U.S. patent application number 14/154113 was filed with the patent office on 2015-07-16 for modular outboard heat exchanger air conditioning system.
This patent application is currently assigned to MULTISTACK, LLC. The applicant listed for this patent is MULTISTACK, LLC. Invention is credited to Mark PLATT.
Application Number | 20150198353 14/154113 |
Document ID | / |
Family ID | 53521056 |
Filed Date | 2015-07-16 |
United States Patent
Application |
20150198353 |
Kind Code |
A1 |
PLATT; Mark |
July 16, 2015 |
MODULAR OUTBOARD HEAT EXCHANGER AIR CONDITIONING SYSTEM
Abstract
The invention discloses a modular air conditioning, heating, and
heat recovery system. Particularly, the invention discloses a
modular system having the condenser and/or evaporator heat
exchangers mounted outboard of the modules and being easily
removable and separatable by virtue of their positioning and
valving.
Inventors: |
PLATT; Mark; (Sparta,
WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MULTISTACK, LLC |
Sparta |
WI |
US |
|
|
Assignee: |
MULTISTACK, LLC
Sparta
WI
|
Family ID: |
53521056 |
Appl. No.: |
14/154113 |
Filed: |
January 13, 2014 |
Current U.S.
Class: |
62/298 ;
62/259.1 |
Current CPC
Class: |
F25D 23/006 20130101;
F24F 3/044 20130101; F24F 13/32 20130101; F24F 2221/36
20130101 |
International
Class: |
F24F 13/32 20060101
F24F013/32; F25D 23/00 20060101 F25D023/00; F24F 3/044 20060101
F24F003/044 |
Claims
1. Air conditioning apparatus, comprising: a plurality of modular
air conditioning units, each of said modular units having a
compressor, at least one evaporator heat exchanger having at least
one cooling load heat exchange fluid inlet, at least one cooling
load heat exchange fluid outlet, at least one cooling fluid inlet
and at least one cooling fluid outlet, at least one condenser heat
exchanger having at least one cooling fluid inlet and at least one
cooling fluid outlet, at least one header pipe for cooling load
evaporator heat exchange fluid, at least one header pipe for
condenser cooling fluid, a plurality of condenser isolation valves,
a plurality of evaporator isolation valves, and a support
structure, said condenser and said evaporator each being
fluid-isolatable via said condenser isolation valves and said
evaporator isolation valves, respectively, wherein at least one of
said condenser and evaporator are positioned to be removable from
said modular unit unimpeded by other structure.
2. The air conditioning apparatus as defined in claim 1, wherein
both said condenser and said evaporator are positioned to be
removable from said modular unit unimpeded by other structure.
3. The air conditioning apparatus as defined in claim 1, wherein at
least one of said condenser and evaporator is disposed at the
periphery of said modular unit.
4. The air conditioning apparatus as defined in claim 1, wherein
both of said condenser and evaporator are disposed at the periphery
of said modular unit.
5. The air conditioning apparatus as defined in claim 1, wherein at
least one of said condenser and evaporator are disposed outboard of
said header pipes.
6. The air conditioning apparatus as defined in claim 1, wherein
both of said condenser and evaporator are disposed outboard of said
header pipes.
7. The air conditioning apparatus as defined in claim 1, wherein
said header pipes are connectable via releasable and reattachable
couplings.
8. The air conditioning apparatus as defined in claim 2, wherein
said header pipes are connectable via releasable and reattachable
couplings.
9. The air conditioning apparatus as defined in claim 3, wherein
said header pipes are connectable via releasable and reattachable
couplings.
10. The air conditioning apparatus as defined in claim 4, wherein
said header pipes are connectable via releasable and reattachable
couplings.
11. The air conditioning apparatus as defined in claim 5, wherein
said header pipes are connectable via releasable and reattachable
couplings.
12. The air conditioning apparatus as defined in claim 6, wherein
said header pipes are connectable via releasable and reattachable
couplings.
