Abstract: An air handler (or air handler section) includes an enclosure containing various internal HVAC components and a bi-directional alignment system that during factor assembly of the enclosure helps align the enclosure's entire roof to the internal components. To help align the roof in a widthwise direction, a tapered lead-in edge in the upper corners of a block-off panel for an evaporator, filter rack, damper, fan and/or other HVAC component engages a roof rail that runs along the length of the roof. The upper corners of the block-offs also include a landing edge that engages the underside of the roof rail to help support the weight of the roof. Cross rails attached to the underside of the roof and extending along the width of the enclosure include an inclined lead-in flange that engages the upper edge of the various internal HVAC components, thereby helping align the roof in a lengthwise direction.

Abstract: A refrigerant system includes a compressor with a discharge valve that temporarily restricts the compressor's outflow at startup so that the discharge pressure can quickly rise to force lubricant back to the compressor. The discharge valve also helps prevent an axial face of a rotor of a screw compressor from rubbing against a bearing housing axial face of the compressor's housing. When the system turns off under certain low ambient air temperature conditions, the valve closes to help prevent the system's evaporator from freezing up. The discharge valve includes a novel arrangement of a piston, a valve stem extending from the piston, and a valve plug pivotally attached to the valve stem. The pivotal connection ensures a positive seal between the valve plug and a valve seat. A somewhat restricted fluid passageway between the valve's discharge chamber and piston chamber helps prevent the valve from chattering as the valve opens.

Abstract: A plenum fan comprising a fan wheel disposed within a box-like enclosure includes a secondary inlet cone, a primary inlet cone, and a flexible duct. The two inlet cones convey air to the mouth of the fan wheel. A frame supports the fan wheel and the primary inlet cone such that the frame, the fan wheel and the primary inlet cone comprise a fan assembly. If the fan assembly shifts due to fan thrust or vibration, the fan assembly moves as a unit. The flexible duct connects the primary inlet cone to an inlet of the enclosure while isolating the fan assembly's vibration from the enclosure. The secondary inlet cone extends from the inlet of the enclosure, protrudes into or toward the primary inlet cone and provides a smooth airflow path over the abrupt shape of the flexible duct.

Abstract: A flow device for a refrigerant/compressor system is installed between the outlet of an evaporator and the suction port of a compressor. The device includes a floating element that helps inhibit liquid refrigerant from entering the compressor. Under certain conditions where liquid refrigerant discharges from the evaporator, the floating element floats in the discharged liquid. Upon doing so, the float rises to a generally closed position where the float obstructs a main fluid outlet that leads to the compressor. In the closed position, refrigerant can still pass through the flow device, but through a more restricted outlet. To prevent the float from undesirably rising under the impetus of refrigerant vapor flowing at high flow rates, the floating element itself includes a flow-restricting passageway, radial guides, and/or a streamlined shape. The float can be incorporated within a manifold of a multi-coil or multi-circuited heat exchanger.

Abstract: A refrigerant system includes a dual-connection drain pan for collecting and draining condensate from the exterior surface of a cooling coil. The drain pan includes a first channel and a second channel disposed alongside each other and sloped lengthwise in opposite directions to direct the condensate to either one of two drain outlets at opposite ends of the pan. To drain the condensate to a first outlet, a breakaway removable dam between the two channels is left intact to isolate the second channel from condensate so that the condensate drains from the first channel to the first outlet. Permanently removing the breakaway dam and plugging the first outlet allows condensate to drain from the first channel, into the second channel, and out through the second outlet. In some embodiments, the drain pan, including the two channels and breakaway dam, is formed of a unitary piece of a thermoset polymer.

Abstract: A reversible HVAC heating/cooling refrigerant system includes a novel valve system that allows an outdoor heat exchanger to function as a subcooler during a cooling or defrost mode and function as a receiver tank for storing excess liquid refrigerant during a heating mode. In the heating mode, a cooling expansion valve is kept slightly open to flood the subcooler with liquid refrigerant while a heating expansion valve is regulated to maintain a desired level of superheat at the suction side of the refrigerant system's compressor. The novel valve system also serves as a pressure relief valve to protect the subcooler from excess pressure caused by thermal expansion of liquid refrigerant trapped within the subcooler.

