Note: Descriptions are shown in the official language in which they were submitted.
CA 02772766 2012-03-28
MODULAR BUILDING UTILITIES SYSTEMS AND METHODS
15
BACKGROUND
[0002] Various embodiments described herein relate generally to the field
building utilities
systems, and more particularly to modular systems for building utilities. The
building
utilities may include data, electrical, controls, fire, security, plumbing,
and the like.
[0003] A range of approaches are used in existing HVAC systems. Existing HVAC
systems include, for example, conventional forced air variable volume systems
and systems
employing chilled beams.
[0004] Conventional Building Utilities Installation
[0005] In conventional building construction, generally all building utilities
are designed
separately by an architect and/or engineer. The building utilities are then
separately hung by
various tradesmen.
[0006] Conventional Forced Air Variable Air Volume Systems
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[0007] A conventional forced air variable air volume (VAV) system distributes
air and
water to terminal units installed in habitable spaces throughout a building.
The air and water
are cooled or heated in central equipment rooms. The air supplied is called
primary or
ventilation air. The water supplied is called primary or secondary water.
Steam may also be
used. Some terminal units employ a separate electric heating coil in lieu of a
hot water coil.
The primary air is first tempered through a large air handling unit and then
distributed to the
rest of the building through conventional air duct work. The large air
handling unit may
consist of a supply fan, return fan, exhaust fan, cooling coil, heating coil,
filters, condensate
drain pans, outside air dampers, return dampers, exhaust dampers, sensors,
controls, etc.
Once the primary air leaves the air handling unit the primary air is
distributed through out the
building through air duct work and then to in-room terminal units such as air
distribution
units and terminal units. A single in-room terminal unit usually conditions a
single space, but
some (e.g., a large fan-coil unit) may serve several spaces. Air distribution
units and terminal
units are typically used primarily in perimeter spaces of buildings with high
sensible loads
and where close control of humidity is not desired; they are also sometimes
used in interior
zones. Conventional forced air variable air volume systems work well in office
buildings,
hospitals, hotels, schools, apartments, and research labs. In most climates,
these VAV
systems are typically installed to condition perimeter building spaces and are
designed to
provide all desired space heating and cooling, outside air ventilation, and
simultaneous
heating and cooling in different parts of the building during intermediate
seasons.
[0008] A conventional forced air variable air volume system has several
disadvantages.
For example, because large volumes of air circulated around a building, fan
energy
consumption and temperature losses may be significant. To minimize energy
consumption,
the large air handling unit may recycle the circulated air and only add a
small portion of fresh
air. Such recycling, however, may result in air borne contaminants and
bacteria being spread
throughout the building resulting in "sick building syndrome." Other
disadvantages may
include draughts, lack of individual control, increased building height
required to
accommodate ducting, and noise associated with air velocity. Additionally, for
many
buildings, the use of in-room terminal units may be limited to perimeter
spaces, with separate
systems required for other areas. More controls may be needed as compared to
other
systems. In many systems, the primary air is supplied at a constant rate with
no provision for
shut off, which may be a disadvantage as tenants may prefer to shut off their
heating or air
conditioning or management may desire to do so to reduce energy consumption.
Chilled
beams and/or water based systems may be the most expensive system to install.
Further,
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such systems may be prone to leaks causing water damage (e.g., mold growth).
In many
systems, low primary chilled water temperature and or deep chilled water coils
are required
to control space humidity accurately, which may result in more energy
consumption from a
chiller, cooling tower, and/or pumps. A conventional forced air variable air
volume system
may not be appropriate for spaces with large exhaust requirements such as labs
unless
supplementary ventilation is provided. In many systems, low primary air
temperatures
require heavily insulated ducts. In many systems, the energy consumption is
high because of
the power needed to deliver primary air against the pressure drop of the
terminal units. The
initial cost for a VAV system may be high. In many systems, the primary air is
cooled,
distributed, and may be subsequently re-heated after delivery to a local zone,
thus wasting
energy. In many systems, individual room control is expensive as an individual
terminal unit
or fan coil unit is required for each zone, which may be costly to install and
maintain,
including for ancillary components such as controls. Moving large flow rates
of air thru duct
work is inefficient and wastes energy. Mold and biocides may form in the duct
work and
then be blown into the ambient/occupied space.
[00091 Chilled-Beam Systems
[0010] A chilled beam uses water, not air, to remove heat from a room. Chilled
beams are
a relatively recent innovation. Chilled beams work by pumping chilled water
through radiator
like elements mounted on the ceiling. As with typical air ventilation systems,
chilled beams
typically use water heated or cooled by a separate system outside of the
space. The
building's occupants and equipment (e.g., computers) heat the air, which rises
and is cooled
by the chilled beam creating convection currents. Radiant cooling of interior
elements and
exposed slab soffit enhances this convective flow. Room occupants are also
cooled (or
warmed) by radiant heat transfer to or from the chilled beam.
[00111 Chilled beams, however, have some disadvantages. For example, they are
relatively
expensive due to the use of copper coils. A chilled beam is not easy to
relocate, which may
require major renovation for some office space reconfigurations. They can also
be expensive
to install for a variety of reasons, for example, their weight may be an issue
with regard to
seismic codes; they may take several tradesmen to install; they may require
increased piping,
valves, and controls compared to other systems; and three to four chilled
beams may be
required for every VAV air distribution unit or fan coil unit. Air still needs
to be tempered to
prevent condensation from forming on the chilled beam. They may be unable to
provide the
indoor comfort required in large spaces. They are exposed directly to the
ambient space,
which may result in condensate forming on the chilled beam and dripping on to
products and
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equipment below. Substantially unrestricted airflow to the beam is typically
required. A
chilled beam requires more ceiling area than diffusers of a conventional
system, thus leaving
less room for sprinklers and lights. This can impact the aesthetics of the
interior spaces and
require a higher level of coordination for other systems such as lighting,
ceiling grid, and fire
protection. Mechanical contractors may not be familiar with chilled beams and
may charge
more. Re-circulated air passing through the chilled beam is not filtered as it
would be in a
VAV system. A chilled beam may not be suitable for use in an area with a high
latent load.
Areas such as conference rooms, meeting rooms, class rooms, restaurants, or
theaters with
dense population may be difficult to condition with chilled beams. Portions of
a building that
are open to the outside air typically cannot be conditioned with chilled
beams. Noise may be
an issue with chilled beams due to the use of pressure nozzles, which are
factory set for a
certain performance, derivation from which causes noise thereby limiting the
options of the
building occupants. The building should have a very tight construction for
humid climates.
Naturally ventilated buildings may need to include a sensor to measure dew
point in the space
and/or window position switches that automatically raise the cooling water
temperature or
shut down flows to the chilled beam when high dew points are reached. Chilled
beams may
need to be vacuumed every year. More control valves, strainers, etc. may be
desired.
Typical room design temperature for chilled beams is 75 to 78 degrees F, which
may be too
high for healthcare and pharmaceutical applications. A chilled beam typically
does not
provide a radial-symmetric airflow pattern like most hospitaUlab air
diffusers; instead, they
drive the air laterally across the top of the room, which can disrupt hood
airflow patterns.
[00121 In light of the above, it would be desirable to have improved HVAC
systems and
components with increased advantages and/or decreased disadvantages compared
to existing
HVAC systems and components. In particular, improved HVAC systems and
components
having reduced installed cost, improved controllability, decreased energy
usage, increased
recyclability, increased quality, increased maintainability, decreased
maintenance costs, and
decreased sound would be beneficial.
SUMMARY
[00131 The following presents a simplified summary of some embodiments of the
invention
in order to provide a basic understanding of the invention. This summary is
not an extensive
overview of the invention. It is not intended to identify key/critical
elements of the invention
or to delineate the scope of the invention. Its sole purpose is to present
some embodiments of
the invention in a simplified form as a prelude to the more detailed
description that is
presented later.
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[00141 The present disclosure generally provides modular building utilities
systems
sometimes referred to as a Coordinated and Integrated Modular Building
Utilities Systems
(CIMBUS ). The modular building utilities systems and methods described herein
may
including prefabricating/pre-assembling some or all of a building's utilities
and/or controls
systems on to modules and then shipping to the modules to job sites where they
are
assembled or coupled togehter like a lego set.
[00151 The modular building utilities system (CIMBUS) provides a turnkey
solution for
some or all utilities including power, data, communication, HVAC, process
controls (e.g.,
building automation system (BAS)), security, fire, and the like. The modular
building
utilities system may be like a LEGO set that is prefabricated at an assembly
site and
snapped/assembled together at a construction site. The modular building
utilities system may
reduce that field labor costs by 50% or more, may provide faster building
construction time,
and/or may provide a single BAS automation integration platform for some or
all utilities.
One of the many values of the modular building utilities system may include
the easy of
hanging the modular system, leveling the modular system, prefabricating the
modular system
with some or a majority of utilities, providing a defect free modular system,
providing an
energy efficient modular system, and the like. The modular building utilities
system may
work with solar, geothermal, ice storage, gas, water, chemical systems, and
the like. The
modular building utilities system may have the lowest installed cost for the
reasons described
herein and may provide one controls integration platform.
[00161 An HVAC system may be part of the modular building utilities system.
The HVAC
system and/or the duct modules may be made in such a way which allows pre
fabrication of a
main distribution grid with all the utilities attached at the factory or added
on in the field.
[00171 Currently, multiple trades and engineers are involved with designing
and field
fabricating various building utilities and/or controls in a building.
Generally, most utilities
are hung separately from ceiling platform or walls of the building. Union work
preservation
rights typically prohibit a tradesmen from engaging in each others work (e.g.,
prohibits sheet
metal tradesman from touching a pipefitters or electricians work and the
like). An example
of installing building utilities ma involve a sheet metal tradesman installing
the duct first by
cutting support brackets (e.g., unistrut) and fastening (e.g., using off
thread rod) the support
brackets/duct to the ceiling platforms after they have been leveled.
Pipefitters may then
perform a similar function to build a piping platform (pipefitters may use a
different fastening
system to building the platform). The installation process may be followed by
an electrician,
low voltage communication/data, insulators, and the like. In contrast, once a
modular
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building utilities system is hung, the main distribution for the building
utilities may be
installed quickly and defect free.
[0018] Water based HVAC systems are generally very energy efficient systems,
but may
also be the most expensive systems to install. The modular building utilities
systems
described herein may allow the use of a water based/gas HVAC system with high
energy
efficiencies at a low installed cost since the installed labor cost may be
reduced by up to 50%
or more, which may represent a majority of the construction costs for a
building. By using
ecm pumps and/or ecm fans, standardized sized ducts and/or pipes may be used,
which may
make the pre fabrication process simple and easy. The ecm motors technology
may facilitate
in overcoming any type of pressure differential in the water pipe or air duct
by simply
decreasing/increasing the cfm/gpm relative to the zone/pressure differentials
in the system.
[0019] The modular building utilities systems and/or assemblies described
herein may be
prefabricated/factory manufactured with other building utilities such as the
electrical conduit,
quick connect electrical kits (replace conduit, cable trays, and the like),
process gas piping
(e.g., for hospitals, Pharma, and the like), communications/data cable, DC
power run through
out building utilities systems to power ecm motors and lights. Similarly, DC
to AC
converters may be provided at zone levels to supply 115 volt outlet power or
the building
utilities system may include separate distribution grids for 277/115 volt
and/or a separate DC
grid from solar power.
[0020] The modular building utilities system makes a lot of this possible in a
very cost
effective way by functioning as the main distribution platform within the
building. Once the
modular building utilities system is hung, it may be leveled. Further, the
modular building
utilities system may include expansion slots to add additional field
fabricated items such as
conduit, pipe, and the like. Once these items are added to the modular
building utilities
system, a tradesman does not need to level and/or install piping, conduit,
cables, and the like
separately, which may reduce a tremendous amount of time and/or cost. The cost
savings
using the modular building utilities system may allow for improved equipment
and controls.
[0021] Furthermore, the modular building utilities system may allow the use of
the same or
similar sensors for some or all the utilities and one Building Automated
System (BAS)
integration platform to run/monitor all the utilities, such as light,
electrical, hvac, security,
data, and the like. By prefabricating some or a majority of controls hardware
on to the
modular building utilities system HVAC platform, a majority (e.g., up to 90%
)of a controls
company's field labor may be eliminated. The modular building utilities system
may be
installed and powered (e.g., a power switch may be flipped) and some or all
the front end
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programming may be done remotely. In addition, the HVAC system may be self
balancing.
LED light manufacturers typically have a sensor pak and power pak on each
light. HVAC
systems may have their own sensors. The modular building utilities system may
have a
Personal Integrated Optimized Light Air Fixture (PIOLA) which may combine the
led lights
with an air distribution device. This device may handle a 10' x 10' area for
lights and
HVAC. Supplemental lights may be added as a master slave combination. The Zone
Control
Unit (ZCU) may be the source for the power to the lights in those zones thus
eliminating the
individual power paks for the lights. The ZCU controller could run the master
PIOLA and
the other supplemental lights could be slaves to the master. One sensor array
could be used
for some or all utilities and could be tied into the ZCU controller. Such a
system may make
the LED lights affordable. Further, the modular building utilities system may
supply and/or
include one front end controls integration platform.
[0022] The modular building utilities system may be prefabricated with a drain
pan. The
drain pan may function as a safety net in case of leaking pipes. The drain pan
may be used
primarily in or for data center to protect sensitive equipment, components,
and/or
information. The modular building utilities system may include a primary drain
piping that is
prefabricated or field fabricated onto the modular building utilities system.
The primary
drain piping may remove and/or recycle condensate water. The heat transfer
medium for the
HVAC unit (e.g., ZCU unit) may include water/fluid, gas, direct expansion (DX)
refrigerant,
and/or chemical. The modular building utilities system can be used with
multiple HVAC
systems such as air, water, refrigerant, chilled beams, and the like.
[0023] The present disclosure generally provides heating, ventilation, and air
conditioning
(HVAC) systems, components, and control systems. In many embodiments, an HVAC
system includes distributed zone control units that locally re-circulate air
to zones serviced by
each respective zone control unit. A zone control unit can condition the re-
circulated air by
adding heat, removing heat, and/or filtering. A supply airflow (e.g., a flow
of outside air) can
be mixed in with return airflows extracted from the serviced zones, the
resulting mixed
airflow conditioned prior to discharge to the serviced zones. Automated
control dampers and
a variable speed fan(s) can be used to control flow rates of the mixed air
discharged to each
serviced zone, control the flow rates of the return airflows extracted from
the serviced zones,
and to control the flow rate of the supply airflow mixed in with the return
airflows. In many
embodiments, the supply airflows are provided to the distributed zone control
units by a
central supply airflow source, which can intake outside air and condition the
outside air prior
to discharging the conditioned outside air for distribution to the distributed
zone control units.
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In many embodiments, an HVAC system includes an exhaust air system that
extracts air from
one or more HVAC zones and discharges the extracted air as exhaust air. In
many
embodiments, an HVAC system includes a heat recovery wheel for exchanging heat
and
moisture between the incoming outside intake air and the outgoing exhaust air.
In many
embodiments, an HVAC system includes one or more filters and/or a humidity
adjustment
device for conditioning the supply airflow prior to distribution to the
distributed HVAC zone
control units. In many embodiments, an HVAC zone control unit and/or the
central supply
airflow source incorporates one or more heat exchangers with micro-channel
coils. In many
embodiments, the distributed HVAC zone control units include control
electronics having an
Internet protocol address and can include a resident processor and memory
providing local
control functionality.
[00241 The disclosed modular building utilities system, HVAC systems, zone
control units,
and control systems provide a number of advantages. These advantages may
include reduced
installed system cost; improved air quality; increased Leadership in Energy
and
Environmental Design (LEED) points; improved quality; reduced maintenance
costs;
improved maintainability; reduced sound; reduced energy usage; improved
control system;
improved building flexibility; superior Indoor Air Quality (IAQ); exceeding
American
Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE)
standards;
flexible application in a variety of different types of
buildings/applications; and/or reduced
manufacturing costs and installed cost. In addition, the modular building
utilities system
provides a reduced energy footprint.
[00251 Thus, in a first aspect, a method for providing heating, ventilation,
and air
conditioning (HVAC) to zones of a building is provided. The method includes
providing a
flow of supply air from outside the zones. First and second flows of return
air are extracted
from a first subset of the zones and a second subset of the zones,
respectively. The first and
second return airflows are mixed with first and second portions of the supply
airflow to form
first and second mixed airflows, respectively. Heat is added to and/or removed
from at least
one of the first return airflow, the first supply airflow, or the first mixed
airflow. Heat is
added to and/or removed from at least one of the second return airflow, the
second supply
airflow, or the second mixed airflow. The first mixed airflow is distributed
to the first subset
of zones. And the second mixed airflow is distributed to the second subset of
zones.
[00261 The heat can be added or removed using heat exchanging coils. Each of
the first
and second mixed airflows can be routed through a respective heat exchanging
coil. Heat can
be added to a mixed airflow by routing water having a temperature higher that
a temperature
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of the mixed airflow within the respective heat exchanging coil. Each of the
respective heat
exchanging coils can include a heating coil and a cooling coil. Water having a
temperature
higher than the temperature of the respective mixed airflow can be routed
within the
respective heating coil to add heat to the respective mixed airflow. And water
having a
temperature lower than the temperature of the respective mixed airflow can be
routed within
the respective cooling coil to remove heat from the respective mixed airflow.
A variable rate
pump can be used to control a flow rate of water routed through the respective
heat
exchanging coil. A variable speed fan can be used to draw the respective mixed
airflow
through the respective heat exchanging coil so as to control a flow rate of
the respective
mixed airflow.
[00271 The first subset of zones can include a plurality of zones. One or more
automated
controllable dampers can be used to control a flow rate of return air
originating from one or
more zones of the first subset of zones. And one or more automated
controllable dampers
can be used to control a flow rate of the first mixed airflow distributed to
one or more zones
of the first subset of zones.
[00281 In another aspect, a heating, ventilation, and air conditioning (HVAC)
zone control
unit (ZCU) configured to provide HVAC to a building in conjunction with at
least one
additional of such a zone control unit is provided. In a building having zones
that include a
first and second subset of zones, the ZCU provides HVAC to the first subset of
the zones, and
the at least one additional ZCU provides HVAC to the second subset of the
zones. The ZCU
includes a housing configured to mount to the building local to the first
subset of zones. A
return air plenum is disposed within the housing. A first return air inlet is
configured to input
a first return airflow originating from at least one of the first subset of
zones into the return
air plenum. A supply air inlet is configured to receive a supply airflow into
the plenum from
a supply air duct transporting the supply airflow from outside the zones of
the building. The
supply airflow and the return airflow combine to form a mixed airflow. At
least one heat
exchanging coil is disposed within the housing. A discharge air plenum is
disposed within
the housing. A fan motivates the mixed airflow to pass through the heat
exchanging coil and
discharges into the discharge air plenum. A first discharge outlet is
configured to discharge
air from the discharge air plenum for distribution to at least one zone of the
first subset of
zones. The ZCU can include one or more return airflow inlets and/or one or
more discharge
outlets.
[00291 The ZCU can include one or more automated controllable dampers. For
example,
an automated controllable damper can be used to control a flow rate of the
first return airflow
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input through the first return air inlet. And an automated controllable damper
can be used to
control a flow rate of the second return airflow input through the second
return air inlet. An
automated controllable damper can be used to control a flow rate of the supply
airflow input
through the supply air inlet. And one or more automated controllable dampers
can be used to
control the rate at which the mixed airflow is discharged to one or more zones
serviced by the
ZCU.
[0030] The ZCU can also employ an open air plenum design. In an open air
plenum
design, return air inlets draw return airflows directly from the air
surrounding the ZCU so that
no return airflow ducts are required. Instead, zone installed vents and
natural passageways in
building's ceiling can be used to provide a pathway by which the return
airflows are routed
from the serviced building zones back to the ZCU.
[0031] The at least one heat exchanging coil can include a heating coil and a
cooling coil.
