U.S. patent application number 11/619535 was filed with the patent office on 2007-11-15 for limited loss laminar flow dampers for heating, ventilation, and air conditioning (hvac) systems.
Invention is credited to John C. Karamanos.
Application Number | 20070262162 11/619535 |
Document ID | / |
Family ID | 38228967 |
Filed Date | 2007-11-15 |
United States Patent
Application |
20070262162 |
Kind Code |
A1 |
Karamanos; John C. |
November 15, 2007 |
LIMITED LOSS LAMINAR FLOW DAMPERS FOR HEATING, VENTILATION, AND AIR
CONDITIONING (HVAC) SYSTEMS
Abstract
HVAC devices, systems, and methods include dampers for
controlling the flow of air or other gasses through an HVAC duct,
often while inhibiting turbulence within the duct or pressure loss
within the duct. Embodiments of such dampers may employ a two-part
damper arrangement. In many embodiments, flow will travel through
the middle of the damper uniformly and with a laminar flow. One or
more small, relatively unobtrusive sensor (optionally being
wireless) can be included for controlling operation of the damper,
the sensor(s) optionally measuring the distance between damper
elements, sound, air flow, or the like, with such sensor(s)/damper
combination inhibiting inadvertent pressure drop and turbulence in
flows through the damper. The damper elements may optionally
comprise airfoil cross-sections, with alternative dampers having a
resilient helical configuration that can choke down flow by
inducing a vortex in the flow, allowing static pressure regain to
occur within the duct system.
Inventors: |
Karamanos; John C.; (San
Jose, CA) |
Correspondence
Address: |
TOWNSEND AND TOWNSEND AND CREW, LLP
TWO EMBARCADERO CENTER
EIGHTH FLOOR
SAN FRANCISCO
CA
94111-3834
US
|
Family ID: |
38228967 |
Appl. No.: |
11/619535 |
Filed: |
January 3, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60756037 |
Jan 3, 2006 |
|
|
|
Current U.S.
Class: |
236/49.3 |
Current CPC
Class: |
F24F 2110/30 20180101;
F24F 13/1413 20130101 |
Class at
Publication: |
236/049.3 |
International
Class: |
F24F 7/00 20060101
F24F007/00 |
Claims
1. A damper assembly for use in a heating, ventilation, and air
conditioning (HVAC) system, the assembly comprising: a casing
having an inlet and an outflow with a flow direction extending
therebetween; a first damper member movably disposed within the
casing; and a second damper member movably disposed within the
casing; the damper members having cross-sections and movable
between an open flow configuration and a restricted flow
configuration such that laminar flow is maintained as the flow is
restricted.
2. The assembly of claim 1, further comprising a damper assembly
controller coupled to the damper members.
3. The assembly of claim 1, further comprising a flow sensor
coupled to the damper members, wherein the flow sensor measures
pressure at less than 5 locations across the dampers.
4. The assembly of claim 1, further comprising a first sensor
coupled with the first damper member, wherein the first sensor
detects an orientation of the first damper member relative to the
casing.
5. The assembly of claim 4, wherein the first sensor is disposed
near a trailing end of the first damper member.
6. The assembly of claim 1, further comprising a first sensor
coupled with the first damper member, wherein the first sensor
detects an orientation of the first damper member relative to the
second damper member.
7. The assembly of claim 1, further comprising an air stop.
8. The assembly of claim 1, wherein the first damper member
comprises a trailing end and the second damper member comprises a
trailing end, and the first damper member trailing end and the
second damper member trailing end are configured to be moved toward
each other when the assembly is moved toward the restricted flow
configuration.
9. A damper assembly for use in a heating, ventilation, and air
conditioning (HVAC) system, the assembly comprising: a casing
having an inlet and an outflow with a flow direction extending
therebetween; and a damper member disposed within the casing, the
damper member comprising a helical body deformable between an open
flow configuration and a restricted flow configuration.
10. The assembly of claim 9, wherein the damper in at least one
configuration has a shape suitable for inducing a vortex in a flow
within the casing.
11. A method of controlling a fluid flow in a heating, ventilation,
and air conditioning (HVAC) system, comprising: flowing a fluid
through a casing inlet toward a casing outlet; flowing the fluid
across a plurality of damper members disposed within the casing;
restricting an amount of the fluid passing through the casing by
actuating a first damper member; and maintaining a laminar flow
within the fluid during the actuation of the first damper
member.
12. The method of claim 11, further comprising sensing an
orientation of the first damper member.
13. The method of claim 11, further comprising sensing a pressure
within the casing.
14. The method of claim 11, wherein restricting the amount of fluid
passing through the casing comprises actuating a second damper
member.
15. The method of claim 14, further comprising maintaining the
laminar flow during actuation of the second damper member.
16. The method of claim 14, further comprising sensing an
orientation of the second damper member.
17. The method of claim 14, further comprising sensing an
orientation of the second damper member relative to the first
damper member.
18. The method of claim 14, further comprising sensing an
orientation of the second damper member relative to the casing.
19. The method of claim 14, wherein a cross section of the first
damper member comprises an aerodynamic profile and a cross section
of the second damper member comprises an aerodynamic profile.
20. The method of claim 14, further comprising sensing a distance
between the first damper member and the second damper member.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority from U.S.
Provisional Patent Application No. 60/756,037 filed Jan. 3, 2006
(Attorney Docket No. 025920-000500US). This application is related
to U.S. patent application Ser. No. 11/429,418 filed May 5, 2006
(Attorney Docket No. 025920-000120US), which claims the benefit of
U.S. Patent Application No. 60/678,695 filed May 6, 2005 (Attorney
Docket No. 025920-000100US) and U.S. Patent Application No.
60/755,976 filed Jan. 3, 2006 (Attorney Docket No. 025920-00011US);
and to U.S. patent application Ser. No. 11/180,310 filed Jul. 12,
2005 (Attorney Docket No. 025920-000210US), which is a continuation
of U.S. Pat. No. 6,951,324 (Attorney Docket No. 025920-000200US);
and to U.S. patent application Ser. No. 10/857,211 filed May 24,
2004 (Attorney Docket No. 025920-000300US); and to U.S. patent
application Ser. No. 10/860,573 filed Jun. 2, 2004 (Attorney Docket
No. 025920-000400US). This application is also related to U.S.
Patent Publication No. 2003/0171092. The entire contents of each of
these applications and their priority filings is incorporated
herein by reference for all purposes.
BACKGROUND OF THE INVENTION
[0002] The present disclosure relates to methods, systems and
apparatuses for heating, ventilation, and air conditioning ("HVAC")
systems and, more particularly to limited loss and/or laminar flow
dampers for such systems.
[0003] In general, HVAC systems control the temperature and
humidity of indoor air. In most HVAC systems, air is drawn in,
filtered, cooled and dehumidified or heated and humidified, and
then delivered to an air conditioned space. The greatest portion of
incoming air is drawn from the air conditioned space for
recirculation through the HVAC system. HVAC system includes fans
and ductwork for moving conditioned air to where it is needed while
passing it through cooling and/or a heating sections of the
ductwork.
[0004] One risk which must be addressed in designing and operating
HVAC systems is that of biological contamination by bacteria,
molds, and viruses. In recent years, biological problems in indoor
environments have received considerable attention. Most frequently,
molds, bacteria and/or virus grow wherever water collects in a HVAC
systems ductwork, such as at its cooling sections.
[0005] Poor indoor air quality ("IAQ") and the spread of infectious
disease through a HVAC system, at a minimum, can reduce worker
productivity and increase absenteeism. Even more alarming is the
potential liability for illnesses suffered by workers due to poor
IAQ. The Legionnaires' disease outbreak in Philadelphia in 1976, is
probably the most publicized instance of illness caused by poor
IAQ. Even if contamination by molds and bacteria doesn't affect
workers, their growth within HVAC system equipment creates
maintenance problems which are very costly to correct. Left
uncorrected, these problems exacerbate and, at a minimum,
eventually reduce system's heat transfer efficiency.
[0006] HVAC systems in residential, commercial, education and
research buildings usually include metallic pipes, hollow composite
materials such as tubes, and the like. The systems are typically
supported from and between floor or ceiling joists. The HVAC system
typically includes a primary or main duct. A series of smaller
branch ducts which extend from the main duct are mounted between
adjacent floor or ceiling joists. Such main and branch ducts are
normally supported by metal hangers located between the joists.
Often the branch ducts include pipes and conduit lines for
transporting liquid or gas which are suspended from ceiling joists
or an adjacent wall typically with Unistrut.RTM., threaded rod,
couplings, and various hanger brackets.
[0007] Piping and conduits that supply gas and/or liquids within
buildings require careful preparation. Builders or contractors
typically use ladders or scaffolding to reach areas where piping is
routed so installation may be cumbersome. Occasionally the pipe or
conduits are prepared on the ground and installed by ladder as more
complete assemblies. Pipe and conduit assemblies prepared on the
ground or a floor of a building under construction are more
unwieldy than the unassembled components, but pre-assembly is often
more practical. Furthermore, conditions existing at construction
sites and the number of differing types of components used in
assembling a HVAC system render cataloging those components
impractical if not impossible.
