Method of advanced digital economization

• US 9,494,334 B2
• Filed: 03/15/2013
• Issued: 11/15/2016
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Pro Star Energy Solutions LLC
• Original Assignee: Transformative Wave Technologies LLC (Performance Mechanical Group)
• Inventors: Sipe, Justin James, Miller, Daniel E., Scott, Gerald B., Hellewell, Kenneth
• Primary Examiner(s): Laughlin, Nathan L
• Application Number:
  US13/844,158
• Publication Number:
  US 20140277759A1
• Time in Patent Office: 1,341 Days
• Field of Search: 700276-278
• US Class Current: 1/1
• CPC Class Codes: F24F 11/0001 for ventilation F24F11/30 takes precedence
• 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 11/38 Failure diagnosis
• CPC Class Codes: F24F 11/46 Improving electric energy efficiency or saving
• CPC Class Codes: F24F 11/52 Indication arrangements, e.g. displays
• 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 11/64 using pre-stored data
• CPC Class Codes: F24F 11/65 for selecting an operating mode
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 2011/0002 for admittance of outside air
• CPC Class Codes: F24F 2011/0006 using low temperature external supply air to assist cooling
• CPC Class Codes: F24F 2110/10 Temperature
• CPC Class Codes: F24F 2110/12 of the outside air
• CPC Class Codes: F24F 2140/00 Control inputs relating to system states
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence
• CPC Class Codes: G05B 2219/2614 HVAC, heating, ventillation, climate control
• CPC Class Codes: Y02B 30/54 Free-cooling systems

Abstract

A system and method for advanced digital economization for an HVAC system having an economizer. A digital processing unit is configured to open a damper of an economizer within a dead-band range that allows for preemptive cooling prior to a call for cooling. This economization strategy allows for free cooling (outside air) without having to pay energy costs for cooled (air-conditioned) air. The system and method can be used with or without demand control ventilation (DCV). The method also includes a “self-learning” strategy with outside air and return air sensor to regularly sense past economizer damper modifications and average out recent readings to help set the dead-band range. The method can include the ability to work in conjunction with a variable supply fan speed control, provide fault detection, self-correct, auto-configure, and report system status.

Claims

1. A method to reduce the energy usage of an HVAC system that provides one or more of the following functions:

heating, cooling, or ventilation to an indoor space within a building where the existing HVAC system provides heating when a call for heating is received and provides cooling when a call for cooling is received, as well as an economizer function tied to the ventilation function that provides fresh air and free cooling benefit to the indoor building space;

the method comprising;

providing a controller that can receive sensor data, receive input data from the existing HVAC system that indicates an operating mode, and can send data to the HVAC system for the purposes of operating and monitoring status of the ventilation, economizer, heating, or cooling functions;

providing an outside air sensor that is capable of sensing the outside air conditions and a supply air sensor that is capable of sensing the supply air conditions;

establishing a dead-band range for an HVAC system dead-band state wherein the dead-band range is based on optimum energy savings for free cooling benefit; and

modifying the economizer function of the HVAC system to provide free cooling benefit when the HVAC system is in the dead-band state prior to a call for cooling;

wherein the controller retains a set amount of past modified economizer functions established by the outside air sensor and averages the past modified economizer functions to create a self-learned set point for modifying the dead-band range from which the economizer function is modified, and

wherein the controller continues to monitor and update the set amount of past modified economizer functions and averages those past modified economizer functions to create a variable set point for modifying the dead-band range from which the economizer function is modified.

2. The method according to claim 1 wherein the controller is capable of communicating the status of the economizer function to an operator.

3. The method according to claim 1 wherein the controller further comprises fault detection to determine proper operation of the economizer system.

