U.S. patent number RE46,708 [Application Number 14/984,405] was granted by the patent office on 2018-02-13 for embedded heat exchanger for heating, ventilation, and air conditioning (hvac) systems and methods.
The grantee listed for this patent is John C. Karamanos. Invention is credited to John C. Karamanos.
United States Patent |
RE46,708 |
Karamanos |
February 13, 2018 |
Embedded heat exchanger for heating, ventilation, and air
conditioning (HVAC) systems and methods
Abstract
A zone-control unit for use in a heating, ventilation, and air
conditioning (HVAC) system, the zone-control unit includes a heat
exchanger, an inlet piping assembly coupled with the heat exchanger
for supplying fluid to the heat exchanger, an outlet piping
assembly coupled with the heat exchanger for receiving fluid from
the heat exchanger, a bracket that maintains the inlet piping
assembly and the outlet piping assembly in positional relationship,
and an ancillary component coupled with the heat exchanger.
Inventors: |
Karamanos; John C. (San Jose,
CA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Karamanos; John C. |
San Jose |
CA |
US |
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|
Family
ID: |
1000002778763 |
Appl.
No.: |
14/984,405 |
Filed: |
December 30, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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10092933 |
Mar 6, 2002 |
7478761 |
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60884366 |
Jan 10, 2007 |
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Reissue of: |
11972479 |
Jan 10, 2008 |
8714236 |
May 6, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24F
1/032 (20190201); F24F 13/30 (20130101); F24F
1/26 (20130101); F24F 11/74 (20180101); F24F
1/032 (20190201); F28F 9/002 (20130101); B23P
15/26 (20130101); F28F 27/02 (20130101); F28F
9/0246 (20130101); F24F 2110/30 (20180101); Y10T
29/4935 (20150115); Y10T 29/49826 (20150115) |
Current International
Class: |
F24F
3/08 (20060101); F28F 9/00 (20060101); F28F
9/02 (20060101); F28F 27/02 (20060101); B23P
15/26 (20060101); F24F 1/26 (20110101); F24F
1/00 (20110101) |
References Cited
[Referenced By]
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Dec 2005 |
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WO |
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Other References
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Primary Examiner: Kaufman; Joseph
Attorney, Agent or Firm: Amin, Turocy & Watson, LLP
Parent Case Text
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a .[.nonprovisional.].
.Iadd.continuation-in-part .Iaddend.of, and claims the benefit of
priority .[.from,.]. .Iadd.under 35 U.S.C. .sctn. 120 from U.S.
patent application Ser. No. 10/092,933 entitled, "Self-Contained
Ventilation Flow Control System," filed Mar. 6, 2002, now U.S. Pat.
No. 7,478,761 and .Iaddend.U.S. Provisional .[.Patent.].
Application No. 60/884,366 filed Jan. 10, 2007. This application is
related to U.S. patent application Ser. No. 11/429,418 filed May 5,
2006, U.S. patent application Ser. No. 11/180,310 filed Jul. 12,
2005, U.S. Pat. No. 6,951,324, U.S. patent application Ser. No.
10/857,211 filed May .[.24.]. .Iadd.28.Iaddend., 2004, U.S. patent
application Ser. No. 11/567,301 filed Dec. 6, 2006, U.S. Pat. No.
7,140,236, U.S. patent application Ser. No. 11/560,294 filed Nov.
15, 2006, .Iadd.and .Iaddend.U.S. patent application Ser. No.
11/619,535 filed Jan. 3, 2007.[., and U.S. patent application Ser.
No. 10/092,933 filed Sep. 11, 2003.].. The entire contents of each
of these applications and their priority filings are incorporated
herein by reference for all purposes.
Claims
What is claimed is:
1. A method of manufacturing a plurality of portable piping
structures for installation in a heating, ventilation, and air
conditioning (HVAC) system, comprising: providing a first heat
exchange coil having a first dimension, a first inlet pipe, and a
first outlet pipe, the first inlet and outlet pipes separated by a
first distance; providing a second heat exchange coil having a
second dimension, a second inlet pipe, and a second outlet pipe,
the second inlet and outlet pipes separated by a second distance;
coupling a first inlet piping assembly and a first outlet piping
assembly with the first heat exchange coil to provide a first
portable piping structure of the plurality of portable piping
structures; coupling a second inlet piping assembly and a second
outlet piping assembly with the second heat exchange coil to
provide a second portable piping structure of the plurality of
portable piping structures; coupling a first bracket with the first
inlet piping assembly and the first outlet piping assembly, wherein
the first bracket provides a known spacing distance between a
central longitudinal axis defined by the first inlet piping
assembly and a central longitudinal axis defined by the first
outlet piping assembly; and coupling a second bracket with the
second inlet piping assembly and the second outlet piping assembly,
wherein the second bracket provides the known spacing distance
between a central longitudinal axis defined by the second inlet
piping assembly and a central longitudinal axis defined by the
second outlet piping assembly, wherein the known spacing distance
provided by the first bracket is equal to the known spacing
distance provided by the second bracket, wherein the first
dimension of the first heat exchange coil is different from the
second dimension of the second heat exchange coil, wherein the
first distance between the first inlet and outlet pipes is equal to
the second distance between the second inlet and outlet pipes, and
wherein a first specified quality assurance amount of pressure is
present within the first sealed and closed system and a second
specified quality assurance amount of pressure is present within
the second sealed and closed system, wherein the first portable
piping structure comprises a first pressure gauge that measures and
displays the first specified quality assurance amount of pressure,
and wherein the second portable piping structure comprises a second
pressure gauge that measures and displays the second specified
quality assurance amount of pressure.
2. The method according to claim 1, further comprising coupling a
first ancillary component with the first heat exchange coil of the
first portable piping structure, and coupling a second ancillary
component with the second heat exchange coil of the second portable
piping structure.
3. The method according to claim 2, wherein the first ancillary
component comprises a first direct digital control (DDC) controller
and the second ancillary component comprises a second direct
digital control (DDC) controller.
4. The method according to claim 1, further comprising coupling a
first ancillary component with the first bracket, and coupling a
second ancillary component with the second bracket.
5. The method according to claim 1, further comprising coupling a
first ancillary component with the first inlet piping assembly, and
coupling a second ancillary component with the second inlet piping
assembly.
6. The method according to claim 1, further comprising coupling a
first ancillary component with the first outlet piping assembly,
and coupling a second ancillary component with the second outlet
piping assembly.
7. The method according to claim 1, further comprising sealing the
first inlet piping assembly and the first outlet piping assembly
such that the first portable piping structure comprises a first
sealed and closed system, and sealing the second inlet piping
assembly and the second outlet piping assembly such that the second
portable piping structure comprises a second sealed and closed
system, such that the first sealed and close system is separate
from the second sealed and closed system.
8. The method according to claim 7, further comprising shipping the
first and second sealed and closed portable piping structure
systems to a job site.
9. The method according to claim 1, further comprising coupling the
first and second inlet piping assemblies with a first common inlet
piping assembly, and coupling the first and second outlet piping
assemblies with a second common outlet piping assembly.
10. The method according to claim 1, further comprising placing the
first coil at least partially within a first casing, placing the
second coil at least partially within a second casing, coupling a
first direct digital control (DDC) controller to the first casing,
and coupling a second direct digital control (DDC) controller to
the second casing.
11. The method according to claim 1, further comprising: providing
a third heat exchange coil having a third dimension; providing a
fourth heat exchange coil having a fourth dimension; coupling a
third inlet piping assembly and a third outlet piping assembly with
the third heat exchange coil to provide a third portable piping
structure of the plurality of portable piping structures; coupling
a fourth inlet piping assembly and a fourth outlet piping assembly
with the fourth heat exchange coil to provide a fourth portable
piping structure of the plurality of portable piping structures;
coupling a third bracket with the third inlet piping assembly and
the third outlet piping assembly, wherein the third bracket
provides a known spacing distance between a central longitudinal
axis defined by the third inlet piping assembly and a central
longitudinal axis defined by the third outlet piping assembly; and
coupling a fourth bracket with the fourth inlet piping assembly and
the fourth outlet piping assembly, wherein the fourth bracket
provides the known spacing distance between a central longitudinal
axis defined by the fourth inlet piping assembly and a central
longitudinal axis defined by the fourth outlet piping assembly,
wherein the known spacing distance provided by the third bracket is
equal to the known spacing distance provided by the fourth bracket,
and wherein the known spacing distance provided by the third
bracket is different from the known spacing distance provided by
the first bracket.
12. The method according to claim 1, wherein the first heat
exchange coil comprises a first heating or cooling coil, and
wherein the second heat exchange coil comprises a second heating or
cooling coil.
Description
BACKGROUND OF THE INVENTION
Embodiments of the present invention relate to integrated heating,
ventilation, and air conditioning (HVAC) systems and methods, and
in particular to approaches that include embedded coils and other
heat exchangers.
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.
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.
Piping and conduits that supply gas and/or liquids within buildings
benefit from 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 known HVAC components a challenge.
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, with the distinction generally relating to the
precision with which the unit controls the temperature and humidity
of conditioned air. As used throughout this document, the phrase
terminal unit encompasses either a terminal unit or a lab valve
damper.
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, the 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.
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.
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.
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.
As a thermal load of a space 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.
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.
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.
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.
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.
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.
With current construction site labor costing up to $80.00/hour or
more, 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.
After assembling a HVAC system, it should 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 often have to
identify and replace broken components.
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.
Current techniques for implementing HVAC systems often required
ancillary components such as flow controls, ATC valves, and the
like to be added to HVAC piping structures in the field or at a
jobsite construction location. Relatedly, such ancillary
components, piping structures, and the like may be susceptible to
damage during transport. What is needed are improved HVAC systems
and methods that allow HVAC components to be configured prior to
shipping, and to be shipped without risk of damage. Embodiments of
the present invention provide solutions for at least some of these
needs.
BRIEF SUMMARY OF THE INVENTION
Embodiments of the present invention allow such ancillary
components to be attached with piping structures in a factory
setting, prior to shipment to the installation site. Accordingly,
these enhanced and improved techniques are well suited for
protecting ancillary HVAC system components from damage when they
are attached with a piping structure during transport. These
protective features avoid the situation where a mechanical
contractor be compelled to charge a manufacturer due to damage
incurred during shipping. Moreover, these techniques are very cost
effective, as the pre-piping often does not have to comply with
union work requirements. Embodiments of the present invention
provide efficient solutions to situations where, depending on job
specifications, various piping arrangements and components may be
needed on one project but not on another. Still further, labor
performed in the field is typically not depreciable. By providing
techniques that can be performed in the factory setting, coils and
other ancillary components can be considered capital equipment,
which renders them amenable to lease paybacks, lease financing, and
the like.
Bracket embodiments of the present invention may be configured with
or without a handle. In some cases, a bracket provides a protective
plane whereby damage to HVAC ancillary components is avoided during
shipping, handling, and transport. For example, a bracket may
include a portion that extends a certain distance, such as two to
six inches, beyond a grommet or aperture, such that the bracket
forms a plane or support barrier which prevents unwanted forces
from impacting on a piping structure during transport. Another way
of protecting the portable piping structure is to build or provide
a removable box around the coil and the portable piping structure.
Such protective features make it possible to embed valves,
fittings, controls, sensors, processors, actuators, microchips,
algorithmic devices, and other ancillary components on a coil or
heat exchanger prior to shipping. Exemplary components also include
digital devices, analog devices, and digital/analog combination
devices. Embodiments of the present invention can be used for or
otherwise integrate VAV boxes, fan coil units, air handling units,
or any heating or cooling system or subsystem thereof. Any of a
variety of HVAC ancillary components can be integrated with or
embedded onto a coil or heat exchanger prior to shipping.
Accordingly, these components can be installed on or coupled with a
coil or piping assembly in a factory setting, and can avoid
sustaining damage during subsequent transport to a job installation
site. In some cases, the components may be coupled with the coil or
heat exchanger. Similarly, the components may be coupled with an
input piping that attaches with the coil or heat exchanger, or with
an output piping that attaches with the coil or heat exchanger.
Relatedly, ancillary components may be coupled with one or more
brackets that are coupled with an input piping, or an output
piping, or both.
In some embodiments, ancillary components may be embedded on a
coil, and the assembly may not include a zone control unit. For
example, a leaving air temperature sensor can be coupled with a
coil or a pipe. The coil and piping assembly may also include a
damper with a pickup sensor, a pressure sensor, and the like.
Sensors may be coupled with a controller, such as a DDC controller,
via a wired or wireless connection. The damper can be installed
upstream of the coil, and sealed. In an illustrative example, the
desired ambient air temperature in a room is 70 degrees and a
thermostat can be set accordingly. If the leaving air temperature
sensor detects air having a temperature of 69 degrees, an output
signal can be sent to the controller, and the controller may send a
signal to a valve or actuator so that warmer air is provided to the
room. If or when the leaving air temperature sensor detects air
having a temperature greater than 70 degrees, the output signal
causes the controller to adjust the actuator accordingly, so as to
reduce the air temperature of the room. Feedback loops or systems
can be incorporated into a building, a room, a subset or rooms, and
the like. Control mechanisms can provide for accurate and efficient
temperature control of a building or structure, and can accommodate
for doors and windows opening and closing within the building.
These objectives can be achieved with a system that does not
include a balancing valve.
In some current methods, when a worker needs to couple a coil with
a duct box or other ancillary component it is necessary to perform
this procedure at the actual jobsite, and the components have to be
installed in situ within the confines of building structure or the
existing HVAC system as it was built. Relatedly, in many current
methods, an ancillary component cannot be attached with a piping
structure or coil prior to transport, due to concerns that the
assembly would be damaged during transport. Consequently,
conventional wisdom is that coils are typically required to be
piped in the field. Advantageously, embodiments of the present
invention allow a manufacturer or other entity to pre-pipe,
pre-wire, pre-program, or otherwise prefabricate a coil or a heat
exchanger with any desired ancillary component or piping assembly
in a factory setting, prior to transport to a construction site.
Accordingly, it is possible to test, calibrate, preset, tune, or
otherwise evaluate or control any aspect of a coil assembly in the
factory setting or in a centralized location. Such approaches
provide a significant savings in labor and installation time.