[0008] Generically, a terminal unit, also sometimes referred to as
an air handling unit, is a HVAC system component that is located
near an air conditioned space that regulates the temperature and/or
volume of air supplied to the space. When providing air to a more
critical environment such as a laboratory, an almost identical
ductwork section is frequently referred to as a lab valve damper
rather than as a terminal unit. One difference between a terminal
unit and a lab valve damper is the precision with which the unit
controls the temperature and humidity of conditioned air. As used
throughout this document, the phrase terminal unit may identify
either a terminal unit or a lab valve damper.
[0009] A HVAC system may be assembled using any one of several
different types of terminal units. Generally, the mechanical
portion of a terminal unit includes a casing through which air
flows during operation of a HVAC system. Accordingly, a casing
includes an inlet for receiving air from ductwork of a HVAC system,
and an outlet for supplying air to a space in a building. Casings
are usually fabricated from 22 gauge galvanized sheet steel. Due to
the use of such light material, casings are easily damaged during
shipping to a building site and during installation into the HVAC
system. Those familiar with such damage to terminal unit casings
frequently refer to it as "oil canning" because it resembles how a
light gauge oil can collapses as the liquid flows out.
[0010] In a typical hydronic (all-water) HVAC system, the
mechanical portion of a terminal unit includes a heat exchanging
coil. Heated and/or cooled water is pumped from a central plant
through pipes to the coil. Air from the HVAC system's ductwork
passes through the coil after entering and before leaving the
casing. Usually, a single terminal unit is dedicated for heating
and/or cooling each air conditioned space. Air from the duct
connected to the terminal unit passes through the coil to be heated
and/or cooled by water flowing through the coil before the air
enters the air conditioned space.
[0011] A Variable Air Volume ("VAV") HVAC system, in response to a
control signal from a thermostat or room sensor, supplies only that
volume of hot and/or cold air to an air conditioned space needed to
satisfy the space's thermal load. A VAV HVAC system meets changing
cooling and/or heating requirements by adjusting the amount, rather
than the temperature, of air that flows to a space. For most
buildings, a VAV HVAC system yields the best combination of
comfort, first cost, and life cycle cost.
[0012] A VAV terminal unit is a relatively complex assembly which
includes sheet metal, plumbing, electrical and pneumatic
components. For example, a VAV terminal unit includes an airflow
sensor that senses the velocity of air entering the terminal unit.
To adjust the volume of cold air, a VAV terminal unit frequently
includes a damper which automatically opens and closes as
needed.
[0013] As a space's thermal load decreases, the damper starts
closing thereby reducing the amount of heated or cooled air
supplied to the space. Alternatively, the volume of air entering a
space may be controlled by varying the speed of a fan included in
the terminal unit. For either type of VAV terminal unit, VAV HVAC
systems save energy consumed by fans in comparison with alternative
HVAC systems by continually adjusting airflow to the heating and/or
cooling required.
[0014] To be operable and fully-functional, terminal units for a
hydronic HVAC system often include a coil, ductwork for supplying
air to the coil and receiving air from the coil, plumbing for
supplying water into and receiving water from the coil, and a
control valve for regulating the amount of water flowing through
the coil.
[0015] To match the flow of air through the terminal unit's
ductwork to the profile of the coil, the terminal unit's ductwork
may include transition sections both for air entering the coil and
for air leaving the coil. In addition, a terminal unit may also
include a re-heat coil, and/or a sound attenuator. In a terminal
unit adapted for use in a VAV HVAC system, the terminal unit's
ductwork may also include a damper and a damper actuator or
variable speed fan for controlling the volume of air supplied by
the terminal unit, and an airflow sensor for sensing the volume of
air passing through the terminal unit.
[0016] Usually, all of the various parts needed to assemble a
fully-functional VAV HVAC system's terminal unit arrive at building
construction sites as separate components. Generally, these
components are then assembled into a fully functional terminal unit
at the construction site. Due to cluttered working conditions
usually existing at a construction site where workers skilled in
different crafts, e.g. plumbing, electrical, structural, etc., must
concurrently collaborate to complete the building project,
assembling the various components into a fully functional terminal
unit may occupy the better part of a day. Furthermore, present
practices and equipment are poorly adapted for swiftly constructing
a high quality HVAC system that is easily commissioned.
[0017] For example, because it is less expensive to wire a HVAC
system's terminal units with 24 volt low voltage electrical power
rather than 220 or 110 volt power, presently sections of buildings
include transformer trees which an electrician generally assembles
by installing multiple step down transformers on an electrical
panel. This technique permits wiring 220 or 110 volt electrical
power to the transformer tree on each panel, with the 24 volt low
voltage electrical power then being wired individually from a
transformer on the panel over distances of five (5) to one hundred
(100) feet to a terminal units for energizing its Direct Digital
Control ("DDC") controller, and 2 way or 3 way automatic
temperature control ("ATC") control valve.
[0018] Usually, terminal units are supported from a building using
angle brackets, straps, or thread rod. Usually these support
devices are attached directly to the terminal unit. Terminal unit
casings are usually made using 22 gauge sheet metal. Due to the use
of this light material, casings are easily dented or bent during
installation.
[0019] With current construction site labor costing up to
$80.00/hour, assembling a terminal unit at a construction site may
cost $500.00 to $1,000.00 for labor alone. Furthermore, terminal
units assembled at a construction site generally differ from one
another due to assembly by different craftsmen, and insufficient
use of identical components in assembling each terminal unit. Due
to conditions existing at construction sites and the number of
differing types of components used in assembling a HVAC system,
cataloging the components used in assembling the system is
impractical. Lastly, construction sites generally lack any
facilities for individually pre-testing building components, such
as terminal units, assembled on-site.
[0020] After assembling a HVAC system, it must be activated, tested
and commissioned to ensure IAQ. Testing a HVAC system only after it
is completely assembled inevitably results in many hours of
problem-solving and leak-hunting. Usually, there are leaky joints,
broken valves, damaged pipes, leaky coils and improperly assembled
components that must be tracked down which further increases
building costs. After finding a faulty component, it must be
identified, ordered and replaced which takes time and delays
completion of the building project. Furthermore, years after a
building project is complete to maintain IAQ a building manager
responsible for the HVAC system's maintenance will surely have to
identify and replace broken components.
[0021] The preceding considerations arising from construction site
assembly of fully functional terminal units slows construction,
increase building costs, requires rework when a terminal unit
experiences an initial failure, and ultimately makes more difficult
and expensive maintaining a building's HVAC system years after
those responsible for its assembly are no longer available.
[0022] A variety of dampers are used in the HVAC industry. Many of
these dampers, when installed in an HVAC system, have an associated
air flow monitoring device to sense the pressure drop or otherwise
measure the air moving across the damper, and to adjust the
position of the damper so as to control airflow therethrough. The
sensors are often located in the inlet or outlet of the damper.
Unfortunately, many dampers and/or sensors induce turbulence, and
in some cases rely on sensing pressures or the like at large
numbers of locations distributed across the duct, increasing
pressure drops, noise, and energy use.
[0023] In light of the above, it would generally be desirable to
provide improved HVAC devices, systems, and methods. It would be
particularly desirable to provide improved techniques and devices
for controlling flow of air and other gasses within the ductwork of
an HVAC system.
BRIEF SUMMARY OF THE INVENTION
[0024] Improved HVAC devices, systems, and/or methods include
dampers for controlling the flow of air or other gasses through an
HVAC duct, often while inhibiting turbulence within the duct and/or
pressure loss within the duct at least when the damper is in an
open flow configuration. By limiting flow turbulence, these
embodiments may facilitate relatively simple flow measurement
techniques, allowing sufficiently accurate flow measurements
without, for example, having to resort to a multi-axis flow sensor.
Embodiments of such dampers may employ a two-part damper
arrangement. In many embodiments, flow will travel through the
middle of the damper uniformly and with a laminar flow. One or more
small, relatively unobtrusive sensors (optionally being wireless)
can be included for controlling operation of the damper, the
sensor(s) optionally measuring the distance between damper
elements, sound, air flow, or the like, with such sensor(s)/damper
combination inhibiting inadvertent pressure drop and turbulence in
flows through the damper. The damper elements may optionally
comprise airfoil cross-sections, with alternative dampers having a
resilient helical configuration that can choke down flow by
inducing a vortex in the flow, allowing static pressure regain to
occur within the duct system. Such dampers may have control
advantages, enhance energy efficiency, limit noise, and/or provide
enhanced performance characteristics.
[0025] In a first aspect, embodiments of the present invention
provide a damper assembly or system for use in a heating,
ventilation, and air conditioning (HVAC) system. The damper
assembly or system includes a casing having an inlet and an outflow
with a flow direction extending therebetween, a first damper member
movably disposed within the casing, and a second damper member
movably disposed within the casing. The damper members each have a
cross-sections and are movable between an open flow configuration
and a restricted flow configuration such that laminar flow is
maintained as the flow is restricted. The assembly may also include
a damper assembly controller coupled to the damper members. In some
cases, the assembly includes a flow sensor coupled to the damper
members. Optionally, the flow sensor may measure pressure at less
than 5 locations across the dampers. In some cases, the assembly
includes a first sensor coupled with the first damper member. The
first sensor can detect an orientation of the first damper member
relative to the casing. In some cases, the first sensor is disposed
at or near a trailing end of the first damper member. A first
sensor may detect an orientation of the first damper member
relative to the second damper member. The assembly may also include
one or more air stops. In some aspects, the assembly includes a
first damper member having a trailing end and a second damper
member having a trailing end, and the first damper member trailing
end and the second damper member trailing end are configured to be
moved toward each other when the assembly is moved toward a
restricted flow configuration.
