping assembly are disposed exterior to the casing;

mounting a water pump directly on the HVAC unit to provide an embedded pump mechanism on the HVAC unit that is in fluid communication with at least one of the thermal transfer mechanism, the inlet piping assembly, or the outlet piping assembly, the water pump disposed along a fluid path between the mounting location of the inlet piping assembly and the mounting location of the outlet piping assembly;

positioning a fan along the airflow path within the casing;

subsequent to securing the inlet and outlet piping assemblies of the HVAC unit to the bracket, coupling the thermal transfer mechanism of the HVAC unit with the inlet and outlet piping assemblies, and fluidly coupling the water pump along the fluid path between the inlet piping assembly and the outlet piping assembly; and

(b) installing the HVAC unit to the HVAC system by mounting the bracket to the HVAC system; and

maintaining alignment of the HVAC unit thermal transfer mechanism, the HVAC unit inlet piping assembly, and the HVAC unit outlet piping assembly while mounting the HVAC unit in the HVAC system.

2. The method of claim 1, wherein the water pump comprises a variable rate water pump.

3. The method of claim 1, wherein the water pump comprises a variable rate water pump having an electronically commutated motor.

4. The method of claim 1, wherein the water pump comprises a variable rate water pump operable between about 0 and about 15 gallons per minute.

5. The method of claim 1, wherein the water pump is controlled by pulse width modulation.

6. The method of claim 1, wherein the water pump is controlled by a signal of between about 0 volts and about 10 volts.

7. The method of claim 1, wherein the fan comprises a variable rate fan.

8. The method of claim 1, wherein the fan comprises a variable rate fan having an electronically commutated motor.

9. The method of claim 1, wherein the thermal transfer mechanism, the inlet piping assembly, the outlet piping assembly, and the water pump are pre-fabricated, sealed, and pressurized prior to shipment to a construction site for installation.

10. A method of preparing multiple heating, ventilation, and air conditioning (HVAC) units for delivery to a construction site for installation in an HVAC system, the method comprising:

coupling a first thermal transfer mechanism with a first inlet piping assembly and a first outlet piping assembly, the first inlet piping assembly configured to supply fluid to the first thermal transfer mechanism and the first outlet piping assembly configured to receive fluid from the first thermal transfer mechanism;

mounting a first water pump with a member selected from the group consisting of the first thermal transfer mechanism, the first inlet piping assembly, and the first outlet piping assembly to provide an embedded first water pump;

placing at least a portion of the first thermal transfer mechanism along a first air flow path within a first casing, such that at least a portion of the first inlet piping assembly and at least a portion of the first outlet piping assembly are disposed exterior to the first casing;

positioning a first fan along the first airflow path within the first casing;

coupling a first bracket with the first casing, the first inlet piping assembly at a mounting location of the first inlet piping assembly, and the first outlet piping assembly at a mounting location of the first outlet piping assembly, so as to maintain the first casing, the first inlet piping assembly, and the first outlet piping assembly as components of a first heating, ventilation, and air conditioning (HVAC) unit in positional relationship, the water pump disposed along a fluid path between the mounting location of the first inlet piping assembly and the mounting location of the first outlet piping assembly;

coupling a second thermal transfer mechanism with a second inlet piping assembly and a second outlet piping assembly, the second inlet piping assembly configured to supply fluid to the second thermal transfer mechanism and the second outlet piping assembly configured to receive fluid from the second thermal transfer mechanism;

mounting a second water pump with a member selected from the group consisting of the second thermal transfer mechanism, the second inlet piping assembly, and the second outlet piping assembly to provide an embedded second water pump;

placing at least a portion of the second thermal transfer mechanism along a second air flow path within a second casing, such that at least a portion of the second inlet piping assembly and at least a portion of the second outlet piping assembly are disposed exterior to the second casing;

positioning a second fan along the second airflow path within the second casing; and

coupling a second bracket with the second casing, the second inlet piping assembly at a mounting location of the second inlet piping assembly, and the second outlet piping assembly at a mounting location of the second outlet piping assembly, so as to maintain the second casing, the second inlet piping assembly, and the second outlet piping assembly as components of a second heating, ventilation, and air conditioning (HVAC) unit in positional relationship the water pump disposed along a fluid path between the mounting location of the second inlet piping assembly and the mounting location of the second outlet piping assembly.

11. The method of claim 10, wherein the water pump comprises a variable rate water pump.

12. The method of claim 10, wherein the water pump comprises a variable rate water pump having an electronically commutated motor.

