Patent Publication Number: US-2023160599-A1

Title: Variable speed airflow zone board

Description:
BACKGROUND 
     The embodiments herein generally relate to a heating, ventilation, and air conditioning (HVAC) system and more specifically to a zone board for an HVAC system. 
     Multi-zone HVAC systems are known, and include a component(s) for changing the temperature and condition of air (a furnace, air conditioner, heat pump, etc.). For simplicity, these components may be referred to collectively as a temperature changing component. Also, an indoor air handler drives air from the temperature changing component through supply ducts to several zones within a building. Each of the supply ducts typically have dampers that may be controlled to restrict or allow flow of air into each zone to achieve a desired temperature. 
     In these systems, sizes of the ducts leading to each of the zones may vary due to restrictions, etc., which could occur along the length of the ducts. Thus, while modern HVAC systems are being adapted for the consideration of sophisticated controls, accurately controlling the flow of air into each of the several zones would require knowledge of the relative sizes of the ducts. As an example, if there were two ducts leading to two zones, with one of the two ducts being smaller than the other, the smaller duct would tend to receive less airflow than the larger duct. Knowledge of the sizes of the ducts is thus important, to provide the ability to achieve close control over airflow to these zones. Current systems require multiple sensor inputs (for temperature, humidity, etc.) and setpoints from each zone to control the temperature changing component and the zone dampers, which may be incompatible with current thermostats. 
     BRIEF SUMMARY 
     According to one embodiment, a zone board for a heating, ventilation, and air-conditioning (HVAC) system is provided. The zone board including: a controller connector configured to electrically connect a controller to the zone board, the controller being configured to control operation of the HVAC system; a unit connector configured to electrically connect an indoor air handler to the zone board; and a thermostat connector configured to electrically connect a thermostat in a first zone to the zone board, wherein the thermostat connector is a 24-volt printed circuit board connector. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include a damper connector configured to electrically connect a damper for the first zone to the zone board. 
     According to an embodiment, a heating, ventilation, and air-conditioning (HVAC) system is provided. The HVAC system including: a controller; an indoor air handler; a thermostat for a first zone; and a zone board including: a controller connector configured to electrically connect the controller to the zone board, the controller being configured to control operation of the HVAC system; a unit connector configured to electrically connect the indoor air handler to the zone board; and a thermostat connector configured to electrically connect the thermostat to the zone board, wherein the thermostat connector is a 24-volt printed circuit board connector. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include a damper for the first zone, wherein the zone board further includes a damper connector configured to electrically connect the damper for the first zone to the zone board. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the indoor air handler further includes a variable speed blower. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the thermostat is a 24-volt thermostat. 
     According to another embodiment, a computer implemented method of operating a heating, ventilation, and air-conditioning (HVAC) system is provided. The computer implemented method includes: receiving an electronic signal from a thermostat for a first zone via a 24-volt thermostat connector in a zone board; and commanding an indoor air handler to provide conditioned air to the first zone in accordance with the electronic signal received from the thermostat. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include activating a variable speed blower of the indoor air handler to provide the conditioned air to the first zone in accordance with the electronic signal received from the thermostat. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include actuating a damper for the first zone to provide the conditioned air to the first zone in accordance with the electronic signal received from the thermostat. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that actuating a damper for a second zone to provide the conditioned air to the first zone in accordance with the electronic signal received from the thermostat. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include performing a duct assessment. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the duct assessment is performed to determine how much air to deliver to each zone. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the duct assessment is performed prior to receiving the electronic signal from the thermostat for the first zone via the 24-volt thermostat connector in the zone board. 
     In addition to one or more of the features described above, or as an alternative, further embodiments may include that the duct assessment is performed to measure and calculate relative zone duct sizes. 
     Technical effects of embodiments of the present disclosure include utilizing 24-volt printed circuit board connectors to connect 24-volt thermostats to a zone board to better control distribution of air to different zones. 
     The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, that the following description and drawings are intended to be illustrative and explanatory in nature and non-limiting. 