A first variable rate pump can be used to route water having a temperature
higher than the
mixed airflow through the heating coil at a controlled rate. And a second
variable rate pump
can be used to route water having a temperature lower than the mixed airflow
through the
cooling coil at a controlled rate.
[0032] The ZCU can include handle brackets, which include handle features that
provide
for convenient handling/transport of the ZCU. The handle brackets can include
support
provisions for ZCU system components (e.g., heating coil piping, cooling coil
piping,
controllable valves, variable rate pumps, etc.).
[0033] The ZCU can be sealed and pressurized for testing and/or shipping. For
example,
the ZCU can be sealed, pressurized, and then shipped to the job site in the
pressurized state.
The pressure level can be monitored to detect any leaks, or to verify the
absence of leaks as
evidenced by a lack of drop in the pressure level over a suitable time period.
Exemplary
brackets and related methods that can be employed are disclosed in United
States Patent
Nos.: U.S. 6,951,324, U.S. 7, 140,236, U.S. 7,165,797, U.S. 7,387,013, U.S.
7,444,731,
U.S. 7,478,761, U.S. 7,537,183, and U.S. 7,596,962; and United States Patent
Publication
No. U.S. 2007/0108352 Al; the full disclosures of which are hereby
incorporated herein by
reference.
[0034] The ZCU can include a local control unit to control the ZCU. The local
control unit
has its own Internet Protocol (IP) address and be connectable to the Internet
via a
communication link. The communication link can include, for example, a hard-
wired
CA 02772766 2012-03-28
communication link and/or a wireless communication link. The local control
unit can be
configured to control lighting in the first subset of zones, power management,
and/or HVAC.
[00351 The modular building utilities system may provide a single controls
integration
platform comprising and/or communicatively coupled with one or more sensors
(e.g., photo,
motion, temperature, infrared, and the like.
100361 A sensor(s) can be coupled with the local control unit to measure a
compound
concentration level. The local control unit can use the measured concentration
level to
control a flow rate of the supply airflow input into the ZCU to control a
resulting
concentration level of the measured compound. The sensor(s) can include at
least one of a
carbon-dioxide (CO2) sensor or a total organic volatile (TOV) sensor. The
local control unit
can transmit the measured compound concentration level to an external device.
[00371 Lighting for serviced building zones can also be controlled via the ZCU
local
control unit. For example, lights (e.g., light emitting diode (LED) lights)
can be located on
air diffusers and controlled by the ZCU local control unit (e.g., as a
master/slave control
combination). Lighting and sensors can be co-located. For example, a sensor
pack and a
LED light(s) can be co-located on a return air grill. Additional zone lights
(e.g., LED lights)
can be employed via master slave combination off of the ZCU local control
unit.
[00381 Power may be provided to the lights from the modular building utilities
system
and/or the modular building utilities system may provide power to the ZCU,
which in turn
provides power to the lights. The ZCU and/or modular building utilities system
may include
one or more transformers for the lights and/or other power requirements.
Similarly, the ZCU
and/or modular building utilities system may include one or more converters
(e.g., DC to AC
or vice versa) and/or include a DC and/or AC power supply.
[00391 In another aspect, an HVAC system for providing HVAC to zones of a
building is
provided. The system includes first and second HVAC ZCUs, such as the above-
described
ZCU. The system further includes a supply airflow duct transporting a flow of
supply air. A
first portion of the supply airflow is provided to the first ZCU and a second
portion of the
supply air is provided to the second ZCU. The system further includes an air-
handling unit
that intakes the supply airflow from external to the zones of the building and
discharges the
supply airflow into the supply airflow duct.
[00401 The HVAC system can include at least one supply line providing a heat
transfer
fluid to the at least one heat exchanging coil and at least one return line
for returning the heat
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transfer fluid discharged from the at least one heat exchanging coil. The
fluid may include
gas, water, chemical, and/or any other heat transfer fluid.
[00411 In another aspect, a prefabricated assembly is provided that is
configured for use in
an HVAC system providing HVAC to zones of a building. The HVAC system has a
plurality
of distributed ZCUs, with each of the ZCUs providing HVAC to a respective
subset of the
zones. The prefabricated has a length and includes a length of duct having
first and second
ends. The duct is configured to transport a flow of supply air from the first
end to the second
end. The duct is adaptable to include a discharge port to discharge a portion
of the supply
airflow to one of the distributed ZCUs. Brackets that include mounting
features are coupled
with the duct along the length of the duct. A supply line and a return line
are supported by at
least one of the mounting features. The supply line and the return line are
provided to supply
and return water from a heat exchanging coil of one or more of the distributed
ZCUs. The
prefabricated assembly is configured so that corresponding components of a
plurality of the
prefabricated assemblies can be coupled to provide for the transport of the
flow of supply air
along a combined length of the coupled assemblies and for the transport of the
supply and
return water along the combined length. The prefabricated assembly includes
mounting
surfaces to mount the assembly to the building. The prefabricated assembly may
include
components and/or equipment for process gas, water, chemical, plumbing,
electrical, data,
communications, security, HVAC, fire, and the like.
[00421 The prefabricated assembly can include additional features. For
example, the
prefabricated assembly can be configured so that at least one electrical
conduit can be
supported by at least one of the mounting features. The prefabricated assembly
can include at
least one cable tray supported by at least one of the mounting features. The
prefabricated
assembly can include at least one wireless transmitter or a wireless repeater
coupled with at
least one of the brackets. The prefabricated assembly can include control
wires connectable
to the distributed ZCUs to transmit at least one of control signals or data at
least to or from
the distributed ZCUs. The prefabricated assembly may also include hot water
heaters, DC
and/or AC converters, plumbing piping, process gas piping (e.g., oxygen,
nitrogen, carbon
dioxide, and the like), data cables, security cables and/or equipment, and the
like.
[00431 In another aspect, a method for providing HVAC to first and second
zones of a
building is provided. The method includes providing first and second flows of
supply air
from outside the zones via an air duct. A first flow of return air is
extracted from a first zone
and a second flow of return air is extracted from a second zone. The first
flow of return air is
mixed with the first flow of supply air in a first zone control unit so as to
form a first mixed
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flow. The second flow of return air is mixed with the second flow of supply
air in a second
zone control unit so as to form a second mixed flow. Heated water is directed
to the first and
second zone control units from a hot water source. Cooled water is directed to
the first and
second zone control units from a cold water source. Although water is
described, the fluid
may alternatively or additionally include direct expansion refrigerants,
chemicals, and/or any
other heat transfer medium. In response to a low temperature in the first
zone, heat transfer
within the first zone control unit from the heated water to the first mixed
airflow is increased.
In response to a high temperature in the first zone, heat transfer within the
first zone control
unit from the cooled water to the first mixed airflow is increased. In
response to a low
temperature in the second zone, heat transfer within the second zone control
unit from the
heated water to the second mixed airflow is increased. In response to a high
temperature in
the second zone, heat transfer within the second zone control unit from the
cooled water to
the first mixed airflow is increased. The first mixed airflow is distributed
to the first zone.
And the second mixed airflow is distributed to the second zone. The ZCU may
also provide
heating and/or cooling at zone levels.
[00441 Heat transfer can be increased within the zone control units using
several
approaches. For example, heat transfer can be increased by varying the return
airflows by
altering a fan speed within each zone control unit. And/or heat transfer can
be increased by
varying flow of the heated water or the cooled water within each zone control
unit.
[00451 Humidity control can be employed. For example, a mixed airflow can be
dehumidified in a zone control unit by cooling the mixed airflow to full
saturation to form
condensate (which is removed, for example, via a sump pump a condensate return
line). The
dehumidified mixed airflow can then be reheated (e.g., via a heater coil).
[00461 Common zone control units can be employed. For example, the first zone
control
unit can be interchangeable with the second zone control unit, even if the
first zone has
significantly different heating and cooling load characteristics than the
second zone.
[00471 The modular building utilities system may allow economies of scale
thereby
reducing overall costs. The modular building utilities system may be used in
various projects
including hotels, offices, campus, pharma, healthcare, and the like.
[00481 The method can include installing the HVAC system in the building using
pre-
assembled assemblies. For example, the HVAC system can be installed in the
building by
coupling the first zone control unit to the duct, the hot water source, and
the cold water
source using a first assembly and coupling the second zone control unit to the
duct, the hot
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CA 02772766 2012-03-28
water source, and the cold water source using a second assembly. Each of the
first and
second assemblies includes a supply air duct, a hot water line, and a cold
water line supported
by a bracket.
[00491 In another aspect, a set of prefabricated assemblies are provided that
are configured
for use in an HVAC system providing HVAC to zones of a building. The HVAC
system has
a plurality of zone control units (ZCUs), each of the ZCUs locally providing
HVAC to a
respective subset of the zones. Each of the prefabricated assemblies has a
length and includes
a length of duct having first and second ends. The duct is configured to
transport a flow of
supply air from the first end to the second end. The duct is adaptable to
include a discharge
port to discharge a portion of the supply air to an associated one of the
distributed ZCUs.
Brackets are coupled with the length of the duct. The brackets include
mounting features.
The set of prefabricated assemblies includes a supply line to supply water to
and a return line
to return water from a heat exchanging coil of one or more of the distributed
ZCUs. The
supply and return lines are supported by at least one of the mounting
features. Corresponding
components of a plurality of the prefabricated assemblies can be coupled to
provide for the
transport of the flow of supply air along a combined length of the coupled
assemblies and for
the transport of the supply and return water along the combined length. The
prefabricated
assemblies include mounting surfaces to mount the assemblies to the building.
[00501 The duct and/or piping of the modular building utilities system may
stay the same
size throughout a portion or all of the modular building utilities system by
using localized
pumps and fans to overcome pressure differentials in the system. To overcome
such
differentials, a temperature reset controls strategy may be employed.
[00511 Embodiments of the present invention encompass methods of installing a
heating,
ventilation, and air conditioning (HVAC) unit in an HVAC system. Exemplary
methods may
include steps such as securing an inlet piping assembly of the HVAC unit to a
bracket,
securing an outlet piping assembly of the HVAC unit to the bracket, coupling a
thermal
transfer mechanism of the HVAC unit with the inlet piping assembly and the
outlet piping
assembly, fluidly coupling a water pump with at least one of the thermal
transfer mechanism,
the inlet piping assembly and the outlet piping assembly, placing at least a
portion of the
thermal transfer mechanism along an air flow path within a casing of the HVAC
unit such
that at least a portion of the inlet piping assembly and at least a portion of
the outlet piping
assembly are disposed exterior to the casing, positioning a fan along the
airflow path within
the casing, mounting the HVAC unit by mounting the bracket to the HVAC system,
and
maintaining alignment of the HVAC unit thermal transfer mechanism, the HVAC
unit inlet
14
CA 02772766 2012-03-28
piping assembly, and the HVAC unit outlet piping assembly while mounting the
HVAC unit
in the HVAC system. In some cases, the water pump includes a variable rate
water pump. In
some cases, the water pump includes a variable rate water pump having an
electronically
commutated motor. In some cases, the water pump includes a variable rate water
pump
operable between about 0 and about 15 gallons per minute. Optionally, the
water pump can
be controlled by pulse width modulation. Relatedly, the water pump can be
controlled by a
signal of between about 0 volts and about 10 volts. In some instances, the fan
includes a
variable rate fan. In some instances, the fan includes a variable rate fan
having an
electronically commutated motor. In some instances the water pump, fan, and/or
any other
equipment or controls may be powered by solar power, which may power a DC ECM
moter
that may run a DC/AC converter that provides 115 volt (or other voltage) AC
power to one or
more receptacles.
[0052) In some aspects, embodiments of the present invention encompass methods
of
preparing a heating, ventilation, and air conditioning (HVAC) unit for
delivery to a
construction site for installation in an HVAC system. Exemplary methods may
include steps
such as coupling a thermal transfer mechanism with an inlet piping assembly
and an outlet
piping assembly, where the inlet piping assembly is configured to supply fluid
to the thermal
transfer mechanism and the outlet piping assembly is configured to receive
fluid from the
thermal transfer mechanism. Method steps may also include fluidly coupling a
water pump
with at least one of the thermal transfer mechanism, the inlet piping
assembly, and the outlet
piping assembly, placing at least a portion of the thermal transfer mechanism
along an air
flow path within a casing, such that at least a portion of the inlet piping
assembly and at least
a portion of the outlet piping assembly are disposed exterior to the casing,
positioning a fan
along the airflow path within the casing, and coupling a bracket with the
casing, the inlet
piping assembly, and the outlet piping assembly, so as to maintain the casing,
the inlet piping
assembly, and the outlet piping assembly in positional relationship. In some
cases, the water
pump includes a variable rate water pump. In some cases, the water pump
includes a variable
rate water pump having an electronically commutated motor. In some cases, the
water pump
includes a variable rate water pump operable between about 0 and about 15
gallons per
minute. Optionally, the water pump can be controlled by pulse width
modulation. In some
instances, the water pump can be controlled by a signal of between about 0
volts and about 10
volts. In some embodiments, the fan may include a variable rate fan. In some
cases, the fan
may include a variable rate fan having an electronically commutated motor.
CA 02772766 2012-03-28
[0053] In yet another aspect, embodiments of the present invention include a
heating,
ventilation, and air conditioning (HVAC) unit for transporting fluid in an
(HVAC) system.
Exemplary HVAC units may include a thermal transfer mechanism, an inlet piping
assembly
coupled with the thermal transfer mechanism for supplying fluid to the thermal
transfer
mechanism, an outlet piping assembly coupled with the thermal transfer
mechanism for
receiving fluid from the thermal transfer mechanism, and a water pump in fluid
communication with at least one of the thermal transfer mechanism, the inlet
piping
assembly, and the outlet piping assembly. HVAC units may also include a
bracket that
maintains the thermal transfer mechanism, the inlet piping assembly, and the
outlet piping
assembly in positional relationship, a casing defining an airflow path, and a
fan disposed
along the airflow path within the casing. In some cases, at least a portion of
the thermal
transfer mechanism can be disposed along the air flow path within the casing,
at least a
portion of the inlet piping assembly and at least a portion of the outlet
piping assembly can be
disposed exterior to the casing, and at least a portion of the bracket can be
disposed exterior
to the casing. In some instances, the water pump includes a variable rate
water pump having
an electronically commutated motor. In some instances, the water pump includes
a variable
rate water pump operable between about 0 and about 15 gallons per minute.
Optionally, the
fan may includes a variable rate fan having an electronically commutated
motor.
[0054] Embodiments of the present invention also encompass a modular building
utilities
system for installation in a building. The modular system may include a first
assembly
having a first duct for transporting air, a first bracket coupled with the
first duct, a first inlet
piping coupled with first bracket and disposed exterior to the first duct, a
first outlet piping
coupled with the first bracket and disposed exterior to the first duct, and a
first adjustable
fastening mechanism coupled with the first bracket for adjustably coupling the
first bracket
with the building. The modular system may also include a second assembly
having a second
duct for transporting air, a second bracket coupled with the second duct, a
second inlet piping
coupled with second bracket and disposed exterior to the second duct, a second
outlet piping
coupled with the second bracket and disposed exterior to the second duct, and
a second
adjustable fastening mechanism coupled with the second bracket for adjustably
coupling the
second bracket with the building. The first bracket may maintain the first
inlet piping, the
first outlet piping, and the first duct in a first positional relationship and
the second bracket
may maintain the second inlet piping, the second outlet piping, and the second
duct in a
second positional relationship. The first and second positional relationships
may provide
alignment between the first and second ducts, the first and second inlet
pipings, and the first
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CA 02772766 2012-03-28
and second outlet pipings, respectively, so as to facilitate coupling of the
first and second
ducts, the first and second inlet pipings, and the first and second outlet
pipings, respectively.
[00551 The modular system may further include a zone control unit (ZCU)
configured to
provide HVAC to one or more zones of the building. In one embodiment the ZCU
comprises
a 3 pipe configuration having an inlet pipe, an outlet pipe, and a primary
drain pipe. In other
embodiments, the ZCU may include a 5 pipe system having a primary drain pipe
and one or
more inlet pipes and outlet pipes. The ZCU and/or modular building utilities
system may
also include a drain pan separate from the primary drain piping. The drain pan
may be used
for backup in critical environments, such as data centers and the like or used
in any other
environment. The first duct may include a discharge port configured to supply
a portion of
the air to the ZCU; and the first inlet piping and first outlet piping may be
coupled with a coil
of the ZCU to provide fluid communication between the coil and the first inlet
piping and
first outlet piping. The first bracket may include a cable tray configured to
support one or
more electrical wires. The first and/or second assembly may include an
enclosure disposed
around the at least one of the first assembly and the second assembly to
protect the assembly.
The first and/or second bracket may include a wireless transmitter and/or a
wireless repeater.
The first bracket may also include a drain pan coupled with and extending
along the length of
the first bracket and the second bracket may also include a drain pain coupled
with and
extending along the length of the second bracket. The first drain pan and the
second drain
pan may be configured to collect condensate of the modular system. The first
and second
brackets may provide alignment between the first and second drain pans,
respectively, to
facilitate coupling of the first and second drain pans so that the condensate
may be
transported at least partially along the length of the first and second
assemblies to a
condensate reclamation system.
[00561 Embodiments of the present invention may further include a method of
assembling
a modular assembly at an assembly site for transportation to an installation
site, where the
modular assembly is configured to include various building utilities. The
method may
include obtaining a first duct having a first end and a second end, the first
duct configured to
transport air between the first end and the second end. The method may also
include
obtaining a first inlet piping having a first end and a second end, the first
inlet piping
configured to transport a fluid between the first end and the second end. The
method may
further include obtaining a first outlet piping having a first end and a
second end, the first
outlet piping configured to transport a fluid between the first end and the
second end. The
method may additionally include obtaining a first bracket having a plurality
of mounting
17
CA 02772766 2012-03-28
features and a first adjustable fastening mechanism for adjustably coupling
the first bracket
with the building. The method may additionally include obtaining a second
bracket having a
plurality of mounting features and a second adjustable fastening mechanism for
adjustably
coupling the second bracket with the building. The method may additionally
include
coupling via one or more of the plurality of mounting features, the first
bracket with the first
end of the first duct, the first inlet piping, and the first outlet piping,
wherein the first inlet
piping and the first outlet piping are disposed exterior to the first duct,
and wherein the first
bracket maintains the first end of the first duct, the first inlet piping, and
the first outlet piping
in a first positional relationship. The method may additionally include
coupling via one or
more of the plurality of mounting features, the second bracket with the second
end of the first
duct, the first inlet piping, and the first outlet piping, wherein the second
bracket maintains
the second end of the first duct, the first inlet piping, and the first outlet
piping in the first
positional relationship.
[00571 The method may additionally include sealing the first and second ends
of the first
duct, the first inlet piping, and/or the first outlet piping, pressurizing the
sealed first duct, the
first inlet piping, and/or the first outlet piping to a predetermined
pressure, and measuring the
pressure in the pressurized duct, inlet piping, and/or outlet piping after an
amount of time to
determine whether the duct, inlet piping, and/or outlet piping is holding
pressure. The
method may additionally include transporting the modular assembly from the
assembly site to
the installation site, where the step of pressurizing is performed at the
assembly site, and
where the step of measuring the pressure is performed at the installation
site. The method
may additionally include obtaining a cable tray having a first end and a
second end, where the
cable tray is configured to support one or more electrical cables, coupling
the first bracket
with the first end of the cable tray via a mounting feature of the plurality
of mounting
features, and coupling the second bracket with the second end of the cable
tray via a
mounting feature of the plurality of mounting features. Coupling the first and
second
brackets with the first and second ends of the cable tray, respectively, may
be performed at
the installation site. Alternatively or additionally, coupling the first and
second brackets with
the first and second ends of the cable tray, respectively, may be performed at
the assembly
site. The modular building utilities system may snap or assembly together like
blocks of a
LEGO set to facilitate installation of the building utilities. The modular
building utilities
system may include one or more components or equipment for power, data, HVAC,
and the
like.
