Systems and methods for ventilating a building

Systems and methods are disclosed for ventilating a building using a rooftop heating ventilating and air conditioning system that in one instance involve determining a first outdoor airflow into the system through a barometric relief damper; subtracting the first outdoor airflow from a minimum required outdoor airflow rate to arrive at second outdoor airflow; and setting an outdoor damper to provide an outdoor airflow through the outdoor damper that is greater than or substantially equal to the second outdoor airflow. Other systems and methods are disclosed.

FIELD

This application is directed, in general, to heating, ventilating and air conditioning or cooling (HVAC) systems, and more specifically, to methods and systems involving determining and employing a ventilation airflow rate in HVAC systems.

BACKGROUND

Heating, ventilating, and air conditioning (HVAC) systems can be used to regulate the environment within an enclosed space. Typically, an air blower is used to pull air (i.e., return air) from the enclosed space into the HVAC system through ducts and push the air into the enclosed space through additional ducts after conditioning the air (e.g., heating, cooling or dehumidifying the air). Unless otherwise indicated, as used throughout this document, “or” does not require mutual exclusivity. Various types of HVAC systems may be used to provide conditioned air for enclosed spaces.

For example, some HVAC units are located on the rooftop of a commercial building. These so-called rooftop units, or RTUs, typically include one or more blowers and heat exchangers to heat or cool the building, and baffles to control the flow of air within the RTU. Some RTUs also include an air-side economizer that allows selectively providing fresh outside air (i.e., ventilation or ventilating air) to the RTU or to recirculate exhaust air from the building back through the RTU to be cooled or heated again.

At least one type of an economizer includes two damper assemblies driven by a common actuator. The damper blades are linked such that when the outdoor damper is open, the return air damper is closed. When a building is occupied, the outdoor damper of the economizer is typically opened a small amount (e.g., ten to twenty five percent) to allow fresh air into the building to meet ventilation requirements. When the outdoor air is colder than the return air and cooling is needed, the outdoor damper is typically opened to a hundred percent to allow the cooler outdoor air to enter the building. These two functions of an economizer are often referred to as a ventilation mode and a free cooling mode, respectively.

DETAILED DESCRIPTION

FIG. 1illustrates a schematic diagram of an illustrative embodiment of an heating, ventilating, and air conditioning or cooling (HVAC) system100that includes an enclosure101(e.g., a cabinet) with openings for exhaust air, ventilation air, return air and supply air. The enclosure101includes exhaust vents102and ventilation vents103at the corresponding exhaust air and ventilation air openings. Within the enclosure101, the system100includes an exhaust fan105, economizer110, a cooling element120, an indoor fan or blower130and a heating element140. Additionally, the system100includes a fan controller150and a HVAC controller160. The fan controller150is coupled to the blower130via a cable155. The cable155is a cable used with HVAC systems. It should be apparent that other coupling devices or techniques may be used, e.g., wireless. The HVAC controller160can be connected (not illustrated) to various components of the system100, including a thermostat119for determining outside air temperature, via wireless or hardwired connections for communicating data. Cabling or wireless communications systems may be employed. Also included within the enclosure101is a partition104that supports the blower130and provides a separate heating section.

The system100is a rooftop unit (RTU). One skilled in the art will understand that the system100can include other partitions or components that are typically included within an HVAC system such as an RTU. While the illustrative embodiment of the system100is discussed in the context of a RTU, the scope of the disclosure includes other HVAC applications that are not roof-top mounted.

The blower130operates to force an air stream170into a structure, such as a building, being conditioned via an unreferenced supply duct. A return airstream180from the building enters the system100at an unreferenced return duct.

A first portion181of the air stream180re-circulates through the economizer110and joins the air stream170to provide supply air to the building. A second portion of the air stream180is air stream182that is removed from the system100via the exhaust fan105.

The economizer110operates to vent a portion of the return air180and replace the vented portion with the air stream175. Thus air quality characteristics such as CO2concentration and humidity may be maintained within defined limits within the building being conditioned. The economizer110includes an indoor damper111, an outdoor damper113and an actuator115that drives (opens and closes) the indoor and outdoor dampers111,113(i.e., the blades of the indoor and outdoor dampers111,113). Though the economizer110includes two damper assemblies, one skilled in the art will understand that the concepts of the disclosure also apply to those economizers or devices having just a single damper assembly, an outdoor damper assembly. As used herein, “damper assembly” may men one or two or more dampers.

The controller160includes an interface162and a ventilation director166. The ventilation director166may be implemented on a processor or a memory of the controller160. The interface162receives feedback data from sensors and components of the system100and transmits control signals thereto. As such, the controller160may receive feedback data from, for example, the exhaust fan105, the blower130or the fan controller150, the economizer110and the thermostat119, and transmit control signals thereto if applicable. One skilled in the art will understand that the location of the controller160can vary with respect to the HVAC system100.