Description
[0001] This application claims the benefit of U.S. Provisional
Application 61/053,553 filed 15 May 2008.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to modular refrigeration systems and
relates particularly to such refrigeration systems for use in air
conditioning installations. The invention discloses a unique
outboard arrangement of the evaporator and condenser heat
exchangers for facilitating removal and maintenance of those
elements.
[0004] Air conditioning installations for modern buildings, such as
large office structures, shopping complexes, warehouses and the
like, conventionally comprise air treatment units to which water or
other heat exchange fluid is pumped whereby air is cooled (in
summer) or heated (in winter) and circulated to the areas to be
conditioned. The heat exchange fluid for cooling is generally
circulated through an evaporator/chiller of a refrigeration system
which removes heat from the fluid. The heat is given up to a second
heat exchange fluid which circulates passed the condenser of the
refrigeration system. The second heat exchange fluid may also
comprise water or other liquid or may comprise air in an air cooled
or evaporative cooler system. Such systems may also be designed to
operate on reverse cycle and act as heat pumps to heat the air to
be conditioned. The refrigeration system will, of course, have
cooling/heating capacity appropriate to the capacity of the air
conditioning installation. Alternatively, the system may be
arranged as a dedicated heat recovery system, whereby the system
will be sized to maximize the heat recovery requirement.
[0005] For high capacity installations, as may be incorporated in
office and apartment complexes, a refrigeration system of high
output is necessary to be able to handle the maximum load expected.
In practice, such high output refrigeration systems tend to be more
prone to breakdown and failure than do lower output refrigeration
units. Such breakdowns and failures often leave the building in
which the system is installed without any air conditioning until
the breakdown or failure is remedied. In high capacity systems,
breakdowns and failures can often take days and, sometimes, weeks
to repair.
[0006] Further, in the design and construction of many modern
building structures, provision is made for the expansion of the
building structure, that is, the building is constructed in a
number of stages spread over a period of time. Because of the
difficulty in expanding a predesigned air conditioning system, it
is generally necessary to design and install the system to have the
air conditioning capacity for the completed building structure.
This means, therefore, that the system is running, inefficiently,
at less than full load capacity until such time as all building
stages are completed.
[0007] In other instances, building structures are extended after
the initial design and construction, and such extensions often
require the air conditioning system for the initial building
structure to be completely replaced with a new system to be able to
handle the load of the extended building structure. Further, in
densely populated urban areas, such as New York City,
transportation of a conventional single large unit may require a
shutdown of traffic routes during transportation of the unit to its
installation location. Shutdowns are extremely difficult to arrange
and result in extremely high costs. These problems are completely
avoided by the present invention.
[0008] 2. Description of Related Art
[0009] In the past, the condensers for refrigeration units have
been connected in series as are the water circuits of the
evaporator/chillers thus requiring each refrigeration unit to have
individual design criteria in accordance with the variation in
temperature of the water circulating through the individual, series
connected condensers and evaporator/chillers.
[0010] It is desirable to provide an improved refrigeration system
which obviates the disadvantages of the known systems.
[0011] It is also desirable to provide an improved refrigeration
system which allows the design and construction of an air
conditioning system for a building or like structure, which air
conditioning system is less prone to breakdown and failure than
known air conditioning systems.
[0012] It is also desirable to provide an improved refrigeration
system particularly for air conditioning and in which a breakdown
or failure of part of the refrigeration system does not prevent
operation of the air conditioning plant.
[0013] It is further desirable to provide an improved air
conditioning system using discrete refrigeration units which can be
removed, repaired and/or replaced without major disruption of the
operation of the air conditioning system.
[0014] It is a further object of the invention to provide condenser
and/or evaporator heat exchangers outboard from the other component
of a module, and isolatable through valving, to facilitate the
removal and maintenance of these elements.