[0026] In another aspect, embodiments of the present invention
provide a damper assembly or system for use in a heating,
ventilation, and air conditioning (HVAC) system. The damper
assembly or system includes a casing having an inlet and an outflow
with a flow direction extending therebetween, and a damper member
disposed within the casing, the damper member comprising a helical
body deformable between an open flow configuration and a restricted
flow configuration. The damper in at least one configuration may
have a shape suitable for inducing a vortex in a flow within the
casing.
[0027] In yet another aspect, embodiments of the present invention
provide a method of controlling a fluid flow in a heating,
ventilation, and air conditioning (HVAC) system. The method
includes flowing a fluid through a casing inlet toward a casing
outlet, flowing the fluid across a plurality of damper members
disposed within the casing, restricting an amount of the fluid
passing through the casing by actuating a first damper member, and
maintaining a laminar flow within the fluid during the actuation of
the first damper member. The method may also include sensing an
orientation of the first damper member. In some cases, the method
includes sensing a pressure within the casing. The step of
restricting the amount of fluid passing through the casing may
include actuating a second damper member. Relatedly, the method may
also include maintaining the laminar flow during actuation of the
second damper member. Optionally, the method may include sensing an
orientation of the second damper member. For example, the method
may include sensing an orientation of the second damper member
relative to the first damper member. In some cases, the method
includes sensing an orientation of the second damper member
relative to the casing. A cross section of the first damper member
can include an aerodynamic profile and a cross section of the
second damper member can include an aerodynamic profile. In some
cases, the method includes sensing a distance between the first
damper member and the second damper member.
[0028] These and other features, objects and advantages will be
understood or apparent to those of ordinary skill in the art from
the following detailed description of the preferred embodiment as
illustrated in the various drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a perspective view of an fully-functional
zone-control unit ready for installation in a HVAC system which
includes a zone-control unit having a casing from which a pair of
handles project for supporting inlet and outlet piping assemblies
included in the fully-functional zone-control unit, according to
one embodiment of the present invention.
[0030] FIG. 2 is an elevational view of a plate that is included in
the handles illustrated in FIG. 1 which project from the
zone-control unit's casing and support the piping assemblies,
according to one embodiment of the present invention.
[0031] FIGS. 2A and B illustrate a zone-control unit according to
one embodiment of the present invention.
[0032] FIGS. 3A and B illustrate a zone-control unit according to
one embodiment of the present invention.
[0033] FIGS. 4A and B illustrate a zone-control unit according to
one embodiment of the present invention.
[0034] FIG. 5 illustrates a zone-control unit according to one
embodiment of the present invention.
[0035] FIG. 6 illustrates a zone-control unit according to one
embodiment of the present invention.
[0036] FIG. 7 illustrates a zone-control unit according to one
embodiment of the present invention.
[0037] FIGS. 8A-8G illustrate differing HVAC units having
standardized components, along with aspects of those
components.
[0038] FIG. 9 illustrates interfacing of HVAC unit support
structures, showing that the support structures can be used to
suspend and support the HVAC unit for use in an HVAC system.
[0039] FIGS. 10A and 10B illustrate a quality control process and
method for providing HVAC units and assembling and HVAC system.
[0040] FIG. 11 schematically illustrates a cross-sectional view of
a two part damper having two airfoil-shaped dampers to inhibit
turbulence.
[0041] FIG. 12 schematically illustrates a rear view of the damper
of FIG. 11.
[0042] FIGS. 13A-13C schematically illustrate differing alternative
actuation mechanisms for dampers similar to those of FIG. 11.
[0043] FIG. 14A-C illustrate an alternative damper configuration
having a deformable helical damper body for inducing a vortex in
flow through an associated duct.
DETAILED DESCRIPTION OF THE INVENTION
[0044] The perspective view of FIG. 1 illustrates a
fully-functional HVAC terminal unit referred to by the general
reference character 100. The fully-functional zone-control unit 100
depicted in FIG. 1, which illustrates one embodiment of the present
invention, preferably includes a mechanical terminal unit 102
having a casing 104 visible in FIG. 1. The casing 104, which can be
made from various materials of differing thicknesses, is frequently
made from galvanized sheet steel material. Frequently, the casing
104 is lined with a thermal insulation material, not visible in
FIG. 1, which may be chosen from various different types such as
fiberglass insulation, rigid duct board fiber insulation,
polyolefin, closed cell, foam insulation, etc. In some embodiments,
insulation contained in zone-control unit 100 complies with an
industry standard, such as a standard set by the Office of
Statewide Health and Planning Department (OSHPOD).
[0045] For VAV zone-control units 100, the mechanical terminal unit
102 preferably includes a damper assembly, not visible in FIG. 1.
The damper assembly is supported for rotation within the casing 104
by a shaft which extends through and beyond the casing 104. The
mechanical terminal unit 102 of a zone-control unit 100 that
includes the damper assembly also includes a DDC controller 112
depicted in FIG. 3. The DDC controller 112 is coupled to a damper
motor, not visible in any of the FIGS., which rotates the damper
assembly. The DDC controller 112 receives a signal from a
thermostat or room sensor and responsive thereto controls operation
of the damper assembly to regulate the amount of heating or cooling
provided by air leaving the zone-control unit 100. The DDC
controller 112 may be selected from various different types such as
pneumatic, analog electronic or direct digital electronic. The
mechanical terminal unit 102 also includes an airflow sensor, also
not visible in FIG. 1, which is usually located near an air inlet
to the casing 104 and may be selected from various types for
sensing the velocity of air entering the casing 104.
[0046] To heat or cool air flowing through the mechanical terminal
unit 102, the casing 104 includes a coil 122 that is located near
the air inlet thereto, and which adapts the mechanical terminal
unit 102 for inclusion in a hydronic HVAC system. The casing 104
includes both an inlet collar, not visible in FIG. 1, and an outlet
connection 124 each of which is adapted to mate with a building's
HVAC ductwork. If a zone-control unit 100 were to be assembled at a
construction site, the mechanical terminal unit 102 would arrive
there with the various components listed above mostly assembled,
other than the DDC controller 112 and the damper motor, by the
terminal unit's manufacturer.
[0047] The mechanical terminal unit 102 is preferably selected from
among various different types and styles sold by Krueger based in
Richardson, Tex. Krueger is a division of Air Systems Components
(ASC) which is part of the Dayton, Ohio Air System Components
Division of Tomkins Industries, Inc. of London, England.
[0048] To fashion the mechanical terminal unit 102 into a
zone-control unit 100 ready for installation into a building's HVAC
system, various plumbing components must be added for circulating
either hot or cold water through the coil 122. For supplying water
to the coil 122 the zone-control unit 100 includes an inlet piping
assembly 202. The piping assembly 202 includes an L-shaped section
of pipe 204 which connects at one end to a lower header of the coil
122, not visible in FIG. 1. At its other end, the pipe 204 ends at
a union 208. The other half of the union 208 connects to a
tailpiece 212 which receives both a pressure/temperature ("P/T")
port 214 and a drain 216. The drain 216 includes a ball valve
integrated 3/4'' male garden hose end connection to facilitate
draining the coil 122 when maintenance or repairs become necessary.
A ball valve 222, which includes a strainer, connects to a side of
the tailpiece 212 away from the union 208 to permit stopping hot or
cold water from circulating through the coil 122. An opposite side
of the valve 222 from the tailpiece 212 receives a length of pipe
224 which adapts the piping assembly 202 for connecting to a
building's plumbing.
[0049] The zone-control unit 100 also includes an outlet piping
assembly 232 for receiving water from the coil 122. A short length
of pipe 234 which ends in a tee 236 connects to an header 238 of
the coil 122. A manual air vent 242 is connected to and projects
upward above the tee 236 to facilitate eliminating air from the
piping assemblies 202, 232 following first assembling the HVAC
system, or reassembly of the zone-control unit 100 when maintenance
or repairs become necessary. An L-shaped section of pipe 244 is
connected to and depends below the tee 236. Similar to the pipe
204, an end of the pipe 244 furthest from the tee 236 ends at a
union 246. The other half of the union 246 connects to a 2 way or 3
way ATC control valve 252. The ATC control valve 252 may either be
of a type depicted in FIG. 1 that provides only on-off control, or
be of a type that provides proportional control, not illustrated in
any of the FIGS. An electrical signal supplied to the ATC control
valve 252 from the DDC controller 112 via a control signal cable
114 energize operation of the ATC control valve 252.