The interface162may be an interface that employs a known protocol for communicating (i.e., transmitting and receiving) data. The interface162may be configured to receive both analog and digital data. The data may be received over wired, wireless or both types of communication mediums. In some illustrative embodiments, a communications bus may be employed to couple at least some of the various operating units to the interface162. Though not illustrated, the interface162includes input terminals for receiving feedback data.

The feedback data received by the interface162includes data that corresponds to a pressure drop across the outdoor damper113and damper position of the economizer110. In some illustrative embodiments, the feedback data also includes the supply airflow rate. Various sensors of the system100are used to provide this feedback data to the HVAC controller160via the interface162. In some illustrative embodiments, a return pressure sensor190is positioned in the return air opening to provide a return static pressure. The return pressure sensor190measures the static pressure difference between the return duct and air outside of the HVAC system100. In one illustrative embodiment, a supply pressure sensor192is also provided in the supply air opening to indicate a supply pressure to the HVAC controller160. The supply pressure sensor192measures the static pressure difference between the return duct and the supply duct. Pressure sensor193is used to provide the pressure drop across outdoor damper113of the economizer110. The pressure sensor193is a pressure transducer that determines the static pressure difference across the outdoor damper113. The pressure sensor193includes a first input194and a second input195for receiving the pressure on each side of the outdoor damper113. The pressure sensors discussed herein can be the type of pressure sensors typically used in HVAC systems.

The HVAC controller160is configured to determine supply airflow according to various techniques. For example, in one illustrative embodiment, the HVAC controller160is configured to calculate the supply airflow rate based on a set of blower curves, fan power and fan speed.

Economizer damper position is provided to the HVAC controller160via the actuator115. The actuator115is configured to rotate or move the indoor and outdoor dampers111,113, of the economizer110in response to a received signal, such as control signals from the HVAC controller160(i.e., the ventilation director166). The actuator115may be an electrical-mechanical device that provides a signal that corresponds to the economizer damper position (i.e., blade angle of the outdoor damper113of the economizer110). The signal is an electrical signal that is received by the ventilation director166which is configured to determine the relative angle of the outdoor damper113based on the signal from the actuator115. A lookup table or chart may be used by the processor117to determine a relative blade angle with respect to an electrical signal received from the actuator115. The angle can be based on (i.e., relative to) the ventilation opening of the HVAC system100. In some illustrative embodiments, the economizer damper position can be determined via other means. For example, an accelerometer coupled to a blade (or multiple accelerometers to multiple blades) of the outdoor damper113may be used to determine the economizer damper position. The outdoor damper113is opened at 100 percent when the blades thereof are positioned to provide maximum airflow of ventilation air175into the system100through the ventilation opening. InFIG. 1, the blades of the outdoor damper113would be perpendicular to the ventilation opening or the frame surrounding the ventilation opening when opened at 100 percent. In the illustrated embodiment, the blades of the outdoor damper113would be parallel to the ventilation opening when opened at zero percent.

The ventilation director166is configured to determine an operating ventilation airflow rate of the HVAC system100through the ventilation vents103based on the static pressure difference across the outdoor dampers113, the economizer damper position and economizer ventilation data. In embodiments presented further below, the air entering through the exhaust vents (or barometric relief damper) will be considered as well. In some illustrative embodiments, the ventilation director166also employs the supply airflow rate to calculate the operating ventilation airflow rate. In one illustrative embodiment, using the supply airflow rate for the calculation is based on the economizer damper position being above 50 percent. In one illustrative embodiment, the economizer ventilation data is developed during manufacturing or engineering of the system100or similar type of HVAC systems. During development, a ventilation airflow rate is measured in, for example, a laboratory, at a variety of operating conditions. Various sensors or other type of measuring devices are employed during the development to obtain the measured data for the various operating conditions to develop a known relationship that can be used. Economizer ventilation data is developed from the measured data and loaded into the HVAC controller160, such as a memory thereof. During operation in the field, the HVAC controller160(e.g., the ventilation director166) receives the feedback data and calculates the ventilation airflow rate employing the feedback data and the economizer ventilation data.FIG. 3provides a more detailed illustrative embodiment of a ventilation director166.

The ventilation director166is further configured to adjust a position of the economizer110based on the economizer damper position and a desired ventilation airflow rate. The desired ventilation airflow rate can be preprogrammed into a memory of the HVAC controller160during manufacturing. The ventilation flow rate may be required by applicable standards or may be a desired outdoor airflow rate. In some illustrative embodiments, the desired ventilation airflow rate is entered into the HVAC controller160in the field during, for example, installation, a maintenance visit or a service visit. The ventilation director166generates a signal that directs the actuator115to adjust a position of the blades of the economizer110based on the desired ventilation airflow rate through the ventilation vents103. In some illustrative embodiments, this signal represents a difference between the operating ventilation airflow rate and the desired ventilation airflow rate.