4. The method according to claim 1 wherein the controller further comprising auto-configuration.

5. The method according to claim 1 wherein the dead-band range is calculated using a time reference.

6. The method according to claim 1 wherein the controller further comprising self-correction routines.

7. The method according to claim 1 wherein the ventilation function is modulated between a fully closed and a fully opened position to maintain a specific supply air setpoint wherein the HVAC system is equipped with variable fan speed control;

and wherein the controller is capable of controlling or sensing the fan speed.

8. A method to reduce the energy usage of an HVAC system that provides one or more of the following functions:

heating, cooling, or ventilation to an indoor space within a building where the existing HVAC system provides heating when a call for heating is received and provides cooling when a call for cooling is received, as well as an economizer function tied to the ventilation function that provides fresh air and free cooling benefit to the indoor building space;

the method comprising;

providing a controller that can receive sensor data, receive input data from the existing HVAC system that indicates an operating mode, and can send data to the HVAC system for the purposes of operating and monitoring status of the ventilation, economizer, heating, or cooling functions;

providing an outside air sensor that is capable of sensing the outside air conditions and a supply air sensor that is capable of sensing the supply air conditions;

establishing a dead-band range for an HVAC system dead-band state wherein the dead-band range is based on optimum energy savings for free cooling benefit; and

modifying the economizer function of the HVAC system to provide free cooling benefit when the HVAC system is in the dead-band state prior to a call for cooling;

wherein the system also includes a return air sensor that senses return air conditions;

wherein the return air sensor is used to establish a dead-band range; and

wherein the controller retains a set amount of past modified economizer functions established by the return air sensor and averages the past modified economizer functions to create a self-learned set point for modifying the dead-band range from which the economizer function is modified; and

further wherein the controller continues to monitor and update the set amount of past modified economizer functions and averages those past modified economizer functions to create a variable set point for modifying the dead-band range from which the economizer function is modified.

9. A method to reduce the energy usage of an HVAC system that provides one or more of the following functions:

heating, cooling, or ventilation to an indoor space within a building where the existing HVAC system provides heating when a call for heating is received and provides cooling when a call for cooling is received, as well as an economizer function tied to the ventilation function that provides fresh air and free cooling benefit to the indoor building space;

the method comprising;

providing a controller that can receive sensor data, receive input data from the existing HVAC system that indicates an operating mode, and can send data to the HVAC system for the purposes of operating and monitoring status of the ventilation, economizer, heating, or cooling functions;

providing an outside air sensor that is capable of sensing the outside air conditions and a supply air sensor that is capable of sensing the supply air conditions;

establishing a dead-band range for an HVAC system dead-band state wherein the dead-band range is based on optimum energy savings for free cooling benefit; and

modifying the economizer function of the HVAC system to provide free cooling benefit when the HVAC system is in the dead-band state prior to a call for cooling;

wherein the system also includes a return air sensor that senses return air conditions; and

wherein the outside, return, and supply air sensors are used to verify economizer efficiency.

10. A method to reduce the energy usage of an HVAC system that provides one or more of the following functions:

heating, cooling, or ventilation to an indoor space within a building where the existing HVAC system provides heating when a call for heating is received and provides cooling when a call for cooling is received, as well as an economizer function tied to the ventilation function that provides fresh air and free cooling benefit to the indoor building space;

the method comprising;

providing a controller that can receive sensor data, receive input data from the existing HVAC system that indicates an operating mode, and can send data to the HVAC system for the purposes of operating and monitoring status of the ventilation, economizer, heating, or cooling functions;

providing an outside air sensor that is capable of sensing the outside air conditions and a supply air sensor that is capable of sensing the supply air conditions;

establishing a dead-band range for an HVAC system dead-band state wherein the dead-band range is based on optimum energy savings for free cooling benefit; and

modifying the economizer function of the HVAC system to provide free cooling benefit when the HVAC system is in the dead-band state prior to a call for cooling;

wherein the system also includes a return air sensor that senses return air conditions and further comprises a mixed air sensor; and

wherein the outside, return, and mixed air sensors are used to verify economizer efficiency.