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CA 02772766 2012-03-28
[00581 The method may additionally include coupling the first duct with a zone
control unit
(ZCU) configured to provide HVAC to one or more zones of the building, where
the first
duct provides fluid communication between the ZCU and the air within the duct
and coupling
a coil of the ZCU with the first inlet piping and first outlet piping, where
the first inlet piping
supplies a hot or cold fluid to the coil to heat or cool a volume of air, and
where the first
outlet piping receives a hot or cold fluid from the coil after the volume of
air is heated or
cooled. The method may additionally include coupling a drain pan with the
first and second
brackets so that the drain pan extends along the length of the modular
assembly. The drain
pan may be configured to collect condensate and transport the condensate along
the length of
the modular assembly. Each of the brackets may includes a handle configured to
maneuver
the bracket and/or modular assembly. The bracket may be configured to maintain
support
and/or positional relationship for the pipe assembly while the bracket is
maneuvered by the
handle. One or more of the brackets may be coupled with a drain pan that may
be used as a
backup safety feature in one or more environments, such as data centers.
[00591 Embodiments of the present invention may additionally include a method
of
installing a modular system that includes obtaining a first modular assembly
having a first
duct for transporting air, a first bracket coupled with the first duct, a
first inlet piping coupled
with the first bracket and disposed exterior to the first duct, a first outlet
piping coupled with
the first bracket and disposed exterior to the first duct, and a first
adjustable fastening
mechanism coupled with the first bracket for adjustably coupling the first
bracket with the
building. The method may also include securing the first modular assembly to
the building
via the first adjustable fastening mechanism and leveling the first modular
assembly so that
opposing ends of the first modular assembly are substantially level. The
method may further
include obtaining a second modular assembly having a second duct for
transporting air, a
second bracket coupled with the second duct, a second inlet piping coupled
with the second
bracket and disposed exterior to the second duct, a second outlet piping
coupled with the
second bracket and disposed exterior to the second duct, and a second
adjustable fastening
mechanism coupled with the second bracket for adjustably coupling the second
bracket with
the building. The method may additionally include securing the second modular
assembly to
the building via the second adjustable fastening mechanism and leveling the
second modular
assembly so that opposing ends of the second modular assembly are
substantially level. The
method may additionally include coupling the first modular assembly with the
second
modular assembly in a fluid tight relationship to provide air transportation
along the
combined length of the coupled first and second ducts and to provide fluid
transportation
19
CA 02772766 2012-03-28
along the combined length of the first and second inlet piping and first and
second outlet
piping.
[0060] The method may additionally include obtaining a cable tray configured
to support one
or more electrical cables and coupling the cable tray with at least one of the
first bracket or
the second bracket so that the cable tray extends along the length of at least
one of the first
modular assembly or second modular assembly. In some embodiments, the modular
building
utilities system may include separate data cable, electrical cables, and the
like that are not
included or positioned in the cable tray. For example, the cables could be
coupled directly
with the bracket or run through electrical conduit attached to the bracket.
The method may
additionally include positioning electrical cables in the cable tray to
provide electrical
communication to one or more zones of the building. The method may
additionally include
obtaining a third modular assembly having a third duct for transporting air, a
third bracket
coupled with the third duct, a third inlet piping coupled with the third
bracket and disposed
exterior to the third duct, a third outlet piping coupled with the third
bracket and disposed
exterior to the third duct, and a third adjustable fastening mechanism coupled
with the third
bracket for adjustably coupling the third bracket with the building. The
method may
additionally include securing the third modular assembly to the building so
that the third
modular assembly comprises a substantially perpendicular orientation with
respect to the first
modular assembly and coupling the third modular assembly with the first
modular assembly
to provide fluid communication between the first and third ducts, first and
third inlet piping,
and first and third outlet piping. The first modular assembly and the second
modular
assembly may each include a drain pan that extends along the length of the
respective
modular assembly. The drain pan of the first modular assembly may be coupled
with the
drain pan of the second modular assembly to form a substantially continuous
drain pan
extending along the length of the coupled assemblies. The continuous drain
pans may be
configured to collect condensate from the first and/or second assembly and
transport the
condensate to a condensate reclamation system. The method may additionally
include
obtaining a fourth piping, obtaining a fifth piping, after securing the first
modular assembly to
the building, coupling the fourth piping with the first modular assembly,
after securing the
second modular assembly to the building, coupling the fifth piping with the
second modular
assembly, and coupling the fourth piping with the fifth piping to provide
fluid transportation
along the combined length of the fourth and fifth piping.
[0061] Embodiments of the present invention may additionally include a method
of
installing a modular system in a heating, ventilating, and air conditioning
(HVAC) system of
CA 02772766 2012-03-28
a building. The method may include assembling a first modular assembly at an
assembly
site, the first modular assembly having a first duct for transporting air, a
first bracket coupled
with the first duct, a first inlet piping coupled with the first bracket and
disposed exterior to
the first duct, a first outlet piping coupled with the first bracket and
disposed exterior to the
first duct, and a first adjustable fastening mechanism coupled with the first
bracket for
adjustably coupling the first bracket with the building. The method may also
include
assembling a second modular assembly at an assembly site, the second modular
assembly
having a second duct for transporting air, a second bracket coupled with the
second duct, a
second inlet piping coupled with the second bracket and disposed exterior to
the second duct,
a second outlet piping coupled with the second bracket and disposed exterior
to the second
duct, and a second adjustable fastening mechanism coupled with the second
bracket for
adjustably coupling the second bracket with the building. The method may
further include
transporting the first modular assembly and the second modular assembly to an
installation
site, installing the first modular assembly in the building, installing the
second modular
assembly in the building, and coupling the first and second ducts, the first
and second inlet
piping, and the first and second outlet piping so as to provide fluid
communication between
the first and second ducts, the first and second inlet piping, and the first
and second outlet
piping.
[0062] For a fuller understanding of the nature and advantages of the present
invention,
reference should be made to the ensuing detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0063] FIG. 1 diagrammatically illustrates an modular building utilities
system having
distributed zone control units that provide localized air recirculation, in
accordance with
many embodiments.
[0064] FIG. 2 is a perspective view illustrating installed distribution
assemblies for a
modular building utilities system having distributed zone control units, in
accordance with
many embodiments.
[0065] FIG. 3 is a perspective view illustrating the installed distribution
assemblies of the
modular building utilities system of FIG. 2 from a closer view point.
[0066] FIG. 4 is a perspective view illustrating a junction between a
vertically-oriented
distribution assembly and a horizontally-oriented distribution assembly of the
modular
building utilities system of FIG. 2.
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CA 02772766 2012-03-28
[0067] FIGS. 5A-B are perspective views illustrating a horizontally-oriented
distribution
assembly of the modular building utilities system of FIG. 2.
[0068] FIG. 6 illustrates details of prefabricated distribution assemblies
used in a modular
building utilities system having distributed zone control units, in accordance
with many
embodiments.
[0069] FIG. 7 illustrates details of brackets used in a prefabricated
distribution assembly of
a modular building utilities system having distributed zone control units, in
accordance with
many embodiments.
[0070] FIG. 8 is a perspective view illustrating the installation of two zone
control units of
a modular building utilities system having distributed zone control units, in
accordance with
many embodiments. The figure illustrates one zone control unit having an open
plenum
while the other zone control unit includes a ducted return.
[0071] FIG. 9 is a perspective view illustrating supply and return lines used
to couple a
zone control unit with a distribution assembly of a modular building utilities
system having
distributed zone control units, in accordance with many embodiments. The zone
control unit
may also be coupled with the modular building utilities system using
electrical connections,
air, fluid, gas, condensate connections, and the like.
[0072] FIG. 10 is a perspective view illustrating details of a distribution
assembly of a
modular building utilities system having distributed zone control units and a
supply air duct
port and associated supply air duct used to transfer a flow of supply air from
the distribution
assembly to a zone control unit, in accordance with many embodiments.
[0073] FIG. 11 is a top view diagrammatic illustration of a modular building
utilities
system zone control unit that provides localized air recirculation via return
air ducts and a
circulation fan section disposed between a cooling coil section and a heating
coil section, in
accordance with many embodiments.
[0074] FIG. 12 is a side view diagrammatic illustration of the modular
building utilities
system zone control unit of FIG. 11. The figure illustrates the zone control
unit with valve
packages and/or ECM pumps.
[0075] FIG. 13 is a top view diagrammatic illustration of a modular building
utilities
system zone control unit that provides localized air recirculation via return
air ducts and a
combined heating/cooling coil section, in accordance to many embodiments.
22
CA 02772766 2012-03-28
[0076] FIG. 14 is a side view diagrammatic illustration of the modular
building utilities
system zone control unit of FIG. 13.
[0077] FIG. 15 is a top view diagrammatic illustration of a modular building
utilities
system zone control unit with direct intake of local recirculation air and a
circulation fan
disposed between a cooling coil section and a heating coil section, in
accordance with many
embodiments.
[0078] FIG. 16 is a photograph of a prototype zone control unit, in accordance
with many
embodiments.
[0079] FIG. 17 is a photograph of the prototype zone control unit of FIG. 16,
illustrating
internal components and showing flow strips employed during testing.
[0080] FIG. 18 schematically illustrates modular building utilities system
zone control
units, in accordance with many embodiments.
[0081] FIGS. 19A and 19B illustrate a micro-channel coil design, in accordance
with many
embodiments. The micro-channel design can be used with various fluids (e.g.,
liquids or
gas).
[0082] FIG. 20 is a perspective view illustrating a control damper of a
modular building
utilities system zone control unit, in accordance with many embodiments.
[0083] FIG. 21 diagrammatically illustrates the distribution of outside supply
air, heated
water, cooled water, and the discharge of exhaust air to and from zones of a
multi-floor
building, in accordance with many embodiments. The figure also illustrates the
modular
building utilities system installed in a building.
[0084] FIGS. 22 and 23 diagrammatically illustrate a number of configurations
that can be
used for the routing of supply air, return air, and exhaust air in an HVAC
system having
distributed zone control units, in accordance with many embodiments.
[0085] FIG. 24 schematically illustrates a control system for a modular
building utilities
system zone control unit.
[0086] FIG. 25 schematically illustrates a control system for a modular
building utilities
system zone control unit, the control system comprising a local control unit
with an Internet
protocol address, in accordance with many embodiments.
23
CA 02772766 2012-03-28
[0087] FIG. 26 schematically illustrates a control system for a modular
building utilities
system zone control unit, the control system comprising a local control unit
that receives
input from a zone mounted sensor(s) and controls zone lighting, power
management, and the
like in accordance with many embodiments.
[0088] FIG. 27 is a simplified diagrammatic illustration of a method for
providing heating,
ventilation, and air conditioning (HVAC) to zones of a building, in accordance
with many
embodiments.
[0089] FIG. 28 diagrammatically illustrates an algorithm for controlling a
zone control unit
for zone cooling and heating, in accordance with many embodiments.
[0090] FIG. 29 diagrammatically illustrates an algorithm for controlling a
zone control unit
for zone pressurization, in accordance with many embodiments.
[0091] FIG. 30 diagrammatically illustrates an algorithm for controlling a
zone control unit
for supply air and mixed airflow control, in accordance with many embodiments.
[0092] FIG. 31 diagrammatically illustrates an algorithm for determining
whether to
operate a zone control unit so as to provide both heating and cooling to zones
serviced by the
zone control unit, in accordance with many embodiments. The algorithm may
comprise a
temperature reset algorithm. The temperature difference between room
temperature and the
temperature at or near the coil may determine how much gallons per minute
(GPM) of fluid
(e.g., refrigerant, water, etc.) and/or cubic feet per minute (CFM) of air to
supply to the coil.
[0093] FIG. 32 diagrammatically illustrates an algorithm for controlling a
flow rate of
supply air, in accordance with many embodiments.
[0094] FIG. 33 diagrammatically illustrates an algorithm for controlling the
flow of heated
and cooled water through heat exchanging coils of a zone control unit, in
accordance with
many embodiments.
[0095] FIG. 34 diagrammatically illustrates an algorithm for controlling a
zone control unit
to reduce energy usage via the selection of flow rates for return air and
supply air, in
accordance with many embodiments.
[0096] FIGS. 35 and 36 show aspects of modular building utilities systems
according to
embodiments of the present invention. The modular building utilities system
may have
valves, pumps, etc. directly prefabricated onto the modular building utilities
system. Further,
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CA 02772766 2012-03-28
the modular building utilities system may have embedded thermal transfer units
(e.g.,
embedded in the duct) and/or be coupled with one or more thermal transfer
units.
[0097] FIGS. 37A-B illustrate aspects of brackets that may be used with the
distribution
assemblies in accordance with many embodiments. The brackets may be coupled
with
components and/or equipment for data, security, fire, electrical, speakers,
and the like.
[0098] FIGS. 38A-C illustrate aspects of additional brackets that may be used
with the
distribution assemblies in accordance with many embodiments.
[0099] FIGS. 39A-B illustrate aspects of additional brackets that may be used
with the
distribution assemblies in accordance with many embodiments.
[0100] FIGS. 40A-B illustrate aspects of brackets that maybe used with the
distribution
assemblies in accordance with many embodiments.
[0101] FIG. 41 illustrates aspects of an additional bracket that may be used
with the
distribution assemblies in accordance with many embodiments.
[0102] FIGS. 42A-B illustrate aspects of a jig that may be used with the
distribution
assemblies in accordance with many embodiments.
[0103] FIGS. 43A-B illustrate aspects of a field erected housing unit that may
include a
distribution assembly in accordance with many embodiments.
[0104] FIG. 44 illustrates aspects of an enclosure that may be used to enclose
the
distribution assemblies in accordance with many embodiments.
[0105] FIG. 45 illustrates aspects of brackets that may be used with the
distribution
assemblies in accordance with many embodiments.
[0106] FIGS. 46A-D illustrate aspects of a fan section that may be used with
the
distribution assemblies in accordance with many embodiments.
[0107] FIGS. 47 and 48 illustrates aspects of a modular system that may
include modular
assemblies and/or zone control units in accordance with many embodiments.
[0108] FIG. 49 illustrates a method of assembling a modular assembly in
accordance with
many embodiments.
[0109] FIG. 50 illustrates a method of installing a modular system in a
building in
accordance with many embodiments.
CA 02772766 2012-03-28
[01101 FIG. 51 illustrates another method of installing a modular system in a
building in
accordance with many embodiments.
[01111 FIG. 52 illustrates another method of installing a modular building
utilities system
in a building in accordance with many embodiments.
[01121 FIG. 53 illustrates aspects of a zone control unit in accordance with
many
embodiments.
DETAILED DESCRIPTION
[01131 In the following description, various embodiments of the present
invention will be
described. For purposes of explanation, specific configurations and details
are set forth in
order to provide a thorough understanding of the embodiments. The present
invention can,
however, be practiced without the specific details. Furthermore, well-known
features may be
omitted or simplified in order not to obscure the embodiment being described.
[01141 HVAC System Configuration
[01151 Referring now to the drawings, in which like reference numerals
represent like parts
throughout the several views, FIG. 1 diagrammatically illustrates an HVAC
system 10 that
includes a zone control unit 12, a supply air system 14, an exhaust air system
16, a boiler 18,
and a chiller 20. While the illustrated HVAC system 10 includes one zone
control unit 12
servicing three HVAC zones 28, 30, 32, additional zone control units can be
used, and each
zone control unit can serve one or more HVAC zones. Likewise, one or more
supply air
systems, exhaust air systems, boilers, and/or chillers can be used in any
particular HVAC
system.
[01161 The zone control unit 12 discharges mixed airflows 22, 24, 26 to
building zones 28,
30, 32, respectively. The zone control unit 12 extracts return airflows 34,
36, 38 from
building zones 28, 30, 32, respectively. A supply airflow 40 (e.g., an outside
airflow) can be
combined with the recirculation airflows 34, 36, 38 within the zone control
unit in a
controlled manner via automated dampers to form a mixed airflow. Heat can be
added or
extracted from the mixed airflow via one or more coils located within the zone
control unit
prior to discharging the mixed airflow for delivery to the building zones 28,
30, 32. For
example, the mixed airflow can be drawn through a heating coil and a cooling
coil located
within the zone control unit. The boiler 18 can be used to add heat to a flow
of water that is
circulated through the heating coil. The chiller 20 can be used to extract
heat from a flow of
water that is circulated through the cooling coil. Other suitable approaches
can also be used
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CA 02772766 2012-03-28
to add heat to or extract heat from the mixed airflow, for example, a heat
pump system can be
used to add or extract heat via a heat exchanger located within the zone
control unit. A
number of HVAC zone control unit configurations, in accordance with many
embodiments,
will be discussed in more detail below.
[01171 The supply air system 14 can be used to distribute intake outside air
to provide the
supply airflow 40 to each of the distributed zone control units in an HVAC
system. The
supply air system 14 intakes outside air 42, filter the outside air 42 via
filters 44, add heat to
the outside air via a heater coil 46, and/or remove heat from the outside air
via an air
conditioning coil 48. Other approaches can also be used to add heat to or
extract heat from
the air inducted by the supply air system 14, for example, a heat pump system
can be used to
add or extract heat via a heat exchanger located within the supply air system.
The supply air
system 14 includes a fan section 52, which can employ a variable speed motor,
for example,
an electronically commutated motor (ECM), for controlling the amount of
outside air
inducted by the supply air system 14 in response to system demands. The supply
air system
14 is coupled with a duct system 50 to deliver the supply airflow 40 to the
zone control unit
12, as well as to any additional zone control unit employed by the HVAC system
10. The
ducts described herein may present any of a variety of cross section shapes
includeing
without limitation: round, rectangular, and square shapes. Relatedly, ducts
can be
manufactured from or include any of a variety of materials including without
limitation:
flexible, acoustical, fabric, polycarbonate, sheet metal, aluminum, steel,
stainless steel,
plastic, wire, wood, sheet rock, fiber board, insulated, non-insulated, and
the like.
[01181 The exhaust air system 16 can be used to extract exhaust airflows 54,
56, 58 from
building zones 28, 30, 32, respectively. The exhaust air system 16 and the
supply air system
14 can be coupled via a heat recovery wheel 60 to exchange heat and moisture
between the
outside air inducted by the supply air system 14 and the combined exhaust
airflows
discharged by the exhaust air system 16. The exhaust air system 16 includes a
fan section 62,
which can employ a variable speed motor, for example, an electronically
commutated motor
(ECM), for controlling the amount of exhaust air discharged by the exhaust air
system 16 in
response to system demands.
[01191 HVAC System Distribution Assemblies
[01201 In the above-described HVAC system 10, a supply airflow 40 is delivered
to the
zone control unit 12 and heated and cooled water are circulated to the zone
control unit 12.
In many embodiments, an integrated distribution system is used to deliver the
supply airflow
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CA 02772766 2012-03-28
and circulate heated and cooled water to each of the distributed zone control
units employed
within a building HVAC system. Such an integrated distribution system can
employ a
number of joined distribution assemblies that each includes a supply air duct
to distribute
supply air to the zone control units, and supply and return water or gas pipes
to circulate the
heated and cooled water to the zone control units. The water or gas may be
circulated with or
without ECM pumps.
[01211 For example, FIG. 2 illustrates an installed distribution system 70 of
a modular
building utilities system having distributed zone control units, in accordance
with many
embodiments. The distribution system 70 includes a roof-mounted air handler 72
that
discharges a supply airflow (e.g., outside air) into a vertically-oriented
distribution assembly
74. The vertically-oriented distribution assembly 74 in turn distributes the
supply airflow to
horizontally-oriented distribution assemblies 76, 78, 80, which in turn
distribute the supply
airflow to zone control units distributed along the horizontally-oriented
distribution
assemblies 76, 78, 80. FIG. 3 illustrates the installed distribution system of
FIG. 2 from a
closer view point.
[01221 FIG. 4 illustrates a junction between the vertically-oriented
distribution assembly
74 and one of the horizontally-oriented distribution assemblies 76, 78, 80.