FIG. 2illustrates a block diagram of an illustrative embodiment of a controller200that is configured to direct the operation of or at least part of the operation of an HVAC system, such as HVAC system100. As such, the controller200is configured to generate control signals that are transmitted to the various components to direct the operation thereof. The controller200may generate the control signals in response to feedback data that is received from the various sensors or components of the HVAC system. The controller200includes an interface210that is configured to receive and transmit the feedback data and control signals. The interface210may be a typical interface that is used to communicate (i.e., receive and transmit) data for a controller, such as a microcontroller.

The interface210may include a designated input terminal or input terminals that are configured to receive feedback data from a particular component. The controller200also includes a processor220and a memory230. The memory230may be the type of memory typically located within a controller, such as a microcontroller, that is constructed to store data and computer programs. The memory230may store operating instructions to direct the operation of the processor220when initiated thereby. The operating instructions may correspond to algorithms that provide the functionality of the operating schemes disclosed herein. For example, the operating instructions may correspond to the algorithm or algorithms that implement the method illustrated inFIG. 5. The processor220may be a microprocessor or other processor. The controller200also includes a display240for visually providing information to a user. The interface210, processor220memory230, and display240may be coupled together via various means to communicate information. The controller200may also include additional components typically included within a controller for a HVAC unit, such as a power supply or power port.

The controller200is configured to receive feedback data from the HVAC system including feedback data that corresponds to, for example, a pressure difference across an outdoor damper of an economizer, supply airflow rate and economizer damper position of the HVAC system. Additionally, the controller200is configured to determine an operating ventilation airflow rate of the HVAC system based on operating data, such as, the outdoor damper pressure difference, the supply airflow rate and the economizer damper position during operation. In some illustrative embodiments, the controller200also receives and employs condition data, such as, the outside ambient temperature and the elevation at the HVAC system, when calculating the ventilation airflow rate. The controller200calculates the ventilation airflow rate employing the feedback data, that includes the operating and condition data of the HVAC system, with the appropriate corresponding economizer data. In one illustrative embodiment, the economizer data is predetermined economizer ventilation data that is specific for particular HVAC systems or types of HVAC systems.

The controller200is further configured to adjust a position of an economizer of the HVAC system based on the economizer damper position and a desired ventilation airflow rate. In other embodiments, the controller200may also consider airflow into the system from the barometric relief damper. In one illustrative embodiment, the controller200generates and transmits control signals to an actuator of the economizer to adjust the economizer damper position. In addition to the operation schemes disclosed herein, the controller200can be configured to provide control functionality beyond the scope of the present disclosure.

The controller200may be configured to generate alarms and status based on the ventilation airflow rate. In some illustrative embodiments, the controller200is configured to employ the ventilation airflow rate to determine a prorated ventilation airflow rate and direct the operation of an HVAC system based thereon.

Referring now primarily toFIG. 3, an illustrative embodiment of ventilation director300is presented. The ventilation director300may be embodied as a series of operation instructions that direct the operation of a processor when initiated thereby. In one illustrative embodiment, the ventilation director300is implemented in at least a portion of a memory of an HVAC controller, such as a non-transitory computer readable medium of the HVAC controller. The ventilation director300includes a ventilation airflow determiner310and a ventilation changer320.

The ventilation airflow determiner310is configured to calculate the operating ventilation airflow rate based on feedback data and economizer ventilation data. The economizer ventilation data is measured data that was obtained under various operating conditions in a laboratory environment. In one illustrative embodiment, the economizer ventilation data is specific for a particular type of HVAC system.

The ventilation airflow determiner310receives feedback data, such as operating data and condition data, from the HVAC system. The feedback data includes the outdoor damper pressure difference, the supply airflow rate and the economizer damper position—and may also include outdoor air entering through the barometric relief damper. In one illustrative embodiment, the outdoor damper pressure difference is received from a pressure transducer, such as pressure sensor193, that determines the pressure difference. In some illustrative embodiments the return duct pressure drop is employed for the outdoor damper pressure difference. The return duct pressure drop may be determined via a number of means and provided to the ventilation airflow determiner310for the outdoor damper pressure difference.

In typical applications, the return static pressure is within a range of a tenth of an inch to a half of an inch (0.1 inch to 0.5 inch) of water column. In some illustrative embodiments, the ventilation airflow rate ranges from 10 percent to 30 percent of the design airflow rate for the HVAC system. This 30 percent ventilation airflow rate of the designed system airflow rate can usually be obtained with a damper opening of 35 percent.

The elevation of the HVAC system can be stored in a memory of an HVAC controller. In one illustrative embodiment, the elevation is stored in the ventilation airflow determiner310. The elevation is a parameter that is typically entered by a user during initial setup. The elevation may be entered, for example, during installation or a service visit. The outdoor temperature can be provided by a thermometer associated with the HVAC system. As discussed with respect toFIG. 1, the supply airflow rate can be provided by various means and the economizer damper position can be provided from feedback data of an economizer actuator.