Moreover, it may not be necessary to balance or adjust a coil or
ancillary components when they are installed in the field.
Still further, embodiments of the present invention therefore
provide for self-balancing control of an HVAC system. In other
words, a coil assembly may not include a balancing element, but
instead may include an embedded ATC valve, for example. The ATC can
be coupled with a controller. In some cases, balancing elements can
introduce additional pressure into an HVAC system, and therefore
the system may require more horsepower for operation. By
eliminating the need for a balancing element, it is possible to
provide a system that has a lower energy requirement. Accordingly,
the system may qualify for LEED points or an improved LEED rating
(e.g. Leadership in Energy and Environmental Design Green Building
Rating System.TM.).
In one aspect, embodiments of the present invention provide a
zone-control unit for use in a heating, ventilation, and air
conditioning (HVAC) system. The zone-control unit includes a heat
exchanger, an inlet piping assembly coupled with the heat exchanger
for supplying fluid to the heat exchanger, an outlet piping
assembly coupled with the heat exchanger for receiving fluid from
the heat exchanger, a bracket that maintains the inlet piping
assembly and the outlet piping assembly in positional relationship,
and an ancillary component coupled with the heat exchanger.
In some cases, the ancillary component includes a direct digital
control (DDC) controller. The ancillary component may be coupled
with the heat exchanger. Optionally, the ancillary component may be
coupled with the bracket. In some cases, the heat exchanger, the
inlet piping, and the outlet piping form a closed and sealed
system. The heat exchanger, the inlet piping, and the outlet piping
may contain a pressurized fluid.
Embodiments of the present invention encompass zone-control units
for use in a heating, ventilation, and air conditioning (HVAC)
system. A zone-control unit may include a casing, a coil disposed
at least partially within the casing, an inlet piping assembly
coupled with the coil for supplying fluid to the coil, an outlet
piping assembly coupled with the coil for receiving fluid from the
coil, and a bracket that maintains the casing, the inlet piping
assembly, and the outlet piping assembly in positional
relationship. The zone-control unit may also include an ancillary
component coupled with the coil, the bracket, or the casing. In
some cases, the ancillary component includes a direct digital
control (DDC) controller. The ancillary component may be coupled
with the coil. Optionally, the ancillary component may be coupled
with the bracket. In some cases, the ancillary component is coupled
with the casing. The coil, the inlet piping, and the outlet piping
may form a closed and sealed system. The coil, the inlet piping,
and the outlet piping may contain a pressurized fluid.
Embodiments of the present invention also include methods of
manufacturing a plurality of portable piping structures. Exemplary
methods include providing a first heat exchange coil having a first
dimension, providing a second heat exchange coil having a second
dimension, coupling a first inlet piping assembly and a first
outlet piping assembly with the first heat exchange coil to provide
a first portable piping structure of the plurality of portable
piping structures, and coupling a second inlet piping assembly and
a second outlet piping assembly with the second heat exchange coil
to provide a second portable piping structure of the plurality of
portable piping structures. Methods may also include coupling a
first bracket with the first inlet piping assembly and the first
outlet piping assembly, where the first bracket provides a known
spacing distance between a central longitudinal axis defined by the
first inlet piping assembly and a central longitudinal axis defined
by the first outlet piping assembly. Methods may also include
coupling a second bracket with the second inlet piping assembly and
the second outlet piping assembly, where the second bracket
provides the known spacing distance between a central longitudinal
axis defined by the second inlet piping assembly and a central
longitudinal axis defined by the second outlet piping assembly.
According to some embodiments, methods may include coupling a first
ancillary component with the first heat exchange coil of the first
portable piping structure, and coupling a second ancillary
component with the second heat exchange coil of the second portable
piping structure. According to some embodiments, the first
ancillary component may include a first direct digital control
(DDC) controller and the second ancillary component may include a
second direct digital control (DDC) controller. Optionally, methods
may include coupling a first ancillary component with the first
bracket, and coupling a second ancillary component with the second
bracket. Further, methods may include coupling a first ancillary
component with the first inlet piping assembly, and coupling a
second ancillary component with the second inlet piping assembly.
Still further, methods may include coupling a first ancillary
component with the first outlet piping assembly, and coupling a
second ancillary component with the second outlet piping assembly.
According to some embodiments, methods may include sealing the
first inlet piping assembly and the first outlet piping assembly
such that the first portable piping structure comprises a sealed
and closed system, and sealing the second inlet piping assembly and
the second outlet piping assembly such that the second portable
piping structure comprises a sealed and closed system.
The methods and apparatuses of the present invention may be
provided in one or more kits for such use. For example, the kits
may comprise a system for use in an HVAC system. Optionally, such
kits may further include any of the other system components
described in relation to the present invention and any other
materials or items relevant to the present invention. The
instructions for use can set forth any of the methods as described
herein. It is further understood that systems according to the
present invention may be configured to carry out any of the method
steps described herein.
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
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.
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.
FIG. 3 is a perspective view of an alternative embodiment,
fully-functional zone-control unit which includes a NEMA enclosure
that adapts the unit for installation outside a building, according
to one embodiment of the present invention.
FIG. 4 is a perspective view of the alternative embodiment,
fully-functional zone-control unit of FIG. 3 that includes a shield
which protects coils included in the casing from mechanical damage,
according to one embodiment of the present invention.
FIG. 5 is a perspective view of an alternative embodiment
fully-functional zone-control unit similar to that depicted in FIG.
1, which includes a cradle located beneath the zone-control unit
for supporting inlet and outlet piping assemblies included in the
fully-functional zone-control unit, according to one embodiment of
the present invention.
FIG. 6 is a perspective view of an alternative embodiment
fully-functional zone-control unit in accordance with the present
disclosure, similar to that depicted in FIG. 1, which includes a
pair of sleeve mounting brackets that surround the casing, and
support the zone-control unit when it is installed in a HVAC
system.
FIG. 7 is an exploded perspective view of one of the zone-control
unit mounting brackets depicted in FIG. 6.
FIG. 8 is an elevational view taken along a line 8-8 in FIG. 7.
illustrating mating of a pair of handles included in the
zone-control unit mounting bracket depicted in FIGS. 6 and 7.
FIG. 9 is a perspective view of another alternative embodiment
fully-functional zone-control unit in accordance with the present
disclosure, similar to that depicted in FIG. 1, which includes four
columnar mounting brackets that are secured to the casing, and
support the zone-control unit when it is installed in a HVAC
system.
FIG. 10 is a perspective view of an electrical components enclosure
for a fully-functional zone-control unit in accordance with the
present disclosure adapted for use inside a building.
FIG. 11 is an elevational view of yet another alternative
embodiment of a fully-functional zone-control unit in accordance
with the present disclosure, in which appears a portion of the
zone-control unit appearing in FIG. 1, that includes flexible
braided hoses which facilitate connecting the zone-control unit's
inlet and outlet piping assemblies to a building's plumbing.
FIGS. 12A and B illustrate a zone-control unit according to one
embodiment of the present invention.
FIGS. 13A and B illustrate a zone-control unit according to one
embodiment of the present invention.
FIGS. 14A and B illustrate a zone-control unit according to one
embodiment of the present invention.
FIG. 15 illustrates a zone-control unit according to one embodiment
of the present invention.
FIG. 16 illustrates a zone-control unit according to one embodiment
of the present invention.
FIG. 17 illustrates a zone-control unit according to one embodiment
of the present invention.
FIGS. 18A-18E illustrate a heat exchanger/coil packaged with
ancillary components.
FIGS. 19A-19B illustrate differing HVAC units having standardized
components, along with aspects of those components.
FIG. 20 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.
FIGS. 21A and 21B illustrate a quality control process and method
for providing HVAC units and assembling and HVAC system.
FIG. 22 shows a control assembly for an HVAC system according to
embodiments of the present invention.
FIG. 23 shows a zone control unit or heat exchanger smart control
configuration according to embodiments of the present
invention.
FIG. 24 shows graph of a front end mathematical calculation or
algorithm based on desired performance and time values.
FIG. 25 depicts an HVAC component assembly according to embodiments
of the present invention.
FIG. 26 shows an HVAC component assembly according to embodiments
of the present invention.
FIG. 27 shows an HVAC component assembly according to embodiments
of the present invention.
FIGS. 28A-28C illustrate various views of an HVAC unit assembly
according to embodiments of the present invention.
FIG. 29 shows an HVAC component assembly according to embodiments
of the present invention.
FIGS. 30A-30C illustrate various views of an HVAC unit assembly
bracket according to embodiments of the present invention.
FIGS. 31A-31F illustrate aspects of portable piping assemblies
according to embodiments of the present invention.
FIG. 32 illustrates aspects of an HVAC casing according to
embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
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).
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 figures, 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.
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.
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.
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.
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. An electrical signal
supplied to the ATC control valve 252 from the DDC controller 112
via a control signal cable 114 can energize operation of the ATC
control valve 252.
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.
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 embodiments of 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.
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.
Also in accordance with embodiments of 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,
fluids, or liquids 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 embodiments of
the present invention indicates that about 3 to 7% of new coils 122
are defective and must be replaced.
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, or any other desired negative or positive pressure,
including a vacuum. 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.
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.
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. Relatedly, insulation can be
applied to or incorporated into a zone-control unit or portable
piping structure at the factory, instead of in the field or at the
job site. Thus, units or structures can be made at the factory,
pre-assembled, pre-calibrated, and pre-insulated, thus providing
further cost savings and efficiencies.
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. For example, damage may occur to
seals between a coil and a pipe, or between two pipes, or even to a
seal or cap of a pipe or coil. 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.
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.
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.RTM., 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.
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 relationships
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. Exemplary embodiments encompass an
apparatus as generally depicted in FIG. 2 for use as a portable
piping structure bracket with a universal handle. The bracket can
be manufactured in multiple sizes, multiple configurations, with
any desired constellation of piping openings or couplings, and can
include any desired material or fastening mechanisms. Brackets can
have any desired shape or configuration, and often include a
portion that extends beyond piping apertures that provides
protective mechanism for the piping, to prevent the piping from
damage during transport or handling.
In renovating existing buildings by adding an up-to-date HVAC
system, sometimes there exists no interior space for installing
zone-control units 100. To permit installing zone-control units 100
on a renovated building's roof where its components are exposed to
environmental hazards, an alternative embodiment of the
zone-control unit 100, depicted in FIG. 3, includes a weatherproof
NEMA enclosure 552. For this alternative embodiment zone-control
unit 100, all of the electrical components together with their
wiring are located within the NEMA enclosure 552, and outdoor grade
conduit 554 encloses the cable 114 that interconnects the DDC
controller 112 and the ATC control valve 252. Accordingly, in
addition to the DDC controller 112, the NEMA enclosure 552 also
encloses a on-off switch 562 and a transformer 564 for supplying 24
volt electrical power to the DDC controller 112.
Cooling for the components of the mechanical terminal unit 102
enclosed within the NEMA enclosure 552 may be provided by a
mini-fan mounted within the NEMA enclosure 552. Alternatively,
these components of the mechanical terminal unit 102 may be cooled
by air flowing through the HVAC system's ductwork. For example, one
end of a small duct may be connected into the plenum upstream from
the coil 122 with the other end connecting to the NEMA enclosure
552. The ATC control valve 252 may also be cooled by enclosing it
and connecting its enclosure to the HVAC system's plenum by a small
duct. If the electrical wires connecting the coil 122 to the ATC
control valve 252 are enclosed within a one (1) inch diameter
outdoor grade conduit 554, cool air first supplied to the ATC
control valve 252 flows to the NEMA enclosure 552 through the
outdoor grade conduit 554.
The NEMA enclosure 552 may be selected from among NEMA Type 3R, 4
or 10 enclosures. NEMA Type 3R, 4 or 10 enclosures all provide a
degree of protection for personnel against incidental contact with
equipment enclosed therein. NEMA Type 3R enclosures are constructed
for either indoor or outdoor use providing a degree of protection
against falling dirt, rain, sleet, and snow, and are undamaged by
the external formation of ice on the enclosure. NEMA Type 4
enclosures are also constructed for either indoor or outdoor use
again providing a degree of protection against falling dirt, rain,
sleet, snow, windblown dust, splashing water, and hose-directed
water, and are also undamaged by the external formation of ice on
the enclosure. NEMA Type 10 enclosures are designed to contain an
internal explosion without causing an external hazard, i.e. NEMA
Type 10 enclosures meet the requirements of the Mine Safety and
Health Administration, 30 CFR, Part 18.
As described thus far, zone-control units 100 have exposed U-shaped
portions 566 of tubes, best illustrated in FIG. 3, through which
water circulates that are located at the end of the coil 122
furthest from the piping assemblies 202, 232. To reduce the
possibility that the exposed U-shaped portions 566 of these tubes
might be damaged either during transportation of the zone-control
unit 100 and/or its installation into a HVAC system, as illustrated
in FIG. 4 an alternative embodiment of the zone-control unit 100
includes a shield 568 preferably made from sheet steel
material.
The shield 568 is secured to the coil 122 and perhaps also the
casing 104, and covers the U-shaped portions 566 of tubes included
in the coil 122. Though not illustrated in FIG. 4, the shield 568
may be lined with insulation to further reduce heat loss from the
U-shaped portions 566 of the coil 122 in addition to the heat loss
reduction provided by installing an uninsulated shield 568.
FIG. 5 is a perspective view of an alternative embodiment
zone-control unit 100 in accordance with the present invention
similar to the zone-control unit 100 depicted in FIG. 1. The
zone-control unit 100 depicted in FIG. 4 includes a
rectangularly-shaped cradle 572 disposed beneath and secured to the
mechanical terminal unit 102. In the embodiment of the zone-control
unit 100 depicted in FIG. 4, plates 506b, for mechanically securing
the piping assemblies 202, 232 to the casing 104, omit the handles
502 established by the holes 512 formed in the plates 506a. Instead
the plates 506b are narrower and L-shaped with a foot 574 which is
secured to the cradle 572. The cradle 572 is pierced by holes 576
respectively located near each of its four corners, only three of
which are visible in FIG. 4. In one embodiment, threaded rods 578
respectively pass through each of the holes 576 for supporting the
cradle 572 from ceiling joists or an adjacent wall. Alternatively,
an isolation spring (not illustrated in any of the figures) may be
secured through each of the holes 576 and to an end of the threaded
rod 578 nearest the hole 576. The cradle 572 is also pierced by a
rectangularly-shaped hole 582 along an edge of the cradle 572
nearest to the piping assemblies 202, 232. The hole 582 provides
the cradle 572 with a handle 584 for the zone-control unit 100
illustrated in FIG. 4 similar to the handles 502 provided by the
holes 512 depicted in FIG. 1 that pierce the plates 506a.