Abstract: A test setup for a permanent magnet motor provides a method for identifying symmetry or asymmetry in the magnetic fields of the motor's permanent magnets. The setup comprises a test circuit that includes a fixed reference node that provides a stable reference to which the motor's common node can be compared. Observing the waveform of the voltage between the two nodes while the motor is running helps identify an imbalance in the magnetic fields of the motor's permanent magnets.

Abstract: A method of controlling a refrigerant chiller system is particularly suited for chillers where the water being chilled (or some other liquid) flows through the chiller's evaporator at a flow rate that is variable and is not directly known. To effectively control the chiller and maintain the temperature of the water leaving the evaporator at a desired target temperature, the cooling capacity of the chiller's evaporator is estimated based the degree of valve opening of an expansion valve, a pressure differential across the expansion valve, and a change in enthalpy per unit mass of the refrigerant flowing through the evaporator. In some embodiments, the chiller system includes multiple refrigerant circuits that are hermetically isolated from each other.

Abstract: A control method regulates an electronic expansion valve of a chiller to maintain the refrigerant leaving a DX evaporator at a desired or target superheat that is minimally above saturation. The expansion valve is controlled to convey a desired mass flow rate, wherein valve adjustments are based on the actual mass flow rate times a ratio of a desired saturation pressure to the suction pressure of the chiller. The suction temperature helps determine the desired saturation pressure. A temperature-related variable is asymmetrically filtered to provide the expansion valve with appropriate responsiveness depending on whether the chiller is operating in a superheated range, a saturation range, or in a desired range between the two.

Abstract: A chiller includes a main condenser that has a refrigerant condensate sump with an internal weir or standpipe that maintains at least a minimum liquid seal between the outlets of the main condenser and a heat-recovery condenser. The main condenser is used for normal cooling operation, and the heat-recovery condenser is for supplying an external process with heat that would otherwise be wasted. In addition to providing a liquid seal, the sump and weir combination provides a reliable source of liquid refrigerant to cool the chiller's compressor motor and creates a trap for collecting foreign particles that might exit either of the chiller's two condensers.

Abstract: A refrigerant system for cooling a comfort zone is selectively operable in a cooling-only mode and a reheat mode. The system operates in the cooling mode to meet sensible and latent cooling demands of a room or area in a building when the room temperature is appreciably above a target temperature. The reheat mode is for addressing the latent cooling or dehumidifying demand when the room temperature is near or below the target temperature. In some embodiments, a generally inactive condenser stores excess refrigerant during the reheat mode, thereby avoiding the need for a separate liquid refrigerant receiver. To maintain a desired level of subcooling in the reheat coil, refrigerant can be transferred accordingly between the inactive condenser and the reheat coil. In some embodiments, the system's evaporator and reheat coil can be connected in a series or parallel flow relationship.

Abstract: A refrigerant system adjusts, in a coordinated prioritized manner, the variable capacities of a compressor, evaporator fan and a condenser fan to minimize the system's overall power consumption while maintaining a comfort zone within a target comfort range. The target comfort range is defined by desired temperature and humidity limits. When the comfort zone is within the target comfort range, the system periodically attempts to reduce the compressor capacity. If the attempt succeeds, the evaporator fan capacity is then minimized. The condenser fan capacity can also be minimized provided the refrigerant system can maintain at least a minimum saturated suction temperature of the refrigerant flowing from the condenser to the compressor.

Abstract: To protect the bearings, lubricant and seals of a refrigerant compressor, the compressor includes one or more inductors for mitigating a high frequency common mode current that produces a high frequency shaft voltage. Each inductor is a ring of magnetic material encircling three insulated cables that convey three-phase power from an adjustable frequency drive to the compressor's motor. Without the inductors, the high frequency shaft voltage can become damagingly high due to the length of a cast iron housing that can be particularly long if the housing contains both a motor and several centrifugal impellers. The high frequency shaft voltage is just one component of a composite adverse shaft voltage. Another component, known as an operationally induced shaft voltage, can be reduced by a grounding contact, so instead of using just an inductor or just a contact, both can be used to provide a total solution to the problem.