The ventilation airflow determiner310is configured to calculate the ventilation airflow rate employing a combination of equations, feedback data and the economizer ventilation data. In some illustrative embodiments, the economizer ventilation data is stored in look-up tables.

The ventilation airflow determiner310calculates the ventilation airflow rate differently according to the current economizer damper position. When the current economizer damper position is 50 percent or less, the ventilation airflow determiner310employs Equation 1 to calculate the ventilation airflow rate.
Ventilation Airflow Rate=1096*CA(ΔP/ρ)1/2  (Equation 1)

In Equation 1, ΔP is the outdoor damper pressure difference and CA is the damper effective open area expressed in squared feet (i.e., ft2). The value 1096 is a conversion constant that is used to make the measurement units more useable. The effective open area CA is calculated employing a flow coefficient table of the economizer ventilation data established for the HVAC system. Flow coefficient data is a parameter developed from testing of HVAC systems that is a function of damper position and relates outdoor damper position to the effective open area CA. The ventilation airflow determiner310is configured to select the appropriate flow coefficient data from the economizer ventilation data based on the economizer damper position. For a current economizer damper position that is 50 percent or less, a first table of flow coefficient data is selected and employed. Table 1 is an example of a flow coefficient table that is selected for an economizer damper position less than or equal to 50 percent. The values in Table 1 are unique for a particular economizer damper assembly and are provided as an example. The flow coefficients for two HVAC models, Model A and Model B, are provided in Table 1. One skilled in the art will understand that flow coefficient tables for other particular HVAC systems can be developed and stored with a controller of the particular HVAC systems. In some illustrative embodiments, the ventilation airflow determiner310is configured to determine the effective air opening CA by interpolation of the data in a flow coefficient table such as Table 1.

TABLE 1Flow Coefficients for Economizer DamperPosition Equal To or Less Than Fifty PercentCACA% OPENMODEL AMODEL B00.00.050.0557360.04812100.0839340.095381150.1132640.125026200.1514110.166996250.2083130.219794300.2784740.289318350.3548230.390838400.4606480.538106450.5883030.718347500.7221450.942691

In Table 1, “% Open” represents the outdoor damper blade position relative to the frame of the HVAC system at the ventilation opening. In one illustrative embodiment, the % Open is calculated using an actuator feedback signal. The relationship between the % Open and the actuator feedback signal is typically dependent on the characteristics of the actuator and the design of the economizer. In one illustrative embodiment, the relationship between % Open and the actuator feedback signal is represented with Equation 2.
% Open=100×(Vfeedback−Voffset)/8  (Equation 2)

Vfeedbackand Voffsetcorrespond to the type of actuator that is used. Vfeedbackis the feedback voltage output by the actuator. Voffsetis a voltage value that corresponds to a fully closed economizer. In one illustrative embodiment, Voffsetis nominally two volts, Vfeedbackis two volts when the damper is 0% open and Vfeedbackis ten volts when 100% open. The number 8 in Equation 2 is a conversion constant that is specific to the type of actuator employed.

Voffsetmay vary from part to part. For example, in one illustrative embodiment Voffsetcan vary between 2.1 volts to 2.75 volts with a closed damper. As such, instead of using a fixed offset based on the actuator specification, in some illustrative embodiments a measured offset is used. To determine the measured offset, the actuator is commanded to go to its minimum position during calibration. After waiting the amount of time required to move to its minimum position, the ventilation airflow determiner310measures the feedback voltage. If the feedback voltage is within the normal variation of offset voltage, the current feedback is recorded as the offset voltage. If the feedback voltage is not within the normal variation of offset voltage, an error code is generated and the default offset is used.

During operation, hysteresis in the relationship between the actuator feedback signal and the actual position of the economizer damper blades can occur. As such, the ventilation director300(i.e., the ventilation airflow determiner310or the ventilation changer320) can reposition the damper blades. The flow diagram ofFIG. 4presents an illustrative embodiment of such a method.

Returning to Equation 1, p is the density of air entering the outdoor damper. In one illustrative embodiment, the ventilation airflow determiner310calculates the air density p employing Equation 3.
P=0.075((460+64)/(460+TOD))(Patm/14.696)  (Equation 3)

In Equation 3, TODis the outdoor temperature in Fahrenheit and Patmis the atmospheric pressure calculated by Equation 4.
Patm=14.696*(1−6.876E−6*ALT)5.25588(Equation 4)

In Equation 3, ideal gas relationships are being used to correct air density for temperature and pressure variations. 0.075 is a reference density of air at 64 F and 14.696 psia (sea level). The first term 460+64/46+T corrects the reference density for temperature (460 is used to convert the temperature to the absolute ranking scale). The term Patm/14.696 corrects for atmospheric pressure. Thus, the density is calculated using TODand Patmand ideal gas relationships. Equation 4 is a standard equation used by the national weather service to calculate atmospheric pressure as a function of elevation wherein the terms have been converted for US units.