Galvanized or stainless steel sheet material forming the cradle 572
includes linear, V-shaped troughs 586 formed therein in an X-shape
which extend between diagonal pairs of holes 576. The troughs 586
cause the center of the cradle 572 where the troughs 586 intersect
to be the lowest point thereof. Consequently, any water leaking
from the piping assemblies 202, 232 collects at the middle of the
cradle 572. The cradle 572 preferably includes a threaded fitting
(not illustrated in any of the figures) that is located at the
intersection of the troughs 586. The cradle 572 may have a flask
(not illustrated in any of the figures) secured to the threaded
fitting so any water which collects at the middle of the cradle 572
may flow through the fitting and be collected in the flask.
Alternatively, a moisture sensor (not illustrated in any of the
figures) may be secured to the threaded fitting for sending an
electrical signal to a monitoring station if water collects at the
middle of the cradle 572.
Arranged in this way, the handle mounting brackets 504, plates 506b
and the cradle 572 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 handle 584 facilitates handling zone-control units
100 during their installation into the HVAC system such as
maneuvering zone-control units 100 into position for installation
into a building's ductwork. During installation, the handle
mounting brackets 504, plates 506b and the cradle 572 maintain
positional relationships between the mechanical terminal unit 102
including the coil 122 and the piping assemblies 202, 232 because
the handle mounting brackets 504, plates 506b and the cradle 572
mechanically bind the entire zone-control unit 100 together into a
single unit.
FIG. 6 illustrates an alternative embodiment of the zone-control
unit 100 that further facilitates its installation into a
building's ductwork. In this embodiment, a pair of sleeve mounting
brackets 602, which replace the handle mounting brackets 504
depicted in FIG. 1, surround the casing 104 near opposite ends
thereof. As better illustrated in FIG. 7, each sleeve mounting
bracket 602 includes a substantially planar, generally rectangular
frame 604 which extends outward from and surrounds the casing
104.
Stiffeners 606a through 606d, which may be formed integrally with
the frame 604, project at right angles from interior edges 608 of
the frame 604 to extend respectively along sides of the casing
104.
Because each sleeve mounting bracket 602 replaces one handle
mounting bracket 504 illustrated in FIG. 1, for the embodiment
depicted in FIG. 6 the handle 502 is secured to either one or the
other of vertically oriented sides 612 of the frame 604. Thus, the
sleeve mounting bracket 602 permits attaching handles 502 to either
side of the frame 604 for supporting the piping assemblies 202,
232.
A pair of hanging plates 616 respectively extend at right angles
from upper edges 614 of the vertically oriented sides 612 of the
frame 604, and are preferably formed integrally with the sides 612.
An aperture 622 pierces each of the hanging plates 616 thereby
adapting it to receive one end of a threaded rod or of a seismic
fastening product for suspending the zone-control unit 100 when
installed in a HVAC system. The sleeve mounting bracket 602 also
includes a pair of reinforcing plates 626 each of which spans
between a depending edge 628 of the hanging plates 616 and an upper
edge 629 respectively of the stiffeners 606b and 606d, and is
welded thereto.
An elongated tab 632 projects upward as part of a horizontally
oriented top side 634 of the frame 604. Fasteners 642, such as
sheet metal screws, secure to the tab 632 a handle 644, which is
shaped similar to or the same as the handle 502. Similar to the
handle 502, as best illustrated in FIG. 8 the handle 644 preferably
includes a curved edge 646. For suspending zone-control units 100
within a building using the handle 644 secured to the tab 632 of
the sleeve mounting bracket 602, an L-shaped upper mounting bracket
652 depicted in FIG. 7 is secured to a joist or other building
structural member. A handle 654 identical to the handle 644 is
secured to the upper mounting bracket 652 with fasteners 656 such
as sheet metal screws. As illustrated in FIG. 8, a curved edge 658
of the handle 654 receives and mates with the curved edge 646 of
the handle 644. Configured in this way, the mated handles 644, 654
provide a hanger for suspending the zone-control unit 100 which
seismically isolates the zone-control unit 100 from the building.
Seismic and vibration insulation between the building and the
zone-control unit 100 can be enhanced by inserting between the
curved edges 654, 658 a sheet of elastomeric material such as
rubber (not illustrated in any of the figures). The handles 644,
654 can also be further secured to each other with fasteners such
as screws. While the curved edges 654, 658 are preferred for
coupling the handles 644, 654 together, other locking mechanisms
can be used such as clips or/and screws, or metal on metal, etc. If
the zone-control unit 100 needs to be located further from the
joist or other structural member than that provided by the handles
644, 654, appropriate lengths of sheet metal may be interposed
between the tab 632 and the handle 644 and/or between the upper
mounting bracket 652 and the handle 654.
FIG. 9 illustrates yet another alternative embodiment of the
zone-control unit 100 that further facilitates its installation
into a building's ductwork. Analogously to the sleeve mounting
bracket 602 of FIGS. 6-8, in the embodiment of FIG. 9 four (4)
columnar mounting brackets 672 replace the handle mounting brackets
504 depicted in FIG. 1. Those elements depicted in FIG. 9 that are
common to the sleeve mounting bracket 602 illustrated in FIGS. 6-8
carry the same reference numeral distinguished by a prime ("'")
designation. Comparing FIG. 9 with FIGS. 6-8 reveals that each
columnar mounting bracket 672 includes the side 612', the apertured
hanging plate 616', the reinforcing plate 626 and either the
stiffener 606b' or 606d' of the sleeve mounting bracket 602.
Because each pair of columnar mounting brackets 672 lack the top
side 634 of the sleeve mounting bracket 602 with its tab 632 and
the handle 644 fastened thereto, when installed in a HVAC system
the zone-control unit 100 illustrated in FIG. 9 must be hung from
threaded rod or a seismic fastening product. The sleeve mounting
brackets 602 and the columnar mounting brackets 672 may be formed
from 14 gauge sheet steel.
Using 14 gauge sheet steel for the sleeve mounting brackets 602 and
the columnar mounting brackets 672 may significantly increase the
structural rigidity the lighter 22 gauge sheet steel generally used
in fabricating the casing 104 of the mechanical terminal unit 102.
Thus, either the sleeve mounting brackets 602 or the columnar
mounting brackets 672 may be used advantageously in securing a
zone-control unit 100 to a pallet for shipping to a building site.
For example, either the sleeve mounting brackets 602 or the
columnar mounting brackets 672 may be appropriately pierced by an
aperture (not illustrated in any of the FIGS.) that receives
strapping for securing the zone-control unit 100 to a pallet. Thus,
both the sleeve mounting brackets 602 and the columnar mounting
brackets 672 facilitate shipping zone-control units 100 to a
building site without defects and/or damage.
FIG. 10 depicts an electrical components enclosure 702, analogous
to the NEMA enclosure 552 depicted in FIG. 3, which may be included
in a zone-control unit 100 in accordance with the present
disclosure that is suitable for installation only inside a
building. Those elements depicted in FIG. 10 that are common to the
zone-control unit 100 depicted in FIG. 1 and to the NEMA enclosure
552 illustrated in FIG. 3 carry the same reference numeral
distinguished by a prime ("'") designation. With respect to the
casing 104 included in the zone-control unit 100, the electrical
components enclosure 702 may be secured to the top, to the bottom
or to the side of the casing 104 opposite to that on which the
piping assemblies 202, 232 and handles 502 are located.
Differing from the on-off switch 562 that is located inside the
NEMA enclosure 552 depicted in FIG. 3, the on-off switch 562'
illustrated in FIG. 10 and an associated LED power indicator 704
are both located in a separate utility box 706 attached outside the
electrical components enclosure 702. However, similar to the NEMA
enclosure 552 depicted in FIG. 3, both the DDC controller 112' and
the transformer 564' are located within the electrical components
enclosure 702 depicted in FIG. 10.
Including an individual transformer 564' in each zone-control unit
100 eliminates any need for an electrician to assemble multiple
step down transformers on an electrical panel, or to install 24
volt low voltage wiring between a remotely located transformer and
a terminal unit as described above. If the zone-control unit 100 is
installed near a light and power conduit within the building,
supplying the zone-control unit 100 with electrical power requires
perhaps only a 1 to 5 foot connection of electrical wire and/or
conduit. Buildings equipped with newer low energy (high efficiency)
lighting, require less electrical power than that required by
prior, less efficient lighting. DDC controllers, such as the DDC
controller 112 and 112' respectively depicted in FIGS. 3 and 10,
draw less than one-half (0.5) ampere of 115 volt alternating
current ("AC") electrical power. Therefore, the zone-control unit
100 can be connected to a building's individual lighting circuits
without a danger of electrical overload.
Differing from the NEMA enclosure 552 depicted in FIG. 3, the
utility box 706 may include a second on-off switch 712 and power
outlet 714 located in the utility box 706. The on-off switch 712
and the power outlet 714 provide a source of electrical power at
the zone-control unit 100 to be used when servicing the
zone-control unit 100. The embodiment of the electrical components
enclosure 702 depicted in FIG. 10 also includes a service lamp 716
connected to an on-off switch 718. Analogous to the on-off switch
712 and the power outlet 714, the service lamp 716 facilitates
servicing the zone-control unit 100.
For the electrical components enclosure 702 depicted in FIG. 10,
electrical wires 722 connect the on-off switch 562' to the
transformer 564' for energizing operation of the DDC controller
112' with 115 volt alternating current ("AC") electrical power. The
electrical components enclosure 702 also preferably includes
another set of electrical wires 724 connected to the transformer
564' which alternatively permit energizing operation of the
zone-control unit 100 with 277 volt AC electrical power.
The electrical components enclosure 702 also preferably includes a
pressure sensor inlet 732 for receiving air from the HVAC system's
ducts connected to the zone-control unit 100. Within the electrical
components enclosure 702, the pressure sensor inlet 732 supplies
air from the ducts to the DDC controller 112' via tubes 734. The
electrical components enclosure 702 also includes a length of
electrical wire 738 connected to the DDC controller 112' which
facilitates connecting the zone-control unit 100 to a temperature
sensor located in the zone of the HVAC system supplied by the
zone-control unit 100.
In general, DDC HVAC system controllers such as the DDC controller
112 and 112' respectively depicted in FIGS. 3 and 10 continually
monitor and provide individual zones with a supply of fresh air.
Presently, conventional 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.
Presently, DDC controllers such as the 112 and 112' respectively
depicted in FIGS. 3 and 10 are equipped with Local Area Network
("LAN") communications capability. To facilitate installing the
zone-control unit 100, as illustrated in FIG. 10 the electrical
components enclosure 702 is preferably equipped with a 100 ft.
length of LAN cable 742 connected to the DDC controller 112'.
Establishing the LAN that interconnects groups of zone-control
units 100 all which include LAN cables 742 requires only that the
LAN cable 742 of all but one of the zone-control units 100 in the
group be connected to another one of the group's zone-control units
100.
To further facilitate installing zone-control units 100 into a
building's HVAC system, FIG. 11 illustrates yet another alternative
embodiment of the zone-control unit 100 which replaces the caps 284
on the piping assemblies 202, 232 with fittings 802 for connecting
to flexible braided hoses 804 or other HVAC piping or hose
components. Fittings 802 may be any type of fitting suitable for
joining pipes, hoses, and the like. Fittings 802 may include
press-fittings, push fittings, and various kinds of solder-less
fittings. Another valve 806 connects to each end of the braided
hoses 804 furthest from the piping assemblies 202, 232. Similar to
the caps 284, closing both valves 806 connected to the end of each
of the braided hoses 804 permits pressurizing both braided hoses
804, the piping assemblies 202, 232 and the coil 122 for leak
testing, the 24 hour pre-shipment qualification pressure test, and
assuring that the zone-control unit 100 remains leak free until
installed into ductwork of a building's HVAC system.
A copper tee plumbing fitting 808 may connect to each valve 806 on
the braided hoses 804 furthest from the piping assemblies 202, 232
on the side of the valves 806 furthest from the braided hoses 804.
By including the tee plumbing fitting 808 in the zone-control unit
100, this particular embodiment permits a building's mechanical
contractor, who is responsible for its plumbing, to make straight
runs of copper pipe for the HVAC system's water which are located
reasonably close to places where zone-control units 100 are to be
installed, e.g. within 2 feet.
Then when installing zone-control units 100 into the building's
ductwork, rather than being required to plumb the HVAC system's
piping to the piping assemblies 202, 232, zone-control units 100
can be connected with the HVAC system's piping by cutting out a
small length of the previously plumbed piping, and inserting the
tee plumbing fitting 808 into the piping followed by sweating the
connection of the tee plumbing fitting 808 to the HVAC system's
piping.
FIG. 12A 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. 12B 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.
Bracket 1500 may include any of a variety of suitable materials,
including metals, composites, and the like. 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. In some embodiments, bracket 1500 may not
include an opening. 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. In
some embodiments, a portable piping structure may include a heat
exchanger coupled with a bracket and a pipe. The bracket is often
also coupled with the pipe.
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.
In some embodiments, a mechanical pressure/temperature port may be
replaced, supplemented, or operatively coupled with one or more
analog or digital electronic sensors, including sensors enabled for
wireless communication, that detect or sense flow volume, for
example in gallons per minute (gpm), or other flow variables such
as pressure, temperature, and the like. Advantageously, the
incorporation of such electronic sensors can eliminate the need for
a technician to manually access a heat exchanger to perform
troubleshooting or diagnostic procedures with gauges. These
electronic sensors can replace such gauges, and can be
pre-calibrated or pre-programmed at a manufacturer factory prior to
installation. Accordingly, many of all flow variables can be
monitored remotely through a building automation control system. A
technician can check these variables remotely or wirelessly with a
personal digital assistant (PDA), a laptop, or other suitable
device. These sensors may also be operatively coupled with a damper
assembly controller, a direct digital controller, an analog
electronic controller, or other desired component of a zone-control
unit.