BRIEF SUMMARY OF THE INVENTION
[0015] According to one aspect of the present invention there is
provided a refrigeration system formed by a plurality of modular
units, each unit comprising at least one refrigeration circuit
separate from the or each circuit of the or each other unit, a
support structure or housing carrying the or each circuit of the
unit, said support structure accommodating at least one passage for
flow of heat exchange fluid in heat exchange relation with at least
one heat exchange element of the circuit, said flow passage being
adapted for communication with a corresponding flow passage of the
or each other unit, and control means for controlling operation of
the assembly of units.
[0016] Each modular unit preferably has an evaporator circuit in
the housing and separated from a condenser circuit in the housing.
With this arrangement, the housing defines one passage for the flow
of heat exchange fluid in heat exchange relation with the
evaporator circuit and a second passage for flow of a second heat
exchange fluid in heat exchange relation with the condenser
circuit. The module include separate evaporator and/or condenser
heat exchangers. These heat exchangers may be mounted outboard of
the other elements of the module, and may be isolatable by
valving.
[0017] In a particular form of the invention, headers are provided
on or incorporated in the housing to convey heat exchange fluid to
and from the flow passages in the housing. The headers of each
housing are adapted to be connected to headers of the or each
adjacent unit. In one embodiment, the headers are arranged inboard
of the evaporator and/or condenser heat exchangers.
[0018] In various embodiments the condenser and/or evaporator may
be mounted above, below, or to the side of the header pipes.
[0019] The condenser and/or evaporator are totally arranged to be
removable unimpeded by any other elements of the modular unit.
[0020] Preferably, the control system is operative to cause
progressive actuation of the units in sequence in response to
increasing load demand, the sequence of actuation being
automatically changed at periodic intervals whereby to
substantially equalize usage of all units over a prolonged period.
In a particularly preferred embodiment, one of the modular units is
designated a master unit and is provided with electric control
means to which other, slave units are connected whereby operation
of all units is controlled by the master unit. The control means so
arranged that, in the event of a failure of one of the modular
units, that unit is electrically disconnected from service and an
appropriate alarm indication is given. For this purpose, each
modular unit is provided with appropriate sensors to monitor
operation of the respective units.
[0021] According to another aspect of the invention there is
provided a refrigeration system comprising a plurality of
refrigeration units, each unit having compressor means, a
refrigerant condensing circuit incorporating a condenser, a
refrigeration evaporator circuit incorporating an evaporator, means
for circulating a first heat exchange fluid passed the evaporator
and means for circulating a second heat exchange fluid passed the
condenser, characterized in that each unit includes a modular
support structure or housing for the respective evaporator and the
respective condenser, the support structure accommodating at least
one flow passage for the first heat exchange fluid in heat exchange
relation with the evaporator, structure for mounting the
compressor, header structure for supplying the first heat exchange
fluid to said at least one flow passage and for conveying said
fluid therefrom, and structure for passing the second heat exchange
fluid through the condenser.
[0022] In the most preferred form, each modular housing has sides
which abut opposed sides of adjacent units, the header structure of
abutted units being interconnected to form common manifolds for
supply and return of the respective heat exchange fluids. Each unit
preferably comprises two refrigerant compressors with separate
condenser and evaporator circuits. The modular structure houses one
or more evaporators in one compartment which defines a single flow
passage for the first heat exchange fluid. The modular structure of
each unit also houses one or more condensers in a second
compartment which defines a single flow passage for the second heat
exchange fluid.
[0023] Each said header structure may comprise a fluid supply pipe
and a fluid return pipe communicating with the respective flow
passages, the supply and return pipes of each unit having
connection means for coupling two respective pipes of adjacent
units.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0024] FIG. 1 is a perspective view of a plurality of
interconnected modular refrigeration units in accordance with the
present invention,
[0025] FIG. 2 is a perspective view of one modular refrigeration
unit in accordance with the invention,
[0026] FIG. 3 is a top view of a modular unit,
[0027] FIG. 4 is a side view of a modular unit,
[0028] FIG. 5 is a side view of a modular unit,
[0029] FIG. 6 is a side view of a modular unit.