In Equation 4, ALT is the elevation of the HVAC system in feet and is a user entered parameter. An elevation of 650 feet, which is approximately the median elevation, is entered as a default elevation. This can be entered during manufacturing of an HVAC system or when programming a controller of the HVAC system. Additionally, a default outdoor temperature of 70 degrees Fahrenheit may also be used. Calculating the air density based on elevation and temperature increase the accuracy of the ventilation measurement across wide temperatures and at high altitudes.

When the current economizer damper position is greater than 50 percent, the ventilation airflow determiner310employs a different flow coefficient table to calculate the ventilation airflow rate. For example, Table 2 represents a flow coefficient table for a particular type of HVAC system when the current economizer damper position is greater than 50 percent. In some illustrative embodiments, the ventilation airflow determiner310is configured to determine the percentage of outdoor air by interpolation of the data in a flow coefficient table such as Table 2. Once the percentage of outdoor air is known, the ventilation airflow determiner310multiplies the percentage of outdoor air by the total supply airflow to determine the ventilation airflow rate. As with Table 1, the flow coefficients for two different models of HVAC systems are provided as an example.

Thus, the ventilation airflow determiner310selects the appropriate flow coefficient table to employ based on the current economizer damper position and determines the operating ventilation airflow rate that is provided to the ventilation changer320. The ventilation changer320receives the operating ventilation airflow rate and a desired ventilation airflow rate. Based on these received airflow rates, the ventilation changer320adjusts the economizer damper position to obtain the desired ventilation airflow rate. The desired ventilation airflow rate may be received via a user interface, such as a touch screen or keypad or Internet, associated with an HVAC controller or the ventilation director300. In one illustrative embodiment, the desired ventilation airflow rate is stored and received from a memory, such as the memory of an HVAC controller. The various ventilation airflow rates may be provided to a user via a display of an HVAC controller.

The ventilation changer320, therefore, uses the ventilation airflow rate determined above to automatically adjust the damper actuator position command delivered to the actuator to achieve a user specified ventilation rate. In some illustrative embodiments, the ventilation changer320is configured to minimize movement of the actuator. As such, concerns about reliability limitations of an economizer actuator are minimized. Accordingly, in some illustrative embodiments, a ventilation changer320is configured to change the damper position once per a designated time. In some illustrative embodiments, the ventilation changer320is configured to change the damper position only once in every 10 minutes. In other illustrative embodiments, the ventilation changer320is configured to change the damper position when the operating state of the fan system has changed. The basis for determining when to change the damper position and the designated time for changing the damper position are adjustable.

In some illustrative embodiments, designated events may be predetermined to use as a basis for determining when to change the damper position. For example, a change in supply air fan speed and a change in ventilation set point can be used to trigger a change in damper position. In one illustrative embodiment, the ventilation changer320is configured to continuously integrate the error between the actual ventilation rate and the desired rate when waiting to make a control move. In one illustrative embodiment, the ventilation changer320, when determining it is time to make a control move, determines the next position of the damper blades of the outdoor damper with following procedure:

(1) Calculate an integral offset of the actuator where the integral offset=−1*Integrated Error/Integral Gain. If the absolute value of the integral offset is greater than the desired ventilation rate, then the integral offset is set equal to the integral offset multiplied by the desired ventilation rate divided by the absolute value of the integral offset. To prevent over opening or over closing the damper, a ventilation rate more than some limit, e.g., twice the normal ventilation rate may not be employed.

(2) Calculate the new ventilation target airflow using the following by adding the desired ventilation rate and the integral offset together.

(3) Calculate the current ventilation airflow rate using a procedure defined above with respect to the ventilation airflow determiner310.

(4) Acquire the current outdoor damper pressure difference.

(5) Acquire the current supply airflow.

(6) Acquire the current economizer damper position.

(7) Calculate the new predicted damper pressure difference employing the following equation, Equation 5, wherein CurrentDP is the current economizer damper position, CurrentCFM is the current supply airflow and VentTarget is the ventilation target. For Equation 5, the ventilation changer320can employ the return duct static pressure difference as the pressure difference across the outdoor damper. Typically, the return duct pressure drop is proportional to the square of the airflow rate through the return duct. In this illustrative embodiment, the ventilation changer320assumes that the airflow through the return duct is equal to the supply airflow rate minus the ventilation airflow rate.
newDP=CurrentDP*((CurrentCFM−VentTarget)/(CurrentCFM−CurrentVent))2(Equation 5)

(8) Calculate the new CA employing Equation 6.
newCA=VentTarget/(newDP)0.5(Equation 6)

(9) Use the economizer ventilation data (such as Table 1) to determine the economizer damper position, i.e., the new damper position associated with the new CA, and determine the position difference between the new damper position and the current damper position. If the absolute value of the position difference is less than Deadband (i.e., less than the steps at which the actuator can move, such as 1.5% step), then set the new damper position as the new damper position. Otherwise, set the new damper position equal to the current position.