The vertically-
oriented distribution assembly 74 includes a trunk supply air duct 82 that can
be suitably
sized to transport the supply air distributed to the downstream zone control
units. Likewise,
the horizontally-oriented distribution assembly 76, 78, 80 includes a supply
air duct 84 that
can be suitably sized to transport the portion of the supply air distributed
to respective
downstream zone control units. Because the disclosed HVAC systems employ
distributed
zone control units that locally re-circulate air to respective zones, the
required minimum size
of the supply air ducts is significantly smaller than duct sizes required by
conventional forced
air HVAC systems, which do not employ local re-circulation of air. As a
result, the sizes of
the supply air ducts employed in the disclosed HVAC systems can be selected to
reduce the
number of different duct sizes employed without substantial detriment due to
the significantly
reduced minimum size of the ducts. For example, the vertically-oriented
distribution
assembly 74 illustrated employs a supply air duct 82 having a single constant
cross-section,
and each of the horizontally-oriented distribution assemblies 76, 78, 80
employ a supply air
duct 84 having a common, albeit smaller, cross-section. At the junction, a
transition duct 86
and a duct coupling section 88 are used to couple the supply airflow ducts of
the vertically
and horizontally-oriented distribution assemblies together.
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[01231 The distribution assemblies includes four water supply and return lines
92, 94, 96,
98 used to circulate heated and cooled water to and from the distributed zone
control units,
and further includes a condensate return line 100 used to remove condensate
water from the
zone control units. At the junction, the supply and return lines of the
horizontally-oriented
distribution assembly are coupled into the corresponding lines of the
vertically oriented
distribution assembly.
[01241 FIG. 5A illustrates one of the horizontally-oriented distribution
assemblies 76, 78,
80 as installed. The horizontally-oriented distribution assembly includes a
plurality of
brackets 102 distributed along the length of the distribution assembly. Each
of the brackets
102 is hung from via a hanger 104 and is disposed under and supports the
supply air duct 84.
Each of the brackets 102 includes mounting features used to support the four
water supply
and return lines and the condensate return line. The mounting features may be
used to
support a variety of piping that may be used to transfer water, process gases,
refrigerant,
oxygen, argon, nitrogen, C02, and the like. For example, the piping may be hot
and/or cold
water piping, chemical piping, fire sprinkler piping, and the like. The pipes
of the piping may
be include a variety of materials (insulated or non-insulated) such as copper,
PVC,
polycarbonate, black iron, stainless steel, and the like. The brackets 102 may
also include or
be coupled with drain pans that may extend longitudinally along the length of
the distribution
assembly and that are configured to collect condensate from the distribution
assembly (e.g.,
the duct, piping, conduits, and the like). The drain pan may be built into the
bracket or may
be coupled with the bottom portion of the bracket. The drain pan may add an
extra layer of
protection against water leaks. The drain pans of adjacent distribution
assemblies 76, 78, 80
may be coupled together to provide a continuous or integrated raceway that the
collected
condensate may run down. At the end of the raceway (e.g., where the
horizontally-oriented
distribution assemblies 76, 78, 80 couple with the vertically-oriented
distribution assembly
74) may be a condensate collection reservoir or pump that pump the condensate
into a
condensate reclamation system for later use (e.g., pumps the condensate
through condensate
return line 100 to a water reclamation system for use as wastewater in toilets
and the like).
The drain pans may also be coupled with condensate collection bottles under
the drain pan.
The drain pans may be made of different materials and shapes, such as the
rectangular and
triangular or V shaped drain pans shown in FIG. 6. The drain pans may be
prefabricated/pre-
assembled with the distribution assemblies 76, 78, 80 or may be installed just
prior to or after
installation of the assemblies. The brackets 102 also include mounting
features used to, for
example, support additional components such as electrical conduits and cable
trays used to
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CA 02772766 2012-03-28
route power and/or control cables to systems distributed in the building
(e.g., to the zone
control units, to lighting, telephone, computers, outlets, wireless repeaters,
wireless
transmitters, fire suppression sprinklers, smoke detectors, water heaters,
DC/AC and/or
AC/DC converters, insulation, controls hardware, and the like). The conduit
may be
manufactured of a variety of materials including: flexible, steel, stainless
steel, aluminum
plastic, wire, polycarbonate, and the like. Likewise, the conduit can be used
to transfer a
variety of cables including electrical, wire, light, communications, data,
wireless
communications, cat 5 networking, and the like. The brackets 102 can also be
used to
support sensors and/or electronic devices. For example, wireless repeaters
and/or wireless
transmitters can be distributed throughout the building via attachment to
selected brackets
102 so as to provide wireless internet connectivity in the building. A 3 pipe
assembly or 5
pipe assembly including a drain pipe may be connected to the bracket.
[0125] The distribution assemblies 74, 76, 78, 80 can be prefabricated prior
to installation
in a building. In many embodiments, the distribution assemblies 74, 76, 78, 80
include
prefabricated subassemblies that are assembled on site prior to installation.
For example,
each of the horizontally-oriented distribution assemblies 76, 78, 80 can be
fabricated from a
number of prefabricated modules that are separately transported to a building
site, mounted to
the building (e.g., by lifting the prefabricated modules up to be hung via the
above-described
hangers from the ceiling of the building), and then joined to the adjacent
prefabricated
modules into a combined assembly. Alternatively, the prefabricated modules can
be joined
into a combined assembly before being lifted and hung from the ceiling (e.g.,
while disposed
on the floor). FIG. 6 and FIG. 7 illustrate details of such prefabricated
distribution
assemblies that can be used in an HVAC system having distributed zone control
units, in
accordance with many embodiments. Additional details of such prefabricated
distribution
assemblies are disclosed in United States Provisional Patent Application No.
61/317,929,
entitled "Modular Building Utilities Superhighway Systems and Methods,"
(Attorney Docket
No. 025920-001200US), filed on March 26, 2010; and United States Provisional
Patent
Application No. 61/321,260, entitled "Modular Building Utilities Superhighway
Systems and
Methods," (Attorney Docket No. 025920-00121 OUS), filed on April 6, 2010; the
entire
disclosures of which are incorporated by reference above.
[0126] HVAC Zone Control Unit Installation
[0127] FIG. 8 illustrates two example installations 110, 112 of zone control
units 114, 116,
respectively, in accordance with many embodiments. In the example
installations 110, 112,
the zone control units 114, 116 are mounted adjacent to a horizontally-
oriented distribution
CA 02772766 2012-03-28
assembly 118 so as to provide for convenient coupling between the distribution
assembly 118
and the zone control units 114, 116 with respect to provisions for the supply
airflow, the
circulation of heated and cooled water to and from the zone control units, and
the removal of
condensate from the zone control units. In the first example installation 110,
return air ducts
120, 122, 124 are used to transport return airflow extracted from building
zones serviced by
the first zone control unit 114 to return air inlets of the first zone control
unit 114. In the
second example installation 112, no return air ducts are employed so that the
return air inlets
of the second zone control unit 116 intake return airflows directly from
adjacent to the second
zone control unit 116. The second example installation 112 can be used, for
example, when a
suitable route exists for return airflows to travel between the building zones
serviced by a
zone control unit and the zone control unit. For example, vents can be
installed in the ceiling
panels of the serviced building zones to allow for return airflows to exit the
serviced zones
into the ceiling cavity in which the zone control unit is located.
[0128] FIG. 9 illustrates the coupling of the zone control unit 114 to the
horizontally-
oriented distribution assembly 118. The zone control unit and/or distribution
assembly may
include electrical quick connect kits. Coupling water lines 126 are used to
couple the heat
exchanging coils of the zone control unit 114 with the supply and return water
lines of the
distribution assembly 118 and to couple the condensate retum.line of the
distribution
assembly 118 with a sump discharge line of the zone control unit 114. FIG. 10
illustrates
details a supply airflow duct port 128 of the distribution assembly 118 and an
associated
supply airflow duct 130 used to transfer a flow of supply air from the
distribution assembly
118 to the zone control unit 114.
[0129] In many embodiments, the distribution system illustrated in FIG. 1
through FIG. 10
is pre-engineered and prefabricated accordingly so that required on-site
fabrication is reduced
or eliminated. For example, a method of manufacturing and installing the
distribution
assemblies 74, 76, 78, 80 can proceed as follows:
1. Perform thermal load calculations for the building.
2. Prepare a design drawing(s) showing where the zone control units, air duct,
electrical, piping etc. is going to be installed.
3. Fabricate air duct in sections such as 10, 20, 30, 40, etc. foot sections
and label
based on the design drawing(s).
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4. Cut in openings/duct connections for the duct to attach to adjacent duct
and to the
zone control units.
5. Insulate the air duct.
6. Attach the brackets and fastening system to the air duct.
7. Pre-fabricate water pipe and insert through the bracket mounting features
(e.g.,
staggered holes/grommets).
8. Couple features to the pipes used to couple the zone control units with the
pipes and
used to couple adjacent prefabricated distribution assembly modules (e.g.,
valve bodies,
pressure gauges and stainless steel hose kits).
9. Seal the pipe ends and hoses, and pressurize to a suitable testing pressure
(e.g., 100
psig).
10. Insulate the pipe and all other components requiring insulation.
11. Same procedure for fire sprinklers, process gas pipe, direct expansion
refrigerant
(DX gas), electrical cables, data cables, communication cables/equipment,
plumbing fixtures
and/or pipes, etc. Process gas piping may be used to transport oxygen,
nitrogen, carbon
dioxide, and/or any other gas.
12. Leave for a suitable time frame (e.g., overnight, other specified time
period) to
make sure there are no leaks by making sure the pressure is the same as the
day before or
time frame before.
13. Install the electrical conduit and cable trays (or this can be done in the
field after the
brackets have been hung).
14. Wrap the entire module in a large plastic bag and seal off both ends.
15. Tag the modules as per the details on the design drawing(s).
16. Cut small slits in the plastic bag over the handles of the brackets so
only the handles
are exposed.
17. Load the modules on to a transporting service. Use the handles so as not
to damage
the modules.
18. Deliver the modules to the project site in order by assembly nomenclatures
for easy
assembly, installation and hanging of the modules.
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CA 02772766 2012-03-28
19. Unload the modules from the transporting service.
20. Unload using handles so as not to damage the modules.
21. Transport the modules to the location in the building shown on the design
drawing(s).
22. Lift the horizontally-oriented distribution assembly modules towards the
ceiling
with a man lift or other lifting device via the handles.
23. Install the vertically-oriented distribution assembly modules in the shaft
of the
building.
24. Fasten the horizontally-oriented distribution assembly modules to the
ceiling using
the bracketing system - cable, off thread rod or other fastening
device/system.
25. Make final adjustments after module is level.
26. Cut ends of plastic bag at duct work and piping ends and assemble into the
next
module/air duct.
27. Install zone control units and connect to duct and pipe.
28. Install flex duct from the distribution assembly modules to the zone
control units for
the transfer of supply airflows (outside air) to the zone control units.
29. Couple the hose kits (e.g., stainless steel, plastic, copper, and the
like) to the zone
control unit hot water supply/return, chilled water supply/return and drain
(option for drain
plug in zone control units unit to hold pressure).
30. Optionally repeat items 20 - 26 for any other assemblies and zone control
units.
31. Re-pressurize the zone control modules to 100 psig and leave overnight, or
re
pressurize entire piping/module run.
32. The next day, check the gauges for the pressure reading to make sure there
are no
leaks. If the pressure is not the same as the night before then the leak may
be in one of the
stainless steel hose connections to the zone control units. Troubles shoot and
repair.
33. If pressure is the same as the night before, then connect the pipes to the
next module
with press fittings. (Alternatively, all the pipes and assemblies may be
connected and the
entire section of piping, conduit, duct, etc. can be pressurized together).
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CA 02772766 2012-03-28
34. Apply the above sequence to connect the vertically-oriented distribution
assemblies
to a wall of the building and/or to the horizontally-oriented distribution
assemblies.
(Alternatively, this procedure may be done before the zone control units and
horizontal
distribution assemblies are connected).
35. Electrician and low voltage tradesman can now come in and run the
electrical
wires/conduit and the cable wiring. Or the conduit and trays may be already
installed on the
brackets/modular assemblies.
36. The holes and rectangular box/cable tray are symmetrical and level through
out the
building. Thus, no hanging or support is required for the electrical, cables
etc. Therefore, the
installation time is very quick. All the pipe, duct, electrical, cables may be
located on the
brackets and follow the duct through out the building.
37. This may make it easier to locate all these things and provide more room
to work on
these components.
38. The components may take up less ceiling space and may be located
symmetrically
around the duct. It may be possible to have an extra floor(s) in the same
building footprint by
using this bracketing system.
[0130] HVAC Zone Control Unit Configurations
[0131] FIG. 11 is a top view diagrammatic illustration of an HVAC zone control
unit 140,
in accordance with many embodiments. The HVAC zone control unit 140 includes a
return
air section 142, a cooling coil section 144, a fan section 146, a heating coil
section 148, and a
supply air section 150.
[0132] In operation, return airflows from serviced building zones enters the
return air
section 142 via return air inlet collars 152, 154, 156. Automated return air
dampers 158, 160,
162 are used to control the flow rate of the return airflows entering the
return air section 142
through the return air inlet collars 152, 154, 156, respectively, which
provides for better
control of the associated building zone. For example, a return air damper 158,
160, 162 can
be closed when the associated zone is not occupied. The return air dampers
158, 160, 162
can be configured with damper shafts located on the bottom of the HVAC zone
control unit
140 for access from the bottom of the zone control unit. Supply airflow can
enter the return
air section 142 via a supply airflow inlet collar 164. A supply airflow damper
166 can be
used to control the flow rate of the supply airflow flowing into the return
air section 142. For
example, the supply airflow damper 166 can be used in conjunction with an
airflow probe to
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CA 02772766 2012-03-28
control and measure the flow rate of the supply airflow (e.g., outside air)
that is input into the
return air section, which can be used to provide better indoor air quality as
well as control
costs associated with the introduction of outside air (e.g., heating cost,
cooling cost, humidity
adjustment cost, etc.). The return air section 142 can include an access
provision 168 (e.g.,
an access panel, a hinged access door) for access to the interior of the
return air section (e.g.,
for maintenance, repair, etc.). The return air section 142 can include a
return air temperature
sensor 170 for monitoring the temperature of the mixed airflow. The
temperature of the
mixed airflow can be used to adjust system operational parameters. The return
air section
142 can include an air filter 172 (e.g., a 2 inch pleated air filter) for
filtering the mixed
airflow prior to discharge from the return air section into the cooling coil
section 144. The
return air section can share a common footprint with the supply air section
150. A common
damper can be used at two or more locations (e.g., a common 12 inch by 12 inch
damper can
be used for the return air dampers 158, 160, 162). The return air inlet
collars 152, 154, 156
can be sized for an associated zone airflow requirement (e.g., CFM
requirement). The return
air section 72 can be configured such that the return air inlet collars 152,
154, 156 and the
supply airflow inlet collar 164 are easily installable after the HVAC zone
control unit has
been installed to minimize shipping and installation damage. The return air
section 142 can
be insulated (e.g., with 1 inch engineered polymer foam insulation (EPFI) -
closed cell
insulation).
[01331 In many embodiments, a carbon dioxide (CO2) sensor and/or a total
organic volatile
(TOV) sensor(s) are installed in the return air section 142 to sample the
return airflows. The
sensor(s) can be connected into a controller for the zone control unit for use
in controlling the
flow rate of supply air added to the return airflows and for controlling the
rate of mixed
airflow discharged to the zones serviced by the zone control unit. The
sensor(s) can be
installed in between the return air dampers to sample the return air as there
is an invisible air
curtain where the supply airflow (outside air) is coming in and mixing with
the return
airflows. Or a separate sensor(s) can be installed on each return air damper.
By sensing the
concentration of the measured compound (e.g., parts per million (ppm) of CO2
and/or
TOV(s)), the zone control unit can vary the rate of the supply airflow
introduced to control
the concentration of the measured compound. For example, when the
concentration of CO2
exceeds a specified level, the zone control unit can increase the flow rate of
the supply
airflow added to the return airflows (e.g., by opening the supply airflow
damper and/or
closing the return airflow dampers), and can also increase the flow rate of
the mixed airflow
discharged to the zones serviced by the zone control unit. The measured
concentration levels
CA 02772766 2012-03-28
can also be transmitted from one or more of the zone control units for
external use. For
example, for critical environments the concentration levels can be centrally
monitored for use
in making adjustments (e.g., by a central monitoring system, by a building
operator, by a
plant manager, etc.). With such an integrated sensor(s), the zone control
units can employ the
measured concentration levels to accomplish fine-tuned adjustments to
operating parameters,
thereby saving energy and providing excellent environmental control, which may
be
especially beneficial when critical environmental control is required.
[01341 The cooling coil section 144 receives air discharged by the return air
section 142.
The zone control unit and/or modular assembly may include a temperature reset
with ECM
pumps, fans, and the like, which may eliminate valves thereby reducing the
pressure drop
thereby providing better energy control. The cooling coil section 144 includes
a cooling coil
174. The cooling coil 174 can use a cooled medium (e.g., cooled water,
refrigerant) to absorb
heat from the mixed airflow. In many embodiments, the cooling coil 174 employs
micro-
channel technology. The cooling coil 174 can be arranged in a variety of ways
(e.g., a planar
arrangement, a u-shaped arrangement, 180 to 360 degree arrangements, etc.).
Arranging the
cooling coil 174 for increased surface area provides for the ability to
realize a more compact
zone control unit. The cooling coil 174 can employ, for example, 3/8 inch
copper tubes (or
micro channel technology) for better heat transfer. The cooling coil 174 can
employ high
performance fins for better heat transfer. The cooling coil can employ fins
that provide for a
reduced pressure drop across the cooling coil as compared to industry standard
coils, for
example, seven to eight fins per inch can be used as compared to the industry
standard of 10
fins per inch. In many embodiments, the cooling coil 174 is coupled with the
chiller 20
(shown in FIG. 1) so that a cooling fluid (e.g., chilled water) is circulated
between the chiller
and the cooling coil 174 and heat is transferred from the mixed airflow to the
chiller via the
cooling fluid. The cooling coil section 144 can include a condensate pan and
pump 176 (e.g.,
using plastic and/or aluminum construction to reduce or eliminate corrosion)
for managing
any condensate produced. The condensate pump can be factory installed. The
condensate
pump can be mounted and wired, and can be piped from a strainer and allow back
flushing to
reduce fouling and increase energy efficiency. The condensate pump can be
wired to a
control system and an alarm can be signaled if the condensate pump fails. An
access
provision 178 (e.g., an access panel, a hinged access door) can be provided
for access to the
interior of the cooling coil section for a range of purposes (e.g.,
inspection, access to the
condensate pan and condensate pump, maintenance, access to coiling coil,
cleaning of the
cooling coil, repair, etc.). The cooling coil section 144 can be configured to
produce a
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desired temperature drop in the airflow (e.g., a 30 degree Fahrenheit drop -
entering airflow
temperature at 80 degrees and a leaving airflow temperature at 50 degrees).
The cooling coil
section 144 provides for cooling local to the building zone as opposed to a
large and
expensive air handling unit. The cooling coil section 144 can be insulated
(e.g., with 1 inch
engineered polymer foam insulation (EPFI) -closed cell insulation).
[0135] The fan section 146 receives the mixed airflow from the cooling coil
section 144.
The fan section 146 includes a fan 180 driven by a motor 182. The motor 182
can be a
known electric motor, for example, a variable speed motor (e.g., an ECM motor)
for
controlling the rate of the mix airflow through the HVAC zone control unit
140. The
motor 182 can be a DC motor that can be run directly off of solar panels.