    
    
     
       BRIEF DESCRIPTION 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG.  1    is a perspective view of an exemplary heating, ventilation, and air-conditioning (HVAC) system, according to an embodiment of the present disclosure; 
         FIG.  2    is a block diagram of an exemplary HVAC system and a zone board for the HVAC system, according to an embodiment of the present disclosure; and 
         FIG.  3    is a flow diagram illustrating an exemplary computer implemented method of operating an HVAC system, such as the exemplary HVAC system(s) of  FIGS.  1  and  2   , according to an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     Referring now to  FIG.  1   , a heating, ventilation, and air-conditioning (HVAC) system  20  is illustrated in accordance with an embodiment of the present disclosure. The HVAC system  20  is a multi-zone HVAC system (e.g., including at least four zones, which may be referred to as a first zone  210 , a second zone  220 , a third zone  230 , and a fourth zone  240 ). A temperature changing component  22  for changing the condition of air, e.g., an indoor unit  29  (furnace/heater coil) and/or an outdoor unit  27  (air conditioning/heat pump), is associated with an indoor air handler  24 . The air handler  24  takes air from return ducts  26  and drives the air into a plenum  31 , and a plurality of supply ducts  28 ,  30 ,  32 ,  33  associated with distinct zones  210 ,  220 ,  230 ,  240  in a building. The air handler  24  includes a blower  25  (which may be fixed speed or variable speed). As shown, a damper  34  is provided on each of the supply ducts  28 ,  30 ,  32 ,  33 . 
     A controller  200 , such as a microprocessor control controls the dampers  34 , the temperature changing component  22  (e.g., the outdoor unit  27  and the indoor unit  29 ), the indoor air handler  24 , and also communicates with a thermostat  130  associated with each of the zones  210 ,  220 ,  230 ,  240 . It should be appreciated that, in certain instances, these thermostats  130  may replace the typical temperature/humidity inputs and setpoints provided by multiple smart sensors (e.g., one or more temperature sensor and/or humidity sensor) that may be positioned within each zone. 
     The controller  200  may be an electronic controller including a processor and an associated memory comprising computer-executable instructions (i.e., computer program product) that, when executed by the processor, cause the processor to perform various operations. The processor may be, but is not limited to, a single-processor or multi-processor system of any of a wide array of possible architectures, including field programmable gate array (FPGA), central processing unit (CPU), application specific integrated circuits (ASIC), digital signal processor (DSP) or graphics processing unit (GPU) hardware arranged homogenously or heterogeneously. The memory may be but is not limited to a random access memory (RAM), read only memory (ROM), or other electronic, optical, magnetic or any other computer readable medium. 
     The thermostat  130  allows a user to set desired temperature, noise levels, etc. for each of the zones  210 ,  220 ,  230 ,  240  relative to the others. Moreover, the thermostat  130  preferably include a temperature sensor for providing an actual temperature back to the controller  200 . The thermostat  130  may be an electronic controller including a processor and an associated memory comprising computer-executable instructions (i.e., computer program product) that, when executed by the processor, cause the processor to perform various operations. The processor may be, but is not limited to, a single-processor or multi-processor system of any of a wide array of possible architectures, including field programmable gate array (FPGA), central processing unit (CPU), application specific integrated circuits (ASIC), digital signal processor (DSP) or graphics processing unit (GPU) hardware arranged homogenously or heterogeneously. The memory may be but is not limited to a random access memory (RAM), read only memory (ROM), or other electronic, optical, magnetic or any other computer readable medium. 
     As disclosed, the controller  200  is able to receive configuring information with regard to each of these system components so that controller  200  understands individual characteristics of the elements of the HVAC system  20 , which may include, but are not limited to, the temperature changing component  22  (e.g., the outdoor unit  27  and the indoor unit  29 ), the indoor air handler  24 , the variable speed blower  25 , supply ducts  28 ,  30 ,  32 ,  33 , damper  34 , and thermostat  130 . Details of this feature may be as disclosed in co-pending U.S. patent application Ser. No. 10/752,628, filed on Jan. 7, 2004, and entitled “Self-Configuring Controls for Heating, Ventilating and Air Conditioning Systems.” The disclosure of each of these applications is incorporated herein by reference. 
     In the prior art, the amount of air driven by the air handler  24  to each of the zones  210 ,  220 ,  230 ,  240  sometimes become excessive. Dampers  34  may be opened or closed to restrict or allow additional airflow into the zones  210 ,  220 ,  230 ,  240 . While there are dampers  34  that are driven to either be full open or full closed, the embodiments disclosed herein may include a damper  34  having not only full open and full closed positions, but also several incrementally closed positions. In one example, there are 16 incremental positions for the damper  34  between full open and full closed. As any one of the dampers  34  is closed to reduce conditioning in that zone, additional airflow is driven to the more open of the dampers  34 . This may sometimes result in too much air being delivered to one of the zones  210 ,  220 ,  230 ,  240 , which can cause excessive temperature change, and undue noise. In the prior art, pressure responsive bypass valves may be associated with the ducting  28 ,  30 ,  32 ,  33  or upstream in plenum  31 . The bypass of the air has undesirable characteristics, as it requires additional valves, ducting, etc., and thus complicates assembly. Typically, the bypass air is returned to the temperature changing component  22  through return duct  26 . Thus, the air approaching temperature changing component  22  has already been changed away from ambient, and may be too cold or too hot for efficient operation. 