The ventilation director300(i.e, either the ventilation airflow determiner310or the ventilation changer320or a combination thereof) can also perform diagnostics, detect faults with the economizer and generate alarms. The alarms could be visually presented on a display of a controller or communicated to a monitor or monitoring service. An audible alarm may also be generated. The diagnostics can be used to warn a user of a fault which could cause an inaccurate measurement of ventilation airflow. An example of an alarm resulting from receiving feedback data from the economizer actuator includes Damper Stuck. Damper Stuck can be determined by comparing actuator feedback position to command position. During operation of the damper actuator, the feedback position of the damper is compared with the desired position. Once the actuator has stopped moving, if the feedback position in not within a prescribed tolerance of the desire position, the algorithm indicates a fault. The ventilation director300, will continue to monitor the feedback position and automatically clear the fault should the feedback start to match the command.

In one illustrative embodiment, the ventilation director300is also configured to perform damper pressure sensor diagnostics. Based on normal operating data that can be stored in an HVAC controller, the ventilation director300can compare the outdoor damper pressure difference with the percent of damper opening and generate an alarm if the measured pressure is out of range compared to the stored operating data. An error can be recorded and an alarm generated based on the comparison.

The ventilation director300can also be configured to employ the ventilation airflow rate to determine the damper position necessary to deliver required ventilation only when the compressor is running. As such, humidity problems associated with a continuous fan can be reduced or eliminated and operation of the HVAC system can still comply with Indoor Air Quality standards established by governing bodies, such as the ASHRAE 62.1 standard. In one illustrative embodiment, the ventilation director300is configured to determine a prorated ventilation airflow rate and deliver the required ventilation as described below. An hour is used in the illustrative embodiment discussed below but other amounts of time may also be used in different embodiments.

(1) At the beginning of each hour: a. determine the fraction of compressor on time during the past hour (i.e., runfrac); b. calculate the required ventilation rate (when compressor is on using Equation 7 employing runfrac and the ventilation rate when the compressor is on continually (QventCONT). The constant 1.2 in Equation 7 is a margin of safety which ensures the correct amount of ventilation is delivered even if the compressor runs 20% less than the previous hour.
QventCompOn=1.2(QventCONT/runfrac)  (Equation 7)

(2) When the compressor is on, set the ventilation controller setpoint to Qvent comp ON.

(3) When the compressor is off, set the ventilation setpoint to 0.

(4) Integrate the amount of ventilation airflow delivered over an hour. If the integrated amount exceeds Qvent cont*60 then set the ventilation setpoint=0.

Referring now primarily toFIG. 4, illustrated is a flow diagram of an illustrative embodiment of a method400of repositioning the dampers of an economizer. In some illustrative embodiments, hysteresis results in the relationship between the actuator feedback signal and the actual position of the economizer damper blades. In some illustrative embodiments, the hysteresis can be significant enough to cause a ten percent error in the relationship between the actuator feedback and the damper blade position. The method400can be employed to correct this problem. In one illustrative embodiment, a ventilation airflow determiner is configured to perform the method400. The method400represents an algorithm that can be implemented as a series of operating instructions.

The method400begins in a step405with a change in the position of the dampers being desired. In a decisional step410, a determination is made if the new desired damper position is less than the current damper position. Thus, step410includes comparing the current damper position (e.g., the current percentage of opening) to the desired damper position (e.g., the desired percentage of opening). If the desired position is less than the current position, then the method continues to step420where the actuator is closed directly to the desired position. If the desired position is not less than (i.e., greater than) the current position, then the method continues to step430where the actuator is opened to the desired position plus an actuator specific buffer. In one illustrative embodiment, the actuator specific buffer is based on the amount of slack of the drive train of the actuator. In some illustrative embodiments, the actuator specific buffer is 1.5 volts. The method400then ends in a step440where the actuator is closed to the new desired position.

One skilled in the art will understand that the buffer employed can vary based on the type of actuator and the actual installation. The value (e.g., voltage) of the buffer can be determined during calibration. The method400represents compensating for hysteresis employing a final close operation (step440). A similar compensation can be performed by ending in an open operation. For example, in step430, the actuator could be opened to the new position with the addition of a negative buffer (e.g., −1.5 volts). As such, in step440, the actuator would be opened to the new position.

FIG. 5illustrates an illustrative flow diagram of a method500of measuring and managing ventilation airflow of a HVAC system. The method500may be carried out under the direction of a computer program product. In one illustrative embodiment, a controller of an HVAC system is employed to carry out the method500. The method500begins in a step505.

In a step510, feedback data is received from an HVAC system. In one illustrative embodiment, the feedback data corresponds to the pressure difference across an outdoor economizer damper and economizer damper position of the HVAC system. Additionally, the feedback data may include the supply airflow rate. The feedback data is typically real time data obtained during operation of the HVAC system.