Because the HVAC
zone control unit provides for control over the air temperature of the mixed
airflow
discharged to the HVAC zones, an increased flow rate of the mixed airflow can
be used,
which increases the flow rate of the mixed airflow discharged into the
building zones for
better throw and mixing. The use of increased flow rate may help to reduce or
eliminate
stratification in the building zones serviced. The fan 180 can be a high
efficiency plastic
plenum or axial fan. The motor 182 can be an ECM motor for reduced energy
usage and can
be a variable speed ECM motor for adjusting the flow rate of the mixed airflow
discharged to
the building zone(s). Locating the fan section 146 between the cooling coil
section 144 and
the heating coil section 148 may provide for better acoustics. The use of a
plenum fan may
allow for better airflow velocity across the cooling coil and the heating
coil. In the
embodiment of FIG. 11, the fan section 146 draws the mixed airflow through the
cooling coil
and blows the mixed airflow through the heating coil. The use of a plenum fan
may allow for
a smaller footprint for the fan section 146. The fan section 146 can be
insulated (e.g., with 1
inch engineered polymer foam insulation (EPFI) -closed cell insulation).
Another fan section
can be employed in series with the fan section 146, for example, downstream of
the filters.
Such an additional fan section can be used to account for an additional amount
of pressure
drop associated with HEPA and/or ultra low particle air (ULPA) filters, which
may be used in
certain applications such as laboratory applications. In some embodiments, an
HVAC unit
can be manufactured with an integrated fan 180. Exemplary fan mechanisms may
include a
motor 182 such as an electronically commutated motor (ECM) motor. Motor 182
can operate
to control or modulate air flow across a thermal transfer device or coil of an
HVAC unit.
Hence, fan 180 can provide a selected air flow rate through an HVAC unit, so
as to achieve a
desirable energy savings or comfort protocol. As shown in FIG. 11, at least a
portion of a
thermal transfer mechanism such as coil 174 can be placed along an air flow
path 187 within
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a casing 145 (e.g at coil section 144) such that at least a portion of an
inlet piping assembly
and at least a portion of an outlet piping assembly coupled with the coil are
disposed exterior
to the casing. Relatedly, fan 180 can be positioned along the airflow path 187
within casing
145 (e.g. at fan section 146). The use of ECM pumps and/or ECM fans may
provide for a
variety of controls strategies based off a temperature reset algorithm,
strategy, and/or
equipment. For example, the cubic feet per minute (CFM) of air and/or the
gallons per
minute (GPM) of fluid may be adjusted based on the temperature and heating or
cooling
needs. The CFM may be increased with the GPM is increased, held constant, or
decreased.
Similarly, the GPM may be increased with the CFM is increased, held constant,
or decreased.
The variance of the CFM and/or GPM provide multiple energy savings options and
heating/cooling options.
[0136] The fan section 146 discharges the mixed airflow into the heating coil
section 148,
which contains a heating coil 184. The heating coil 184 can be coupled with
the boiler 18
(shown in FIG. 1) so that a heating fluid (e.g., heated water) is circulated
between the boiler
and the heating coil and heat is transferred into the mixed airflow from the
boiler via the
heating fluid. In many embodiments, the heating coil 184 employs micro-channel
technology. The heating coil 184 can be arranged in a variety of ways (e.g., a
planar
arrangement, a u-shaped arrangement, 180 to 360 degree arrangements, etc.).
Arranging the
heating coil 184 for increased surface area provides for the ability to
realize a more compact
unit. The heating coil 184 can employ, for example, 3/8 inch copper tubes for
better heat
transfer. The heating coil can employ high performance fins for better heat
transfer. The
heating coil can employ fins that provide for a reduced pressure drop across
the heating coil
as compared to industry standard coils, for example, seven to eight fins per
inch can be used
as compared to the industry standard of 10 fins per inch. The heating coil
section 148 can be
configured to produce a desired temperature rise in the airflow (e.g., a 30
degree Fahrenheit
rise - entering airflow temperature at 70 degrees and a leaving airflow
temperature at 100
degrees). The heating coil section 148 can be insulated (e.g., with 1 inch
engineered polymer
foam insulation (EPFI) -closed cell insulation).
[0137] The mixed airflow is discharged from the heating coil section 148 into
the supply
air section 150. The supply air section 150 can include a high efficiency
particulate air
(HEPA) filter 186. The supply air section 150 can include a humidity sensor
188 and can
include a supply air temperature sensor 190. An access provision 192 (e.g., an
access panel,
a hinged access door) can be provided for access to the interior of the supply
air section (e.g.,
for maintenance, repair, etc.). Supply airflows are discharged from the supply
air section 150
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to one or more serviced building zones via one or more supply air outlet
collars 194, 196,
198. The supply air section 150 can include one or more actuated supply air
dampers 200,
202, 204 for controlling the airflow rate through the supply air outlet
collars 194, 196, 198,
respectively, which provides for better control of airflow to the associated
zone. For
example, a supply air damper 200, 202, 204 can be closed when the associated
zone is not
occupied. The supply air dampers 200, 202, 204 can be configured with damper
shafts
located on the bottom of the HVAC zone control unit 140 for access from the
bottom of the
zone control unit. The supply air section can share a common footprint with
the return air
section 142. A common damper can be used at two or more locations (e.g., a
common 12
inch by 12 inch damper can be used for the supply air dampers 200, 202, 204).
The supply
air outlet collars 194, 196, 198 can be sized for associated zone airflow
requirements. The
supply air section can be configured such that the supply air outlet collars
194, 196, 198 are
easily installable after the HVAC zone control unit has been installed to
minimize shipping
and installation damage. The supply air section can be insulated (e.g., with 1
inch engineered
polymer foam insulation (EPFI) -closed cell insulation).
[0138] FIG. 12 is a side view diagrammatic illustration of the HVAC zone
control unit 140
of FIG. 11. As further illustrated by FIG. 12, the return air section 142 can
include a filter
access provision 206 for access to the air filter 172 (shown in FIG. 11).
Likewise, the supply
air section 150 can include an access provision 208 for access to the HEPA
filter 186.
Cooling fluid control valves 210 can be used to control the circulation of
cooling fluid
between the cooling coil 174 (shown in FIG. 11) and the chiller 20 (shown in
FIG. 1). The
control valves 210 can be modulating control valves to provide for variable
control of the
temperature drop produced in the cooling coil section 144 so as to provide
variable control of
the temperature of the air supplied to the building zones services by the HVAC
zone control
unit 140. Likewise, heating fluid control valves 212 can be used to control
the circulation of
heating fluid between the heating coil 184 (shown in FIG. 11) and the boiler
18 (shown in
FIG. 1). Instead of or in addition to the boiler, the heating fluid may be
provided by
geothermal sources, a heat pump, and or DX/water source. The control valves
212 can be
modulating control valves to provide for variable control of the temperature
increase
produced in the heating coil section 148 so as to provide variable control of
the temperature
of the air supplied to the building zones services by the HVAC zone control
unit 140.
Alternatively, variable rate water pumps, for example, variable rate water
pumps employing
an ECM motor, can be employed to regulate the rate at which cooled water is
circulated
through the cooling coil section 144 and to regulate the rate at which heated
water is
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circulated through the heating coil section 148. This may provide faster
response time,
variable flow, and/or complete or near complete shut off. The HVAC zone
control unit 140
can include an electrical and controls enclosure 214 for housing HVAC zone
control unit
related electrical and controls components. The HVAC zone control unit 140 can
include one
or more mounting provisions 216.
[01391 FIG. 13 is a top view diagrammatic illustration of an HVAC zone control
unit 220,
in accordance with many embodiments, that includes a combined heating/cooling
section 222
in place of the separate cooling section 144 and heating section 148 discussed
above with
reference to FIGS. 11 and 12. The HVAC zone control unit 220 includes the
above
discussed return air section 142, fan section 146, and supply air section 150,
which can
contain the above discussed related components. The combined heating/cooling
section 222
can include a cooling coil 224 and a heating coil 226, which as discussed
above with
reference to HVAC zone control unit 40, can employ micro-channel technology.
The use of
micro-channel technology may result in a decreased pressure drop across the
cooling and
heating coils. A wireless thermostat 228 can be used to provide for control of
the HVAC
zone control unit. FIG. 14 is a side view of the HVAC zone control unit 220,
showing the
location of components that were discussed above with reference to FIGS. 11,
12, and 13.
[01401 FIG. 15 is a top view diagrammatic illustration of an HVAC zone control
unit 230,
in accordance with many embodiments, that includes a return air section 232
with a direct
return airflow intake and a supply air section 234. The HVAC zone control unit
230 includes
the above discussed cooling coil section 144, fan section 146, and heating
coil section 148,
which can contain the above discussed related components. The return air
section 232 can
share a common footprint with the supply air section 234. The return air
section 232 includes
return air filters 236 disposed on the exterior surface of the return air
section. For example,
the return air filters 236 can partially or completely surround the return air
section. The
return air section 232 can be conically shaped, which may serve to produce
desired airflow
patterns due to the increasing cross-sectional area of the return air section
in the direction of
airflow, which corresponds to the increased amount of airflow at the exit of
the return air
section as compared to the beginning of the return air section. The return air
section 232 can
include above discussed components (e.g., the labeled components). The supply
air section
234 can be conically shaped, which may serve to produce desired airflow
patterns due to the
decreasing cross-sectional area of the supply air section in the direction of
airflow, which
corresponds to a decreased amount of airflow just prior to the supply air
outlet collar 196 as
compared to the beginning of the supply air section. The supply air section
234 can include
CA 02772766 2012-03-28
above discussed components (e.g., the labeled components). The return air
section 232 and
the supply air section 234 can share a common footprint, which may provide for
the use of
common components.
[0141] FIG. 16 is a photograph of a prototype zone control unit 240 having a
transparent
top panel installed to allow viewing of airflow during testing. FIG. 17 is
another photograph
of the prototype zone control unit 240, showing internal components and flow
strips 242
employed during testing.
[0142] FIG. 18 illustrates an HVAC zone control unit 250 and an HVAC zone
control unit
260, in accordance with many embodiments. The HVAC zone control unit 250
includes a
round coil 252 that provides for direct intake of a return airflow. A supply
airflow (e.g.,
outside air) enters at one end, is mixed with the return airflow to form a
mixed airflow, and
the mixed airflow exits from the other end of the zone control unit 250. The
amount of heat
added to, or removed from, the mixed airflow can be used to control the
temperature of the
mixed airflow as desired. The HVAC zone control unit 260 further includes a
supply airflow
intake collar 262 that houses an optional supply airflow control damper 264
for controlling
the flow rate of the supply airflow (e.g., outside airflow) used. The HVAC
zone control unit
260 further includes a supply airflow section 266 that houses one or more
mixed airflow
dampers 268 for controlling the flow rate of the mixed airflow discharged to
one or more
serviced building zones.
[0143] FIGS. 19A and 19B illustrate micro-channel coils that can be used as
discussed
above. A micro-channel coil can include a plurality of parallel flow tubes
through which a
working fluid is transferred between headers and enhanced fins for
transferring heat to or
from the parallel flow tubes to the airflow via enhanced fins, for example,
aluminum fins. As
discussed above, a micro-channel coil heat exchanger coil can employ a fin
arrangement that
provides for reduced pressure drop across the coil as compared to industry
standard coils, for
example, seven to eight fins per inch can be used as compared to the industry
standard of 10
fins per inch.
[0144] FIG. 20 illustrates a control damper 270 for an HVAC zone control unit.
The
control damper 270 includes an array of louvers 272 that are controllably
actuated to vary the
flow rate of the respective airflow through the control damper 270 under the
control of a
control unit for the zone control unit.
[0145] FIG. 53 illustrates another configuration of a ZCU. The ZCU may include
one or
more dampers. Positioned adjacent the one or more dampers may be a thermal
transfer
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CA 02772766 2012-03-28
unit(s) that may be pre-piped with valves, pumps. The thermal transfer unit(s)
may ship
under pressure. Disposed within the ZCU may be a fan. The ZCU may include a
port to
receive return air. Positioned adjacent or near the return air port may be a
thermal transfer
unit(s) that may be pre-piped with valves, pumps, and the like. The thermal
transfer unit(s)
may ship under pressure. Positioned adjacent or near the thermal transfer
unit(s) may be a
filter. The ZCU may also include a port to receive outside air. A filter may
be positioned
adjacent or near the outside air port.
[0146] Distribution System Configurations
[0147] FIG. 21 through FIG. 23 illustrate a number of distribution system
configurations
that can be used for the routing of the supply airflow (e.g., outside air),
the mixed airflows
discharged to the serviced zones, the return airflows, and the exhaust
airflows. For example,
as illustrated in FIG. 21, the horizontally-oriented distribution assemblies
used to service the
zones on a building floor can be ceiling mounted and the exhaust airflows (EA)
from the
serviced zones can be discharged into a vertical shaft of the building (e.g.,
a vertical shaft
where the vertically-oriented distribution assembly is installed) for
subsequent discharge
from the vertical shaft to outside of the building via an exhaust airflow
outlet 274. The
exhaust airflow outlet 274 can be suitably separated from one or more outside
air inlets 276
used to intake outside air for delivery to the distributed zone control units.
As illustrated in
FIG. 22 and FIG. 23, the mixed airflow can be introduced into the serviced
zones from
ceiling mounted diffusers and/or floor mounted diffusers, and the exhaust
airflows can be
extracted from the ceiling and/or the floor.
[0148] HVAC Zone Control Unit Control System
[0149] FIG. 24 illustrates a control system 280 for an HVAC zone control unit.
The
control system 280 includes a thermostat 282, a local control unit 284
configured to control
an HVAC zone control unit 286, and a computer 288 hosting a building
automation control
program 290. The computer may operate as part of a main frame computing
system, data
center, cloud computing system, and the like. The thermostat 282 is coupled
with the local
control unit 284 via a communication link 292. The local control unit 284
communicates
with the computer 288 via a communication link 294. The control system 280 can
be used to
control the above described HVAC zone control units. Aspects of additional
control systems
that can be used to control the above described HVAC zone control units are
described in
numerous patent applications and publications, for example, in U.S. Patent
Publication No.
2009/0062964, filed Aug. 27, 2007; U.S. Patent Publication No. 2009/0012650,
filed Oct. 5,
42
CA 02772766 2012-03-28
2007; U.S. Patent Publication No. 2008/0195254, filed Jan. 24, 2008; U.S.
Patent Publication
No. 2006/0287774, filed Dec. 21, 2006; U.S. Patent No. 7,343,226, filed Oct.
26, 2006; U.S.
Patent No. 7,274,973, filed Dec. 7, 2004; U.S. Patent No. 7,243,004, filed
Jan. 7, 2004; U.S.
Patent No. 7,092,794, filed Aug. 15, 2006; U.S. Patent No. 6,868,293, filed
Sep. 28, 2000;
and U.S. Patent No. 6,385,510, filed Dec. 2, 1998, the entire disclosures of
which are hereby
incorporated herein by reference.
[0150] FIG. 25 illustrates a control system 300, in accordance with many
embodiments, for
an HVAC zone control unit, for example, the above described HVAC zone control
units. The
control system 300 includes an HVAC local control unit 302 configured to
control an HVAC
zone control unit 304; and one or more external control devices (e.g., an
internet access
device 306 (for example, laptop, PDA, etc.), a remote server 308 hosting an
HVAC control
program 310). In many embodiments, the local control unit 302 has its own
Internet Protocol
(IP) address. The local control unit 302 receives commands from and can supply
data to the
one or more external control devices via the Internet 312. The local control
unit 302 is
connected to the Internet 312 via a communication link 314. The communication
link 314
can be a hard-wired communication link and can be a wireless communication
link. In many
embodiments comprising a wireless communication link 314, the local control
unit 302
comprises wireless communication circuitry 316 for communicating over the
Internet 312 via
ZigBee communication protocol and 900 MHz frequency hopping and 802.11 WIFI
WiFi X
open protocol. In many embodiments, the local control unit 302 comprises a
temperature
sensor 318. The one or more external control devices can be used to access the
IP address for
the local control unit 302, optionally enter security information (e.g., user
IDs, passwords,
security code, etc), and adjust control variables (e.g., temperature, etc.).
The control
system 300 provides for the elimination of the thermostat and/or provides for
remote control
of the HVAC zone control unit, and enables both local and/or remote hosting of
HVAC
control programs. For example, the local control unit 302 can include a memory
and
processor for storing and executing a control program for the HVAC zone
control unit 304.
The control unit 302 may also include a sensor pak(s) for lights, HVAC, power
management,
and the like. The communication circuitry 316 comprising ZigBee communication
protocol
and 900 MHz frequency hopping provides a universal board application with open
protocol
and/or Wi Fi open protocol that would allow the use of these technologies
based on
application.
[01511 FIG. 26 illustrates a control system 320 for an HVAC zone control unit
that
includes a local control unit 322 that receives input from a zone mounted
sensor(s) 324 and
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CA 02772766 2012-03-28
controls zone lights 326, in accordance with many embodiments. The control
system 320
may allow for building automation system (BAS) hardware to be preinstalled,
which may
eliminate the need for field labor installation. The control system 320 (e.g.,
BAS system)
may provide a single software integration platform for all, some, or a
majority of the building
utilities. The control system 320 includes components used in the control
system 300 of
FIG. 25, as designated by the like reference numbers used. In addition, the
control system
320 further includes the zone mounted sensor(s) 324 and/or one or more of the
zone mounted
lights 326. For example, the sensor(s) 324 and/or one or more of the zone
mounted lights
326 can be mounted on a ceiling mounted return airflow diffuser 328 in one or
more building
zones serviced by the HVAC zone control unit. The local control unit 322 can
be configured
to provide control of the zone lights 326, and can be configured to monitor
power
consumption of the zone lights 326. Thus, the local control unit 322 can
control all the
HVAC and lights for a serviced zone(s) and also measure the corresponding
power
consumption for the serviced zone(s). The HVAC, lighting, and/or power
consumption
information/data can be transferred over the Internet 222 and disseminated,
thereby providing
occupant level information/data that can be used to control the occupant's
zone and
implement energy efficient strategies via the remote server 218 or the
internet access device
216. The control system 320 enables zone based billing based on zone energy
consumption.
An application(s) can also be implemented (e.g., on the remote server 218
and/or on an
internet access device 216) for the tenant to monitor energy consumption
and/or implement
energy-efficient HVAC and/or lighting strategies. Such an application(s) can
show energy
usage and utility rates so that the HVAC and/or the lighting in the zone can
be managed
commensurate to energy costs during peak and/or off peak hours of the day.
[0152] The sensor(s) 324 can include one or more types of sensors (e.g., a
temperature
sensor, a humidity sensor, a carbon-dioxide (CO2) sensor, a photocell, a
motion detector, an
infrared sensor, one or more total organic volatile (TOV) sensors, etc.). For
example, a CO2
sensor and/or a total organic volatile (TOV) sensor(s) can provide
concentration
measurement information for a measure compound to the local control unit 212,
which can
use the concentration measurements to control the operation of the zone
control unit, and can
communicate the concentration measurements over the Internet 222, for example,
to the
remote server 218 and/or to the internet access device 216. A motion sensor
and/or an
infrared sensor can be employed to tailor the operation of the zone control
unit in response to
room occupancy.
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CA 02772766 2012-03-28
[0153] A zone control unit control system can also be configured to provide
additional
functionality. For example, a control system can provide built in controls
features such as
tracking utility cost, logging of equipment run time for use in related
maintenance and/or
replacement of the equipment monitored, tracking of zone control unit
operating parameters
for use in setting boiler and/or chiller operating temperatures, tracking zone
control unit
operational parameters for use in trend analysis, etc. The control system may
monitor and/or
report BTUH and/or KW consumption.
[0154] HVAC Methods
[0155] FIG. 27 is a simplified diagrammatic illustration of a method 330 for
providing
HVAC to zones of a building using distributed zone control units, in
accordance with many
embodiments. In the method 330, a first zone control unit is used to service a
first zone of
the building zones, and a second zone control unit is used to service a second
zone of the
building zones. In step 332, first and second flows of supply air from outside
the zones are
provided via an air duct. In step 334, a first return airflow is extracted
from the first zone and
a second return airflow is extracted from the second zone. In step 336, the
first return airflow
is mixed with the first supply airflow in the first zone control unit so as to
form a first mixed
flow. In step 338, the second return airflow is mixed with the second supply
airflow in the
second zone control unit so as to form a second mixed flow. In step 340,
heated water is
directed to the first and second zone control units from a hot water source
(e.g., a boiler). In
step 342, cooled water is directed to the first and second zone control units
from a cold water
source (e.g., a chiller). In step 344, in response to a low temperature in the
first zone, heat
transfer within the first zone control unit is increased from the heated water
to the first mixed
airflow. In step 346, in response to a high temperature in the first zone,
heat transfer within
the first zone control unit is increased from the first mixed airflow to the
cooled water. In
step 348, in response to a low temperature in the second zone, heat transfer
within the second
zone control unit is increased from the heated water to the second mixed flow.