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.
As shown in FIG. 12A, 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.
FIG. 13A 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. 13B 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.
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. In some cases, a coil or heat exchanger,
an inlet piping, and an outlet piping can form a closed and sealed
system. In some cases, a coil or heat exchanger, a inlet piping,
and the outlet piping can contain a pressurized fluid. Optionally,
one or more headers may be coupled with a coil or heat exchanger,
and form part of the sealed and pressurized space.
As shown in FIG. 13A, 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).
FIG. 14A 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. 14B 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.
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.
In some cases, a coil or heat exchanger, an inlet piping, and an
outlet piping can form a closed and sealed system. In some cases, a
coil or heat exchanger, a inlet piping, and the outlet piping can
contain a pressurized fluid. Optionally, one or more headers may be
coupled with a coil or heat exchanger, and form part of the sealed
and pressurized space.
As shown in FIG. 14A, 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).
FIG. 15 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. Zone-control
unit 4000 may also include a custom digital imaging tag 4130 or
custom PC router tag or validation package 4120 containing
information regarding the configuration or manufacture of the unit.
Information may be provided in electronic or paper format, and may
include submittal information, O&M's of unit components,
digital pictures of the product or components, QC sheets, wiring
and piping diagrams, parts lists with model numbers and serial
numbers, and the like. In some cases, a coil or heat exchanger, an
inlet piping, and an outlet piping can form a closed and sealed
system. In some cases, a coil or heat exchanger, a inlet piping,
and the outlet piping can contain a pressurized fluid. Optionally,
one or more headers may be coupled with a coil or heat exchanger,
and form part of the sealed and pressurized space.
FIG. 16 illustrates a side view of a zone-control unit 5000 for use
in an IVAC 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.
FIG. 17 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. 17 is similar
to that shown in FIG. 16. 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. 17 differs from the zone-control unit 5000 shown in
FIG. 16, 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.
FIGS. 18A-18E illustrate a heat exchanger coil 7000 packaged with
components similar to those described above, with some or all of
the components supported by support structures or handles. The heat
exchanger coil, piping, valves, and/or valve controllers may be
pre-assembled prior to shipping to a construction job site, with
some or all of the assembly optionally being performed using
robotic fabrication techniques and systems. The support structures
or handles can facilitate handling and installation of the
assembled unit, protect the unit and components thereof during
shipping, and may also be used to support the unit after
installation. The piping may terminate with sealed piping stubs
during shipping and installation, with a pressure sensor and gauge
allowing quick verification of the piping assembly integrity. Along
with heat exchanger/coil units, other HVAC units such as fan coil
units and the like may benefit from the systems and methods
described herein. Standardization, quality control and tracking,
and other improved structures and method described herein may also
be implemented with such units. In some cases, a coil or heat
exchanger, an inlet piping, and an outlet piping can form a closed
and sealed system. In some cases, a coil or heat exchanger, a inlet
piping, and the outlet piping can contain a pressurized fluid.
FIGS. 19A-19B 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.
Proportional valves (including those having characteristics similar
to those graphically illustrated in FIG. 19A, 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. 19B illustrates an HVAC hot
water coil piping package unit 8000, while FIGS. 12A and 13A
illustrate an HVAC proportional hot water valve package unit and a
2 way water valve package unit, respectively. FIG. 12B illustrates
a support structure or handle which may be used in both, and FIG.
14A illustrates a 3 way water valve package unit. 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. In some
embodiments, zone-control units or heat exchanges can have pipe
components with dimensions or configurations that are standardized
or customized. For example, zone-control units can be manufactured
to provide spun copper caps that are of a standard length or
dimension, that are separated by a standard distance, and that are
oriented in a standard direction. Relatedly, zone-control units can
be manufactured to provide piping assemblies, pipes, and other
piping aspects that conform with a prescribed specification. In
some cases, pipe components such as piping assemblies or end caps
can have equal or otherwise prescribed lengths, or can spaced apart
from each other at certain known or predetermined distances.
Similarly, zone-control units can be configured so as to provide a
standardized or customized distance between the piping assemblies
of a single unit. Accordingly, sets of two or more zone-control
units can be manufactured according to certain piping component
specifications (e.g. length, dimension, orientation, and the like).
Such standardization or customization can be applied to any of a
variety of sizes and configurations of zone-control units or heat
exchangers, and can provide heretofore unrecognized advantages and
efficiencies in building construction and repair. For example,
multiple zone-control units, each having a different size and
configuration, can be manufactured having a standardized distance
between piping assemblies or end caps, or between central
longitudinal axes defined by such components.
FIG. 20 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.
FIGS. 21A and 21B 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.
FIG. 22 shows a control assembly 22000 for an HVAC system according
to one embodiment of the present invention. Control assembly 22000
includes a controller 22100, a LAN 22200, a front end computer
software 22300, a remote monitoring component 2240, and a
thermostat or room sensor 22700. Control assembly 22000 may also
receive a variety of inputs 22500 from, and transmit a variety of
outputs 22600 to, a zone control unit or other HVAC component such
as a proportional hot water valve package (PICCV), a two way water
valve package (CCV), and the like. In some cases, control assembly
22000 can be in operative association with, for example, a factory
precalibrated self balancing zone control unit or heat exchanger.
Zone control units can include pressure/temperature ports,
discharge air sensors, analog or digital pressure gauges,
temperature resistors, and the like which can provide input to
controller 22100. Similarly, controller 22100 can provide output to
various components of a zone control unit, such as proportional
actuators. These interconnectivities can allow a zone control unit
to regulate pressure automatically. In some cases, a thermostat or
room sensor 22700 may have a setpoint, and contain a digital
display for showing pressure, gpm, space temperature, leaving air
temperature, setpoint, and the like. Often these attributes or
aspects thereof are transmitted from controller 22100 to thermostat
22700. Relatedly, room temperature, setpoints, and other variables
can be transmitted from thermostat 22700 to controller 22100.
Connectivity between various components of control assembly 22000,
and between components of control assembly 22000 and other HVAC
components, can be hardwired, wireless, or a combination
thereof.
In one embodiment, a zone control unit includes a Belimo PICCV
pressure independent automatic control valve or other pressure
independent balancing valve on a heat exchanger such that water
field balancing is eliminated or reduced. Components and sensors
can be pre-calibrated at the factory. A sensor can be mounted in a
plenum near the heat exchanger that senses leaving air temperature,
pressure, and other variables. The plenum can be added at the
factory. A room sensor or thermostat can be mounted in a desired
room or zone. Controllers such as a DDC controller can be used with
this system, and can be mounted, wired and pre-programmed at the
factory. The controller can take inputs from the various sensors
that are pre-wired to the controller at the factory. An exemplary
sequence of operation can be described as follows. The temperature
in the room is 70.degree. F. and the occupant wishes to raise the
temperature to 72.degree. F. by adjusting the room sensor or
thermostat to the desired set point. That signal is sent to the DDC
controller. The leaving air temperature sensor senses or reads
70.degree. F. at a heat exchanger discharge, and provides an input
signal to the DDC controller. The DDC controller processes the two
inputs: the room sensor and the leaving air sensor. The controller
then sends a signal to the actuator on the automatic temperature
control (ATC) valve actuator to open the valve and increase the gpm
flow to heat exchanger coil thus raising the leaving air
temperature (LAT) to an effective set point (e.g. 74.degree. F.)
until the room sensor measures the room air at 72.degree. F. A
balancing valve can be pressure independent and set at the factory
so as to maintain a gpm regardless of pressure. In some cases, if
more flow or hotter water is needed, a controller can send signals
to a computer with front end software, and the computer can send
signals to pumps or a boiler to adjust the temperature or gpm. Once
the room sensor measures the desired set point, the controller
closes the ATC valve thus limiting the gpm/flow through the heat
exchanger device and maintaining the desired set point to extreme
or programmed tolerances. This sequence of operation can occur
every second. If the room temperature sways in any direction by
even 0.01.degree. F. or less, the LAT temperature can be adjusted
immediately at the heat exchanger to maintain the desired
temperature. This process can save significant amounts of energy,
can control the space temperature precisely, can provide for better
indoor air quality, and can qualify the system for LEED building
points/Green building initiative. Furthermore, the entire water
side of the system can be completely self balancing. The need for
technicians to go to the job site and balance, calibrate, take
readings, and the like can be eliminated or reduced. Regulation can
be accomplished through the building automation control system and
can be self correcting automatically. This can be accomplished by
providing a portable piping structure on the heat exchanger, which
confers the ability to ship the heat exchanger with the portable
piping structure attached, without incurring damage. By doing this,
it is possible to add these features and benefits, including
pre-calibration and pre-programming, to the portable piping
structure of the heat exchanger on a cost effective basis, and also
to associated products into which heat exchangers are installed.
Similarly, it is possible to add these features and benefits to
stand alone heat exchangers.
These approaches are well suited for a variety of environments,
including biotech laboratories, clean rooms, offices, and the like.
These techniques can provide for constant, real-time adjustments to
maintain desired setpoints. Embodiments disclosed herein can be
used to replace or reduce the need for manual balancing, and can
modulate ATC valves to keep gpm appropriately adjusted.
FIG. 23 shows an embodiment of a zone control unit or heat
exchanger smart control configuration 23000. Configurations such as
these can be used for one or more zones or products. A controller
23100, which optionally includes a read out or display, receives
input from liquid sensors 23200 such as flow sensors, pressure
sensors, and the like. Controller 23100 also receives input from
air sensors 23300 such as leaving air temperature sensors, pressure
sensors, and the like. Controller 23100 can provide output to an
air damper actuator 23400, a liquid valve actuator 23500, or other
zone control unit or heat exchanger component. Controller 23100 may
also receive data from, and transmit data to, a LAN, which may be
in operative association with one or more controllers 23700 of
other devices in the building, and with a computer 23800 containing
operational software. Controller 23100 may also receive data from,
and transmit data to, a thermostat 23900 with a room sensor and a
setpoint adjustment with read out. Thermostat 23900 can display any
parameter of a zone control unit or heat exchanger including flows,
temperatures, pressures, and the like. Similarly, thermostat 23900
can display all data transmitted between controller 23100 and
thermostat 23900. A technician can trouble shoot this configuration
via readouts from thermostat 23900, controller 23100, or other
components. In some embodiments, a technician can trouble shoot
from a wireless PDA which is in operative association with one or
more components of configuration 23000. Any parameter of
configuration 23000 can be set at a manufacturer's factory and can
be pre-calibrated. For example, air and water balancing and
calibration can be done at the factory. Thereafter, any air and
water balancing changes in the field can be accomplished via a
computer which may be remotely linked with the configuration. In
this way, a system can be self-balancing and energy efficient.
Moreover, the system exhibits improved indoor air quality (IAQ)
control, comfort, and response time.
Table 1 shows an example of a PICCV pressure independent ATC valve
three point floating with ninety second stroke time values.
TABLE-US-00001 TABLE 1 Set- Range point Actual Value Open .degree.
F. Stroke Time .1-2 72 71 1 10% 75 9 70 2 20% 80 9 69 3 30% 85 9 68
4 40% 90 9 67 5 50% 95 45 second stroke time 66 6 60% 100 9 65 7
70% 105 9 64 8 80% 110 9 63 9 90% 115 9 62 10 100% 120 90 seconds
full open
FIG. 24 shows graph of a front end mathematical calculation or
algorithm based on desired performance and time values. Units can
be accordingly bench tested and pre-calibrated and balanced at the
factory.
Although zone control units, thermal transfer units, and other
elements of environmental control systems discussed herein are
often referred to in terms of HVAC units, it is appreciated that
such zone control units, thermal transfer units, and the like may
find use in any of a variety of control systems. Moreover, although
transfer units are often described as, for example, coil
structures, embodiments encompassed herein include any of a variety
of transfer unit or control unit configurations. Piping structures
and configurations disclosed herein can be used in any of a variety
of heat exchanger devices, systems, or methods.
Heat exchangers can include fluid coils, steam coils, hot water
coils, chilled water coils, de-humidification coils, sensible water
coils, and the like. According to some embodiments, the terms "heat
exchanger" and "coil" may be used interchangeably. Heat exchangers
may also encompass evaporative coolers (e.g. direct, indirect, or
combination), condenser water systems, air washers, humidifiers,
plate and frame heat exchangers, shell and tube heat exchangers,
and the like. Heat exchangers can transfer heat from one fluid to
another, often without the fluids coming in direct contact with
each other. Heat transfer can occur in a heat exchanger when a
fluid changes from a liquid to a vapor (evaporator), a vapor to a
liquid (condenser), or when two fluids transfer heat without a
phase change. The transfer of energy can be caused by a temperature
difference. In many HVAC or heating, ventilation, air conditioning,
and refrigeration (HVAC&R) applications, heat exchangers are
selected to transfer either sensible or latent heat. Sensible heat
applications involve the transfer of heat from one liquid to
another. Latent heat transfer results in a phase change of one of
the liquids; transferring heat to a liquid by condensing steam is a
common example. Heat exchangers for HVAC or HVAC&R applications
can include counter-flow shell-and-tube or plate units. While both
types physically separate the fluids transferring heat, their
construction may be very different, and each can have unique
application and performance qualities.
Equipment for cooling and dehumidifying an air stream under forced
convection can incorporate a coil section that contains one or more
cooling coils assembled in a coil bank arrangement. Such coil
sections can be used as components in room terminal units, larger
factory-assembled self-contained air conditioners, central station
air handlers, and field built-up systems. In currently used
approaches, applications of each coil type may be limited to the
field within which the coil is rated. Other limitations may be
imposed by code requirements, proper choice of materials for the
fluids used, the configuration of the air handler, and economic
analysis of the possible alternatives for each installation.
Coils can be used for heating and air cooling with or without
accompanying dehumidification. Examples of cooling applications
without dehumidification include (1) pre-cooling coils that use
well water or other relatively high-temperature water to reduce
load on the refrigerating equipment and (2) hot water/chilled-water
coils that remove/add sensible heat from a chemical
moisture-absorption apparatus. A heat pipe coil can also be used as
a supplementary heat exchanger for preconditioning in air-side
sensible cooling. Coil sections can provide air sensible cooling
and dehumidification simultaneously.