13. The method of claim 10, wherein the water pump comprises a variable rate water pump operable between about 0 and about 15 gallons per minute.

14. The method of claim 10, wherein the water pump is controlled by pulse width modulation.

15. The method of claim 10, wherein the water pump is controlled by a signal of between about 0 volts and about 10 volts.

16. The method of claim 10, wherein the fan comprises a variable rate fan.

17. The method of claim 10, wherein the fan comprises a variable rate fan having an electronically commutated motor.

18. The method of claim 10, wherein the first thermal transfer mechanism, the first inlet piping assembly, the first outlet piping assembly, and the first water pump are pre-fabricated, sealed, and pressurized prior to shipment to a construction site for installation.

19. A heating, ventilation, and air conditioning (HVAC) unit for transporting fluid in an (HVAC) system, the HVAC unit comprising:

a thermal transfer mechanism;

an inlet piping assembly coupled with the thermal transfer mechanism for supplying fluid to the thermal transfer mechanism;

an outlet piping assembly coupled with the thermal transfer mechanism for receiving fluid from the thermal transfer mechanism;

a water pump coupled to a member selected from the group consisting of the thermal transfer mechanism, the inlet piping assembly, and the outlet piping assembly to provide an integrated pump mounted on the HVAC unit;

a bracket that maintains the thermal transfer mechanism, the inlet piping assembly, and the outlet piping assembly in positional relationship,

wherein the water pump is disposed along a fluid path between a first mounting location between the inlet piping assembly and the bracket and a second mounting location between the outlet piping assembly and the bracket;

a casing defining an airflow path; and

a fan disposed along the airflow path within the casing;

wherein at least a portion of the thermal transfer mechanism is disposed along the air flow path within the casing, at least a portion of the inlet piping assembly and at least a portion of the outlet piping assembly are disposed exterior to the casing, and at least a portion of the bracket is disposed exterior to the casing.

20. The HVAC unit of claim 19, wherein the water pump comprises a variable rate water pump having an electronically commutated motor.

21. The HVAC unit of claim 19, wherein the water pump comprises a variable rate water pump operable between about 0 and about 15 gallons per minute.

22. The HVAC unit of claim 19, wherein the fan comprises a variable rate fan having an electronically commutated motor.

23. The HVAC unit of claim 19, wherein the thermal transfer mechanism, the inlet piping assembly, the outlet piping assembly, and the water pump are pre-fabricated, sealed, and pressurized prior to shipment to a construction site for installation.

27. The method of claim 22, wherein the first thermal transfer mechanism, the first inlet piping assembly, the first outlet piping assembly, and the first flow control device are pre-fabricated, sealed, and pressurized prior to shipment to a construction site for installation.

24. A method of installing a heating, ventilation, and air conditioning (HVAC) unit in an HVAC system, the method comprising:

(a) obtaining an HVAC unit manufactured by providing a bracket with mounting features configured to support an inlet piping assembly and an outlet piping assembly;

securing an inlet piping assembly of the HVAC unit to the bracket at a mounting location of the inlet piping assembly;

securing an outlet piping assembly of the HVAC unit to the bracket at a mounting location of the outlet piping assembly;

coupling a thermal transfer mechanism of the HVAC unit with the inlet piping assembly and the outlet piping assembly, wherein at least a portion of the thermal transfer mechanism is positioned along an air flow path disposed within a casing of the HVAC unit and wherein at least a portion of the inlet piping assembly and at least a portion of the outlet piping assembly are disposed exterior to the casing;

mounting a flow control device directly to the HVAC unit to provide an embedded flow control device on the HVAC unit that is in fluid communication with at least one of the thermal transfer mechanism, the inlet piping assembly, or the outlet piping assembly, wherein the flow control device comprises a member selected from the group consisting of a pump and a control valve and wherein the water pump disposed along a fluid path between the mounting location of the inlet piping assembly and the mounting location of the outlet piping assembly;

positioning a fan along the airflow path within the casing;

subsequent to securing the inlet and outlet piping assemblies of the HVAC unit to the bracket, coupling the thermal transfer mechanism of the HVAC unit with the inlet and outlet piping assemblies, and fluidly coupling the flow control device to along the fluid path between the inlet piping assembly and the outlet piping assembly; and

(b) installing the HVAC unit to the HVAC system by mounting the bracket to the HVAC system; and

maintaining alignment of the HVAC unit thermal transfer mechanism, the HVAC unit inlet piping assembly, and the HVAC unit outlet piping assembly while mounting the HVAC unit in the HVAC system.