In step 350, in
response to a high temperature in the second zone, heat transfer within the
second zone
control unit is increased from the second mixed flow to the cooled water. In
step 352, the
first mixed flow is distributed to the first zone. And in step 354, the second
mixed flow is
distributed to the second zone. The above-described zone control units can be
used in
practicing the method 330.
[0156] HVAC Zone Control Unit Control Methods
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[0157] FIGS. 28 through 34 illustrate control algorithms that can be used to
control the
above-described HVAC zone control units, in accordance with many embodiments.
Stand
alone independent zones may be configured to work only where there are people,
a demand,
and/or occupancy. This may significantly reduce the energy footprint of the
building. FIG.
28 illustrates a control algorithm 360 that is used to control the speed at
which the zone
control unit fan(s) operates and the position of the airflow dampers through
which the mixed
airflow is discharged to the building zones serviced by the HVAC zone control
unit. When
the measured temperature of the service zoned falls within a specified band
362
encompassing a current temperature set point 364 for the serviced zone, the
fan speed(s) and
the discharge airflow damper for the serviced zone are set to deliver a
minimum airflow rate
of the mixed flow to the serviced zone. When the measured temperature of the
serviced zone
falls outside the specified band 362, the fan speed(s) and the discharge
airflow damper
position are adjusted to deliver increased flow rates up to the applicable
maximum flow rate
366, 368 as a function of the temperature variance involved as illustrated.
The control
algorithm 360 is implemented in independent loops, one loop for each zone
serviced by the
zone control unit. Accordingly, the fan speed(s) are set to discharge the
mixed flow at a rate
equal to the combined rates called for by the serviced zones, and the
discharge airflow
dampers for the serviced zones are set to distribute the mixed flow according
to the
determined flow rates for the respective serviced zones.
[0158] FIG. 29 illustrates a control algorithm 370 used to control zone
pressurization. The
algorithm 370 takes the zone discharge airflow rate 372 (i.e., the flow rate
that the mixed
flow is discharged to the zone) and adds a flow rate offset 374 (which can be
either a positive
or negative flow rate offset) to obtain a return airflow rate 376 for the
zone. The calculated
return airflow rate 376 is then used to calculate a return airflow damper
position 378 for the
zone.
[0159] FIG. 30 illustrates an algorithm 380 used to calculate the rate of
supply airflow
(outside air) that is mixed with the return airflows based on occupancy and
space
pressurization requirements. The algorithm 380 also establishes minimum rates
of the mixed
flow discharged to each of the zones serviced by the zone control unit. The
minimum zone
mixed flow discharge rate can be based on the number of people in the zone.
For example,
the minimum mixed for discharge rate for a zone (in units of cubic feet per
minute (CFM))
can be equal to the flow rate offset 374 of FIG. 29 added to the number of
people associated
with the zone times 10. The resulting flow rates of the supply airflow and the
return airflow
rates from each of the serviced zones can be used in combination with the
respective
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temperatures of the supply airflow and the return airflows to determine the
temperature of the
mixed flow transferred to the heat exchanging coils of the zone control unit.
A psychometric
chart algorithm(s) may be written into the program for optimum indoor air
quality
commensurate with a heat transfer coefficient of the thermal transfer
units/coil and
psychometric chart parameters. This may allow for tight control of
temperatures resulting in
energy and/or cost savings.
[01601 FIG. 31 illustrates an algorithm 390 used to determining whether to
operate an
HVAC zone control unit so as to provide both heating and cooling to zones
serviced by the
zone control unit. In some instances, the zones serviced by a zone control
unit may have
conflicting heating/cooling requirements. For example, one serviced zone may
have a current
temperature and a thermostat setting requiring heat to be added to the zone,
while another
serviced zone may have a current temperature and a thermostat setting
requiring heat to be
extracted from the zone. In such an instance, the zone control unit can be
operated in a
change-over mode in which the mixed flow is alternately heated and cooled and
the discharge
of the mixed flow is controlled to discharge the heated mixed flow primarily
to the zone(s)
requiring heat and to discharge the cooled mixed flow primarily to the zone(s)
requiring the
removal of heat. For example, the flow rate discharged to a particular zone
can be
maximized when the mode of the zone control unit matches the heating/cooling
requirements
of the zone and can be minimized when the mode of the zone control unit
disagrees with the
heating/cooling requirements of the zone. Because zone pressurization may
require that a
minimum mixed airflow rate be discharged to each zone at all times, a certain
amount of
reheating and/or re-cooling of the serviced zones may result. To account for
this, the zone
control unit can be configured with an increased heating/cooling capacity to
account for the
resulting additional reheating and re-cooling requirements. The algorithm 390
can be
periodically executed (e.g., every 10 minutes) to change over between heating
and cooling if
such a mixed heating/cooling requirement is present. In the absence of such a
mixed
heating/cooling requirement, the zone control unit remains in the applicable
heating/cooling
mode.
[0161] FIG. 32 illustrates an algorithm 400 for controlling the speed of the
supply fan(s)
used to discharge the mixed airflow to the serviced zones. The supply fan(s)
speed 402,
determined in the algorithm 360 of FIG. 28, along with a measured static
pressure 404 (if
employed) are fed into a static pressure control loop 406 that adjusts the
supply fan(s)
speed 402 up or down according to a standard variable air volume static
pressure loop. A
static pressure set point can be set at a suitable level just high enough to
overcome variable
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CA 02772766 2012-03-28
air volume box static pressure drop (e.g., .3 inch H20). A P gain or ramp
function can be used
to minimize noise due to changing fan speed during a heating/cooling mode
changeover.
[0162] FIG. 33 illustrates an algorithm 410 for controlling the now rates of
heated and
cooled water through the heat exchanging coils of an HVAC zone control unit.
The flow
rates of the heated and cooled water can be controlled via controllable valves
and/or via
variable flow rate pumps (e.g., a pump with the highly efficient
electronically commutated
permanent magnet motor (ECM technology)). The algorithm 410 can also be used
to control
the temperatures of the heated and cooled water directed to the distributed
zone control units
based on the heating/cooling requirements of one or more of the distributed
zone control
units.
[0163] FIG. 34 illustrates an algorithm 420 for controlling an HVAC zone
control unit to
reduce energy consumption via the selection of flow rates for the return
airflow and the
supply airflow. A supply airflow enthalpy calculator 422 calculates the
enthalpy of the
supply airflow based on the supply airflow temperature 424 and the supply
airflow
humidity 426. Similarly, a return airflow enthalpy calculator 428 calculates
the enthalpy of
the mixed airflow based on the mixed airflow temperature 430 and the mixed
airflow
humidity 432. The calculated results can be used to select the airflows so as
to minimize
energy usage (e.g., by selecting the lowest energy airflow to maximize when
cooling is called
for and by selecting the highest energy airflow to maximize when heating is
called for).
Enthalpy can be calculated and/or looked up from a table. While enthalpy can
be calculated
from temperature and relative humidity as these quantities may be the least
expensive to
commercially measure, dew point, grains, and wet bulb can also be used. The
algorithm 420
may not be usable when return air space pressurization is in use due to the
lack of mechanism
by which a zone control unit can dump excess air to the outdoors. Such a
dumping of excess
air to the outdoors can instead be accomplished via an exhaust fan(s).
[0164] FIG. 35 shows an HVAC unit 3500 packaged with ancillary components,
including
a thermal transfer mechanism 3510, an inlet piping assembly 3520, an outlet
piping assembly
3530, and an embedded pump mechanism 3540. The thermal transfer mechanism,
piping,
pump, and other ancillary components can 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. In addition, the thermal transfer
unit may be
embedded with the necessary piping, conduit, and the like during a
manufacturing process.
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
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CA 02772766 2012-03-28
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 (e.g., cube AHUs described herein) 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.
[01651 In some instances, thermal transfer mechanism 3510 includes a heat
exchanger coil,
which may be pre-fabricated on the HVAC unit along with the piping and pump.
In some
cases, pump mechanism 3540 includes a variable speed pump. Optionally, pump
mechanism
3540 may include a variable speed water pump having an electronically
commutated motor
(ECM). In operation, one or more water pumps can regulate the rate at which
water is
circulated through inlet piping assembly 3520, outlet piping assembly 3530, or
thermal
transfer mechanism 3510, or any combination thereof. In some cases, HVAC units
can be
constructed with such water pumps such that flow through inlet piping assembly
3520, outlet
piping assembly 3530, or thermal transfer mechanism 3510 is controlled without
the use of
valves such as automatic control valves. Relatedly, HVAC units can be
constructed with
such water pumps in the absence of balancing valves or pressure drops. ECM
motor
embodiments can employ DC (e.g. solar) technology, and in some cases can
operate to vary
the flow into a thermal transfer device from about 0 to about 15+ GPM. In some
instances,
the water pumps may be circular pumps. In some cases, the water pumps may be
operable at
flow rates of 3 gpm, 5 gpm, and the like. Some water pumps may provide
variable flow rates
between about 0 and about 15 gmp, and may be adjustable on a real-time basis.
Some water
pumps may include check valves or on/off actuators. Exemplary HVAC units can
be
manufactured by integrating or embedding pump mechanisms 3540 with inlet
piping
assembly 3520, outlet piping assembly 3530, or thermal transfer mechanism
3510. Hence,
HVAC units can provide fluid communication between pump mechanism 3540 and
inlet
piping assembly 3520, outlet piping assembly 3530, or thermal transfer
mechanism 3510.
Such constructions can eliminate the need for field fabrication of ancillary
components,
controls, and the like. In some cases, pump mechanism 3540 may operate on 0 to
10 volts
and pulse width modulation as controls outputs. A building automation controls
contractor
may wire into the pump 0 to 10 volt signal to control the pump based on sensor
inputs. In
some instances, water pumps can be operable based on input from pressure
sensors located at
selected positions on an HVAC system. Pump mechanism 3540 can provide a
selected flow
rate (e.g. gpm) through inlet piping assembly 3520, outlet piping assembly
3530, or thermal
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CA 02772766 2012-03-28
transfer mechanism 3510, so as to achieve a desirable energy savings or
comfort protocol.
By using ECM technology and tying it to a temperature reset algorithm and/or
sensor(s) on a
controller, the CFM and/or GPM across and into a coil may be varied, which may
provide
dynamic automation control strategies. This may save energy while providing
optimal indoor
air quality.
[0166] Pump mechanism 3540 can operate to add heat to or remove heat from air
circulating through the HVAC unit by routing water through thermal transfer
mechanism
3510, the routed water having a temperature higher or lower than the air
temperature. For
example, a variable rate pump can control a flow rate of water routed through
a heat
exchanging coil. In some cases, airflow through the HVAC unit can be modulated
with a
variable speed fan to control a flow rate of the air. As shown in FIG. 35, at
least a portion of
thermal transfer mechanism 3510 can be disposed or placed within a casing
3550. Similarly,
at least a portion of inlet piping assembly 3520 and at least a portion of
outlet piping
assembly 3530 can be disposed or placed outside of casing 3550.
[0167] FIG. 36 shows an HVAC unit 3600 packaged with ancillary components,
including
a thermal transfer mechanism 3610, an inlet piping assembly 3620, an outlet
piping assembly
3630, and an embedded pump mechanism 3640. The thermal transfer mechanism,
piping,
pump, and other ancillary components can 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. 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.
[0168] In some instances, thermal transfer mechanism 3610 includes a heat
exchanger coil,
which may be pre-fabricated on the HVAC unit along with the piping and pump.
In some
cases, pump mechanism 3640 includes a variable speed pump. Optionally, pump
mechanism
3640 may include a variable speed water pump having an electronically
commutated motor
(ECM). In operation, one or more water pumps can regulate the rate at which
water is
circulated through inlet piping assembly 3620, outlet piping assembly 3630, or
thermal
CA 02772766 2012-03-28
transfer mechanism 3610, or any combination thereof. In some cases, HVAC units
can be
constructed with such water pumps such that flow through inlet piping assembly
3620, outlet
piping assembly 3630, or thermal transfer mechanism 3610 is controlled without
the use of
valves such as automatic control valves. Relatedly, HVAC units can be
constructed with
such water pumps in the absence of balancing valves or pressure drops. ECM
motor
embodiments can employ DC (e.g. solar) technology, and in some cases can
operate to vary
the flow into a thermal transfer device from about 0 to about 15+ gpm. In some
instances, the
water pumps may be circular pumps. In some cases, the water pumps may be
operable at
flow rates of 3 gpm, 5 gpm, and the like. Some water pumps may provide
variable flow rates
between about 0 and about 15 gpm, and may be adjustable on a real-time basis.
Some water
pumps may include check valves or on/off actuators. Exemplary HVAC units can
be
manufactured by integrating or embedding pump mechanisms 3640 with inlet
piping
assembly 3620, outlet piping assembly 3630, or thermal transfer mechanism
3610. Hence,
HVAC units can provide fluid communication between pump mechanism 3640 and
inlet
piping assembly 3620, outlet piping assembly 3630, or thermal transfer
mechanism 3610.
Such constructions can eliminate the need for field fabrication of ancillary
components,
controls, and the like. In some cases, pump mechanism 3640 may operate on 0 to
10 volts
and pulse width modulation as controls outputs. A building automation controls
contractor
may wire into the pump 0 to 10 volt signal to control the pump based on sensor
inputs. In
some instances, water pumps can be operable based on input from pressure
sensors located at
selected positions on an HVAC system. Pump mechanism 3640 can provide a
selected flow
rate (e.g. gpm) through inlet piping assembly 3620, outlet piping assembly
3630, or thermal
transfer mechanism 3610, so as to achieve a desirable energy savings or
comfort protocol.
[01691 Pump mechanism 3640 can operate to add heat to or remove heat from air
circulating through the HVAC unit by routing water through thermal transfer
mechanism
3610, the routed water having a temperature higher or lower than the air
temperature. For
example, a variable rate pump can control a flow rate of water routed through
a heat
exchanging coil. In some cases, airflow through the HVAC unit can be modulated
with a
variable speed fan to control a flow rate of the air. As shown in FIG. 36, at
least a portion of
thermal transfer mechanism 3610 can be disposed or placed within a casing
3650. Similarly,
at least a portion of inlet piping assembly 3620 and at least a portion of
outlet piping
assembly 3630 can be disposed or placed outside of casing 3650.
[01701 Embodiments of the present invention may incorporate aspects of zone
control units
and other HVAC piping or piping and coil assemblies, methods of installing
zone control
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units and other HVAC piping or piping and coil assemblies, methods of
preparing zone
control units and other HVAC piping or piping and coil assemblies for
delivery, methods of
transporting zone control units and other HVAC piping or piping and coil
assemblies,
methods of mounting zone control units and other HVAC piping or piping and
coil
assemblies to surfaces such as HVAC duct surfaces, methods of manufacturing or
fabricating
zone control units and other HVAC piping or piping and coil assemblies,
control systems
which can be used to control zone control units and other HVAC piping or
piping and coil
assemblies, quality control methods for zone control units and other HVAC
piping or piping
and coil assemblies, and bracket or handle configurations which may be used in
conjunction
with or incorporated into zone control units and other HVAC piping or piping
and coil
assemblies, such as those described in U.S. Patent Publication Nos.
2003/0085022,
2003/0085023, 2005/0056752, 2005/0056753, 2006/00 1 1 796, 2006/0130561,
2006/0249589,
2007/0068226, 2007/0108352, 2007/0262162, 2008/0164006, 2008/0307859,
2009/0057499,
and 2010/0252641, the entire disclosures of which are incorporated herein by
reference.
[01711 UNIVERSAL HANDLE BRACKET
[01721 FIGS. 37-41 and 45 Illustrate various handle brackets that may be used
with the
HVAC systems and assemblies described herein. In some embodiment, the brackets
may not
include a handle. For example, the handle brackets may be fitted around one or
more ducts
so that the duct and piping may be mounted to the ceiling and/or walls of a
building. The
handle brackets can be made in multiple configurations, sizes, and of various
materials. They
may be contoured to fit or couple with round duct, rectangular duct, and the
like. The handle
brackets may be configured to protect ancillary equipment/modules when shipped
to a job
site on a transporting platform. The handle brackets may further facilitate
handling and
installation of the HVAC system or assembly at the job site while protecting
the assembled
equipment. The handle bracket may be prefabricated or pre-assembled with one
or more
pieces of equipment and/or component (e.g., piping, ducts, cable trays,
conduit, sprinkler
systems, radios, speakers, wireless hardware, networking, electrical outlets,
lights, air
distribution devices, thermal transfer devices, fans, water heaters, AC/DC
and/or DC/AC
converters, pumps, valves, controls hardware/networking equipment, dampers,
electrical
switch gear, circuit breakers, electrical disconnects and the like) so that
the HVAC assembly
is ready for installation at the job site. In other embodiments, the handle
bracket may be
partially prefabricated or partially assembled with one or more components
referred to above
so that the remainder of the assembly occurs at the job site. Assembly at the
job site may
occur before, during, or after installation. For example, various conduit,
piping, electrical
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CA 02772766 2012-03-28
equipment (e.g., networking, outlets, pumps, and the like) may be coupled with
the handle
bracket after the HVAC system is installed in the building. Additional details
and features of
the handling bracket may be found in U.S. Patent No. 6,951,324, U.S. Patent
No. 7,165,797,
and U.S. Patent No. 7,444,731, the entire disclosures of which are
incorporated herein in their
entirety for all purposes as if set forth herein.
[0173] The piping assembled with the handle bracket may include valves
packages, thermal
transfer devices, controls, and the like. The piping may also include 24- 48
inch long
stainless steel hose kits for connecting vertical pipe and thermal transfer
units as described in
U.S. Patent No. 7,596,962, the entire disclosure of which is incorporated
herein in its entirety
for all purposes as if set forth herein. The handle brackets may include a
variety of mounting
features, such as one or more apertures. The apertures may be made of various
sizes or may
include a certain size, such as 2 '/2 inches in diameter so as to accommodate
1/2" to 2 1/4"
round pipe conduit. To accommodate differing sized conduit, pipes, and/or
other needs, one
or more grommets and/or gaskets may be placed in the apertures. The grommets
may be
made of rubber, plastic, calcium, polycarbonate, and the like. The outside
diameter of the
grommet may be configured to the size of the apertures (e.g., 2'/2 inches),
while the inside
diameter may vary from 1/2" to 2 1/4 inches or larger. The apertures may
likewise include a
variety of shapes such as round, rectangle, octagon, and the like. The
grommets and/or
gaskets may eliminate vibration or the transmission of vibrations in the
handle bracket.
[0174] As described herein, the prefabricated or pre-assembled handle brackets
and piping
may be hung from the ceiling of a building. For example, FIG. 5B illustrates a
side view of a
handle bracket supporting a round duct. The handle bracket is mounted to the
ceiling via one
or more cables and cable fasteners. The cable may be attached around the duct
using a c-
clamp fastener and may be attached to the handle bracket by a cable fastener
that fits into
beveled apertures in the handle bracket as described herein. The cable may be
tightened/fastened within the cable fastener by using a setting pin that
allows the cable to
slide through the cable fastener in a released position and secures the cable
within the cable
fastener in a locked position. An embodiment of features of the handle bracket
that facilitate
attachment is provided in FIGS. 40A-B. The cable and/or cable fasteners may
facilitate
leveling the distribution assembly. The leveled distribution assembly may
allow electrical
conduit, cable trays, and the like to be inserted through the holes/grommets
on the bracket
without requiring these individual components to be leveled. Fire sprinklers
can be run
through the brackets and/or supported by the brackets.