Abstract: Two vertically offset thermistors for sensing a fluid such as oil and refrigerant in a compressor shell are monitored by a method that takes into account rapidly changing conditions within the shell. The system can determine the fluid's sump temperature, high/low liquid levels, and can determine whether the thermistors are sensing the fluid as a liquid, gas, or a mixture of the two, such as a foam or mist of liquid and gas. For greater accuracy, thermistor readings can be dithered and filtered to provide temperature or voltage values having more significant digits than the readings originally processed through a limited-bit A/D converter. For faster response, limited microprocessor time is conserved by sampling thermistor readings at strategic periods that enable the microprocessor to identify certain conditions and temperatures via simple delta-temperature ratios and undemanding equations rather than resorting to exponential functions or lookup tables to determine time constants.

Abstract: Lubrication of bearing surfaces in a scroll compressor is enhanced by a vent arrangement which makes use of increased centrifugal force, achieved by locating the outlet of the vent arrangement radially outside of the nominal circumference of the compressor's drive shaft, to both remove refrigerant gas from compressor locations where such gas can inhibit the flow and delivery of lubricant to such surfaces and to increase the lift of lubricant out of the compressor's lubricant sump. Oil retained in the upper surface of the compressor drive shaft is made immediately available for bearing lubrication upon compressor start-up to further enhance compressor lubrication.

Abstract: A sound-abating flow disruptor quiets a PTAC refrigerant system by disturbing the airflow between an energized electric heater and an adjacent fan wheel. In some embodiments, the flow disruptor is a perforated metal plate that attenuates a whistle, which appears to be caused by vortex shedding in the confined area between the energized heater and the fan. In some cases, the heater comprises selectively energizable heating elements of various wattage. The heating elements closest to the fan wheel are the lower wattage ones to minimize the heat near the fan.

Abstract: A refrigerant PTAC system, such as those commonly found in hotel rooms, can be selectively configured in a hardwire or wireless configuration with respect to its thermostat. The system is controlled in response to the better of two temperature sensors, which is determined based on the PTAC's configuration and the validity of the readings provided by the sensors. While the PTAC is controlled in response to a preferred temperature sensor, the alternate sensor may be monitored for diagnostics or other reasons. In the event that the preferred sensor fails to provide valid readings, the controller automatically switches to controlling the system in response to the alternate sensor. To minimize manufacturing costs and the variety of stocked parts, the PTAC's controller preferably includes two substantially identical transceivers.

Abstract: A refrigerant system comprising a compressor, a condenser, an electronic expansion valve, and an evaporator is controlled in a normal operating mode to meet moderate cooling loads; however, when the load approaches that which is sufficient to induce liquid refrigerant carryover from the evaporator to the compressor, the system is controlled in a capped operating mode to limit a certain thermodynamic variable rather than controlled to meet the high load. In the normal mode, the compressor and/or the expansion valve might be controlled in response to the amount of superheat of the refrigerant leaving the evaporator or the level of liquid refrigerant in the evaporator. In the capped operating mode, the compressor and/or the expansion valve might be controlled to limit a variable such as the compressor's capacity, the saturated pressure or dynamic pressure of the refrigerant entering the compressor, or the refrigerant's mass flow rate.

Abstract: An HVAC system includes a desiccant wheel, wherein the wheel's speed varies with airflow, the wheel is energized for at least a set period at startup, and/or a heat recovery system (e.g., an air-to-air heat exchanger) upstream of the wheel enhances the system's ability to dehumidify air.

Abstract: A stepper motor driving a driven member is calibrated by periodically driving the member from its current operational position to an end stop of the driven member's total travel range; however, the driven member approaches the end stop in a series of ever-shorter travel segments. The first travel segment is less than ? the total travel range to compensate for a possible sudden speed reversal, which can be accidentally triggered by the driven member reaching and “bouncing off” the end stop. Limiting the commanded first travel segment to less than ? the total travel range prevents the driven member from reaching an opposite travel limit should the driven member suddenly reverse direction at three times the normal forward speed, wherein such triple speed is characteristic of reverse-speed situations.