[0050] A side of the ATC control valve 252 furthest from the union
246 connects to a union 254. Connecting the ATC control valve 252
into the piping assembly 232 on both sides with unions 246, 254
facilitates its replacement when maintenance or repairs become
necessary. A tailpiece 262, connected to the other side of the
union 254 furthest from the ATC control valve 252, receives both a
P/T port 264 and a manual air vent 266. The P/T ports 214 and 264
facilitate measuring pressure and/or temperature of water
circulating through the coil 122. The vent 266 facilitates
eliminating air from the piping assembly 232 following first
assembling the HVAC system, or reassembly of the zone-control unit
100 when maintenance or repairs become necessary. A manual
balancing valve 272 connects to the other side of the tailpiece 262
from the furthest from the union 254. An opposite side of the valve
272 from the tailpiece 262 receives a length of pipe 274 which,
similar to the pipe 224, adapts the piping assembly 232 for
connecting to a building's plumbing. The valves 222, 216, 272 and
other plumbing fittings included in the piping assemblies 202, 232
are preferably manufactured by HCI of Madison Heights, Mich. The
valves 222, 272 permit isolating from the building's plumbing, when
maintenance or repairs become necessary, the coil 122 and those
portions of the piping assemblies 202, 232 which connect to the
valves 222, 272.
[0051] As described thus far, the zone-control unit 100 including
the piping assemblies 202, 232 are substantially the same as those
which a skilled sheet metal worker, controls contractor,
electrician, and pipe fitter might collectively assemble at a
building site. However, in assembling zone-control units 100 in
accordance with the present invention for a particular building
project or significant portion thereof, all of the lengths of pipe,
plumbing fittings, valves, vents, P/T ports, etc. are the same.
Consequently, when a repair become necessary a building manager or
the manager's personnel responsible for maintaining the HVAC system
may confidently order a replacement part knowing that it will
surely fit because the plumbing of each zone-control unit 100 is
not unique. Rather, in accordance with the present invention the
plumbing of zone-control units 100 is uniform throughout the
building or significant portion thereof. Furthermore, because
plumbing of zone-control units 100 is uniform throughout the
building or significant portion thereof, acting either from
prudence or caution a building manager may confidently maintain an
inventory of plumbing components for the zone-control units 100 to
have on hand when they need repair thereby significantly reducing
downtime while also maintaining IAQ.
[0052] In addition to being assembled with uniform plumbing, in
accordance with the present invention tags 282 are attached to each
valve 252, 272 or other component that are likely to eventually
require replacement. After the HVAC system has been commissioned,
when a failure occurs and is located, the presence of an
identifying tag 282 attached to a failed component simplifies its
replacement and reduces the time required therefor. The tags 282
are particularly helpful if components from different manufacturers
and/or different catalogs have been incorporated into the HVAC
system. The tags 282 are preferably engraved plastic, but may also
be made from metal, paper, or any other appropriate material. The
tags 282 may carry barcodes or plain language, for example, and may
be customized to provide information in the manner most useful for
a particular project. In accordance with the present invention,
performance requirements for each zone-control unit 100 such as
GPM, CFM, CV and so on are marked thereon in an accessible and well
defined location.
[0053] Also in accordance with the present invention, each pipe
224, 274 is sealed by a spun copper cap 284 which is five (5) times
thicker than the pipe 224, 274, and the assembled piping assemblies
202, 232 include a pressure gauge 286. Following fabrication and
sealing of the piping assemblies 202, 232, they are pressure tested
with, for example, a gas such as air. Other gasses or a liquid may
be used as appropriate for materials used in the piping assemblies
202, 232. A typical pressure range used in testing assembled piping
assemblies 202, 232 and coil 122 is 20-400 psi, and in one
embodiment is preferably 140 psi. While pressurized, the piping
assemblies 202, 232 and the coil 122 are checked for leaks, e.g.
with a soap solution. Any defects in assembly found during pressure
testing are repaired and/or defective components replaced. For
example, experience in assembling zone-control units 100 in
accordance with the present invention indicates that about 3 to 7%
of new coils 122 are defective and must be replaced.
[0054] When inspection and pressure testing indicates that no leaks
appear to exist in the piping assemblies 202, 232 and the coil 122,
they are then sealed and re-pressurized to at least 100 psi,
preferably 140 psi. After pressurization, the piping assemblies
202, 232 and the coil 122 remain sealed for 24 hours throughout
which they must hold the pressurization to confirm that the
zone-control unit 100 is undergoing installation into a HVAC
system. After the piping assemblies 202, 232 and the coil 122 pass
this 24 hour quality assurance test, zone-control units 100 can be
ready for shipping to a construction site. In accordance with one
embodiment of the present invention, the piping assemblies 202, 232
and coil 122 of zone-control units 100 ready for installation
remain pressurized continuously after their 24 hour quality
assurance test at a pressure of at least 60 psi until they are
about to be installed into a building's HVAC system. In some cases,
the shipping pressure can be 40 psi, or any other desired
pressure.
[0055] Immediately before installing a zone-control unit 100 at a
construction site, their readiness for installation can be
confirmed by checking the pressure gauge 286. If the pressure gauge
286 fails to indicate a specified pressure, then the zone-control
unit 100 may need further testing and/or repair, and should not be
installed into the HVAC system. Instead an identically assembled
zone-control unit 100 having a pressure gauge 286 which indicates
the specified pressure may be immediately substituted for a
defective one, and the defective zone-control unit 100 may either
be repaired and re-tested at the construction site, or it may be
returned to its vendor for repair.
[0056] Identifying and replacing faulty piping assemblies 202, 232
and/or coil 122 in this way prior to installing the zone-control
unit 100 saves time and money. The present invention can eliminate
an inability to test the piping assemblies 202, 232 and coil 122 of
each zone-control unit 100 assembled at a construction site until
the entire HVAC system is completely assembled and ready for
commissioning. Off-site assembly and testing of zone-control units
100, rather than assembling the components at the construction
site, improves quality control by individually assuring that each
zone-control unit 100 is ready for installation in a HVAC system.
In this way the present invention saves time and money that would
otherwise be spent tracking down leaks that occur using traditional
on-site assembly of zone-control units 100. Furthermore, by
preventing pinhole leaks in the zone-control unit 100, which
inevitably result in mold, biochemical hazards, etc., the present
invention significantly improves IAQ both initially and throughout
the HVAC system's service life.
[0057] One problem which arises with assembling zone-control units
100 at a location remote from a construction site is that during
their transportation to the site and during installation into a
building's ductwork zone-control units 100 may be manipulated by
the piping assemblies 202, 232 and/or the coil 122 of the
mechanical terminal unit 102. Such handling of zone-control units
100 during installation may damage seals between the components as
well as the components themselves. Furthermore, such damage may not
be noticed until the HVAC system is pressurized for commissioning
or at a later date. At that time, locating a leak or malfunctioning
part may be time-consuming, virtually impossible and cost
prohibitive. To reduce any possibility that a zone-control unit 100
might be damaged while being transported from its assembly, test
and qualification location to a construction site and to facilitate
handling the zone-control unit 100 during its installation into the
HVAC system, in accordance with the embodiment of the present
invention illustrated in FIG. 1 each zone-control unit 100 also
includes a pair of handles 502 that are preferably secured to the
casing 104 of the mechanical terminal unit 102 near opposite ends
thereof.
[0058] Each of the handles 502 includes an L-shaped handle mounting
bracket 504 which is rigidly secured to a wall 132 of the
mechanical terminal unit 102 which is nearest to the piping
assemblies 202, 232. As depicted in FIG. 1, the handle mounting
brackets 504 are secured near opposite ends of the wall 132 of the
zone-control unit's casing 104. Each of the handles 502, for
example illustrated in FIG. 2, is formed by a plate 506a of sheet
metal. Each plate 506a include a plurality of holes 508 through
which fasteners pass for securing the plate 506a to a portion of
the handle mounting bracket 504 that projects outward from the wall
132. The handle mounting brackets 504 and the plates 506a can be
made from 12 gauge sheet steel. The handle mounting brackets 504
can be galvanized and the plates 506a can be powder coated, and can
be made from various materials and gauge sizes.
[0059] For use with the zone-control unit 100, each plate 506a is
also pierced by a rectangularly-shaped hole 512, and by a pair of
circularly-shaped holes 514 illustrated with dashed lines in FIG.
2. The holes 512 are large enough to accept many lifting devices
including human hands, forklift, Unistrut, pipe or other lifting
device. Each hole 512 has a curved edge 518 to prevent hand
injuries, and may lack any sharp edges or non-rolled edges. The
holes 514 each receive a grommet 522 that fits snugly around the
piping assemblies 202, 232 where they pass through plates 506a.
[0060] Arranged in this way, the handle mounting brackets 504 and
plates 506a provide a structure for mechanically coupling the
mechanical terminal unit 102 and the piping assemblies 202, 232
together thereby reducing any possibility that the zone-control
unit 100 might be damaged while being transported from its
assembly, test and qualification location to a construction site.
Furthermore, the handles 502 protect zone-control units 100 during
shipping, and facilitate their handling during installation into
the HVAC system such as maneuvering zone-control units 100 into
position in a building's ductwork. During installation, the handle
mounting brackets 504 and plates 506a maintain positional
relation-ships between the mechanical terminal unit 102 including
the coil 122 and the piping assemblies 202, 232 because the handle
mounting brackets 504 and plates 506a mechanically bind the entire
zone-control unit 100 together into a single unit.