An HVAC coil assembly can include a means of cleaning air to
protect the coil from dirt accumulation and to keep dust and
foreign matter out of the conditioned space. Although cooling and
dehumidification are among their principal functions, cooling coils
can also be wetted with water or a hygroscopic liquid to aid in air
cleaning, odor absorption, or frost prevention. Coils can also be
evaporatively cooled with a water spray to improve efficiency or
capacity.
In finned coil embodiments, the external surface of the tubes is
primary, and the fin surface is secondary. The primary surface
generally consists of rows of round tubes or pipes that may be
staggered or placed in line with respect to the airflow. Flattened
tubes or tubes with other non round internal passageways can be
used. The inside surface of the tubes is often smooth and plain.
Some coil designs have various forms of internal fins or turbulence
promoters (either fabricated or extruded) to enhance performance.
The individual tube passes in a coil can be interconnected by
return bends through the process of brazing (or hairpin bend tubes)
to form the serpentine arrangement of multi pass tube circuits.
Coils can include different circuit arrangements and combinations
offering varying numbers of parallel water flow passes within the
tube core.
Cooling coils for water, aqueous glycol, brine, or halocarbon
refrigerants can have aluminum fins on copper tubes. Copper fins on
copper tubes and aluminum fins on aluminum tubes (excluding water)
can also be used. Adhesives can be used to bond header connections,
return bends, and fin-tube joints, particularly for
aluminum-to-aluminum joints. Certain coils can include an
all-aluminum extruded tube-and-fin surface.
Core tube outside diameters can be 5/16, 3/8, 1/2, 5/8, 3/4, and 1
inch, with fins spaced 4 to 18 per inch. Tube spacing can range
from 0.6 to 3.0 inch on equilateral (staggered) or rectangular
(in-line) centers. Spacing may depend on the width of individual
fins and on other performance considerations. Fins can be spaced
according to the job to be performed, with attention given to air
friction, possibility of lint accumulation, and frost accumulation,
especially at lower temperatures.
Tube wall thickness and the use of alloys other than copper can be
determined by the coil's working pressure and safety factor for
hydrostatic burst (pressure). Maximum allowable working pressure
(MAWP) for a coil can be derived, for example, according to ASME's
Boiler and Pressure Vessel Code, Section VIII, Division 1 and
Section II (ASTM material properties and stress tables). The entire
contents of this code are incorporated herein by reference.
Pressure vessel safety standards compliance and certifications of
coil construction may be required by regional and local codes
before field installation. Fin type and header construction can
also play a part in determining wall thickness and material. Local
job site codes and applicable nationally recognized safety
standards can be consulted in coil design and application.
Air-cooling constructions can have a shiny aluminum air-side
surface. For some applications, a fin surface may include copper or
have a brown or blue-green dip-process coating. These coatings can
protect the fin from oxidation that can occur when common airborne
corrosive contaminants are diluted on a wet (dehumidifying)
surface. Corrosion protection may be important as indoor air
quality (IAQ) guidelines continue to call for higher percentages of
outside air. In some cases, baked-on or anodized coating can
improve the expected service life compared to plain aluminum fins
under similar conditions. In some situations, uncoated fins on
non-dehumidifying, dry cooling coils may not be affected by normal
ambient airborne chemicals, except, to some extent, in a saline
atmosphere. Often, once a coil is installed, little can be done to
improve air-side protection.
Incoming air stream stratification across a coil face can reduce
coil performance. Proper air distribution can be defined as having
a measured airflow anywhere on the coil face that does not vary
more than 20%. Moisture carryover at a coil's air leaving side or
uneven air filter loading may be an indication of uneven airflow
through the coil. Corrective procedures can include installation of
inlet air straighteners or an air blender if several airstreams
converge at the coil inlet face. Additionally, in some cases
condensate water should not be allowed to saturate the duct liner
or stand in the drain pan or trough. Relatedly, in some cases the
coil frame (or its bottom sheet metal member) should not be allowed
to sit in a pool of water, to prevent rusting.
Exemplary coils include water and aqueous glycol coils. In some
cases, desired performance of water-type coils may involve
eliminating air and water traps in the water circuit and the proper
distribution of water. Unless properly vented, air may accumulate
in the coil tube circuits, reducing thermal performance and
possibly causing noise or vibration in the piping system. Air vent
and drain connections are often installed in the field at the job
site on the piping components, but this typically does not
eliminate the need to install, operate, and maintain the coil tube
core in a level position. Individual coil vents and drain plugs are
often incorporated on the ancillary field piping. Water traps in
tubing of a properly leveled coil are often caused by (1) improper
non draining circuit design and/or (2) center-of-coil downward sag.
Such a situation may cause tube failure (e.g. freeze-up in cold
climates or tube erosion because of untreated mineralized
water).
Depending on performance requirements, fluid velocity inside the
tube can range from approximately 1 to 8 fps for water and 0.5 to 6
fps for glycol. In some turbulators or grooved tube cases, in-tube
velocities should not exceed 4 fps. The design fluid pressure drop
across the coils can vary from about 5 to 50 ft of water head. For
some nuclear HVAC applications, ASME Standard AG-1, Code on Nuclear
Air and Gas Treatment, a minimum tube velocity of 2 fps may be
desired or necessary. ARI Standard 410 may require a minimum of 1
fps or a Reynolds number of 3100 or greater. In some cases, such
configurations may yield more predictable performance. The entire
contents of these standards are incorporated herein by
reference.
In some cases, the water may contain considerable sand and other
foreign matter (e.g. pre-cooling coils using well water, or where
minerals in the cooling water deposit on and foul the tube
surface). It may be desirable to filter out such sediment. Where
build-up of scale deposits or fouling of the water-side surface is
expected, a scale factor can be included when calculating thermal
performance of the coils. Cupronickel, red brass, bronze, and other
tube alloys can help protect against corrosion and erosion
deterioration caused by internal fluid flow abrasive sediment. The
core tubes of properly designed and installed coils can feature
circuits that (1) have equally developed line length, (2) are
self-draining by gravity during the coil's off cycle, (3) have the
minimum pressure drop to aid water distribution from the supply
header without requiring excessive pumping head, and (4) have equal
feed and return by the supply and return header. Design for proper
in-tube-water velocity can determine the circuitry style required
or desired. Multirow coils can be circuited to the cross-counter
flow arrangement and oriented for top-outlet/bottom-feed
connection.
The cooling capacity of water coils can be controlled by varying
either water flow or airflow. Water flow can be controlled by a
three-way mixing, modulating, and/or throttling valve. For airflow
control, face and bypass dampers can be used. In some cases, when
cooling demand decreases, the coil face damper starts to close, and
the bypass damper opens. In some cases, airflow is varied by
controlling fan capacity with speed controls, inlet vanes, or
discharge dampers. Chapter 45 of the 2003 ASHRAE Handbook-HVAC
Applications addresses air-cooling coil control to meet system or
space requirements and factors to consider when sizing automatic
valves for water coils. The entire contents of this handbook are
incorporated herein by reference.
In an HVAC system, the relation of the fluid flow arrangement in
the coil tubes to coil depth can influence performance of the heat
transfer surface. Often, air-cooling and dehumidifying coils are
multi row and circuited for counter flow arrangement. Inlet air may
be applied at right angles to the coil's tube face (coil height),
which may also be at the coil's outlet header location. Air can
exit at the opposite face (side) of the coil where the
corresponding inlet header is located. In some cases, counter flow
can produce the highest possible heat exchange in the shortest
possible (coil row) depth, because it may have the closest
temperature relationships between tube fluid and air at each (air)
side of the coil. The temperature of the entering air may more
closely approach the temperature of the leaving air. The potential
of realizing the highest possible mean temperature difference can
thus be arranged for optimum performance. Coil hand can refers to
either the right hand (RH) or left hand (LH) for counter flow
arrangement of a multi row counter flow coil. A manufacturer can
establish a RH or LH convention for their own coils.
A typical arrangement of coils can be present in a field built-up
central station system. A cooling coil (and humidifier, when used)
can include a drain pan under each coil to catch condensate formed
during cooling (and excess water from the humidifier). A drain
connection can be downstream of the coils, be of ample size, have
accessible cleanouts, and discharge to an indirect waste or storm
sewer. The drain may also include a deep-seal trap so that no sewer
gas can enter the system. Precautions can be taken if there is a
possibility that the drain might freeze. The drain pan, unit
casing, and water piping can be insulated to prevent sweating.
Coil design features (e.g. fin spacing, tube spacing, face height,
type of fins), together with the amount of moisture on the coil and
the degree of surface cleanliness, can determine the air velocity
at which condensed moisture blows off the coil. Often, condensate
water begins to be blown off a plate fin coil face at air
velocities above 600 fpm. It may be desirable to prevent water blow
off from coils into air ductwork external to the air-conditioning
unit. However, water blow off may not be a problem if coil fin
heights are limited to, for example 45 inches, and the unit is set
up to catch and dispose of condensates.
When selecting a coil, various factors can be considered. Job
requirements may involve cooling, dehumidifying, and the capacity
required to properly balance with other system components (e.g.,
compressor equipment in the case of direct-expansion coils).
Factors may also encompass entering air dry-bulb and wet-bulb
temperatures, available cooling media and operating temperatures,
space and dimensional limitations, air and cooling fluid
quantities, including distribution and limitations. Factors may
also include allowable frictional resistances in air circuit
(including coils), allowable frictional resistances in cooling
media piping system (including coils), characteristics of
individual coil designs and circuitry possibilities, individual
installation requirements such as type of automatic control to be
used, the presence of a corrosive atmosphere, any design pressures,
and the durability of tube, fins, and frame material.
A cooling coil's airflow resistance (air friction) may depend on
the tube pattern and fin geometry (tube size and spacing, fin
configuration, and number of in-line or staggered rows), coil face
velocity, and amount of moisture on the coil. The coil air friction
may also be affected by the degree of aerodynamic cleanliness of
the coils core. Burrs on fin edges may increase coils friction and
increase the tendency to pocket direct of lint on the faces. A
completely dry coil, removing only sensible heat, may offers
approximately one-third less resistance to airflow than a
dehumidifying coil removing both sensible and latent heat. For a
given surface and airflow, increasing the number of row or fins
often increases airflow resistance. Therefore, final selection can
involve economic balancing of the initial cost of the coil against
the operating costs of the coil geometry, combinations available to
adequately meet the performance requirements.
The heat transmission rate of air passing over a clean tube (with
or without extended surface) to a fluid flowing within it may be
impeded by certain thermal resistances: (1) surface air-side film
thermal resistance from the air to the surface of the exterior fin
and tube assembly, (2) metal thermal resistance to heat conductance
through the exterior fin and tube assembly, and (3) in-tube
fluid-side film thermal resistance, which impedes heat flow between
the internal surface of the internal metal and the fluid flowing
within the tube. For some applications, an additional thermal
resistance can be factored in to account for external and/or
internal surface fouling. Often, the combination of metal and
tube-side film resistance is considerably lower than the air-side
surface resistance.
Valves are often embodied by manual or automatic fluid-controlling
elements in a piping system. Valves can be constructed to withstand
a specific range of temperature, pressure corrosion, and mechanical
stress. Valves can function to start, stop, and direct flow. Valves
can also regulate, control, or throttle flow. Moreover, valves can
prevent backflow, and can relieve or regulate pressure.
Any of a variety of service conditions can be considered when
specifying or selecting a valve. A type of valve desired may depend
on whether a fluid is liquid, vapor, or gas. A valve may be
selected on the basis of whether the fluid is a true fluid or
whether it contains solids. The selection may depend on whether the
fluid remains a liquid throughout its flow, or whether it
vaporizes. The selection may depend on whether the fluid is
corrosive or erosive. Similarly, the selection can depend on the
pressure and temperature of the fluid, and whether these parameters
vary in the system. In some cases, the selection for the valve or
valve material may depend on whether a worst case (e.g. maximum or
minimum values) is considered. Flow considerations may also be
taken into account. A valve selection may depend on whether a
pressure drop is critical. In some cases, a valve design can be
chosen for maximum wear. Other criteria involve whether the valve
is used for simple shutoff or for throttling flow, whether the
valve is used to prevent backflow, and whether the valve is used
for directing (e.g. mixing or diverting) flow. The frequency of
operation may also have an impact on valve selection. Criteria can
involve whether the valve is operated frequently, whether the valve
is normally open with infrequent operation, and whether the valve
operation is manual or automatic.
A ball valve often includes a precision ball held between two
circular seals or seats. Ball valves can have various port sizes. A
90 degree turn of the handle can change operation from fully open
to fully closed. Ball valves for shutoff service may be fully
ported. Ball valves for throttling or controlling and/or balancing
service can have a reduced port with a plated ball and valve handle
memory stop. Ball valves may be on one-, two-, or three-piece body
design.
Automatic valves can be considered as control valves that operate
in conjunction with an automatic controller or device to control
the fluid flow. The "control valve" as used here can include a
valve body and an actuator. The valve body and actuator may be
designed so that the actuator is removable and/or replaceable, or
the actuator may be an integral part of the valve body.
Computer-based control of automatic control valves can provide many
benefits, including speed, accuracy, and data communication. Often,
care should be exercised in selecting the value of control loop
parameters such as loop speed and dead band (allowable set-point
deviation). In some cases, high loop speed coupled with zero dead
band can cause the valve-actuator to seek a new control position
with each control loop cycle unless the actuator itself has some
type of built-in protection against this. For example, a 1 s
control loop with zero dead band can result in 30,000,000
repositions (corrections) in 1 year of service. Generally, valves
control the flow of fluids by an actuator, which can move a stem
with an attached plug. A plug can seat within the valve port and
against the valve seat with a composition disk or metal-to-metal
seating. Based on the geometry of the plug, distinct flow
conditions can be developed.
Automatically controlled valves can be applied to control many
different variables, including temperature, humidity, flow, and
pressure. In some cases, a valve can be used directly to control
flow or pressure. In some cases, when flow is controlled, a
pressure drop is implied, and when pressure is controlled, some
maximum flow rate is implied. These two factors can be considered
in selecting control valves. Control valves can be used with hot
water, chilled water, steam, and virtually any fluid. The fluid
characteristics can be considered in selecting materials for the
valve. In some cases, requirements may be strict for use with
high-temperature water and high-pressure steam.
