Direct expansion air conditioning system with separate outdoor air latent cooling and return air sensible cooling arrangements

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a national stage entry of PCT/AU2015/000522 filed Aug. 28, 2015, which claims convention priority from Australian provisional patent application 2014903479 filed on 1 Sep. 2014, the contents each of which are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

The present invention relates to an improved air conditioning system, specifically a direct expansion air conditioning system where air supplied to a conditioned space is directly cooled by a refrigerant supplied evaporator.

BACKGROUND OF INVENTION

Conventional air conditioning design theories were challenged in the 1990's by a series of innovative thoughts developed by the late Dr Allan Shaw. These thoughts culminated with the air conditioning control system described in Dr Shaw's Australian patent 728987. This patent, and the system it describes, is now owned by the present applicant and will be referred to throughout this specification as the “Shaw system”.

The Shaw system is a system that operates air conditioning functions in parallel to separate the process of treating latent loads (typically to remove moisture from outdoor air) and sensible loads (typically internal air which is dry). The Shaw system differs from conventional air conditioning processes in that, rather than drawing untreated outdoor air and then cooling it within the total air conditioning system, incoming outdoor air is pre-treated (dehumidified and cooled) by a first, separate outdoor-air heat exchanger before being merged with typically dry (treated or untreated) inside air that generally has been cooled by a second heat exchanger. The two air streams are merged, to then be delivered to a conditioned space.

Additionally, the Shaw system includes the passage of the same cooling medium stream (typically water) through both heat exchangers, in series, to maximize efficiency.

The Shaw system thus describes broad concepts of two evaporator coils, configured into one refrigeration circuit. However, the description of the method of operation of the refrigeration circuit in Australian patent 728987 is only briefly conceptualised.

An aim of the present invention is to enhance the Shaw system, in particular by providing improved refrigeration componentry and control methodology that more clearly allows for the adoption of the Shaw system in a direct expansion air conditioning system, with the incorporation of additional energy efficiency componentry and control methodology.

Having said that, the present invention also aims to provide an air conditioning system that is well suited to allow compliance with building standards that relate to ventilation amenity in buildings, while at the same time reducing energy usage by the building to desirably low levels.

In this respect, there is increasing importance being placed upon the use of adequate proportions of outside air to provide a building's occupants with a healthy and comfortable environment. Indeed, requirements for the maintenance of CO₂levels in buildings below unhealthy and dangerous levels are increasingly being mandated in countries via local building codes and standards. An example is Standard 62.1 of the ASHRAE 62 Standard titled “Ventilation and Acceptable Indoor Air Quality in Commercial, Institutional and High-Rise Residential Buildings”.

However, the use of higher proportions of outside air (to help achieve compliance with the maintenance of CO₂levels in buildings below unhealthy and dangerous levels), such as by opening dampers by greater extents or for longer periods, typically requires higher energy usage in air conditioning systems, particularly when the ambient conditions include higher temperatures or higher humidity levels. At a time when building owners are also under pressure to reduce overall energy usage, this tension between adequate ventilation with outside air and low energy use is driving the development of improved air conditioning systems.

Before turning to a summary of the present invention, it must be appreciated that the above description of the prior art has been provided merely as background to explain the context of the invention. It is not to be taken as an admission that any of the material referred to was published or known, or was a part of the common general knowledge in Australia or elsewhere.

SUMMARY OF INVENTION

The present invention provides an air conditioning system, the air conditioning system being capable of treating a conditioned space by treating outdoor air from outside the conditioned space and treating air returned from inside the conditioned space, and mixing the outdoor air with the returned air to form supply air for the conditioned space, the air conditioning system including:

- an outdoor air latent cooling treatment stage and a return air sensible cooling treatment stage, and
- an air mixer for mixing outdoor air with return air to form the conditioned space supply air;
  
  wherein the outdoor air latent cooling treatment stage includes a dehumidification evaporator and the return air sensible cooling treatment stage includes a sensible evaporator, both evaporators being coupled to a direct expansion refrigeration circuit, and wherein the dehumidification evaporator thermal capacity is regulated in response to conditioned space humidity and the sensible evaporator thermal capacity is regulated in response to conditioned space dry bulb temperature.

In one form of the present invention, the two evaporators will be configured in parallel so as to separately treat outdoor air and return air. In another form of the present invention, the two evaporators will be configured in series such that the outdoor air is treated by the dehumidification evaporator, the treated outdoor air to then be mixed with untreated return air, with the mixed air stream then being treated by the sensible evaporator. In the preferred arrangement, the evaporators are configured in parallel, which will be the arrangement that is generally described in the following description.

The dehumidification evaporator provides latent cooling to the outdoor air used to ventilate the conditioned space. In a preferred form, air is induced by a system supply air fan and airflow is regulated by an automated damper, with the ambient airflow volume measured by a differential pressure sensor and an included ambient air sensor preferably incorporating carbon dioxide, dry bulb and humidity sensing. Liquid refrigerant flow through the dehumidification evaporator is preferably regulated through the evaporator by automated stop and metering valves.

The sensible evaporator provides sensible cooling to the conditioned space return air. In a preferred form, air is again induced by the system supply air fan with the supply airflow being regulated by a variable frequency drive coupled to the supply air fan, and with the return airflow volume being measured by a differential pressure sensor and an included return air sensor that preferably incorporates carbon dioxide, dry bulb and humidity sensing. Liquid refrigerant flow through the sensible evaporator is again preferably regulated through the evaporator by automated stop and metering valves.