[0061] DDC controllers include a communication capability that
permits a central computer to monitor a building's HVAC system's
operating status, and to coordinate operation of the various
portions of the system including all of its terminal units. DDC
controllers are equipped with Local Area Network ("LAN")
communications capability. To facilitate installing the
zone-control unit the electrical components enclosure is optionally
equipped with a 100 ft. length of LAN cable connected to the DDC
controller Establishing the LAN that interconnects groups of
zone-control units may involve the LAN cables of all but one of the
zone-control units in the group be connected to another one of the
group's zone-control units.
[0062] FIG. 2A illustrates a side view of a zone-control unit 1000
for use in an HVAC system, according to one embodiment of the
present invention, and FIG. 2B illustrates the corresponding end
view. Zone-control unit 1000 includes a duct or casing 1100, a
thermal transfer unit 1200, an inlet piping assembly 1300, an
outlet piping assembly 1400, and at least one bracket 1500. In some
embodiments, bracket 1500 can be a powder-coated handle shipping
bracket. Inclusion of bracket 1500 can allow zone-control unit 1000
to be pre-engineered, sealed, pressure-tested, and shipped to
job-site in working condition, free of defects. Zone-control unit
1000 may include military rubber Nitrile grommets 1510 for
isolation between bracket 1500 and piping assemblies 1300 and 1400.
Grommets 1510 can help secure and protect zone-control unit 1000,
and can help reduce or eliminate the possibility of galvanic
corrosion at the interface between bracket 1500 and piping
assemblies 1300 and 1400. Grommets 1510 can be manufactured to
withstand heat, and in some cases can withstand a direct flame of
220 degrees F., or higher. Bracket 1500 may include openings that
are designed to fit the fork of a forklift, a steel pole, or a
human hand. Bracket 1500 is well suited for reducing or preventing
field damage. For example, with known systems and methods, field
personnel typically lift or move HVAC components simply by grasping
various piping or probe elements, which often results in
destruction or serious damage to the component. Bracket 1500
confers the ability to ship and maneuver zone-control unit 1000 in
a standardized and safe manner. Often, thermal transfer unit 1200,
which may include a coil, is at least partially disposed within
casing 1100. Inlet piping assembly 1300 is coupled with thermal
transfer unit 1200 for supplying liquid or gas to coil 1200, and
outlet piping assembly 1400 is coupled with coil 1200 for receiving
liquid or gas from coil 1200. This can be accomplished by coupling
a first passage 1310 of inlet piping assembly 1300 with a supply
port 1210 of thermal transfer unit 1200, and coupling a first
passage 1410 of the outlet piping assembly 1400 with a return port
1220 of thermal transfer unit 1200. A second passage 1320 of inlet
piping assembly 1300 can be coupled with an upstream fluid source
1330, and a second passage 1420 of outlet piping assembly 1400 can
be coupled with a downstream fluid destination 1430.
[0063] It is appreciated that inlet piping assembly second passage
1320 and outlet piping assembly second passage 1420 each can be
sealed, inlet piping assembly first passage 1310 can be in sealed
communication with thermal transfer assembly supply port 1210, and
outlet piping assembly first passage 1410 can be in sealed
communication with the thermal transfer assembly return port 1220.
When sealed in this fashion, thermal transfer unit 1200 can contain
a vacuum, a non-pressurized fluid, or a pressurized fluid. Inlet
piping assembly second passage 1320 and outlet piping assembly
second passage 1420 can be manufactured from, for example, 3/4 inch
type L copper water pipe. They can be sealed according to a heating
and spinning procedure that introduces no annealing or distortion
of the pipe. After zone-control unit 1000 is placed in the desired
location relative to the HVAC system, distal tips of inlet piping
assembly second passage 1320 and outlet piping assembly second
passage 1420 can be cut, and connected with other HVAC piping or
hose elements, such as a hot water piping building loop. Relatedly,
zone-control unit 1000 includes a pressure gauge 1710 coupled with
inlet piping assembly 1400. In some embodiments, pressure gauge
1710 may be coupled with thermal transfer unit 1200 or outlet
piping assembly 1300. Inlet piping assembly 1300 may be coupled
with a drain valve 1330, a Y-strainer 1340, a pressure/temperature
port 1350, or a supply shutoff valve 1360, or any combination
thereof. Outlet piping assembly 1400 may be coupled with control
valve 1430, a balancing valve (not shown), a vent (not shown), a
pressure/temperature port 1450, or a return shutoff valve 1460, or
any combination thereof. Control valve 1430 may be an automatic
temperature control (ATC) valve having a compensated ball valve
including an integral pressure limiting and flow setting apparatus.
Valve 1430 can assure consistent flow response regardless of the
head pressure. In some cases, there is no CV setting on the valve.
Relatedly, zone-control unit 1000 may include a field set manual or
factory programmable maximum flow setting. In some embodiments,
valve balancing may be accomplished in less than 30 seconds. Valve
1430 may have a shutoff pressure of 200 psi. Conveniently, valve
1430 may have a pressure sufficient to counteract a heating loop
dead head pressure, which can be 50 psi or more. In related
embodiments, valve 1430 can be a 1/2 inch, a 3/4 inch, or 1 inch
valve. Control valve 1430 may be a modulating Siemens ATC.
[0064] Thermal transfer unit 1200 may be coupled with a vent 1230
such as an air vent. In some instances, vent 1230 is a manual air
vent disposed at or toward the highest point of thermal transfer
unit 1200. Vent 1230 can help ensure proper drainage of air or
other unwanted fluids or gasses that enter the system, which can
have deleterious effects on an HVAC system. For example, unwanted
air in a hot water system can cause cavitation in a hot water pump,
which may cause malfunction or destruction of the pump or other
system components. Vents can also help ensure optimum flow
characteristics when draining thermal transfer unit 1200 or other
zone-control unit 1000 components. Full drainage of such components
can facilitate the removal of unwanted particles such as rust or
other chemical buildup. In some embodiments, vent 1230 is
constructed of a non-corrosive military grade brass. In the
embodiment shown here, zone-control unit 1000 includes a duct
interface 1110 which is coupleable with duct or casing 1100, which
may be attached with or integral to a duct or ductwork of an HVAC
system. Bracket 1500, which may include a handle, supports duct
interface 1100, inlet piping assembly 1300, and outlet piping
assembly 1400 with relative positions appropriate for use in an
HVAC system or other climate control system. In some cases, bracket
1500 may be a handle configured to maintain duct or casing 1100,
inlet piping assembly 1300, and outlet piping assembly 1400 in
positional relationship.
[0065] As shown in FIG. 2A, zone-control unit 1000 can include a
damper assembly controller 1600, which may be coupled with casing
1100. Damper assembly controller 1600 may be configured to receive
a signal from a thermostat or a room sensor (not shown). In some
embodiments, damper assembly controller 1600 can include, for
example, an analog electronic controller, or a direct digital
control (DDC) controller equipped with Local Area Network (LAN)
communication capability. In some cases, controller 1600 can be a
pneumatic DDC. Controller 1600 can also be configured to
operatively associate with or have connectivity with a LonWorks or
BACnet system. Unit 1000 can also include an automatic temperature
control (ATC) valve 1430, which is typically coupled with or part
of outlet piping assembly 1400, and configured to receive a signal
from damper assembly controller 1600, for example, by connection
with plenum rated actuator wires 1432. Other embodiments may employ
wireless signal transmission technologies. In certain embodiments,
ATC valve 1430 is a Nema 1 24V Belimo proportional actuator.
Accordingly, in some embodiments the present invention provides a
proportional hot water valve package (PICCV). Often, zone-control
unit 1000 will be configured to have one piping interface, one
electrical interface, and one sheet metal interface, so as to
provide a "plug and play" unit for ease of shipping and
installation.
[0066] FIG. 3A illustrates a side view of a zone-control unit 2000
for use in an HVAC system, according to one embodiment of the
present invention, and FIG. 3B illustrates the corresponding end
view. Zone-control unit 2000 includes a duct or casing 2100, a
thermal transfer unit 2200, an inlet piping assembly 2300, an
outlet piping assembly 2400, and at least one bracket 2500. Often,
thermal transfer unit 2200, which may include a coil, is at least
partially disposed within casing 2100. Inlet piping assembly 2300
is coupled with thermal transfer unit 2200 for supplying liquid or
gas to coil 2200, and outlet piping assembly 2400 is coupled with
coil 2200 for receiving liquid or gas from coil 2200. This can be
accomplished by coupling a first passage 2310 of inlet piping
assembly 2300 with a supply port 2210 of thermal transfer unit
2200, and coupling a first passage 2410 of the outlet piping
assembly 2400 with a return port 2220 of thermal transfer unit
2200. A second passage 2320 of inlet piping assembly 2300 can be
coupled with an upstream fluid source 2330, and a second passage
2420 of outlet piping assembly 2400 can be coupled with a
downstream fluid destination 2430.
[0067] It is appreciated that inlet piping assembly second passage
2320 and outlet piping assembly second passage 2420 each can be
sealed, inlet piping assembly first passage 2310 can be in sealed
communication with thermal transfer assembly supply port 2210, and
outlet piping assembly first passage 2410 can be in sealed
communication with the thermal transfer assembly return port 2220.