Approaches for balancing hydronic systems include (1) a manual
valve with integral pressure taps and a calibrated port, which
permits field proportional balancing to the deign flow conditions,
and (2) an automatic flow-limiting valve selected to limit the
circuit's maximum flow to the design flow. Manual balancing valves
can be provided with various features, such as manually adjustable
stems for valve port opening or a combination of a venturi or
orifice and an adjustable valve, a stem indicator and/or scale to
indicate the relative amount of valve opening, pressure taps to
provide readout of the pressure difference across the valve port or
the venture/orifice, the capability to be used as a shutoff for
future service of the heat transfer terminal, a locking device for
field setting the maximum opening of a valve, or a body tapped for
attaching drain hose.
Embodiments encompass automatic flow-limiting valves and pressure
independent valves. A differential pressure-actuated flow valve,
also called an automatic flow-limiting valve, can regulate the flow
of fluid to a preset value when the differential pressure across it
is varied. This regulation (1) helps prevent an overflow condition
in the circuit where it is installed and (2) aids the overall
system balance when other components are changing (modulating
valves, pump staging, etc.). Often, the valve body contains a
moving element containing an orifice, which adjusts itself based on
pressure forces so that the flow passage area varies. A balancing
valve can include a flow control device that is selected for a
lower pressure drop than an automatic control valve (e.g. 5 to 10%
of the available system pressure). Selection of any control valve
can be based on the pressure drop at maximum (design) flow to
ensure that the valve provides control at all flow rates. A
properly selected balancing valve can proportionally balance flow
to its terminal with flow to the adjacent terminal in the same
distribution zone.
In current HVAC approaches, various types of heat exchangers can be
manufactured as discussed above to transfer heat. The components to
control/regulate the heat transfer rate and to filter the fluid are
made by various other manufacturers. Often, these other components
are installed, tested, and calibrated in the field at the project
location. Heat exchangers such as coils can ship stand-alone to a
project site and be incorporated into the HVAC system or/and
shipped to a product manufacturer where the coil is inserted into
the product. Then the product is shipped to the project
destination, where the "other" piping components are installed at
the project location. Some of these other piping components include
control valves/automatic temperature controls valves supplied by
the Controls Contractor. The Controls Contractor has a contract to
install all the building automation controls (BAS) in the building.
There are several large Controls companies including Johnson,
Siemens, and Honeywell, and the like. Temperature sensors, pressure
sensors and other control instrumentation are typically supplied by
the Controls Contractor who has a contract to install all the
building automation controls (BAS) in the building. Balancing
valves, including automatic type (pressure independent) and manual
balancing valves are supplied by a water side sales representative
and sold directly to the Piping Contractor. There are several
manufacturers of balancing valves such as Griswold, Flow design,
Nexus, and the like. Isolation valves, drains, air vents and other
ancillary piping components are supplied by a water side sales
representative and sold directly to the Piping Contractor. There
are several manufacturers of these types of products such as Nibco,
Gerhard, and the like. Strainers and other ancillary components to
filter out containments in the water are supplied by a water side
sales representative and sold directly to the Piping Contractor.
The Contractor acts as the systems integrator and tries to assemble
all the components in the field with various union labor trades
such as the Pipefitters union, the Sheet metal union, the
Electricians union, and the like. The Contractor is interested in
maximizing his profit and therefore always buys the most economic
products per job by various manufacturers. Each project uses
different manufacturers depending on which manufacturer meets the
job specifications and is the most economical. The fact the
Contractor buys on low price does not allow him to over
design/engineer a product that meets the majority of the
specifications. Additionally, the Contractor is not a manufacturer.
The end product is non-catalogued components assembled with no
uniformity, standardization of part numbers, nomenclature,
drawings, model numbers, test data, and the like. There is no
standardization of the end product form one project to the other.
The coils and ancillary field piping components are in the
mature/decline stage of the product life cycle. The emphasis is on
cutting production costs, low price and not on innovations. The
fact that the market for the final product is segmented by niche
manufacturers makes it more difficult to innovate. The fact the
unions have work preservation rights upheld by the Supreme Court
does not allow innovation of the ancillary components and coils.
Absent the advantages provided by embodiments of the present
invention, shipping damage of the field components integrated on to
a coil could be cost prohibitive. Multiple piping configurations
currently exist for each product based on the project making it
difficult for universal standardization. Contractors pay 60%+over
OEM/factory costs. Therefore the smallest item that is something
all the owners would like becomes cost prohibitive for the
Contractor to offer. Whereas according to embodiments of the
present invention, it is possible to include this benefit for a
nominal cost and therefore meet 95% of all specifications and
projects by over designing the product. Coil manufacturers
currently and in the past typically could not ship a portable
piping assembly attached to the coil with all the ancillary
components attached without damaging the ancillary components. Or
if tried, it was cost prohibitive and they still had damage of the
product and no standardization of ancillary components. Thus,
manufacturing coils with ancillary components attached was is cost
prohibitive. Many people in the industry do not understand how all
the various components work together. There are typically experts
for each HVAC segment but seldom does anyone understand how all the
various segments work together, including the Wet side, Air side,
Controls, Mechanical & Electrical Engineering and Installation
of final product by various Contractors, such as wet side, air
side, controls, and the like. Mechanical Engineers attend college
for 5 years to learn how to design a project. Union tradesmen
attend a 5 year apprentice program to learn how to install the
various components required in completing a building project in a
timely manner. Manufacturers focus on product design and
manufacturing for their particular product/niche. There are
multiple industrial applications such as biotech, hospital,
commercial, hi rise, campus, hotel, and the like, requiring various
designs and installation techniques. Heretofore, advances in
technology have not been integrated into product designs as
disclosed herein for example due to the segmented market segments.
In commonly known approaches, coils can be made then installed on a
final product such as an air handling unit, fan coil unit, VAV
terminal unit, or a fan powered terminal unit. These units are then
shipped to the field by the manufacturer. The ancillary piping
components to control flow to the coil and temperature output of
the coil are installed by the Contractor in the field due to the
above referenced factors, such as unions, shipping problems,
shipping damage, segmented market, products in the decline/mature
stage of the product life cycle, various performance specifications
and job requirements for each construction project. Currently,
balancing valves are field installed and are used as a way to fix
the flow. Manual balancing valves are field adjusted by water
balancing technicians. Automatic/pressure independent balancing
valves maintain the specified GPM regardless of the pressure drop
across the coil.
Embodiments of the present invention provide for the embedding of
ancillary components directly onto the coil or heat exchanger
itself. Ancillary components include components that control
performance, inputs and outputs, instrumentation, and components
that filter the water and keep it free from sediments such as
strainers, control valves, pressure temperature ports, sensors,
balancing valves, isolation valves, and the like. Ancillary
components can be embedded onto a heat exchanger, and shipped to
the jobsite, or placed into another piece of equipment such as an
air handler, a fan coil unit, a VAV box, and the like.
Embodiments of the present invention provide for the over design of
a base product offering so that it can meet the majority of all
project specifications. This allows for the mass production of a
product in a very cost efficient way. The standardization of
components allows for the purchase of components at a substantially
lower price than a Contractor on an OEM basis. The standardization
allows for cataloging and validation of the product. Embodiments
encompass set operational and maintenance manuals for the product,
and the like. Bracket and supports, in house testing/calibration,
QC and shipping procedures allow the product to be shipped 100%
defect free every time at a very cost efficient manner.
In some embodiments, direct digital microprocessor controllers can
be directly installed on or coupled with a coil. For example,
embodiments encompass making a slight modification to a coil casing
and installing a direct digital microprocessor controller with
multiple input and outputs with their own Internet addressable
points directly on the coil. The DDC microprocessor and its
components can be hard wired or wireless. It can be programmed with
multiple programming languages allowing it to communicate with
various BAS systems manufactured by different vendors.
Embodiments of the present invention also encompass coil
performance control without a balancing valve. For example, it is
possible to eliminate the need for a balancing valve which is
currently used to control the performance of a coil. In an
exemplary embodiment, a leaving air temperature sensor can be
installed downstream of the coil and wired back to DDC controller.
A room sensor/thermostat can be wired to the DDC microprocessor and
resides in the actual room. A manual air vent can be installed at
the highest point of the coil. A strainer is installed, a drain is
installed, and isolation valves are installed. No balancing valves
are now needed. A flow limiter is installed on the automatic
temperature control valve to limit the maximum flow allowable to
the ATC valve. The actuator which is part of the ATC valve receives
a signal from the DDC microprocessor which tells it how much to
open and close. The actuator controls the valve that opens and
closes and controls the amount of flow into the coil and thus
controls the MBH output of the coil. A temperature differential
between the room sensor and the leaving air temperature can
determine how much water is allowed into the coil via the ATC valve
and the MBH output of the coil. The DDC microprocessor can control
the ATC valve with data it is receiving from the leaving air
temperature sensor and the room sensor. An algorithm can be
written, pre-programmed to determine the range or tolerances or
other operating parameters of the components. Optionally, input and
output for such algorithms may be based on psychrometric
principles. A variable frequency drive/inverter (VFD) can be added
to the pumps to control the overall flow of the system based on
various performance parameters. The VFD can tie into the BAS system
as does the DDC microprocessor and its inputs and outputs can be
embedded on the coils. Water balancing can be eliminated or
substantially minimized as the BAS system is now the balancer.
Manual balancing valves and pressure independent balancing valves
can be excluded. An advantage of the pressure independent balancing
valves is that no matter what the pressure drop is at the coil, the
pressure independent balancing valve can maintain the same gallons
per minute through the coil as is required or desired. This is
accomplished by various ways depending on the manufacturer of the
pressure independent balancing valve.
In some embodiments, the pressure drop through the coil/system may
be irrelevant or of minimal impact because the flow can be
controlled based off of set point. In some cases, if the coil mbh
is currently at set point and the pressure increases the gpm
decreases, thus the mbh decreases below the required set point. A
signal is sent to the ATC valve and the valve opens until the flow
going through the coil reaches the leaving air temperature set
point. This can happen on one or more zones instantaneously. By
eliminating the balancing valves from the coils the pressure drop
is reduced and less pump energy is needed to pump the water through
out the system. In some cases, the initial water balancing set up
is eliminated or substantially reduced at a savings of an average
of about $100,000.00.
Superior Indoor Air quality can be achieved as everyone with a
thermostat can now have the desired comfort they require. In
addition, the set point required by the room occupant can be
maintained to the desired set point to very tight tolerances with
little to no fluctuations in the room temperature set point. In
some cases, LEED points are awarded. More zones can be added into a
building as the embodiments disclosed herein are extremely cost
effective. By adding more zones into a building, more people get
their own thermostats and control of their individual environment.
Currently, 1 thermostat/zone can control 10 offices, for
example.
In some embodiments, a server may accumulate data received from
wireless transmitters and sensors placed at various locations on an
HVAC system. Variables such as gpm, btu, output, pressure drop, and
the like can be monitored, along with data from the coil or heat
exchanger. A processor or controller can adjust system operating
parameters based on such data.
In some embodiments, the system is depreciable to the building
owner. In comparison, many known approaches that involve field
labor to assemble the various components are not depreciable.
In some embodiments, coils can be constructed with press fittings.
Often, known coils are brazed at the joints. Press fittings can use
an o ring or some sort of seal. The press fitting can slip over the
copper tube and a tool can be used which is set at the specified
psi required to press the fitting and the seal around the copper
pipe forming a bond and a waterproof seal. A coil can thus be made
with these press fittings and eliminate the need for brazing of the
copper. The coil can be lead free.
In some embodiments, a coil with one or more of the above
referenced components, such as a DDC microprocessor, can ship with
a damper. A VAV box can have a damper, pressure probe, and a
heating coil. The damper and the probe can be encased in galvanized
metal. The coil can be attached to the VAV box by a flanged
connection and screws or slip and drive connections. This complete
assembly can then be installed at the jobsite. It can be hung and
connected to the ductwork. By shipping the coil direct to the
project with one or more of the referenced innovations and the
damper attached/wired to the DDC microprocessor, the Contractor can
slip the coil assembly into the galvanized duct, cut a small
straight hole in the duct upstream of the coil, inserts the damper
assembly with a sensor into the duct, and screw in the base of the
damper to the duct and seal the small duct opening.
Embodiments of the present invention can provide simple and cost
effective solution to some currently used VAV boxes. Embodiments
can also provide an effective application for retrofit of existing
systems. HVAC piping assemblies and other manufactures can be
factory calibrated and tested at the factory. A DDC microprocessor
can be addressed and pre-programmed further reducing field labor
time. With mass production of products, they can ship to the job
site exceeding construction schedule. Contractors can use a fixed
labor pool to install units versus assembling them. This can make
the Contractor more efficient and profitable. Thus, a lower overall
cost savings is provided to the building owner.
In some embodiments, one or more brackets can function as a piping
support for a portable piping structure. It meets or exceeds all
building codes and therefore no additional "support" of the piping
structure is required in the field/project by stationary type
brackets, Unistrut.RTM., and the like, once the heat exchanger is
installed. In contrast, in many current approaches all the piping
and accessories that hook up to the heat exchanger/coil must be
field supported at the job site by various fasteners attached to
the building structure.
FIG. 25 depicts an HVAC component assembly 25000 according to
embodiments of the present invention. Assembly 25000 can include a
duct that provides an airflow passage. The assembly may also
include a heat exchanger having or coupled with an ATC valve, a
galvanized casing, and a microprocessor. The microprocessor can
have connectivity with a leaving air temperature sensor, a room
sensor, and a LAN. The microprocessor can also have connectivity
with the ATC valve and a damper. A damper can include an actuator
and a sensor. The damper can be shipped with the heat exchanger or
coil and installed in the field. The heat exchanger can be
pre-piped, pre-wired, pre-programmed, pre-calibrated, and the like.
The heat exchanger can ship with minimal or no defects. The heat
exchanger can provide "plug and play" connectivity with an HVAC
system.