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CA 02772766 2012-03-28
[0175] All or some of the piping could be pressurized at an assembly site
prior to shipping
and could ship with a pressure gauge under pressure to ensure that ensuring no
leaks develop.
The pressure in the various ducts and/or piping could be measured after an
amount of time
(e.g., overnight) to determine if the pressure has dropped. Alternatively or
additionally, the
piping could be pressurized at a job site once the hose kits are connected to
the thermal
transfer devices (e.g., ZCU), thus ensuring no leaks develop after connecting
the components
of the distribution assembly. If leaks are observed, the leaks may be
immediately fixed.
Pressurizing the piping may include making hose connections to a ZCU unit (or
any thermal
transfer unit) and/or any drain piping so that the unit form a closed loop
and/or is sealed. The
piping may then be pressurized and left for an amount of time (e.g., overnight
or longer).
The pressure may then be measured to determine if a leak is present or if the
unit is ready for
installation. Pressurizing the pipes and measuring the pressure after an
amount of time to
check for leaks may save time and/or cost compared to the conventional method
of checking
for leaks, which typically included a tradesman walking around with a
flashlight looking for
leaks.
[0176] Alternatively or additionally, the piping of one or more distribution
assemblies may
be coupled together and the entire length of piping along the coupled
assemblies may be
pressurized and left for an amount of time to determine the presence of any
leaks. For
example, the ends of the pipes of the coupled assembly may be caped (either
shipped this
way or done at the job site) and the pipe may then be pressurized and left
overnight. The
gauges may be checked the next day to determine if the loop is holding
pressure.
[0177] Turning now to FIGS. 37A-B, illustrated is one embodiment of the handle
bracket
500. The handle bracket 500 may include a plurality of mounting features, such
as a
rectangular cutout for a cable tray 504 and a variety of apertures 506 and
512. Apertures 506
may be used to couple one or more electrical conduits with the handle bracket
500, such as
speaker cables or wire 508. Apertures 512 may be used to couple various piping
with the
handle bracket 500, such as inlet and outlet piping used for transferring hot
and cold fluid to
the coils of the ZCU. The apertures 512 may be staggered to facilitate
coupling of the piping
with the bracket. The water piping holes can be located at a lower point in
case of a leak so
that the water does not drip in and/or on the electrical and/or low voltage
components. The
handle bracket 500 may further include a handle 514 and wireless transmitter,
repeater, or
other wireless hardware 510. The handle bracket may also include an air duct
support 502 or
platform upon which the duct rests. The platform 502 may include one or more
apertures 503
that couple with the cable fasteners. The handle bracket may include other
devices such as
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CA 02772766 2012-03-28
cable trays, remote control transmitters, wireless network equipment (e.g.,
transmitters,
repeaters, routers, and the like). Communication could be vertical and through
ceiling tiles
instead of through walls and/or floors which may deaden the signal.
[01781 FIGS. 38A-C illustrate another embodiment of the handle bracket where
the profile
of the handle bracket is shorter and wider than the handle bracket of the
FIGS. 37A-B. In
one embodiment, the brackets of FIGS. 38A-C may be 30 inches wide by 6-8
inches tall.
This embodiment may decrease the space needed for HVAC and other equipment.
FIG. 38A
shows a handle bracket 500A that may include a cutout 504A that may be used
for a cable
tray, a platform 502A to support an air duct, a handle 514A, a plurality of
apertures 512A that
may be used for various piping such as fluid/gas pipes, electrical conduit
apertures 506A, and
other apertures 507 that may be used for other piping such as fire sprinkler
pipes. The
apertures 512A, 506A, and 507 may be inline with each other to reduce the
space required to
couple the various components. Handle bracket 501 may include a cutout 517
that is
couplable with cutout 514A so that bracket 501 may be suspended from bracket
500A,
thereby allowing additional components to be coupled with the distribution
assembly. FIG.
38B illustrates another embodiment of a low profile handle brackets where the
handle
brackets, 500A & 501, have roughly the same configuration as the handle
bracket of FIG.
38A. However, the handle 514A in bracket 500A of FIG. 38B has been positioned
and
coupled to the sides of bracket 500A and bracket 500A includes a wireless
transmitter 510A.
The handless 514A positioned on the side of bracket 500A may protect the
assembly and
assembled components during shipment of the assembly and allow the assemblies
to be
stacked on top of each other and/or on top of a transporting surface. Bracket
501 likewise
includes shipping brackets 521 that protect the assembly during shipping and
allow the
assemblies to be stacked. All or a portion of shipping bracket 521 and/or
handle 514A may
be removed prior to, during, or after installation of the assemblies. FIG. 38C
illustrates
another embodiment of the shipping brackets 521, where the shipping brackets
do not
protrude beyond the bottom of bracket 500A.
[01791 FIGS. 39A-B illustrate another embodiment of a handle bracket 500B
including
many components similar to the other handle brackets, 500 & 500A, such as
platform 502B,
cutout 504B, conduit apertures 506B, piping apertures 512B, and other
apertures 507A.
Bracket 500B may also include one or more additional coupling features 509
that may be
used to couple or attach various conduit or piping to bracket 500B. The
coupling features
509 may include clips, wires, braces, mechanical fasteners, and the like. The
bottom figure
of FIG. 39A and FIG. 39B show different perspective view and configurations of
bracket
CA 02772766 2012-03-28
500B. The brackets and/or bracket extensions described herein may allow field
mounting of
other utilities, equipment, ancillary devices, and/or components on to the
modular building
utilities system (e.g., distribution assemblies).
[01801 FIGS. 40A-B illustrate a top view of bracket 500. Specifically, the
figures illustrate
platform 502 of bracket 500. Platform 502 may be configured to support and
couple with any
shaped and sized duct, for example, the duct may be square, rectangular, oval,
round, and the
like. In one embodiment bracket 500, and therefore platform 502, is 15 inches
wide and is
configured to support and couple with a round duct approximately 6 to 14
inches in diameter.
The platform 502 may include one or more apertures or tabs 522 that may be
used to couple
with an adapter or extension plate for larger ducts as described in FIG. 40B.
The platform
may also include one or more coupling apertures 526 that are configured to
coupling with a
cable fastener, such as the cable fastener illustrated in FIG. 513. In one
embodiment, the
platform 502 includes a plurality of apertures 526 that are beveled and spaced
approximately
2 inches apart from each other. The apertures may include indicia as shown by
element A
that indicate which apertures to use to couple a certain sized duct (e.g.,
indicia 6 on the right
and left side apertures indicates coupling a 6 inch duct). The bottom of the
apertures 526
may be beveled to allow the bottom of the cable fastener (e.g., Gripple
fastener) to lock in
place once the cable is tightened. Once the modular distribution assembly is
attached to the
ceiling platform and leveled, other devices can be attached to the leveled
brackets and/or
bracket extensions thereby saving time since no or minimal leveling is
required. The other
devices or components may be assembled (e.g., snapped) onto the brackets
and/or bracket
extensions without requiring additional support brackets. Between one or more
of the
apertures 526 may be a slot 524 that allows the cable fastener to transition
between apertures
526. The slots 524 may be designed for easy adjustability of the cabling/cable
fastener
without removing the cable from the fastening device. For example, if a
tradesman
inadvertently locates the cable fastener in the wrong aperture 526 (e.g.,
aperture 6) and
tightens the cable, they may raise the assembly and/or release the setting pin
on the cable
fastener to allow slack in the cable so that the cable fastener drops out of
the beveled end of
the aperture 526. The cable may then be transferred/slid through the slot 524
to a new
aperture 526 and the assembly lowered and/or the setting pin locked after the
cable is
tightened. In other words, the slot allows a tradesman to slide the cable
fastener and the cable
over to the next slot/correct slot. FIG. 40B illustrates an extension 530 that
may be used for
larger ducts. The extension 530 may include one or more apertures 522A that
couple with
aperture 522 of platform 502 via one or more fasteners. For example, the
extension 530 may
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CA 02772766 2012-03-28
be positioned atop the platform 502 and secured to platform 502 to provide
extra width to
bracket 500. Extension 530 may include apertures 526A and slots 524A that
function similar
to apertures 526 and slot 524 of platform 502.
[0181] FIG. 41 illustrates another embodiment of a bracket 500C that may be
used to
couple various piping, conduits, cable trays, ducts, sprinkler pipes, other
equipment and/or
components, and the like. Bracket 500C may include a central portion 532 that
is sized to
fully enclose a duct. For example, the central portion 532 may include a 6
inch by 6 inch
cutout to fully enclose a 6 inch round duct. The bracket 500C may also include
a plurality of
apertures 512C that are shaped and sized to couple with various piping,
conduit, and the like,
such as those described herein. The bracket may further include one or more
cutouts 504C
that may be used to couple with one or more cable trays. The bracket may be
coupled with a
ceiling of a building via one or more cable fasteners 528, such as those
described herein.
Fasteners, such as cable fastener 528, may also couple the bracket 500C with
one or more
additional components, such as an additional supporting brackets 534 and or
other
components such as lighting cables (not shown), lighting fixtures (not shown),
frame work
for a drop/suspended ceiling (not shown), fire sprinkler system (not shown),
ceiling fans (not
shown), speaker system (not shown), and the like. For example, bracket 500C
may be
coupled with one or more additional supporting brackets 534 that include
additional
coupling/supporting features 538 that may be used to couple and/or support
various piping
536, conduit, and/or equipment or components. In addition, bracket 500C may
also include
additional coupling features 535 that allow other components to be coupled
directly with
bracket 500C.
[0182] FIG. 45 illustrates another embodiment of a bracket 500 that includes
an angled
bottom portion 570 that extension substantially perpendicular to the bracket
500 and that may
be used to couple additional components, such as additional piping, conduits,
lighting
fixtures, fire sprinklers, and the like. The bottom portion 570 may include
one or more holes
through which one or more fasteners 572 may be coupled. The fasteners 572 may
be coupled
directly with the bottom portion 570 or hang therefrom (shown by the dashed
lines). The
fasteners 572 may be coupled with additional components 578, such as fire
sprinklers,
lighting fixtures, drop ceiling fixtures, and the like. In this manner,
virtually every
component that is suspended from a building's ceiling may be supported by the
bracket. The
bracket 500 may also include a handle portion 576 that facilitates handling of
the bracket
and/or coupling of other brackets. For example, cutouts portions of other
brackets may be
hung or suspended from the extension of handle portion 576.
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[0183] MANUFACTURING JIG
[0184] FIGS. 42A-B illustrate a jig 600 that may facilitate in manufacturing,
transportation, and/or installation of the distribution assemblies 602. The
jig 600 may be
coupled with a platform 610 such as in an assembly line at an assembly site or
a platform at
an installation site that is raised and lowered to raise and lower the
distribution assembly 602
during installation. The jig 600 may also be coupled with a handle bracket 606
of the
distribution assembly 602. The jig 600 may be spaced 10 feet about on the
platform so that
every handle bracket 606 is coupled with a jig 600. As described herein, a
duct 604 may sit
atop and be assembled with bracket 606. A plurality of pipes, conduits, and/or
cable trays
608 may also be assembled with the bracket 606. The jigs 600 may facilitate in
aligning the
mounting features of the brackets (e.g., the apertures, cutouts, and the
like). Likewise, the
jigs 600 may assure all the pipe and accessories are aligned when the modules
are secured to
the ceiling.
[0185] In an assembly operation at an assembly site, the bracket 606 may be
inserted into
the jigs 600 with a handle side down. The pipes, conduit, fire sprinklers,
valves packages,
hose kits, and the like may then be assembled with the brackets and
subsequently insulated,
pressurized, sealed, leak checked, checked for wiring continuity, and the
like. The duct 604,
which may be pre-insulated with transitions, taps, and the like, may then be
positioned on the
brackets and center justified. For high speed production a spiral duct machine
and copper
coil feeders may be set up in parallel manufacture long runs. The piping 608
may be fed
through the brackets 606 as the spiral machine positions the duct 604 atop the
brackets 606
and/or insulates the duct. The assembly area can be as long as needed to allow
rough dry
fitting of the distribution assemblies 602. The assemblies 602 may then be
tagged, wrapped
in plastic and lifted out of the jigs 600 by handles of the bracket 606 or in
some other way. If
the bracket 606 has handles, the handles may be exposed outside of the
wrapping. In some
embodiments, the jigs 600 may ship to an installation site with and support
the assemblies
602. In other embodiments, the assemblies 602 are lifted out of the jigs 600
and transported
to a transportation surface for shipment to the installation site. FIG. 42B
illustrates different
view of the jig 600 and shows the bracket 606 being removed from the jig. The
manufacturing jig may save time since no leveling or minimal leveling and
individual support
of component installed in field.
[0186] FIELD ERECTED HOUSING
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[0187] FIGS. 43A-B illustrate an embodiment 700 where the distribution
assemblies 702
may be used in field erected housing, or in other words, temporary housing
that may be at
least partially constructed at an assembly site or prefabrication facility and
quickly assembled
at a work site or field location. Such an embodiment may be ideal for military
or work
operations where multiple houses are quickly erected (e.g., Federal Emergency
Management
Agency (FEMA) work sites). For example, the distribution assembly 702 can be
coupled
with the ceiling of a portable house and have any or a variety of desired
components (e.g.,
piping, conduits, cable trays, lighting, and the like) prefabricated/pre-
assembled so that the
roof is snapped into place and all the utilities snap into place with desired
connections in
place for power, HVAC, sensors, and a web based wireless controller controls
desired
components through prefabricated sensors/transmitters. In one embodiment, the
distribution
assembly 702 may be a modular building utilities system with part of the
ceiling structure of
the portable housing unit. The entire modular setup of a field erected housing
unit could be
prefabricated at an assembly site for subsequent installation at a field site.
The field housing
units and/or distribution assembly 702 may be pretested and shipped to field
sites (e.g.,
combat zones) substantially defect free.
[0188] FIG. 43B illustrates a schematic plan view of a field erected housing
unit. The plan
view show a plurality of housing units 720 arranged according to a plan and
coupled with one
or more main electricaUdata conduit 734 and other piping 736 (e.g., water or
gas for heating
and cooling). The electrical/data conduit 734 may be connected to a generator
or fuel cell
732 that provides power the housing units (e.g., a diesel generator, hydrogen
cell, and the
like) or may be connected to a network that provides data and/or other
communication. Each
housing unit 720 may include a quick electrical connection to connect to the
electricaUdata
conduit 734. The piping 736 may be connected to a water source and/or heat
source 730
(e.g., a heat pump configured to cool water or heat it). For example, the
water and/or heat
source 730 may be a water line, heat pump, boiler, gas line, and the like. A
closed loop water
distribution system (or gas/DX), such as fire hoses, could hook up to each
housing module
via the piping 736, which could supply hot and/or cold water to a thermal
transfer unit/coil
(704 of FIG. 43A). A bracket 740 may connect the piping 736 and/or
electrical/data conduit
734 to the distribution assemblies 702 within one or more of the housing units
720. One or
more or all of the components of the field erected housing may be
prefabricated at an
assembly site and shipped to the field site for easy installation.
[0189] FIG. 43A illustrates an embodiment of an individual housing unit 720
having a
distribution assembly 702 therein. The housing unit 720 may be prefabricated
or fabricated
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at the field site using a duct 722, which may be round, flexible, sheet metal,
pvc, and the like.
The duct 722 may be about 2- 6 inches in diameter and traverse the length of
the house. The
duct 722 may be coupled with a thermal transfer unit/coil 704 to provide
heating and cooling
for the housing unit 720. In one embodiment, the thermal transfer unit/coil
704 may be
positioned within the duct 722. In other embodiments, the thermal housing
unit/coil 704 is
positioned exterior to and adjacent the duct 722. The duct 722 may also be
operatively
coupled with a fan 706, such as a fan with an ecm motor, which may operate on
low energy
and can vary the flow. The fan 706 may be disposed within the duct 722. The
distribution
assembly 702 may also be coupled with a small pump with an ecm motor (not
shown), an
electrical/data conduit 726, piping 724, lighting fixtures 716, a panel 718,
dampers 708 &
710, a condensate collection unit 714, and the like.
[01901 The housing unit 720 may include one or more outlets (not shown) that
are
connected with the electrical/data conduit 726 to provide power and/or
communication within
the housing unit 720. The housing unit 720 may also include hot and cold water
faucets (not
shown) for showers and the like. The lighting fixtures 716 may be led lights,
for example,
the lighting fixtures 716 may include 1 - 2 foot flexible snakes with 2" x 2"
LED lights
attached to the snake or along the snake. The occupants would be able to move
the light to
wherever light is needed, thus reducing the overall demand for light within
the housing unit
720. Other lighting fixtures may be used as well. The use of LED lights and an
ecm motor
may allow the housing unit 720 to be run on DC current and/or off solar power
due to the low
voltage requirements of led lights and the ecm motor.
[01911 The panel 718 may be include wireless sensors and/or controls (e.g.,
infrared, temp
sensor, motion sensor, and the like) and a touch screen wireless control
panel. The room
sensors and panel 718 may shut down the lights and/or adjust the lighting
levels based on the
ambient light levels and/or whether the housing units 720 are occupied.
Likewise, the
sensors and panel 718 may adjust the HVAC setting depending on the occupancy
level within
the housing unit 720 and/or the climate settings input by an occupant. The
panel 718 may
allow climate settings to be overridden locally or from a central command and
may allow
monitoring of the KHW levels, light lumens, water usage, and the like. A
central command
could monitor energy usage and implement a global energy strategy based on
fuel supplies,
water supplies, and the like.
[01921 The condensate collection unit 714 may be coupled with thermal transfer
unit/coil
704 and configured to collect condensate water/liquid rung out from the
ambient air from the
thermal transfer unit/coil 704. The collected condensate may be converted to
drinking water,
CA 02772766 2012-03-28
potable water, and the like. Likewise, the condensate collected could be
routed to and
collected in a reservoir for the housing unit 720 or the entire field erected
housing project.
[0193] The thermal transfer unit/coil 704 could include air devices that allow
recirculation
of the air within each housing unit 720. This may keep the air moving to avoid
stagnation
keeping the occupants (e.g., soldiers) energized. Likewise, the air system
(e.g., thermal
transfer unit, air devices, and the like) could include one or more air
freshners that keep the
housing units 720 smelling fresh. The duct 722 could include dampers, 708 &
710, which
may allow for a small flexible duct (e.g., a fabric duct - air moving though
blows it up like a
balloon) to be attached. In addition, each occupant could have their own duct
(not shown) to
cool their area.
[0194] DISTRIBUTION ASSEMBLY ENCLOSURE
[0195] FIG. 44 illustrates a distribution assembly 770 including an enclosure
762 or
security cage positioned around the exterior of the distribution assembly 770.
The security
cage or enclosure 762 may be coupled with the distribution assembly 770 to
protect the
components of the distribution assembly (e.g., the brackets, duct, piping,
conduit, cable trays,
fire sprinklers, lighting components, and the like). Further, the enclosure
762 may be tamper
proof to protect the components from unauthorized access. The enclosure 762
may be
prefabricated/pre-assembled around the distribution assembly or assembled with
the
distribution assembly 762 at an installation site prior to or after
installation. The enclosure
762 may include a plurality of crisscrossing bar that may be fabricates of
wire, Kevlar,
polycarbonate, steel, stainless steel, and the like. The enclosure 762 may
further include
access hatches (not shown) that may be locked to allow only authorized
individuals to access
the assembled components.
[0196] CUBE AHU UNIT
[0197] FIGS. 46A-D illustrate a fan section 4600 that can be used with supply
air section
14 and/or exhaust air section 16 of FIG. 1. The fan section 4600 may be
coupled with a
vertically-oriented distribution assembly to supply to and/or exhaust air from
the
horizontally-oriented distribution assemblies. The fan section 4600 may be
enclosed within a
protective cage as shown in FIG. 46D. The fan section 4600 may also include
one or more
dampers 4602 and/or thermal transfer coils that may function to heat or cool
air introduce
into the fan section 4600. A fan 4604 may be centrally located in the
protective cage. The
fan section 4600 may re-circulate air within the building and/or supply air
from or exhaust air
to the outside environment.