When sealed in this fashion, thermal transfer unit 2200 can contain
a vacuum, a non-pressurized fluid, or a pressurized fluid.
Relatedly, zone-control unit 2000 includes a pressure gauge 2710
coupled with inlet piping assembly 2400. In some embodiments,
pressure gauge 2710 may be coupled with thermal transfer unit 2200
or inlet piping assembly 2300. Inlet piping assembly 2300 may be
coupled with a drain valve 2330, a Y-strainer 2340, a
pressure/temperature port 2350, or a supply shutoff valve 2360, or
any combination thereof. Outlet piping assembly 2400 may be coupled
with control valve 2430, a manual balancing valve 2470, a vent (not
shown), a pressure/temperature port 2450 disposed upstream of
control valve 2430, a pressure/temperature port 2452 disposed
downstream of control valve 2430, or a return shutoff valve 2460,
or any combination thereof. In some cases, balancing valve 2470 may
be a Griswold pressure independent balancing valve. Thermal
transfer unit 2200 may be coupled with a vent 2230 such as an air
vent. In the embodiment shown here, zone-control unit 2000 includes
a duct interface 2110 which is coupleable with duct or casing 2100,
which may be attached with or integral to a duct or ductwork of an
HVAC system. Bracket 2500, which may include a handle, supports
duct interface 2110, inlet piping assembly 2300, and outlet piping
assembly 2400 with relative positions appropriate for use in an
HVAC system or other climate control system. In some cases, bracket
2500 may be a handle configured to maintain duct or casing 2100,
inlet piping assembly 2300, and outlet piping assembly 2400 in
positional relationship.
[0068] As shown in FIG. 3A, zone-control unit 2000 can include a
damper assembly controller 2600, which may be coupled with casing
2100. Damper assembly controller 1600 may be configured to receive
a signal from a thermostat or a room sensor (not shown). In some
embodiments, damper assembly controller 2600 includes a direct
digital control (DDC) controller equipped with Local Area Network
(LAN) communication capability. Unit 2000 can also include an
automatic temperature control (ATC) valve 2430, which is typically
coupled with or part of outlet piping assembly 2400, and configured
to receive a signal from damper assembly controller 2600, in some
embodiments by connection with plenum rated actuator wires 2432,
via wireless signal transmission systems, or the like. In certain
embodiments, ATC valve 2430 is a Nema 1 24V Belimo on/off actuator.
Accordingly, in some embodiments the present invention provides a
two way water valve package (CCV).
[0069] FIG. 4A illustrates a side view of a zone-control unit 3000
for use in an HVAC system, according to one embodiment of the
present invention, and FIG. 4B illustrates the corresponding end
view. Zone-control unit 3000 includes a duct or casing 3100, a
thermal transfer unit 3200, an inlet piping assembly 3300, an
outlet piping assembly 3400, a bypass piping assembly 3800, and at
least one bracket 3500. Often, thermal transfer unit 3200, which
may include a coil, is at least partially disposed within casing
3100. Inlet piping assembly 3300 is coupled with thermal transfer
unit 3200 for supplying liquid or gas to coil 3200, and outlet
piping assembly 3400 is coupled with coil 3200 for receiving liquid
or gas from coil 3200. This can be accomplished by coupling a first
passage 3310 of inlet piping assembly 3300 with a supply port 3210
of thermal transfer unit 3200, and coupling a first passage 3410 of
the outlet piping assembly 3400 with a return port 3220 of thermal
transfer unit 3200. A second passage 3320 of inlet piping assembly
3300 can be coupled with an upstream fluid source 3330, and a
second passage 3420 of outlet piping assembly 3400 can be coupled
with a downstream fluid destination 3430.
[0070] It is appreciated that inlet piping assembly second passage
3320 and outlet piping assembly second passage 3420 each can be
sealed, inlet piping assembly first passage 3310 can be in sealed
communication with thermal transfer assembly supply port 3210, and
outlet piping assembly first passage 3410 can be in sealed
communication with the thermal transfer assembly return port 3220.
Similarly, bypass piping assembly 3800 can be in sealed
communication with inlet piping assembly 3300 and outlet piping
assembly 3400 so as to provide a fluid passage therebetween,
whereby the passage can be open and closed via operation of bypass
shutoff valve 3810. When sealed in this fashion, thermal transfer
unit 3200 can contain a vacuum, a non-pressurized fluid, or a
pressurized fluid. Relatedly, zone-control unit 3000 includes a
pressure gauge 3710 coupled with outlet piping assembly 3400. In
some embodiments, pressure gauge 3710 may be coupled with thermal
transfer unit 3200 or inlet piping assembly 3300. When bypass
shutoff valve 3810 is in the open position, fluid can flow directly
from inlet piping assembly 3300 to outlet piping assembly 3400
without flowing through thermal transfer unit 3200. When bypass
shutoff valve 3810 is in the closed position, fluid can flow from
inlet piping assembly 3300 to outlet piping assembly 3400 through
thermal transfer unit 3200, without flowing through bypass piping
assembly 3800. Inlet piping assembly 3300 may be coupled with a
drain valve 3330, a Y-strainer 3340, a pressure/temperature port
3350, or a supply shutoff valve 3360, or any combination thereof.
Outlet piping assembly 3400 may be coupled with control valve 3430,
a manual balancing valve 3470, a vent (not shown), a
pressure/temperature port 3450 disposed upstream of control valve
3430, a pressure/temperature port 3452 disposed downstream of
control valve 3430, or a return shutoff valve 3460, or any
combination thereof. Thermal transfer unit 3200 may be coupled with
a vent 3230 such as an air vent. In the embodiment shown here,
zone-control unit 3000 includes a duct interface 3110 which is
coupleable with duct or casing 3100, which may be attached with or
integral to a duct or ductwork of an HVAC system. Bracket 3500,
which may include a handle, supports duct interface 3110, inlet
piping assembly 3300, and outlet piping assembly 3400 with relative
positions appropriate for use in an HVAC system or other climate
control system. In some cases, bracket 3500 may be a handle
configured to maintain duct or casing 3100, inlet piping assembly
3300, and outlet piping assembly 3400 in positional
relationship.
[0071] As shown in FIG. 4A, zone-control unit 3000 can include a
damper assembly controller 3600, which may be coupled with casing
3100. Damper assembly controller 3600 may be configured to receive
a signal from a thermostat or a room sensor (not shown). In some
embodiments, damper assembly controller 3600 includes a direct
digital control (DDC) controller equipped with Local Area Network
(LAN) communication capability. Unit 3000 can also include an
automatic temperature control (ATC) valve 3430, which is typically
coupled with or part of outlet piping assembly 3400, and configured
to receive a signal from damper assembly controller 3600 by
connection with plenum rated actuator wires 3432, wireless
transmission systems, or the like. In certain embodiments, ATC
valve 3430 is a Nema 1 24V Belimo three way actuator. Accordingly,
in some embodiments the present invention provides a three way
water valve package (CCV).
[0072] FIG. 5 illustrates a side view of a zone-control unit 4000
for use in an HVAC system, according to one embodiment of the
present invention. Zone-control unit 4000 includes a duct or casing
4100, a thermal transfer unit 4200, an inlet piping assembly 4300,
an outlet piping assembly 4400, and at least one bracket 4500.
Often, thermal transfer unit 4200, which may include a coil, is at
least partially disposed within casing 4100. Inlet piping assembly
4300 is coupled with thermal transfer unit 4200 for supplying
liquid or gas to coil 4200, and outlet piping assembly 4400 is
coupled with coil 4200 for receiving liquid or gas from coil 4200.
Zone-control unit 4000 includes a pressure gauge 4710 coupled with
outlet piping assembly 4400. In some embodiments, pressure gauge
4710 may be coupled with thermal transfer unit 4200 or inlet piping
assembly 4300. Inlet piping assembly 4300 may be coupled with a
basket strainer 4380. Zone-control unit 4000 can be cleaned by
fluid or water pressure without removing basket strainer 4380.
Inlet piping assembly may also be coupled with a blow down drain
4370 for basket strainer 4380. Outlet piping assembly 4400 may be
coupled with a control valve 4430. In the embodiment shown here,
zone-control unit 4000 includes a casing 4100 which may be attached
with a duct or ductwork of an HVAC system. Bracket 4500, which may
include a handle, supports casing 4100, inlet piping assembly 4300,
and outlet piping assembly 4400 with relative positions appropriate
for use in an HVAC system or other climate control system.