DETAILED DESCRIPTION OF THE INVENTION
[0030] With reference to FIG. 1, a refrigeration system for use in
an air conditioning installation, particularly a high capacity
installation, comprises a series of modules 1 arranged in
face-to-face relation. As shown in FIGS. 1 to 6, each module
comprises a support structure 16 on which is mounted two sealed
unit refrigeration compressors 15. The support structure 16 is a
two-level arrangement, a horizontal bottom structure, a horizontal
top structure, and vertical load bearing structures connecting the
top and bottom structures. The structure 16 is divided into two
compartments, a top and a bottom area. The bottom area contains at
least one evaporator 2 and one condenser 3. An appropriate
refrigerant expansion device (not shown) is connected between the
respective evaporator 2 and condenser 3 of each refrigeration
circuit. It has been found that the conventional modular system
having the header pipes 4,5 mounted outboard, and the evaporator 2
and condenser 3 mounted inboard of the header pipes 4,5 presents
serious drawbacks to a modular system. One large drawback is that
the heat exchangers, which are one of the high maintenance elements
of the system, are extremely difficult to access when mounted
inboard. It would normally be required to shut down the entire
system, remove the header pipes 4,5 blocking access to the
evaporator 2/condenser 3 and then after servicing the evaporator
2/condenser 3, reinstalling and reconnecting both the evaporator
2/condenser 3 equipment and the header pipes 4,5 before restarting
the entire system.
[0031] The present invention overcomes the serious drawbacks by new
structure associated with a modular system. In the new invention,
the header pipe 4,5 are arranged in the interior of the module 1,
inboard of either or both of the evaporator 2 and/or condenser 3.
The evaporator 2 and the condenser 3 are mounted at the outermost
region of each modular unit 1. This allows for removal and/or
servicing of the evaporator 2/condenser 3 without the need for
disturbing the header pipes 4,5 and therefore without the need to
shut down the entire system during removal and/or servicing of the
evaporator 2/condenser 3.
[0032] The evaporator 2 and/or condenser 3 are isolatable from the
evaporator header pipe 4 and/or the condenser header pipe 5,
respectively, by an evaporator isolation valve 13 and/or a
condenser isolation valve 12. The evaporator isolation valve 13 is
arranged in a manner similar to the condenser isolation valve 12
shown in the figures. Either one or both of the evaporator 2 and
condenser 3 have valves positioned between the evaporator
2/condenser 3 heat exchanger and the respective header pipes 4,5.
The valves are on one or both of the supply and/or return conduits
or pipes, and are arranged in a manner such that they are open
during normal operation of the module, but can be closed when it is
desired to isolate the evaporator 2/condenser 3 from the respective
fluid connection with the respective header pipe.
[0033] Likewise, isolation valves may be positioned on the
refrigerant fluid supply and return pipes, making the respective
evaporator 2/condenser 3 easily removable and replaceable.
[0034] Isolating the evaporator 2/condenser 3 from their respective
header pipe facilitates several advantages over the prior art. If a
leak is detected in one of the evaporator 2/condenser 3 units, that
unit can be immediately isolated and the leak stopped by merely
closing the isolation valves. Then the evaporator 2/condenser 3 may
be serviced and/or removed at a convenient time, without the
necessity of an immediate shutdown of the entire modular system in
order to address the leak. Meanwhile, the fluid in the respective
header pipes continues to flow normally through the header pipes,
and through all the other operational evaporator 2/condenser 3
elements.
[0035] By being positioned outboard of the other components, the
evaporator 2/condenser 3 may be isolated and removed with great
ease. Other problems aside from leaks, such as blockages and other
failures, can easily be remedied by the structure of the present
invention. Further, by isolating the compressor 15 from the
evaporator 2/condenser 3 by closing the refrigerant isolation
valves 18, compressor problems can likewise be easily
addressed.