The feedback data is applied to economizer ventilation data in a step520. The feedback data applied may include the outdoor economizer damper pressure difference, the supply airflow rate and the economizer damper position. The economizer ventilation data represents ventilation airflow rates of the HVAC system and is based on measured data obtained before installation of the HVAC system.

In a step530, an operating ventilation airflow rate is calculated based on the feedback data and the corresponding economizer ventilation data.

A desired ventilation airflow rate is received in a step540. In a step550, a position of the economizer is adjusted based on the economizer damper position and the desired ventilation airflow rate. In some illustrative embodiments, the adjustment is zero when the operating ventilation airflow rate is at or within a designated percentage of the desired ventilation airflow rate. In some illustrative embodiments, the desired airflow rate is entered by a user in the field. In other illustrative embodiments, the desired airflow rate is predetermined and established before or during installation. In these illustrative embodiments, the desired airflow rate can be changed after installation. The method500ends in a step560.

The above-described methods may be embodied in or performed by various digital data processors, microprocessors or computing devices, wherein these devices are programmed or store executable programs of sequences of software instructions to perform one or more of the steps of the methods, e.g., steps of the method ofFIG. 5. The software instructions of such programs may be encoded in machine-executable form on digital data storage media that is non-transitory, e.g., magnetic or optical disks, random-access memory (RAM), magnetic hard disks, flash memories, or read-only memory (ROM), to enable various types of digital data processors or computing devices to perform one, multiple or all of the steps of one or more of the above-described methods, e.g., one or more of the steps of the method ofFIG. 5. Additionally, an apparatus, such as dedicated HVAC controller, may be designed to include the necessary circuitry to perform each step of the methods disclosed herein.

Referring now primarily toFIGS. 6 and 7, another illustrative embodiment of a heating, ventilating, and air conditioning or cooling (HVAC) System600is presented. The HVAC System600is a rooftop unit (RTU) and is analogous in many respects to the system ofFIG. 1. This system600accounts for the outdoor airflow through exhaust vents or a barometric relief damper622or a gravity exhaust damper. While the illustrative embodiment of system600is discussed in the context of an RTU, the scope of the disclosure includes other HVAC applications that are not rooftop mounted. The system600is shown on roof602. The system600supplies conditioned air through a supply duct system604to room vents606, which are typically through a ceiling608. Thus, supply air flow610is delivered to an interior of the building. As the air continues to flow, the return air612is delivered to a return duct614from where it will be conditioned and returned again or will exit the HVAC System600or some combination.

The HVAC system600includes an enclosure or housing616, which may include one or more partitions618in an interior portion. The enclosure616has a ventilation opening that is covered by ventilation vents620and an exhaust opening covered by the barometric relief damper622, or exhaust vents.

The HVAC system600includes an economizer624that controls ventilation flowing through the ventilation vents620and the amount of return air612that is recycled as shown by airstream626or that is exhausted as shown by exhaust airflow628. The economizer624includes an actuator630that is able to move a plurality of blades that make up an outdoor damper632and a plurality of blades that make up a return damper or indoor damper634. The outdoor damper632and return damper634are part of a damper assembly636and may move in a coordinated fashion. An exhaust fan638may be used to push the exhaust airflow628through the barometric relief damper622. As noted in connection withFIG. 1, the economizer624in economizer mode allows maximum flow of outdoor ventilation airflow640into the system600and primarily exhausts all of the return airflow612as exhaust628. When in economizer mode, the barometric relief damper622provides a low restriction path for the exhaust airflow stream628to exit. At other times, the economizer624may help to regulate the amount of ventilation introduced to meet indoor air quality standards or satisfy desired levels of fresh air. When not in economizer mode, the barometric relief damper622is intended to prevent outdoor airstream/fresh air671from entering, but most units leak at some level for a variety of reasons.

One or more pressure sensors642are included for measuring pressure at different points. In this example, the pressure sensor642measures pressure across the outdoor damper632. In other illustrative embodiments, additional pressure measurements may be made at various locations, for example, across the return damper634. The pressure sensor642may have transducers644and646and may be coupled to a controller648by a cable650or wirelessly or other means. Air leaving the economizer624within the system600travels in conditioning flow path across a cooler or evaporator652, and then with the assistance of blower or fan654is delivered into the supply duct system604. A fan controller656may be used to control the blower654and other components if desired. The fan controller656may be separate from or combined with or the same as controller648.

The HVAC system600may include one or more compressors658to compress a working fluid used in conjunction with condensers660and condenser fans662to develop a cold working fluid delivered to the cooler652during cooling operations. Outdoor air663is pulled across the condenser coils660and exhausted at664to reject heat. Heating coils666are included within the partitioned portion to heat air within a conditioning flow path from the blower654during heating operations.