[0073] FIG. 6 illustrates a side view of a zone-control unit 5000
for use in an HVAC system, according to one embodiment of the
present invention. Zone-control unit 5000 includes a duct or casing
5100, a thermal transfer unit (not shown), an inlet piping assembly
5300, an outlet piping assembly 5400, and at least one bracket
5500. Zone-control unit 5000 also includes a housing 5900 coupled
with casing 5100, such that housing 5900 encompasses ATC valve (not
shown) and other components of zone-control unit 5000 as described
elsewhere herein. For comparative reference with other figures of
the present disclosure, zone-control unit 5000 is depicted here
showing a vent 5230, a drain valve 5330, an inlet piping assembly
second passage 5320 and an outlet piping assembly second passage
5420. A housing cover 5910 of housing 5900 may have an aperture
5920 through which bracket 5500 may extend, or through which
bracket 5500 may be otherwise accessible via an operator's hands, a
forklift, or other maneuvering apparatus used during
transportation, shipping, or installation. Zone-control unit 5000
may also have a validation package 4120, which may include a
digital picture of the zone-control unit 5000 or components
thereof, a quality control sheet, an operations and maintenance
document, a parts list with model and serial numbers, an Indoor Air
Quality (IAQ) certification, or a piping, electrical, and controls
schematic, or any combination thereof. These components of
validation package 4120 may be stored in a plastic pouch and
attached with unit 6000. It is appreciated therefore that the
present invention can be conveniently tested, validated,
standardized, cataloged, and certified prior to shipping or
installation.
[0074] FIG. 7 illustrates a side view of a zone-control unit 6000
for use in an HVAC system, according to one embodiment of the
present invention. In many ways, the embodiment shown in FIG. 7 is
similar to that shown in FIG. 6. Zone-control unit 6000 includes a
duct or casing 6100, an inlet piping assembly 6300, an outlet
piping assembly 6400, and at least one bracket 6500. Zone-control
unit 6000 also includes a housing 6900 coupled with casing 6100,
such that housing 6900 encompasses various components of
zone-control unit 6000 as described elsewhere herein, and to avoid
prolixity are not described in detail here. The zone-control unit
6000 embodiment shown in FIG. 7 differs from the zone-control unit
5000 shown in FIG. 6, however, in a housing cover (not shown) of
zone-control unit 6000 is removed, thereby exposing various
elements contained in housing 6900. In some embodiments, the
zone-control unit complies with a standard such as a Leadership in
Energy and Environmental Design (LEED) standard, an American
Society of Heating, Refrigerating, and Air Conditioning Engineers
(ASHRAE) standard, an Air-Conditioning and Refrigeration Institute
(ARI) standard, or a building code standard, or any combination
thereof. Zone-control unit 6000 may be a capital piece of
equipment, depreciable, and can be stocked by local distributors
anywhere in the world as an "off the shelf" product. Zone-control
unit 6000 is well suited for installation in a new HVAC system, or
for retrofit in an existing HVAC system. It is also appreciated
that the present invention also provides for the manufacture and
installation of the zone-control units discussed herein. Such
manufacture will often occur remotely from a job installation site,
and may be performed by a union member selected from the group
consisting of the United Association of Journeymen and Apprentices
of the Plumbing and Pipefitting Industry of the United States and
Canada, the construction sheet metal union, and the electrical
union. In other embodiments, such union(s) may certify the
fabrication site and/or supplier as being in compliance with the
applicable union rules, that use of certain catalogued HVAC units
complies with applicable union requirements and/or does not
constitute a customized product so as violate work preservation
rules. Relatedly, zone-control units or components thereof may be
constructed by a manufacturing facility that is a signatory to any
of these unions. Such manufacturing facilities may also have an
Underwriter's Laboratory certification. Accordingly, zone-control
units may include or be affixed with certain union, standards, or
certification compliance labels.
[0075] FIGS. 8A-8G generally illustrate standardization of
components in differing HVAC units. Rather than attempting to
minimize the costs of individual components of the many HVAC units
in an HVAC system (which can lead to extensive on-site work,
delays, and large installation labor costs), overall system
installation efficiencies can be enhanced through the use of more
standardized components, even if those components have capacities
that exceed the requirements of some units.
[0076] Proportional valves (including those having characteristics
similar to those graphically illustrated in FIG. 8A, such as the
Belimo.TM. PICCV pressure independent proportional ball valve) and
the like can facilitate integration of a single type of HVAC unit
in multiple locations having differing specifications, tailoring
the functioning of the unit by though appropriate use of the
electronic controller software. FIG. 8B illustrates an HVAC hot
water coil piping package unit 8000, while FIGS. 8C and 8E
illustrate an HVAC proportional hot water valve package unit 8000C
and a 2 way water valve package unit 8000E, respectively. FIG. 8D
illustrates a support structure or handle 8000D which may be used
in both, and FIG. 8F illustrates a 3 way water valve package unit
8000F. FIG. 8G illustrates a support structure or handle 8000G that
can be used with any of the units described herein. Despite the
significant differences between these units, many, most, or all of
the components (including piping components) may be common, with
the aspect ratio of the piping optionally being identical.
[0077] FIG. 9 illustrates engagement between the support structure
or handle 9000 mounted to an HVAC unit and another similar
corresponding support structure, allowing the support structures to
be used as mounting fasteners. A plurality of different
configurations of support structures can be provided with different
sizes, different numbers, sizes, and configurations of holes and
grommets for receiving piping, and the like. One or more supports
may be secured to a joist, beam, or other building structure where
the HVAC unit is to be installed. The unit support structure or
handle is then lifted into engagement with the secured support(s),
and the engaging surface at least temporarily "hanging" or
maintaining the position of the HVAC unit. Fasteners may then affix
the corresponding engaged support structures together to provide a
secure and/or permanent installation. Deformable damping materials
such as rubber, neoprene, resilient polymers, or the like along one
or both of the engaging support surfaces can provide vibration
and/or sound isolation. The support structures or handles may
comprise carbon fiber, stainless steel, aluminum, plastic, or the
like, and the engaging support structures may have similar shapes
(as shown) or different shapes.
[0078] FIGS. 10A and 10B illustrate methods for testing and
validation of HVAC units. HVAC units. Unit ordering and fabrication
can be automated, and testing of piping by pressurizing piping
assemblies, sealing, and verifying an acceptable pressure is
maintained after a test period (for example, 24 hours) ensures
leak-free fabrication. Any re-work can be identified and completed
prior to shipping to a constructions site, and quality control
documentation (optionally comprising a magnetic media such as a
floppy disk, an optical media such as a mini CD, a memory such as a
flash memory stick, or some other tangible media embodying machine
readable computer data, a print-out, a digital photograph, and/or
the like) can be associated with each unit to validate the
components and testing. In some embodiments, such quality control
may be integrated into the HVAC signal transmission system so as to
facilitate remote validation via LAN conductors or a wireless
network system, and/or radiofrequency identification or RFID
techniques and structures may be employed.
[0079] FIGS. 11 and 12 schematically illustrate a two part damper
having two airfoil-shaped damper members. Automatic dampers are
used in HVAC to control air flow. They may be used for modulating
air flow to maintain a desired control variable, such as mixed air
temperature, supply air duct static pressure, or the like. They can
also be used for two-position control to initiate or halt operating
flow, for example, when opening minimum outside air dampers when a
fan is started. Inadvertent damper leakage can be undesirable, as
tight shut-off of flows can reduce energy consumption
significantly. Also, outdoor air dampers should close tightly to
inhibit freezing of coils and pipes in cold climates.
[0080] The two-part damper design of FIGS. 11 and 12 may provide
little or no pressure drop in one, some, or all damper
configurations, with the air always traveling through the middle of
the damper casing being uniform and laminar. The exemplary damper
members may have an airfoil-shaped cross-section, and may pivot
within the casing, slide within the casing, or the like. A small
wireless sensor or sensors can be used for controlling damper
actuation. Such sensors, may, for example, measure the distance
between the two damper members, sound, air flow, or the like. By
avoiding cross flow measurement devices having numerous (often over
5) sensor locations, pressure drop and turbulence of the damper
system may be further inhibited. Characteristics of known dampers
are described and illustrated in a 1997 ASHRAE Fundamentals
Handbook, and known damper assemblies and features thereof are
described and illustrated in pages 6-13 of a 2001 Model SDR Calalog
from Environmental Technologies, Inc., the contents of each of
which are incorporated herein by reference. FIG. 11 shows a side
view of a damper system 11000 according to embodiments of the
present invention. The damper system is shown in a 100% open
configuration, with air or fluid flowing through the system as
indicated by arrow A. Damper system 11000 includes a damper casing
11010, and one or more damper members 11020 disposed within the
damper casing. As shown here, damper members 11020 are attached
with damper shafts 11030 toward a leading end 11022 of the damper
members, and can pivot about damper shafts 11030 as indicated by
arrow B. The damper system also includes one or more air stops
11040, optionally disposed toward leading end 11022 of damper
members 11020, that assist in maintaining laminar air flow and
reducing or avoiding turbulence, particularly when the damper
system is in the 100% open configuration. In the embodiment shown
here, damper members 11020 are coupled with one or more sensors
11050. The sensors are disposed on the trailing end 11024 of the
damper members 11020. Sensors may also or alternatively be disposed
at any location along the damper member, at or near the damper
casing, and the like. Sensors may detect any of a variety of
spatial, positional, or angular orientations of a damper member.
For example, a sensor may detect a distance between damper members,
a distance between a damper member and the damper casing, a
position or an orientation of a damper member relative to the
damper casing, a position or an orientation of a damper member
relative to another damper member, and the like. A sensor may also
detect sound or pressure that is present in the damper system.