     For this reason, it would be desirable to find an alternative way of ensuring undue volumes of air do not flow through any of the ducts  28 ,  30 ,  32 ,  33  into the zones  210 ,  220 ,  230 ,  240 . It is understood that while the figures and associated description describe four zones  210 ,  220 ,  230 ,  240 , the embodiments disclosed herein are also applicable to HVAC systems with more or less than four zones. 
     Referring now to  FIG.  2   , a block diagram of the HVAC system  20  is illustrated in accordance with an embodiment of the present disclosure.  FIG.  2    illustrates, a zone board  300  for the HVAC system  20 . The zone board  300  may be a printed circuit board. The zone board  300  includes a plurality of different connectors for components of the HVAC system  20  to connect to the zone board  300 . 
     The zone board  300  includes one or more damper connectors  310  configured to electrically connect a damper  34  to the zone board  300 . The damper connector  310  may be any type of printed circuit board connector known to one of skill in the art. The damper connector  310  may include three communication links  312 . It is understood that while three communication links  312  are illustrated in  FIG.  2   , the embodiments disclosed herein are applicable to any number of communication links  312  for the damper connector  310 . 
     The zone board  300  includes a controller connector  320  configured to electrically connect the controller  200  to the zone board  300 . The controller connector  320  may be any type of printed circuit board connector known to one of skill in the art. The controller connector  320  may include four communication links  322 . It is understood that while four communication links  322  are illustrated in  FIG.  2   , the embodiments disclosed herein are applicable to any number of communication links  322  for the controller connector  320 . 
     The zone board  300  includes a unit connector  330  configured to electrically connect the indoor air handler  24 , the indoor unit  29 , and/or the outdoor unit  27  to the zone board  300 . The unit connector  330  may be any type of printed circuit board connector known to one of skill in the art. The unit connector  330  may include four communication links  332 . It is understood that while four communication links  332  are illustrated in  FIG.  2   , the embodiments disclosed herein are applicable to any number of communication links  332  for the unit connector  330 . 
     The zone board  300  includes a ventilator unit connector  340  configured to electrically connect a ventilator unit  42  of the HVAC system  20  to the zone board  300 . The ventilator unit connector  340  may be any type of printed circuit board connector known to one of skill in the art. The ventilator unit connector  340  may include four communication links  342 . It is understood that while four communication links  342  are illustrated in  FIG.  2   , the embodiments disclosed herein are applicable to any number of communication links  342  for the ventilator unit connector  340 . 
     The zone board  300  includes a sensor connector  350  configured to electrically connect a temperature sensor  52  of the HVAC system  20  to the zone board  300 . The temperature sensor  52  may be configured to measure a temperature of air leaving the indoor air handler  24 . The sensor connector  350  may be any type of printed circuit board connector known to one of skill in the art. The sensor connector  350  may include three communication links  352 . It is understood that while three communication links  352  are illustrated in  FIG.  2   , the embodiments disclosed herein are applicable to any number of communication links  352  for the sensor connector  350 . 
     The zone board  300  includes a thermostat connector  360  configured to electrically connect a thermostat  130  of the HVAC system  20  to the zone board  300 .  FIG.  2    illustrates four thermostats  130  but it is understood that any number of thermostats  130  may be utilized. Each of the thermostats  130  may come from the same manufacturer or different manufacturers. In an embodiment, the thermostat connectors  360  are 24-volt printed circuit board connectors configured to receive 24-volt inputs from the thermostats  130 . The thermostat connector  360  may be any type of 24-volt printed circuit board connector known to one of skill in the art. The thermostat connector  360  may include seven communication links  362 . It is understood that while seven communication links  362  are illustrated in  FIG.  2   , the embodiments disclosed herein are applicable to any number of communication links  362  for the thermostat connector  360 . The communication links  362  may include communication links R, C, Y1, W1, G, Y2, W2, O, or any other communication link known to one of skill in the art. For example, the communication links may include D 1  and D 2  for accessory inputs. In an embodiment, the thermostat  130  is a 24-volt thermostat. 