[0036] To further enhance the serviceability of the evaporator
2/condenser 3/compressor 15, quick-release couplings may be
incorporated between the isolation valves 13,12,18 and the
respective evaporator 2/condenser 3 and/or compressor 15. This will
allow for extremely simple isolation and removal of the respective
element.
[0037] The bottom area accommodates separate fluid flow passages
which serve to carry separate flows of heat exchange fluid, for
example water, in heat exchange relation with the evaporator 2 and
the condenser 3.
[0038] The heat exchange fluid, i.e. water, which is to be cooled
by the evaporator 2, is supplied to the evaporator 2 by a header
pipe 4 mounted on structure. The header pipe 4 has an opening which
communicates with an inlet extending from the evaporator 2.
[0039] Cooled water is taken from evaporator 2 through the header
pipe 4. The lower header pipe has an opening, which communicates
with an evaporator 2.
[0040] Header pipes 5 are mounted on the support structure 16 and
communicate with the condenser 3 by similar openings and tubes,
respectively. The header pipe conveys cooling fluids such as water
to the condenser 3, the cooling water being removed through the
header pipe 5.
[0041] Each of the header pipes 4,5 are of a length enabling
end-to-end connection with corresponding header pipes of adjacent
modules 1 to form a common series of fluid manifolds. A coupling
which may be releasable is generally indicated at 7, and is used to
form fluid tight connections between the pipe ends. The releasable
coupling may be a compression style, or may be flanged, bolted, or
sleeve type. In one embodiment the releasable couplings are
releasable and then reattachable. The coupling may also be welded,
requiring cutting to separate the units, or may be chemically
attached. The coupling may be any style of coupling known to
connect two headers or pipes. End caps are used to seal the ends of
the header pipes of the last module 1 of the assembly while
appropriate fluid supply and return lines (not shown) are connected
to the header pipes of the first module 1.
[0042] Pipes 14 for conveying refrigerant between the compressors
15, condensers 3 and evaporators 2, respectively extend down and
through the support structure 16 to the respective heat
exchangers.
[0043] There may be side walls on each side of the support
structure which are removable to give access to the components. The
side walls may be sealed against the modules bottom wall, the top
wall on which the compressors are mounted, the partition, and the
front and rear walls to ensure that the compartments are fluid
tight. It will be appreciated, however, that the evaporator coils
and the condenser can be incorporated in a series of one or more
independent heat exchange devices which define the separate
passageways for the respective fluids, thus obviating the need to
provide a fluid tight compartment.
[0044] Support structure 16 may have mounted upon it an electrical
bus bar to which the compressors 15 and other devices are
electrically connected. The bus bar has appropriate connections at
each end to enable the bus bars of adjacent units to be
interconnected to provide continuity of electrical power supply to
each unit.
[0045] Although the compressors 15 mounted on the top wall of the
support structure 16 may be exposed, it is preferred that a top
cover is provided over the compressors 15. The top cover is
removable without removing the respective module from the assembly
to facilitate service and maintenance. Removable front and rear
cover plates, respectively, may also be provided.
[0046] As described above, each module 1 comprises a separate
refrigeration unit comprising two refrigeration circuits. The
refrigeration circuits of each unit are, essentially, independent
of those of each of the other modules, with each circuit including
its own control means in order to control and/or deactuate the
refrigeration unit in the event of an overload or other malfunction
occurring in that unit. The control means includes an electrical
control box 6 mounted on the top of the support structure 16. The
control box 6 receives signals from sensors (not shown) associated
with operation of the refrigeration units and transmits those
signals through electrical connections to a master control panel in
the system, preferably an end module. The master control panel
houses the electrical control circuits for the control of the
assembly of modules 1 in accordance with the desired operation or
control of the air conditioning installation whereby the cooling
effect of the system (or the heating effect if the refrigeration
units are acting in a reverse cycle mode, or the heat recovery
effect) meets the instantaneous requirements of the air
conditioning installation. Under part load conditions, the control
circuits are operative to actuate only one or some of the modules 1
(depending on the load) with other units being brought into
operation as the load increases. Advantageously, the control
circuits are operative to automatically switch, at predetermined
intervals, the order in which the modules 1 are brought into
operation in order to substantially equalize the usage of the
individual modules over a prolonged period of time. The control
circuits may include memory circuits which maintain a constant
record of the hours of operation of each module 1, the information
being used to ensure substantial equalization of usage of the
individual modules over a period of time.