25. The method of claim 24, wherein the thermal transfer mechanism, the inlet piping assembly, the outlet piping assembly, and the flow control device are pre-fabricated, sealed, and pressurized prior to shipment to a construction site for installation.

26. A method of preparing multiple heating, ventilation, and air conditioning (HVAC) units for delivery to a construction site for installation in an HVAC system, the method comprising:

coupling a first thermal transfer mechanism with a first inlet piping assembly and a first outlet piping assembly, the first inlet piping assembly configured to supply fluid to the first thermal transfer mechanism and the first outlet piping assembly configured to receive fluid from the first thermal transfer mechanism;

mounting a first flow control device with a member selected from the group consisting of the first thermal transfer mechanism, the first inlet piping assembly, and the first outlet piping assembly, wherein the first flow control device comprises a member selected from the group consisting of a pump and a control valve to provide an embedded first flow control device;

placing at least a portion of the first thermal transfer mechanism along a first air flow path within a first casing, such that at least a portion of the first inlet piping assembly and at least a portion of the first outlet piping assembly are disposed exterior to the first casing;

positioning a first fan along the first airflow path within the first casing;

coupling a first bracket with the first casing, the first inlet piping assembly at a mounting location of the first inlet piping assembly, and the first outlet piping assembly at a mounting location of the first outlet piping assembly, so as to maintain the first casing, the first inlet piping assembly, and the first outlet piping assembly as components of a first heating, ventilation, and air conditioning (HVAC) unit in positional relationship, the flow control device disposed along a fluid path between the mounting location of the first inlet piping assembly and the mounting location of the first outlet piping assembly;

coupling a second thermal transfer mechanism with a second inlet piping assembly and a second outlet piping assembly, the second inlet piping assembly configured to supply fluid to the second thermal transfer mechanism and the second outlet piping assembly configured to receive fluid from the second thermal transfer mechanism;

mounting a second flow control device with a member selected from the group consisting of the second thermal transfer mechanism, the second inlet piping assembly, and the second outlet piping assembly, wherein the second flow control device comprises a member selected from the group consisting of a pump and a control valve to provide an embedded second flow control device;

placing at least a portion of the second thermal transfer mechanism along a second air flow path within a second casing, such that at least a portion of the second inlet piping assembly and at least a portion of the second outlet piping assembly are disposed exterior to the second casing;

positioning a second fan along the second airflow path within the second casing; and

coupling a second bracket with the second casing, the second inlet piping assembly at a mounting location of the second inlet piping assembly, and the second outlet piping assembly at a mounting location of the second outlet piping assembly, so as to maintain the second casing, the second inlet piping assembly, and the second outlet piping assembly as components of a second heating, ventilation, and air conditioning (HVAC) unit in positional relationship, the flow control device disposed along a fluid path between the mounting location of the second inlet piping assembly and the mounting location of the second outlet piping assembly.

28. A heating, ventilation, and air conditioning (HVAC) unit for transporting fluid in an (HVAC) system, the HVAC unit comprising:

a thermal transfer mechanism;

an inlet piping assembly coupled with the thermal transfer mechanism for supplying fluid to the thermal transfer mechanism;

an outlet piping assembly coupled with the thermal transfer mechanism for receiving fluid from the thermal transfer mechanism;

a flow control device coupled to a member selected from the group consisting of the thermal transfer mechanism, the inlet piping assembly, and the outlet piping assembly to provide an integrated flow control device mounted on the HVAC unit, wherein the flow control device comprises a member selected from the group consisting of a pump and a control valve;

a bracket that maintains the thermal transfer mechanism, the inlet piping assembly, and the outlet piping assembly in positional relationship, wherein the flow control device is disposed along a fluid path between a first mounting location between the inlet piping assembly and the bracket and a second mounting location between the outlet piping assembly and the bracket;

a casing defining an airflow path; and

a fan disposed along the airflow path within the casing;

wherein at least a portion of the thermal transfer mechanism is disposed along the air flow path within the casing, at least a portion of the inlet piping assembly and at least a portion of the outlet piping assembly are disposed exterior to the casing, and at least a portion of the bracket is disposed exterior to the casing.

29. The HVAC unit of claim 28, wherein the thermal transfer mechanism, the inlet piping assembly, the outlet piping assembly, and the flow control device are pre-fabricated, sealed, and pressurized prior to shipment to a construction site for installation.