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[01981 MODULAR BUILDING UTILITIES SYSTEMS AND ASSEMBLIES
[01991 FIG. 47 illustrates a modular building utilities system 4700 for
installation in a
building 4703. The modular building utilities system 4700 may include a first
assembly 4702
having a first duct 4710 for transporting air, a first bracket 4716 coupled
with the first duct, a
first inlet piping 4712 coupled with first bracket and disposed exterior to
the first duct, a first
outlet piping 4714 coupled with the first bracket and disposed exterior to the
first duct, and a
first adjustable fastening mechanism 4718 coupled with the first bracket for
adjustably
coupling the first bracket with the building 4703. The modular system 4700 may
also include
a second assembly 4704 having a second duct 4720 for transporting air, a
second bracket
4726 coupled with the second duct, a second inlet piping 4722 coupled with
second bracket
and disposed exterior to the second duct, a second outlet piping 4724 coupled
with the second
bracket and disposed exterior to the second duct, and a second adjustable
fastening
mechanism 4728 coupled with the second bracket for adjustably coupling the
second bracket
with the building. The first bracket 4716 and/or second bracket 4726 may be
coupled with a
bracket extension 4717, such as the bracket extension of FIG. 41, that allows
for additional
components (e.g., fire, lights, sprinklers, security, and the like), piping,
ancillary devices, and
the like to be prefabricated/pre-assembled with the first and/or second
modular assembly
and/or fabricated/assembled onto the modular assembly at a construction after
the assembly
has been installed in a building.
[02001 The first assembly 4702 and second assembly 4704 may include
standardized pipes
and/or duct sizes. For example, the first duct 4710 of the first assembly 4702
may be the
same size and cross section as the second duct 4720 of the second assembly
4704. Likewise,
the first inlet piping 4712 and first outlet piping 4714 may be the same size
and cross section
as the second inlet piping 4722 and second outlet piping 4724.
[02011 In some embodiments, the first bracket 4716 maintains the first inlet
piping 4712,
the first outlet piping 4714, and the first duct 4710 in a first positional
relationship. Likewise,
the second bracket 4726 maintains the second inlet piping 4722, the second
outlet piping
4724, and the second duct 4720 in a second positional relationship. The first
and second
positional relationships may provide alignment between the first and second
ducts, 4710 and
4720, the first and second inlet piping 4712 and 4714, and the first and
second outlet piping
4714 and 4724, to facilitate coupling of the first and second ducts, the first
and second inlet
piping, and the first and second outlet piping. For example, the first
positional relationship
and. the second positional relationship may axially align the first duct 4710,
the first inlet
piping 4712, and the first outlet piping 4714 with second duct 4720, the
second inlet piping
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4722, and the second outlet piping 4724 as shown by the dashed lines between
the
assemblies. The first and/or second bracket may include a cable tray that is
configured to
support one or more electrical wires or cables as described herein. Likewise,
the first and/or
second bracket may include a wireless transmitter and/or wireless repeater.
Similarly, the
first assembly and/or the second assembly may include an enclosure disposed
the respective
assembly to protect the assembly. The enclosure may be similar to that
protective cage
described in FIG. 44. Likewise, the first and second brackets, 4716 and 4726,
and/or the
bracket extensions 4717 may maintain the other components, devices, and the
like described
herein (e.g., sprinklers, plumbing, etc.) in the first positional relationship
and second
positional relationship to facilitate assembling of the additional components,
device, and the
like.
[02021 FIG. 48 illustrates another embodiment of a modular system. The modular
system
may include a first assembly 4702 having a first duct 4710, a first bracket
4716, a first inlet
piping 4712, a first outlet piping 4714, and a first adjustable fastening
mechanism 4718
similar to the modular assembly of FIG. 47. The first assembly 4702 may be
coupled with a
zone control unit (ZCU) 4730 configured to provide HVAC to one or more zones
of a
building. The first duct 4710 may include a discharge port 4710 configured to
supply a
portion of the air to the ZCU 4730. The first inlet piping 4712 and first
outlet piping 4714
may be coupled with a coil 4734 of the ZCU 4730 so as to provide fluid
communication (e.g.,
liquid, gas, chemical) between the coil and the first inlet piping and first
outlet piping. The
coil may be a heat exchanger and the first inlet piping 4712 may supply a
fluid, such as water
or a refrigerant, to the coil 4732 to heat or cool a volume of air passed
through the coil. The
first outlet piping 4714 may receive the fluid from the coil 4732 after the
volume of air has
been heated or cooled. The coil 4732 may have a series of tubes 4734 and fins
that facilitate
in heating or cooling the volume of air. The first assembly 4702 may also
include a first
drain pan 4740 coupled with the first bracket 4716 and extending along the
first modular
assembly 4702 (alternatively, element 4740 may represent other components
(cable, conduit,
process gas piping, lighting fixtures, and the like) that may be coupled with
the assembly).
The first assembly may also include a condensate water pump through pipe. The
first drain
pan may be configured to collect condensate, such as water, that drips from
the modular
assembly. The drain pan may be for backup purposes in case a fluid leak
develops. This may
be useful in critical area, such as data centers. Although not shown, the
second assembly
may also include a second drain pan. The first and second brackets may provide
alignment
between the first and second drain pans so that the drain pans may be coupled
together to
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form a continuous drain pan along which the condensate may be transported. The
continuous
drain pan may be coupled with a condensate reclamation system. The modular
system 4700
may replace conventional HVAC systems and conventional electrical systems
because some
or all of these components can be coupled with the modular system 4700.
Further the ducts
could be spread out offering better air entrainment and indoor air quality and
also providing
the main electrical distribution system from which lights could be installed
and/or electrical
conduit run off. The ZCU 4730 may also include a bracket 4735 and/or bracket
extension
(not shown) that is configured to couple with a pipe 4741, conduit, cable
tray, component,
device, and the like described herein. The bracket 4735 and/or bracket
extension may
maintain the pipe 4735, conduit, and the like in a positional relationship to
facilitate coupling
the pipe 4735 or other component with a respective pipe 4740 or other
component of the first
assembly 4710.
[0203] The modular building utilities system may include some, a majority, or
all building
utilities such as data, conduit, controls, fire, plumbing, HVAC, low voltage
and line voltage,
DC and AC current, and the like. The modular building utilities system may
reduces 50% or
more of the construction field labor of multiple trades such as electrical,
controls, plumbing,
piping, insulation, HVAC, and the like. Further it may speed up the
construction of the
building, offer standardization, and/or offer one front end building
automation system (BAS)
integration platform (lights, fire, security, fire, data etc). The modular
building utilities
system may be the glue which binds all the utilities in the building together;
it may be the
smart grid inside the building. The thermal transfer medium within the pipes
may be a gas
such as refrigerant, or a liquid such as water and the like.
[0204] MODULAR SYSTEMS AND ASSEMBLIES METHODS
[0205] FIG. 49 illustrates a method 4900 of assembling a modular assembly at
an assembly
site for transportation to an installation site. The modular assembly may be
configured
similar to the modular assembly of FIG. 47-48. At block 4905, a first modular
assembly
having a first end and a second end may be obtained. The first duct may be
configured to
transport air between the first end and the second end. At block 4901, a first
inlet piping
having a first end and a second end may be obtained. The first inlet piping
may be
configured to transport a fluid between the first end and the second end. At
block 4915, a
first outlet piping having a first end and a second end may be obtained. The
first outlet
piping may be configured to transport a fluid between the first end and the
second end. At
block 4920, a first bracket having a plurality of mounting features and a
first adjustable
fastening mechanism for adjustably coupling the first bracket with the
building may be
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obtained. At block 4925, a second bracket having a plurality of mounting
features and a
second adjustable fastening mechanism for adjustably coupling the second
bracket with the
building may be obtained. The first and/or second brackets may include a
handle configured
to maneuver the bracket. The brackets may be configured to maintain support
for the
assembly components while the bracket is maneuvered by the handle. At block
4930, a cable
tray configured to support one or more electrical cables may be obtained.
[0206] At block 4935, the first bracket may be coupled via one or more of the
plurality of
mounting features with the first end of the first duct, the first inlet
piping, the first outlet
piping, and/or the cable tray. The first inlet piping, the first outlet
piping, and/or the cable
tray may be disposed exterior to the first duct and the first bracket may
maintain the first end
of the first duct, the first inlet piping, the first outlet piping, and/or the
cable tray in a first
positional relationship. At block 4940 the second bracket may be coupled via
one or more of
the plurality of mounting features with the second end of the first duct, the
first inlet piping,
the first outlet piping, and/or the cable tray. The second bracket may
maintain the second end
of the first duct, the first inlet piping, the first outlet piping, and/or the
cable tray in the first
positional relationship. In some embodiments, one or more of the first duct,
the first inlet
piping, the first outlet piping, and the cable tray may be coupled with the
modular assembly
after the modular assembly is installed in a building.
[0207] At block 4945, the first and second ends of the first duct, the first
inlet piping,
and/or the first outlet piping may be sealed. At block 4950, the sealed first
duct, first inlet
piping, and/or first outlet piping may be pressurized to a predetermined
pressure. At block
4955, the pressure in the pressurized first duct, first inlet piping, and/or
first outlet piping may
be measured after an amount of time to determine whether the sealed and
pressurized first
duct, first inlet piping, and/or first outlet piping is holding pressure. The
amount of time may
include overnight, several days, and/or transport to an installation site. At
block 4960, the
modular assembly may be transported from the assembly site to the installation
site.
Measuring the pressure as in block 4955 may be performed at the installation
site while
pressurizing the piping and/or duct may be performed at the assembly site. At
block 4965,
the modular assembly may be assembly in a building. Additional piping and/or
components
may be coupled with the modular assembly after installing the assembly in the
building. For
example, a drain pan may be coupled with the first and second brackets so that
the drain pan
extends along the length of the modular assembly. The drain pan may be
configured to
collect condensate and (e.g., water) transport the condensate along the length
of the modular
assembly. Other components that may be added after installation include:
electrical outlets,
CA 02772766 2012-03-28
lights, air distribution devices, thermal transfer devices, fans, pumps,
valves, controls
hardware/networking equipment, dampers, electrical switch gear, circuit
breakers, electrical
disconnects, and the like. Alternatively, some, a majority, or all these
components could be
prefabricated/pre-assembled onto the first and/or second assemblies at an
assembly site.
[0208] At block 4970, the modular assembly may be coupled with a zone control
unit
(ZCU) configured to provide HVAC to one or more zones of the building. For
example, the
first duct may be coupled with the ZCU to provide a portion of the air to the
ZCU and the
first inlet piping and first outlet piping may be coupled with a coil of the
ZCU to supply a
fluid (e.g., heat exchange fluid) and receive the fluid from the coil.
[0209] FIG. 50 illustrates a method 5000 of installing a modular system. At
block 5005, a
first modular assembly may be obtained. The first modular assembly may have a
first duct
for transporting air, a first bracket coupled with the first duct, a first
inlet piping coupled with
the first bracket and disposed exterior to the first duct, a first outlet
piping coupled with the
first bracket and disposed exterior to the first duct, and a first adjustable
fastening mechanism
coupled with the first bracket for adjustably coupling the first bracket with
the building. At
block 5010, the first modular assembly may be secured to the building via the
first adjustable
fastening mechanism and the first modular assembly may be leveled so that
opposing ends of
the first modular assembly are substantially level (e.g., substantially
horizontal). At block
5015, a second modular assembly may be obtained. The second modular assembly
may have
a second duct for transporting air, a second bracket coupled with the second
duct, a second
inlet piping coupled with the second bracket and disposed exterior to the
second duct, a
second outlet piping coupled with the second bracket and disposed exterior to
the second
duct, and a second adjustable fastening mechanism coupled with the second
bracket for
adjustably coupling the second bracket with the building. At block 5020, the
second modular
assembly may be secured to the building via the second adjustable fastening
mechanism and
the second modular assembly may be leveled so that opposing ends of the second
modular
assembly are substantially level.
[0210] At block 5025, first modular assembly may be coupled with the second
modular
assembly in a fluid tight relationship to provide air transportation along the
combined length
of the coupled first and second ducts and to provide fluid transportation
along the combined
length of the first and second inlet piping and first and second outlet
piping. At block 5030, a
cable tray may be obtained. The cable tray may be configured to support one or
more
electrical cables. At block 5035, the cable tray may be coupled with the first
bracket and/or
second bracket so that the cable tray extends along the length of the first
modular assembly
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CA 02772766 2012-03-28
and/or second modular assembly. Electrical cables may then be positioned in
the cable tray
to provide electrical communication to one or more zones of the building. The
first modular
assembly and the second modular assembly may each include drain pan that
extends along
the length of the respective modular assembly. At block 5040, the drain pan of
the first
modular assembly may be coupled with the drain pan of the second modular
assembly to
form a substantially continuous drain pan that extends along the length of the
coupled
assemblies. The drain pans may be configured to collect condensate from the
first and/or
second assemblies and transport the condensate to a condensate reclamation
system.
[02111 At block 5045, a third modular assembly may be obtained. The third
modular
assembly may have a third duct for transporting air, a third bracket coupled
with the third
duct, a third inlet piping coupled with the third bracket and disposed
exterior to the third duct,
a third outlet piping coupled with the third bracket and disposed exterior to
the third duct, and
a third adjustable fastening mechanism coupled with the third bracket for
adjustably coupling
the third bracket with the building. At block 5050, the third modular assembly
may be
secured to the building so that the third modular assembly comprises a
substantially
perpendicular orientation with respect to the first modular assembly. At block
5055, the third
modular assembly may be coupled with the first modular assembly to provide
fluid
communication between the first and third ducts, first and third inlet piping,
and first and
third outlet piping. At block 5060, additional piping, conduit (e.g.,
electrical conduit), and/or
components may be coupled with the first, second, and/or third assemblies.
[02121 FIG. 51 illustrates a method 5100 of installing a modular building
utilities system in
a building. At block 5105, a first modular assembly may be assembled at an
assembly site.
The first modular assembly may include a first duct for transporting air, a
first bracket
coupled with the first duct, a first inlet piping coupled with the first
bracket and disposed
exterior to the first duct, a first outlet piping coupled with the first
bracket and disposed
exterior to the first duct, and a first adjustable fastening mechanism coupled
with the first
bracket for adjustably coupling the first bracket with the building. At block
5110, a second
modular assembly may be assembled at an assembly site. The assembly site may
be the same
assembly site for the first modular assembly or a different assembly site. The
second
modular assembly may also include a second duct for transporting air, a second
bracket
coupled with the second duct, a second inlet piping coupled with the second
bracket and
disposed exterior to the second duct, a second outlet piping coupled with the
second bracket
and disposed exterior to the second duct, and a second adjustable fastening
mechanism
coupled with the second bracket for adjustably coupling the second bracket
with the building.
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[02131 At block 5115, the first modular assembly and the second modular
assembly may be
transported to an installation site. At block 5020, the first modular assembly
may be installed
in the building. At block 5025, the second modular assembly may be installed
in the
building. At block 5030, the first modular assembly may be coupled with the
second
modular assembly. For example, the first and second ducts, the first and
second inlet piping,
and the first and second outlet piping may be coupled so as to provide fluid
communication
between the first and second ducts, the first and second inlet piping, and the
first and second
outlet piping.
[02141 FIG. 52 illustrates a method 5200 of installing a modular building
utilities system in
a building. At block 5205a, a first modular assembly may be obtained. The
first modular
assembly may include one or more ducts, inlet piping, outlet piping, cable
trays, electrical
conduit, sprinkler, speakers, controls, plumbing piping, lighting fixtures,
lights, data cables
and/or components, network cable and/or components, drain pans, drain pipe,
pumps, fans,
and the like. The first modular assembly may maintain one or more of these
components in a
first positional relationship. At block 5205b, a second modular assembly may
be obtained.
The second modular assembly may include the same or similar components to the
first
modular assembly and may maintain one or more of these components in a second
positional
relationship.
[02151 At block5210a the first modular assembly maybe secured to the building
(e.g.,
ceiling) via a first adjustable fastening mechanism. At block 5210b the second
modular
assembly may be secured to the building (e.g., ceiling) via a second
adjustable fastening
mechanism. At block 5215a, the first modular assembly may be leveled so that
opposing
ends of the first modular assembly are substantially level. At block 5215b,
the second
modular assembly may be leveled so that opposing ends of the second modular
assembly are
substantially level. Optionally, after the first and/or second modular
assemblies are secured
to the building and/or leveled, additional components, piping, ancillary
devices, and the like
may be fabricated onto the first and/or second modular assemblies. Fabricating
such
components, piping, devices, and the like may be quick and easy since leveling
is not
required or is minimally required. At block 5220, the first modular assembly
may be coupled
with the second modular assembly. Coupling the assemblies may be facilitated
by the first
and second positional relationships of the components.
[02161 FIG. 53 illustrates an exemplary zone control unit (ZCU) 5300 according
to
embodiments of the present invention. As shown here, ZCU 5300 can include an
outside air
mechanism 5310, a return air mechanism 5320, an outside air filter mechanism
5312, a return
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air filter mechanism 5322, a fan mechanism 5330, and one or more damper
mechanisms
5340. ZCU 5300 may also include or be operatively associated with one or more
thermal
transfer units 5350a, 5350b, 5350c, and 5350d. A thermal transfer unit may be
prepiped with
valves and pumps, and may be shipped in a pressurized state. Hence,
embodiments of the
present invention encompass any of a variety of ZCU configurations which may
use a fan
powered box or mechanism, optionally in association with a multiple outlet
damper plenum
assembly.
[0217] Other variations are within the spirit of the present invention. Thus,
while the
invention is susceptible to various modifications and alternative
constructions, certain
illustrated embodiments thereof are shown in the drawings and have been
described above in
detail. It should be understood, however, that there is no intention to limit
the invention to
the specific form or forms disclosed, but on the contrary, the intention is to
cover all
modifications, alternative constructions, and equivalents falling within the
spirit and scope of
the invention, as defined in the appended claims.
[0218] The use of the terms "a" and "an" and "the" and similar referents in
the context of
describing the invention (especially in the context of the following claims)
are to be
construed to cover both the singular and the plural, unless otherwise
indicated herein or
clearly contradicted by context. The terms "comprising," "having,"
"including," and
"containing" are to be construed as open-ended terms (i.e., meaning
"including, but not
limited to,") unless otherwise noted. The term "connected" is to be construed
as partly or
wholly contained within, attached to, or joined together, even if there is
something
intervening. Recitation of ranges of values herein are merely intended to
serve as a shorthand
method of referring individually to each separate value falling within the
range, unless
otherwise indicated herein, and each separate value is incorporated into the
specification as if
it were individually recited herein. All methods described herein can be
performed in any
suitable order unless otherwise indicated herein or otherwise clearly
contradicted by context.
The use of any and all examples, or exemplary language (e.g., "such as")
provided herein, is
intended merely to better illuminate embodiments of the invention and does not
pose a
limitation on the scope of the invention unless otherwise claimed. No language
in the
specification should be construed as indicating any non-claimed element as
essential to the
practice of the invention.
[0219] Preferred embodiments of this invention are described herein, including
the best
mode known to the inventors for carrying out the invention. Variations of
those preferred
embodiments may become apparent to those of ordinary skill in the art upon
reading the
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foregoing description. The inventors expect skilled artisans to employ such
variations as
appropriate, and the inventors intend for the invention to be practiced
otherwise than as
specifically described herein. Accordingly, this invention includes all
modifications and
equivalents of the subject matter recited in the claims appended hereto as
permitted by
applicable law. Moreover, any combination of the above-described elements in
all possible
variations thereof is encompassed by the invention unless otherwise indicated
herein or
otherwise clearly contradicted by context.
[0220] All references, including publications, patent applications, and
patents, cited herein
are hereby incorporated by reference to the same extent as if each reference
were individually
and specifically indicated to be incorporated by reference and were set forth
in its entirety
herein.