[0047] A microprocessor can be used to control the progressive
switching functions and to match operation of the refrigeration
system to the load requirements of the air conditioning
installation to which the system is connected.
[0048] The modular construction described permits additional slave
modules 1 to be added to the assembly in order to increase the
capacity of the refrigeration system resulting from changes in load
criteria of the air conditioning installation. In the event of a
malfunction in one of the modules 1, that module may be shut down
by the control circuits, while permitting continued operation of
the other modules. Depending on the fault, the defective module may
be repaired in situ while the system is in operation, or the
defective module may be removed from the assembly for repair, a
spare module being incorporated in the assembly to replace the
removed, defective module or the assembly being permitted to
operate without a replacement. Naturally, if a module is removed
from the assembly for repair or maintenance, the header pipes 4,5
of the modules 1 on each side of that to be removed are connected
together by temporary pipe connections to maintain the heat
exchange fluid circuits. Similar temporary electrical connections
are also made.
[0049] One embodiment uses a single compressor, the housing having
a single compartment for the evaporator coil while the condenser
coil is located in an air cooling chamber located above the
compressor. Fans draw air through the chamber to cool the finned
condenser coil.
[0050] In some installations, an evaporative condenser is used and
for this purpose water sprays spray water over the condenser
coil.
[0051] A refrigeration system formed in accordance with the present
invention utilizing a number of modules 1 assembled together to
form a single unit will have a reliability related to the
reliability of the individual modules 1, which is substantially
better than the reliability of a single refrigeration unit of
equivalent output. The reliability is further enhanced, in
accordance with the invention, by the continued operation of other
modules of an assembly if one module is shut down for repair or
maintenance. A system of increased capacity can be obtained in
accordance with the invention simply by adding additional modules,
as required, to take account of any increase in load resulting from
a building extension or the like.
[0052] The use of header pipes to form common manifolds for supply
and return of heat exchange fluid facilitates interconnection of
the separate refrigeration units and allows modular construction of
identical units which can be mass produced for relatively less cost
than fabricated units. The modular units are readily assembled into
complete units of any desired capacity.
[0053] As indicated above, the refrigeration circuits may be
adapted for reverse cycle operation, and for heat recovery use, if
desired.
[0054] It will be understood that the refrigeration system of the
invention can be used for purposes other than air conditioning
installations. Thus, the modular system is particularly useful for
cool storage, cool rooms and freezer rooms in food processing and
handling industries and in any other area requiring the use of
relatively large capacity refrigeration. [0055] 1. Module [0056] 2.
Evaporator Heat Exchanger [0057] 3. Condenser Heat Exchanger [0058]
4. Header Pipes for Cooling Load Evaporator Heat Exchange Fluid
[0059] 5. Header Pipe for Condenser Cooling Fluid [0060] 6. Control
Box [0061] 7. Releasable Coupling [0062] 8. Evaporator Cooling Load
Heat Exchange Fluid Inlet [0063] 9. Evaporator Cooling Load Heat
Exchange Fluid Outlet [0064] 10. Condenser Cooling Fluid Inlet
[0065] 11. Condenser Cooling Fluid Outlet [0066] 12. Condenser
Isolation Valve [0067] 13. Evaporator Isolation Valve [0068] 14.
Refrigerant Supply Conduit [0069] 15. Compressor [0070] 16. Support
Structure [0071] 17. Evaporator Cooling Fluid Inlet [0072] 18.
Refrigerant Isolation Valve [0073] 19. Evaporator Cooling Fluid
Outlet
* * * * *