FIGS. 26 and 27 show HVAC component assemblies according to
embodiments of the present invention. FIGS. 28A-28C illustrate
various views of an HVAC unit assembly according to embodiments of
the present invention. Such manufactures can include a portable
piping shipping bracket with piping grommets and a handle. In some
embodiments, a casing or duct can partially or completely enclose a
portable piping structure. In some embodiments, the manufacture
does not include a handle. Optionally, a manufacture may include
handles at various locations. Manufactures may include one or more
grommets, which may be spaced in an ordered or random fashion. In
some embodiments, a portable piping shipping bracket can be a
single sided bracket, a two sided bracket, a three sided bracket, a
four sided bracket, a five sided bracket, a six sided bracket, a
seven sided bracket, an eight sided bracket, or the like. A bracket
may provide up to 100 percent enclosure of a piping structure. In
some cases, a shipping bracket can have cut-outs or apertures that
allow for access to certain components or accessories associated
with a portable piping structure. In some embodiments, a bracket
may include a single flat piece of aluminum with grommets, and may
be secured to a coil casing, heat exchanger duct, or other
enclosure. In some cases, a coil casing may be extended to allow
for improved support and protection of portable piping structure
components. Embodiments also encompass insulation features coupled
with the manufacture, and any desired aspect ratio option or
component option. Advantageously, bracket embodiments can eliminate
the need for individual support of piping components or portable
piping structure features at or during transport to the jobsite.
Enclosures, casings, or ducts may include handles, or may be devoid
of handles. Enclosures may include grommets, or may be devoid of
grommets. In some embodiments, an enclosure may include a full
complement of sides. For example, a rectangular box enclosure may
include 6 sides. In some embodiments, an enclosure may include less
than a full complement of sides. For example a cube shaped
enclosure may include only five sides, or in some embodiments it
may include only four sides. Optionally, an enclosure may include a
partial side. FIG. 29 shows a portable piping structure supported
and protected by a single sided bracket.
FIGS. 30A-30C illustrate various views of an HVAC unit assembly
bracket according to embodiments of the present invention. In some
cases, such brackets can provide a universal hanging bracket.
Bracket embodiments can be adjustable on a piping structure or duct
or other HVAC unit component by sliding the bracket back and forth.
In some cases, the bracket can be built with hinges at one or more
corners for shipping the bracket loose. Optionally, seismic
aircraft cables with I bolts can ship on the bracket. Brackets can
be standardized to balance loads, such as horizontal loads. A
bracket may be coupled with a handle. In some embodiments, a handle
may be provided on a separate piece. Handles can be mounted to the
frame or any other feature by a fastening system such as bolts or
screws. In some embodiments, bracket frames such as these provide
an adjustable aspect ratio for the handle and system.
Currently, heating and cooling coils manufactured for use in VAV
boxes, fan coils, air handling units (AHU's), or for stand alone
applications often have the inlet and outlet of the supply and
return fluid lines at the very top and bottom of the coil piping
assembly. That is, the inlets and the outlet of the coils are
located at the top and bottom of the coils. In this way, as the
size of the coil increases, so does the distance between the coil
inlet and outlet openings. Embodiments of the present invention
provide a coil or thermal transfer unit having an inlet and outlet
which are spaced apart from each other at a standard or known
distance. Hence, a large coil can have a configuration where the
inlet and outlet are separated by a standard distance, and a small
coil can have a configuration where the inlet and outlet are
separated by the same standard distance. In one exemplary
embodiment, the standard distance between a coil inlet and outlet
is six inches on center. In other embodiments, the standard
distance between a coil inlet and outlet can be four inches on
center, eight inches on center, twelve inches on center, and the
like. Embodiments of the present invention also provide handles,
brackets, and the like having apertures separated by a standard
distance. For example, a standard distance between a first aperture
and a second aperture can be six inches on center. In other
embodiments, the standard distance between a first aperture and a
second aperture can be four inches on center, eight inches on
center, twelve inches on center, and the like. These distances may
refer to the distance between the actual components (e.g. pipe or
aperture) or the distance between central longitudinal axes defined
by such components, for example.
Embodiments of the present invention encompass methods of
manufacturing one or a plurality of portable piping structures. As
depicted in FIG. 31A, exemplary embodiments may include providing a
first heat exchange coil 3110a having a first dimension such as a
width W.sub.1, and a second heat exchange coil 3120a having a
second dimension such as a width W.sub.2. The first heat exchange
coil may have an inlet pipe 3112a defining a central longitudinal
axis 3116a and an outlet pipe 3114a defining a central longitudinal
axis 3118a. Central longitudinal axis 3116a and central
longitudinal axis 3118a are separated by a distance of D.sub.1. The
second heat exchange coil may have an inlet pipe 3122a defining a
central longitudinal axis 3126a and an outlet pipe 3124a defining a
central longitudinal axis 3128a. Central longitudinal axis 3126a
and central longitudinal axis 3128a are separated by a distance of
D.sub.2. In some embodiments, distance D.sub.1 is equal to distance
D.sub.2.
As depicted in FIG. 31B, exemplary embodiments may include coupling
a first inlet piping assembly 3132b with inlet pipe 3112b and
coupling a first outlet piping assembly 3142b with outlet pipe
3114b to provide a first portable piping structure 3152b of a
plurality of portable piping structures 3160b. First inlet piping
assembly 3132b can define a central longitudinal axis 3133b, and
first outlet piping assembly 3142b can define a central
longitudinal axis 3143b. Central longitudinal axis 3133b and
central longitudinal axis 3143b are separated by a distance of
D.sub.1. Similarly, embodiments may include coupling a second inlet
piping assembly 3172b with inlet pipe 3122b and coupling a first
outlet piping assembly 3182b with outlet pipe 3124b to provide a
second portable piping structure 3154b of the plurality of portable
piping structures 3160b. Second inlet piping assembly 3172b can
define a central longitudinal axis 3173b, and second outlet piping
assembly 3182b can define a central longitudinal axis 3183b.
Central longitudinal axis 3173b and central longitudinal axis 3183b
are separated by a distance of D.sub.2. In some embodiments,
distance D.sub.1 is equal to distance D.sub.2. It is appreciated
that first portable piping structure 3152b and second portable
piping structure 3154b can each include a coil or heat exchanger,
such that the respective coils or heat exchangers are of different
sizes or dimensions. Hence, embodiments of the present invention
encompass a plurality of portable piping structures, where coil or
heat exchanger dimensions may vary among the portable piping
structures, while the distance between inlet and outlet pipes,
between inlet and outlet piping assemblies, or between central
longitudinal axes defined by the pipes or piping assemblies are
equal or otherwise standardized for mass production.
FIG. 31C shows a plurality of portable piping structures according
to embodiments of the present invention. Methods for making piping
structures may include coupling a first inlet piping assembly 3132c
with inlet pipe 3112c and coupling a first outlet piping assembly
3142c with outlet pipe 3114c to provide a first portable piping
structure 3152c of a plurality of portable piping structures 3160c.
First inlet piping assembly 3132c can define a central longitudinal
axis 3133c, and first outlet piping assembly 3142c can define a
central longitudinal axis 3143c. Central longitudinal axis 3133c
and central longitudinal axis 3143c are separated by a distance of
D.sub.1. Similarly, embodiments may include coupling a second inlet
piping assembly 3172c with inlet pipe 3122c and coupling a first
outlet piping assembly 3182c with outlet pipe 3124c to provide a
second portable piping structure 3154c of the plurality of portable
piping structures 3160c. Second inlet piping assembly 3172c can
define a central longitudinal axis 3173c, and second outlet piping
assembly 3182c can define a central longitudinal axis 3183c.
Central longitudinal axis 3173c and central longitudinal axis 3183c
are separated by a distance of D.sub.2. In some embodiments,
distance D.sub.1 is equal to distance D.sub.2. As shown here, first
portable piping structure 3152c may be coupled with or include a
first bracket 3191c having a first support 3193c and a second
support 3195c. First bracket 3191c can be coupled with a duct or
casing 3197c. First support 3193c can be coupled with first inlet
piping assembly 3132c, and second support 3195c can be coupled with
first outlet piping assembly 3142c. Similarly, second portable
piping structure 3154c may be coupled with or include a second
bracket 3192c having a first support 3194c and a second support
3196c. Second bracket 3192c can be coupled with a duct or casing
3198c. First support 3194c can be coupled with second inlet piping
assembly 3172c, and second support 3196c can be coupled with second
outlet piping assembly 3182c.
FIG. 31D shows a plurality of portable piping structures according
to embodiments of the present invention. Methods for making piping
structures may include coupling a first inlet piping assembly 3132d
with inlet pipe 3112d and coupling a first outlet piping assembly
3142d with outlet pipe 3114d to provide a first portable piping
structure 3152d of a plurality of portable piping structures 3160d.
First inlet piping assembly 3132d can define a central longitudinal
axis 3133d, and first outlet piping assembly 3142d can define a
central longitudinal axis 3143d. Central longitudinal axis 3133d
and central longitudinal axis 3143d are separated by a distance of
D.sub.1. Similarly, embodiments may include coupling a second inlet
piping assembly 3172d with inlet pipe 3122d and coupling a first
outlet piping assembly 3182d with outlet pipe 3124d to provide a
second portable piping structure 3154d of the plurality of portable
piping structures 3160d. Second inlet piping assembly 3172d can
define a central longitudinal axis 3173d, and second outlet piping
assembly 3182d can define a central longitudinal axis 3183d.
Central longitudinal axis 3173d and central longitudinal axis 3183d
are separated by a distance of D.sub.2. In some embodiments,
distance D.sub.1 is equal to distance D.sub.2. As shown here, first
portable piping structure 3152d may be coupled with or include a
first bracket 3191d having a first support 3193d and a second
support 3195d. First bracket 3191d can be coupled with a duct or
casing 3197d. First support 3193d can be coupled with inlet pipe
3112d, and second support 3195d can be coupled with outlet pipe
3114d. Similarly, second portable piping structure 3154d may be
coupled with or include a second bracket 3192d having a first
support 3194d and a second support 3196d. Second bracket 3192d can
be coupled with a duct or casing 3198d. First support 3194d can be
coupled with second inlet pipe 3122d, and second support 3196d can
be coupled with second outlet pipe 3124d.
FIG. 31E shows a plurality of portable piping structures according
to embodiments of the present invention. Methods for making piping
structures may include coupling a first inlet piping assembly 3132e
with inlet pipe 3112e and coupling a first outlet piping assembly
3142e with outlet pipe 3114e to provide a first portable piping
structure 3152e of a plurality of portable piping structures 3160e.
First inlet piping assembly 3132e can define a central longitudinal
axis 3133e, and first outlet piping assembly 3142e can define a
central longitudinal axis 3143e. Central longitudinal axis 3133e
and central longitudinal axis 3143e are separated by a distance of
D.sub.1. Similarly, embodiments may include coupling a second inlet
piping assembly 3172e with inlet pipe 3122e and coupling a first
outlet piping assembly 3182e with outlet pipe 3124e to provide a
second portable piping structure 3154e of the plurality of portable
piping structures 3160e. Second inlet piping assembly 3172e can
define a central longitudinal axis 3173e, and second outlet piping
assembly 3182e can define a central longitudinal axis 3183e.
Central longitudinal axis 3173e and central longitudinal axis 3183e
are separated by a distance of D.sub.2. In some embodiments,
distance D.sub.1 is equal to distance D.sub.2. As shown here, first
portable piping structure 3152e may be coupled with or include a
first bracket 3191e having a first support 3193e and a second
support 3195e. First bracket 3191e can be coupled with a duct or
casing 3197e. First support 3193e can be coupled with first inlet
cap, fitting, or piping 3103e, and second support 3195e can be
coupled with first outlet cap, fitting, or piping 3105e. Similarly,
second portable piping structure 3154e may be coupled with or
include a second bracket 3192e having a first support 3194e and a
second support 3196e. Second bracket 3192e can be coupled with a
duct or casing 3198e. First support 3194e can be coupled with
second inlet cap, fitting, or piping 3104e, and second support
3196e can be coupled with second outlet cap, fitting, or piping
3106e.
Advantageously, the brackets illustrated in FIGS. 31C-E are well
suited for providing any desired spacing between components to
which they are attached or coupled, according to the principles
shown in FIGS. 31A-B. Furthermore, any of a variety of ancillary
components or subassemblies thereof can be mounted on or coupled
with a bracket, a casing or duct, or a coil or heat exchanger. By
utilizing such efficient manufacturing methods, it is possible for
one union pipe fitter manufacture 30 to 60 portable piping
structure units per hour. In contrast, many commonly used
manufacturing methods require two union pipe fitters a total of
eight hours to pipe up a small stand alone heat exchanger/fluid
coil and/or VAV box with hot water re-heat. By prefabricating the
units with manufacturing procedure embodiments of the present
invention, it is possible to realize real economic efficiencies.
Often, such portable piping assemblies or structures are sealed and
pressurized prior to shipping to a job site, where they can be
installed as part of a larger HVAC system of a building. Moreover,
it is possible to install valves and electronic components for BTUH
monitoring. This can provide a building owner or operator with any
of a variety of programming options to monitor and optimize the
total system for energy usage, LEED points, utility rebates, indoor
air quality (IAQ), comfort, and the like. Also, the entire unit, or
any desired portion or component thereof, can be insulated prior to
shipping to a construction site, a customer, or a secondary
manufacturing facility. According to some methods, it is possible
to transport a stand alone coil, without a full or partial
complement of zone control unit components, to a job site, an air
handler manufacturer, an original equipment manufacturer (OEM), or
any manufacturer or vendor of HVAC or heating, ventilation, air
conditioning and refrigeration (HVACR) systems, components, or
controls. For example, embodiments may include shipping a coil and
ancillary components to a variable air volume (VAV) box
manufacturer. By providing a plurality of coils or heat exchangers
having various sizes, which are configured with inlet and outlet
pipes separated by a standard distance or fixed aspect ratio, the
manufacturing process can be facilitated quickly, and installation
is efficient. A zone control unit or coil can be pre-programmed,
pre-tested, insulated, validated, and certified at a manufacturing
facility or factory. The product can be LEED certified, for example
as part of a GREEN program.