Often, the sensor will be configured so as to present minimal or no
disruption to air or fluid passing through the damper system. For
example, the sensor may be embedded beneath the surface of the
damper member, or may be contiguous with the smooth or aerodynamic
surface of the damper member. As shown here, the side profile or
end view of damper members 11020 present an aerodynamic design or
cross section, similar to an airfoil or wing. The leading end 11022
in combination with the air stop 11040 can present a smooth surface
or profile that introduces minimal or no disruption to laminar
fluid flowing through the damper system. The air stop may be
coupled with the damper casing, the damper element, or both. In
some cases, the air stop is flexible. In some cases, the air stop
is rigid. The air stops, damper members, and sensors operate to
minimize unwanted or inadvertent pressure drop across the damper
system, particularly when the damper system is in an open
configuration. Thus laminar flow of fluid passing through the
damper system is maximized, particularly the fluid passing through
a central area or zone disposed between the two damper members.
[0081] FIG. 12 shows an end view of damper system 11000 according
to embodiments of the present invention. The damper system is shown
in a 10% open configuration, with air or fluid flowing through the
system toward the viewer as indicated by arrow A. Damper system
11000 includes a damper casing 11010, and one or more damper
members 11020 disposed within the damper casing. As shown here,
damper members 11020 are attached with damper shafts 11030 toward a
leading end 11022 of the damper members, and can pivot about damper
shafts 11030 as indicated by arrow B. In the embodiment shown here,
damper members 11020 are coupled with one or more sensors 11050. A
trailing end 11024 of damper member 11020 can be shaped, profiled,
or contoured so as to allow for a 100% shutoff of fluid passing
through the damper system. This shutoff may be accomplished by a
cooperative association between trailing edges or ends 11024 of two
opposing damper members, or between a trailing end 11024 and a
damper casing 11030. In related embodiments, the shutoff can be
accomplished by a cooperative association between sensors that are
disposed at or near the trailing ends of the damper members.
[0082] FIGS. 13A, 13B and 13C schematically illustrate drive
systems for pivoting or sliding of the damper members. FIG. 13A
shows a side view of a damper system 13000a according to
embodiments of the present invention. The damper system is shown in
a 100% closed configuration, with air or fluid flowing through the
system as indicated by arrow A being prevented from passing across
the trailing ends 13024a of damper members 13020a. Damper system
13000a includes a damper casing 13010a, and one or more damper
members 13020a disposed within the damper casing. As shown here,
damper members 13020a are attached with damper shafts 13030a toward
a leading end 13022a of the damper members, and can pivot or rotate
about damper shafts 13030a as indicated by arrow B. The damper
system also includes one or more air stops 13040a, optionally
disposed toward leading end 13022a of damper members 13020a, that
assist in maintaining laminar air flow and reducing or avoiding
turbulence. In the embodiment shown here, damper members 13020a are
coupled with one or more sensors 13050a. The sensors are disposed
on the trailing end 13024a of the damper members 13020a. Sensors
may also or alternatively be disposed at any location along the
damper member, at or near the damper casing, and the like. Sensors
may detect any of a variety of spatial, positional, or angular
orientations of a damper member. For example, a sensor may detect a
distance between damper members, a distance between a damper member
and the damper casing, a position or an orientation of a damper
member relative to the damper casing, a position or an orientation
of a damper member relative to another damper member, and the like.
A sensor may also detect sound or pressure that is present in the
damper system. Often, the sensor will be configured so as to
present minimal or no disruption to air or fluid passing through
the damper system. For example, the sensor may be embedded beneath
the surface of the damper member, or may be contiguous with the
smooth or aerodynamic surface of the damper member. Damper system
13000a may also include a control mechanism 13060a that controls
operation of the damper members. In some embodiments, the control
mechanism includes an input for receiving signals or information
generated by the sensors, or an input for receiving signals,
instructions, information, and the like from various components of
an HVAC system. Control mechanism 13060a may include an actuator
13070a and a linkage arrangement 13080a. Typically, all or part of
the control mechanism is located on the exterior of the damper
casing, or does not otherwise affect the flow of fluid passing
through the damper casing and across the damper members.
[0083] FIG. 13B shows a side view of a damper system 13000b
according to embodiments of the present invention. The damper
system is shown in a 100% closed configuration, with air or fluid
flowing through the system as indicated by arrow A being prevented
from passing across the trailing ends 13024b of damper members
13020a. Damper system 13000b includes a damper casing 13010b, and
one or more damper members 13020b disposed within the damper
casing. As shown here, damper members 13020b are attached with
damper shafts 13030b toward a leading end 13022b of the damper
members, and can pivot or rotate about damper shafts 13030b as
indicated by arrow B. In the embodiment shown here, damper members
13020b are coupled with one or more sensors 13050b. The sensors are
disposed on the trailing end 13024b of the damper members 13020b.
Sensors may also or alternatively be disposed at any location along
the damper member, at or near the damper casing, and the like.
Sensors may detect any of a variety of spatial, positional, or
angular orientations of a damper member. For example, a sensor may
detect a distance between damper members, a distance between a
damper member and the damper casing, a position or an orientation
of a damper member relative to the damper casing, a position or an
orientation of a damper member relative to another damper member,
and the like. A sensor may also detect sound or pressure that is
present in the damper system. Often, the sensor will be configured
so as to present minimal or no disruption to air or fluid passing
through the damper system. For example, the sensor may be embedded
beneath the surface of the damper member, or may be contiguous with
the smooth or aerodynamic surface of the damper member. Damper
system 13000b may also include a control mechanism 13060b that
controls operation of the damper members. In some embodiments, the
control mechanism includes an input for receiving signals or
information generated by the sensors, or an input for receiving
signals, instructions, information, and the like from various
components of an HVAC system. Control mechanism 13060b may include
a gear assembly 13075b that includes one or more gears 13077b.
Typically, all or part of the control mechanism is located on the
exterior of the damper casing, or does not otherwise affect the
flow of fluid passing through the damper casing and across the
damper members.
[0084] FIG. 13C shows a side view of a damper system 13000c
according to embodiments of the present invention. In this figure,
one of two damper members 13020c is shown. Air or fluid flows
through the system as indicated by arrow A. Damper system 13000c
includes a damper casing 13010c, and one or more damper members
13020c disposed within the damper casing. As shown here, damper
members 13020c are coupled with a damper housing or track 13090c,
such that the damper member can slide within or along the track as
indicated by arrow C. Damper members 13020c can be coupled with one
or more sensors 13050c. The sensors are disposed on the trailing
end 13024c of the damper members 13020c. Sensors may also or
alternatively be disposed at any location along the damper member,
at or near the damper casing, and the like. Sensors may detect any
of a variety of spatial, positional, or angular orientations of a
damper member. For example, a sensor may detect a distance between
damper members, a distance between a damper member and the damper
casing, a position or an orientation of a damper member relative to
the damper casing, a position or an orientation of a damper member
relative to another damper member, and the like. A sensor may also
detect sound or pressure that is present in the damper system.
Often, the sensor will be configured so as to present minimal or no
disruption to air or fluid passing through the damper system. For
example, the sensor may be embedded beneath the surface of the
damper member, or may be contiguous with the smooth or aerodynamic
surface of the damper member. Damper system 13000c may also include
a control mechanism 13060c that controls operation of the damper
members. In some embodiments, the control mechanism includes an
input for receiving signals or information generated by the
sensors, or an input for receiving signals, instructions,
information, and the like from various components of an HVAC
system. Control mechanism 13060c may operate to slide or move the
damper member along or within the track. Typically, all or part of
the control mechanism is located on the exterior of the damper
casing, or does not otherwise affect the flow of fluid passing
through the damper casing and across the damper members.
[0085] FIGS. 14A-14C schematically illustrate an alternative damper
assembly having a deformable helical damper member. When in a
restricted flow configuration, such a damper member may induce a
vortex within the duct and/or casing. Static pressure may result
from such a vortex within the duct system, helping to make the
system more energy efficient, quieter, and may provide better
overall HVAC performance characteristics. FIG. 14A shows a side
view of a damper system 14000 according to embodiments of the
present invention. FIGS. 14B and 14C present end views of the
damper system. Damper system 14000 includes a control member 14010,
which optionally includes a metal or a composite, and a deformable
helical damper member 14020. When control member 14010 is rotated
or turned as indicated by arrow A, the damper member 14020 may also
turn or otherwise form to provide or create a vortex in fluid that
passes through the damper system. In some embodiments, the amount
or degree to which the control member is turned or activated
determines the amount of air or fluid being turned down or
otherwise regulated. For example, if the control member is turned a
greater amount, the damper member may prevent a greater amount of
fluid from passing therethrough. Conversely, if the control member
is turned or activated a lesser amount, the damper member may
prevent a lesser amount of fluid from passing therethrough. The
damper system may be operated to any desired configuration, within
a range from 0% open to 100% open.
[0086] Although the present invention has been described in terms
of the presently preferred embodiment, it is to be understood that
such disclosure is purely illustrative and is not to be interpreted
as limiting. Consequently, without departing from the spirit and
scope of the invention, various alterations, modifications, and/or
alternative applications of the invention will, no doubt, be
suggested to those skilled in the art after having read the
preceding disclosure. Accordingly, it is intended that the
following claims be interpreted as encompassing all alterations,
modifications, or alternative applications as fall within the true
spirit and scope of the invention.
* * * * *