The controller648is analogous to the controller160inFIG. 1. The controller648includes at least one memory and at least one processor associated with at least one memory for carrying out numerous operations and functions. The controller648may be coupled to the actuator630such as by a cable668or other means. As previously noted, the controller648may be coupled by the cable650to one or more pressure sensors642. As previously discussed, the correlation of airflow through the economizer636based on the position of the outdoor damper632and the pressure differential across or proximate the outdoor damper632allows for the desired ventilation flow640to be set and controlled by the controller648.

In adjusting the outdoor damper to allow the proper amount of ventilation to enter, typically only air entering the ventilation vents620has been considered. Research has shown, however, that depending on the pressure differential proximate the barometric relief damper622, fresh air671is also entering from there. If that air can be properly accounted for, less ventilation air is required through the outdoor damper632which allows for enhanced efficiency.

Referring now toFIG. 8, an illustrative graph is presented showing data that has been obtained for two different rooftop units in an experimentation. This data is for qualitative purposes only. The abscissa has the pressure differential in inches of water across the barometric relief damper622and the ordinate shows the amount of outdoor airflow that is introduced through the barometric relief damper622under those conditions. The top curve802is for a 18.5 inch by 30 inch barometric relief damper applied to a 5 or 6 ton unit and the lower curve804is for a 17 inch by 30 inch barometric relief damper applied to a 3 or 4 ton unit. Larger units will use a slightly larger barometric relief damper or multiple relief dampers (collectively referred to herein as a single relief damper). For example, in another illustrative embodiment, the barometric relief damper includes three 18.5 inch by 30 inch assemblies. The curves allow the flow through the barometric relief damper622to be estimated with reasonable accuracy using the pressure differential proximate the barometric relief damper. In each instance for an HVAC system being manufactured, such curves can be developed.

The curves may be stored in the controller648, or a look up table stored, or a function may be derived by fitting data points to a curve. In one illustrative laboratory run, the following data was produced in table form:

TABLE 3Outdoor Airflow Through Barometric Relief DamperPressure Difference in Inches WaterOutdoor Airflow Rate (cfm).167.387.5103.71181137

With the known relationship between the pressure differential proximate the barometric relief damper and the flow rate through it, one may account for the airflow through the barometric relief damper in setting the needed ventilation through the ventilation vents, or barometric relief damper. In some systems, the pressure differential may be determined directly using pressure sensors across the barometric relief damper. In others, the pressure may be known across the outdoor damper632because of a pressure sensor, such as sensor642inFIG. 7, and it may be desirable to use that information. In one instance, the variation between the pressure across the outdoor damper and proximate the barometric relief damper may be assumed to be zero. In another embodiment, beginning with the pressure differential across the outdoor damper, a known relationship may be used to better calculate the estimated pressure across the barometric relief damper; for example, the following or other relationship may be used to more accurately estimate the pressure differential:
DPbaro=DPod+DPrd(Equation 8)
where DPodis the pressure difference across the outdoor damper and is measured by a sensor. DPrdis the pressure difference proximate the return air damper and is a function of the damper position and the supply fan airflow rate. When the economizer is in the closed position, DPrdis quite small. If more accuracy is desired, DPrdcan be estimated using the following equation:
DPrd=CA_RD2*Rho_air*(Supply_airflow−ventilization_airflow)2(Equation 9)

Where, CA_RD is the damper flow coefficient which can be determined using a lookup table which is a function of damper position;

Rho_air is the density of air and can often be assumed to be 0.075 lb/ft3.

Supply_airflow is supply airflow rate in CFM which is measured by the software;

Ventilation_airflow is outdoor airflow through the outdoor damper.

Referring now primarily toFIG. 9, one illustrative embodiment of a process for ventilating a building is presented. The process may be executed by the controller648(FIG. 7) or160(FIG. 1). The process begins at step900. A pressure differential at or proximate the exhaust damper is determined at step902. The known relationship of the pressure differential to the amount of flow through the barometric relief damper is then used to determine the amount of outdoor air entering at904.

Thus, given an outdoor airflow or ventilation airflow required to meet an air quality standard (includes a desired ventilation), the necessary ventilation640through the outdoor damper632may be calculated at906. The equation would be as follows:
(required airflow through the outdoor damper)=(required airflow to meet the standard)−(the amount of outdoor air entering through the barometric relief damper)  (Equation 10)

Once the required airflow through the outdoor damper is calculated, the outdoor damper may be adjusted at908and the process ends at910. As used herein, “the amount required by a standard” and like terminology includes a desired level by the operator. If the required airflow through the outdoor damper is calculated to be zero or less, then the outdoor damper is commanded to remain closed.

Although the present invention and its advantages have been disclosed in the context of certain illustrative, non-limiting embodiments, it should be understood that various changes, substitutions, permutations, and alterations can be made without departing from the scope of the invention as defined by the claims. It will be appreciated that any feature that is described in a connection to any one embodiment may also be applicable to any other embodiment.