     Advantageously, by utilizing 24-volt printed circuit board connectors for the thermostat connectors  360  of the controller  200  are configured to receive a great deal more data in the form of electronic signals from each thermostat  130  than previously available. The data or in other words the 24-volt thermostat inputs sent from the thermostat  130  to the thermostat connectors  360  provide discrete signals for a heating call, a cooling call, a continuous fan call, a dehumidification call, a humidify call, and/or a fresh air call. In the conventional zone boards, a zone temperature was provided, and the system determined how to condition the space with heating and/or cooling. The data in the form of electronic signals provided by the thermostats  130  allows the controller  200  to understand how much airflow over a period of time a zone  210 ,  220 ,  230 ,  240  requires and then the controller  200  will command the variable speed blower  25  to deliver that amount of airflow over the period of time, which advantageously may eliminate the need for a bypass valves. In one example, the airflow over a period of time may be measured in cubic feet per minute (CFM). 
     The HVAC system  20  may perform a duct assessment at or after installation and once per day where the damper  34  for each zone  210 ,  220 ,  230 ,  240  is opened individually and the airflow to each zone  210 ,  220 ,  230 ,  240  is measured. The HVAC system  20  uses this information from the duct assessment in addition to the thermostat calls to determine how much air to deliver to each zone  210 ,  220 ,  230 ,  240  and stage the equipment accordingly. For example, if the HVAC system  20  needs to provide heating or cooling to all zones  210 ,  220 ,  230 ,  240 , then the HVAC system  20  will likely run high stage. If only one zone needs heat or cool, the HVAC system  20  may run low stage heating or cooling. The information learned from the duct assessment would help determine what stage the equipment needs to run. The thermostat calls may include but are not limited to, the heat call, the cooling call, the continuous fan call, the dehumidification call, the humidify call, and/or the fresh air call. 
     Referring now to  FIG.  3   , with continued reference to  FIGS.  1 - 2   , a flow diagram illustrating an exemplary computer implemented method  500  of operating an HVAC system  20  is illustrated in accordance with an embodiment of the present disclosure. In embodiment, the computer implemented method  500  is performed by the controller  200 . 
     At block  504 , an electronic signal is received from a thermostat  130  for a first zone  210  via a 24-volt thermostat connector  360  in a zone board  300 . In an embodiment, the method  500  may include that a duct assessment is performed prior to block  504  in block  502 . The duct assessment may be performed to measure and calculate relative zone duct sizes. As previously discussed, during the duct assessment the damper  34  for each zone  210 ,  220 ,  230 ,  240  is opened individually and the airflow to each zone  210 ,  220 ,  230 ,  240  is measured. The HVAC system  20  uses this information from the duct assessment in addition to the thermostat calls to determine how much air to deliver to each zone  210 ,  220 ,  230 ,  240  and stage the equipment accordingly. The thermostat calls may include but are not limited to, the heat call, the cooling call, the continuous fan call, the dehumidification call, the humidify call, and/or the fresh air call. It is understood, that block  50  is optional, and may or may not be included in the method  500 . 
     At block  506 , an indoor air handler  24  is commanded to provide conditioned air to the first zone  210  in accordance with the electronic signal received from the thermostat  130 . Block  506  may further include that a variable speed blower  25  of the indoor air handler  24  is activated to provide conditioned air to the first zone  210  in accordance with the electronic signal received from the thermostat  130 . 
     Block  506  may also include that a damper  34  for the first zone  210  is actuated to provide conditioned air to the first zone  210  in accordance with the electronic signal received from the thermostat  130 . The damper  34  may be opened fully or opened partially to provide the conditioned air to the first zone  210 . 
     Block  506  may also include that a damper  34  for a second zone  220  is actuated to provide conditioned air to the first zone  210  in accordance with the electronic signal received from the thermostat  130 . The damper  34  for the second zone  220  may be closed fully or closed partially to provide the conditioned air to the first zone  210 . 
     While the above description has described the flow process of  FIG.  3    in a particular order, it should be appreciated that unless otherwise specifically required in the attached claims that the ordering of the steps may be varied. 
     As described above, embodiments can be in the form of processor-implemented processes and devices for practicing those processes, such as processor. Embodiments can also be in the form of computer program code (e.g., computer program product) containing instructions embodied in tangible media (e.g., non-transitory computer readable medium), such as floppy diskettes, CD ROMs, hard drives, or any other non-transitory computer readable medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes a device for practicing the embodiments. Embodiments can also be in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes a device for practicing the exemplary embodiments. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits. 
     The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ±8% or 5%, or 2% of a given value. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof. 
     While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.