Hence, embodiments of the present invention encompass portable
piping structure designs having fixed or standardized dimensions or
spacing configurations for the inlet and outlet portions, or for
assemblies coupled therewith, of the coil or heat exchanger. The
dimension or spacing configuration may be fixed or standardized
regardless of the size of the coil or heat exchanger. In some
cases, on an end portion of a copper tube of the coil it is
possible to sweat in or include a fitting. It is also possible to
thread in a valve body to the fitting on the coil. On another side
of the valve body it is possible to thread in a sealed copper air
chamber. From a manufacturing process, in some embodiments it may
only be necessary to add one fitting to a sealed copper air
chamber, and then assemble the valve body to the air chamber piece
and the coil. In some cases, piping on a zone control unit may be
condensed to a coil body only. According to some of these
embodiments, but not exclusively, it is possible to ship such coil
configurations to a manufacturer for use in their product.
Embodiments of the present invention also provide universal coils
that can be used as a right hand or left hand connection, thus
eliminating the need for stocking multiple coil configurations. For
example, a coil or heat exchanger may include a 1/4 inch tap or
thread on both sides of the top and bottom header to make a
universal coil. By using a screw in type device the coil can have a
universal air vent for a top position or a universal drain plug for
a bottom or down position. As shown in FIG. 31F, regardless of
which side is facing upward, it is possible to screw in or
otherwise couple an air vent 3110f on a higher side of the coil
3115f at the tap or thread, and screw in or otherwise couple a
drain cock 3120f on a lower side of the coil 3115f at the tap or
thread. This configuration may require only one elbow and fitting
on each supply and return line, and can be mounted directly on a
coil. The coil casing can be increased to an optimum size to allow
piping components, controls hardware, and the like to be installed
directly on the coil casing. Thus the coil and the piping
components become universal and capable of being installed on or in
any product or duct work.
According to some embodiments of the present invention, a coil
casing can be made with various universal transitions out of
various types of materials, thus providing a universal installation
kit of the coils. As depicted in FIG. 32, a coil or heat exchanger
3200 can be coupled with a transition casing 3210 where a first
portion 3212 of the transition casing provides a larger surface
area than a second portion 3214 of the transition casing. Such
tapered casing configurations can provide sound attenuation to an
HVAC system, and can provide a more uniform air movement over the
coil with less turbulence when compared to some configurations that
do not have a tapered transition casing or duct. The incorporation
of a transition casing allows a VAV box or duct to accommodate
larger coils having more face or surface area. Consequently, the
number of rows in a coil can be reduced. For example, by
incorporating a transition casing it may be possible to replace a
two row coil with a one row coil. Moreover, larger coils having
more face or surface area can confer a lower water pressure drop or
a lower air pressure drop. Such systems typically use less energy
and provide better performance due to reduced fluid resistance, for
example. Hence, lower power air fans and water pumps can be used. A
transition casing can make a portable piping structure quieter and
can provide improved heat transfer as air flows over the entire
coil and eliminates or reduces spotting of the coil where uneven
thermal transfer occurs. Such configurations can qualify for LEED
points. In one exemplary embodiment, it is possible to use a
universal transition for a 20 inch duct or for a 6 inch duct.
Because a tapered transition casing may utilize more material, such
as sheet metal, discharge noise can be reduced.
A stand alone coil can be used as an economical and energy
efficient retrofit coil application, that is pre-piped, pre-wired,
and ready to plug and play. A low profile unit (for example a
smaller pre-piped coil with smaller dimensions) can be created by
the stand alone heat exchanger/coil and allows an engineer,
architect, or contractor more room to design and work on the
construction site. The product can ship pre-balanced and
pre-programmed, thus eliminating or reducing costly union field
labor. The product can be a pre-sealed, zero leakage box thus
saving more energy. A leaving air discharge sensor can be installed
on the heat exchanger, wired into the controls hardware, and
pre-calibrated at the factory. A green/LEED box can be produced
with these enhancements, at an economical cost. A coil casing can
be made as a flanged connection, as compared to a slip and drive
connection, which can help eliminate or reduce leaks. The product
can be overengineered in order to meet 95% or more of all building
specifications, and then mass produced. For example, a plurality of
portable piping structures can be manufactured which can be
incorporated into HVAC systems of a vast majority of residential,
commercial, or industrial applications. All or many of the piping
coil components can be interchangeable on a building, regardless of
the coil size, due to the universality provided by embodiments of
the present invention. In contrast, in many current methods a
contractor will not overengineer a piping assembly at the
construction job site, but rather will cobble together the cheapest
collection of components.
Typically, thermal transfer units and/or coils are manufactured for
either heating or cooling applications. That is, one coil is used
for heating, and another coil is used for cooling. According to
embodiments of the present invention, one coil is manufactured to
do both the heating and cooling. For example, a four way mixing
valve can be used on a coil to mix the fluid medium from 42 degrees
F. up to 200 degrees F. to optimize the leaving air temperature and
ancillary parameters off the coil. The valve may include an input
for receiving cold fluid from a chiller and an input for receiving
warm fluid from a boiler. Cold and warm fluid may be mixed and then
transferred into a coil. The various electronic devices embedded on
the coil can maintain and monitor the performance parameters off
the coil commensurate to what is needed or desired in the occupied
space or zone. Such configurations may include one hot inlet into
the valve, and one cold inlet into the valve. Mixing is
accomplished at the valve, and the mixed fluid then travels to the
coil, and then to a single outlet, for example. Another
configuration include two inlets and two outlets on a coil. A first
inlet and outlet can be used for cooling and a second inlet and
outlet can be used for heating.
Often, as the size of the coil increases, so does the size of the
piping. As the face or surface area of the coil increases, more
piping may be needed or desired for manufacturing the piping and
valve components. A duct, casing, or support structure can have a
fixed dimension (e.g. width, length, or height) which is about 3 to
5 times larger than the pipe diameter. The coils can be assembled,
attached to, located in or on another assembly, such as a VAV box,
AHU, duct work, fan, and the like. Hence, a portable piping
structure may include a duct or casing having a standard or
pre-selected length, width, and/or height. According to some
embodiments, it is possible to manufacture a plurality of such
portable piping structures, where a first portable piping structure
includes a coil having a first size or dimension, and a second
portable piping structure includes a coil having a different second
size or dimension, and the first and second portable piping
structures are each coupled with respective ducts or casings having
similar or standardized configurations.
Various bracketing systems can be used to connect a portable piping
structure or coil with a casing or ancillary components, so as to
ensure little or no damage to the components during shipment. A
duct, casing, square box, or can, optionally including rubber
grommets, can be used as a fastening device, handle, or bracket.
According to some embodiments, a duct, casing, or other container
may include supports for coupling with coils, heat exchangers,
pipes, piping assemblies, caps or fittings, and the like. For
example, a portable piping unit may include a coil attached with a
duct, such that one or more apertures or supports defined by the
duct are coupled with one or more portions of the coil. Ducts or
brackets according to similar embodiments may include handles as
depicted in FIGS. 28A-28C.
Psychrometry is a field of engineering concerned with the
determination of physical and thermodynamic properties of gas-vapor
mixtures. Advantageously, embodiments of the present invention can
incorporate psychrometric principles to provide ambient comfort to
one or more building occupants. For example, a psychrometric ratio
can relate the absolute humidity and saturation humidity to the
difference between the dry bulb temperature and the adiabatic
saturation temperature. A psychrometric chart can be a graph of the
physical properties of moist air at a constant pressure.
Psychrometric variables or thermophysical properties such as
dry-bulb temperature (DBT), wet-bulb temperature (WBT), dew point
temperature (DPT), relative Humidity (RH), humidity ratio (e.g
moisture content, mixing ratio, or specific humidity), specific
enthalpy, specific volume, and the like can be programmed into a
processor or controller of a zone control unit, heat exchanger,
coil, or other HVAC component. Algorithms can be based on
psychrometric variables to obtain a comfortable ambient room
environment for a building occupant. Coil or heat exchanger
properties can be selected based on psychrometric data.
Embodiments of the present invention provide temperature reset
valve for use with portable piping structures. By using a
temperature reset, a leaving air sensor and entering air sensor
along with a BTUH monitoring and/or inlet and outlet water
temperature sensor disposed at or near the coil, it is possible to
control the performance of the coil by adjusting the cfm over the
coil, and the entering/leaving heat transfer medium through the
coil and the building. Further, it is possible to incorporate data
or information from a psychrometric chart into the microprocessor
controller located on the coil or ZCU, optionally by way of written
or encoded software. For example, a controller or processor may
include a tangible medium embodying machine-readable code that is
configured to process information based on a psychrometric chart,
and data such as thermal transfer characteristics/properties of a
thermal transfer device/coil, airflow across the coil, the heat
transfer medium (water, for example) in and out of the coil, and
the leaving air parameters off the coil such as temperature, cfm,
humidity, and the like. Software or other programming can be
configured to control the temperature of the fluid or water
entering and leaving the coil, and the cfm across the coil to meet
or optimize psychrometric chart parameters relative to the current
conditions. The end result can be real time 100% indoor air
quality, a real time totally self balancing system, and a real time
energy efficient system qualifying for GREEN/LEED points. Also, by
monitoring these parameters it is possible to do real time BTUH
monitoring and optimize the HVAC system accordingly and let the
building owner or any other interested party know exactly where
they need to optimize their equipment for the biggest energy
savings/IAQ benefit. Advantageously, by using a temperature reset
along with psychrometric chart data, it is possible to
pre-fabricate a portable piping structure with ancillary components
such as sensors and the like, and also eliminate the need for a
balancing valve at the coil. Hence, such configurations can be
manufactured using less raw materials and installation labor, which
provides improved economic efficiencies. Moreover, the overall
pressure drop in the piping system can go down resulting in the use
of smaller pipe and valves and/or reduced energy consumption by the
HVAC equipment, including pumps, boilers, fans, chillers, and the
like. Accordingly, there are significant benefits which can be
realized by pre-piping or pre-fabricating such configurations, and
testing such configurations on a coil or zone control unit.
By incorporating a temperature reset, it is possible to eliminate a
balancing valve at the device. The gpm to a coil can be controlled
through a temperature reset. No balancing valves may be required at
the device, and thus energy savings are possible. The performance
of the system can be controlled by the building automation system
(BAS). The system can be self balancing. Such configurations are
very conducive to providing and stocking a standardized product
such as a zone control unit.
Embodiments of the present invention may incorporate components
from FlowCon International which involve total authority
technology, or similar components such as DeltaPValves from Flow
Control Industries. Such components may combine a control valve and
a flow limiting valve with a pressure equalizer. The combination
valves can neutralize the effect of variable pressure in the system
and return the authority to the control valve, thermostat, and
coil. Some initial models such as SH (manual) and SM (actuated)
have been supplemented by the SME model. When the valve stem closes
or opens it can allow the valve to adjust flow. The pressure
regulator can instantaneously equalize the pressure and afford the
control valve to precisely modulate as dictated by the thermostat
and BMS system. The outcome can be a highly accurate flow control.
Set points can be attained precisely and quickly as the control
valve is not "hunting" which is caused by fluctuating pressure. The
pressure regulator reacts to the slightest change in flow. The flow
limiter insures the coil does not receive more than the design
flow. A Total Authority Valve can be ideally suited for a variable
flow system used in a current system. Variable flow systems are
often constantly changing flow rates resulting in demands on the
pressure regulator to equalize pressure across the valve and coil.
A Total Authority Valve used in an On/Off application can equalize
flow from initial opening of the control valve portion through the
total open position. Then once again, from open to totally closed.
The SME model can be specifically targeted to provide a high level
of efficiency to variable flows found in VAV, modulating or
variable flow rates, for example in fan coils, water source heat
pumps, zone control units, and any small coil applications. A
"pop-top" type Flow Con actuator for an SME may allow affordability
whereas the SH and SM may cost more. According to embodiments of
the present invention, configurations may exceed many or all
balancing valve specifications and be conducive to stocking zone
control units for fast track business. In some cases, there may be
retrofit/ESCO opportunities for Total Authority approaches. Total
Authority Valves can have precise control to allow systems to be
designed with less equipment, or in retrofit situations, cutting
back on how much capacity is required to heat and cool. Such
accuracy can allow for an accurate Delta-T system design. More
capacity in the same system can be achieved with a higher Delta-T,
and less capacity and lower flow rates can equate to fewer GPM to
cool and heat.
Embodiments of the present invention may incorporate dynamic
balancing components from Griswold with FlowCon's adjustable P.I.
cartridge in the PIC valve. This type of valve may not have the
combination all in one SME type valve. Relatedly, Belimo is of
similar design and both are pressure independent. Embodiments may
also incorporate components from Delta Control Products, now Bray,
which may use the FlowCon E-just cartridge to package a combination
control, flow limiter, and pressure regulator. Embodiments may also
incorporate static balancing devices, which may have no pressure
regulation capability. These components typically limit flow only
and do so when a minimum DeltaP has been reached up to a maximum
DeltaP. Manufacturers of this type of flow limiting device include
FDI, Nexus, Hays, and Griswold stainless steel cartridges with
pressure regulation. Embodiments of the present invention may also
incorporate manual valves available from companies such as Nibco, B
& G, T & A, Griswold, HCI and others. These companies
provide manual balancing valves often referred to as "circuit
setters" which are a type of balancing valve that involves manual
balancing. When balancing a system, once a valve is set and the
next set, the preceding valve(s) are revisited to adjust the
settings again. This is due to the fact that a manual valve
involves an adjustable orifice, not a flow controller. Once
pressure changes in the system after initial setting, the flow rate
changes also. Such devices typically limit flow when the system is
operating at the exact same level as when it was originally set up.
In most systems that typically does not happen because of variable
speed pumps and drives. Static, dynamic, and automatic balancing
(e.g. Total Authority) valves often require at least 50% less cost
in balancing/commissioning as the manual valve. Once set, they may
be set forever if no changes have to be made to the flow and
system. These types of valves allow for 20 to 30% fewer balancing
valves on a project thus reducing static pressure in the system as
a whole. Energy consumption over the manual system may be
considerable and a consideration in applying these valves.
Generally speaking, a 20% savings can be claimed with static and
dynamic and potentially larger savings with Total Authority
Valves.
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.
* * * * *