The present invention thus provides the opportunity to control both dry bulb temperature and humidity within the conditioned space by maintaining separation of the airflow associated with ventilating the conditioned space from the airflow required to offset the sensible heat load of the conditioned space. The use of outdoor air, desirable for maintaining ventilation amenity in a building but usually problematic for the energy usage of air conditioning systems, is advantageous and important in a system in accordance with the present invention.

In this respect, as buildings have become more efficient at sheltering the occupied space from ambient conditions, the relationship between the ratio of latent cooling and sensible cooling has increased, typically resulting in elevated humidity within the building, thereby causing discomfort to occupants. In addition to this, the part load operation of conventional direct expansion refrigerated air conditioning systems preferentially satisfies sensible loads over that of latent loads, thereby accentuating the potential for occupant discomfort from elevated humidity within the conditioned space. On the other hand, the present invention enhances the sophistication of refrigeration componentry to the extent that the latent cooling capacity can be separately regulated from the sensible cooling capacity, thus more easily satisfying comfort conditions with the space.

The system of the present invention may also include a liquid refrigerant receiver that stores transitional refrigerant, preferably being able to provide both storage and regulation of liquid flow through the system. Ideally, the liquid refrigerant receiver is capable of performing at least some oil separation (of the compressor oil from the refrigerant) and will also aid in determination of the required compressor refrigerant mass flow rate to meet system load to achieve enhanced flow of refrigerant and oil through the system. In a preferred form, the liquid refrigerant receiver incorporates liquid level sensing, an automated pressure equalization valve and automated oil return valves.

Ideally, the liquid refrigerant receiver is also capable of providing a greater refrigerant mass charge, reducing the potential for an excessive gas compression ratio and improving evaporator heat transfer efficiency by its use as an oil separator. The present invention preferably incorporates a two stage refrigerant oil separation system that reduces oil flow through the system, which increases evaporator heat transfer efficiency, thereby reducing the potential physical size of the evaporators and improves the performance of refrigerant metering valves to more closely approximate capacity delivery to offset the presented heat load.

Such a two stage refrigerant oil separation system will ideally include a first stage hot gas (oil) separator and a second stage cool liquid (oil) separator, the latter being provided, in a preferred form, by the liquid refrigerant receiver. In this form, both separators return separated oil to the compressor via suction gas refrigerant. In this respect, the traditional use of reduced capacity liquid receiving devices (or the total omission of such devices) in small space, air cooled, direct expansion air conditioning systems reduces the mass of refrigerant within the system, rendering the mass charge more important in the performance of the system and providing an improvement to the energy efficiency of the system over time.

The present invention thus provides not only relative independence of control of latent and sensible capacity delivery through its inclusion of dual evaporators, but it also enhances the variability of capacity delivery through the separation of control of the refrigerant mass flow by the compressor, determined by space loads, to the volumetric use of liquid refrigerant within the system, by the inclusion of the liquid refrigerant receiver and its preferred role as a second stage oil separator. In this respect, it will be appreciated that the present invention ideally meters refrigerant mass flow on the basis of evaporator loads and not the quality of suction gas. This permits the suction gas to return to the compressor with a higher rate of super-heat, thereby enhancing the refrigerant mass flow refrigeration effect.

The present invention preferably also utilizes refrigerant temperature sensing to provide heat rejection relative to the potential for cooling from the ambient dry bulb temperature and the potential for liquid refrigerant sub cooling to enhance the refrigeration effect from the potential for cooling from the ambient wet bulb temperature. In a preferred form, the system of the present invention includes a sub-cool heat exchanger to reject heat into the local ambient air to sub cool liquid refrigerant. In one form, the sub-cool heat exchanger can incorporate an adiabatic pre-cooling media, or a progressive indirect adiabatic cooling process, together with a fan to move air through the condensers, a refrigerant temperature sensor and a variable performance drive to regulate the mass flow rate of the fan.

The refrigeration effect of the system of the present invention may be further enhanced through the reclaim of energy from the latent cooling load to sub-cool the heat of rejection to approach the evaporator operating temperature. A reduction of the temperature of the liquid refrigerant feeding the evaporators enhances the potential refrigeration effect, resulting in a reduced compressor mass flow rate. In this respect, the system of the present invention may also include a system for the capture and utilization of latent cooling condensate to regain energy associated with the latent cooling process, preferably in the form of a sub-cool heat exchanger to sub-cool liquid refrigerant utilizing condensate collected from the dehumidification evaporator of the outdoor air latent cooling treatment stage.

The system of the present invention thus ideally provides a three stage heat of rejection process that incorporates an ambient condenser, the sub-cool heat exchanger and the sub-cool heat exchanger to achieve an enhanced refrigeration effect for the circulating refrigerant mass flow rate. The use of such a three stage heat of rejection process incorporating sub-cooling from the system latent cooling load as determined by the space humidity sensor, and the decoupling of the compressor suction condition from direct management of the refrigerant flow rate, assists to enhance the utilization of the refrigeration effect potential of the low pressure transition from sub-cooled liquid to super-heated gas.

Furthermore, through the preferred use of dry bulb, wet bulb and suction temperature sub-cooling control of head pressure and load determined evaporator temperature, and suction super-heating, a resulting increase in refrigeration effect is seen with reduced compression ratios. This reduces the energy required to develop refrigerant compression, thereby improving the compressor refrigeration coefficient of performance.

Before turning to a more detailed description of a preferred embodiment of a direct expansion air conditioning system in accordance with the above broad descriptions, it will thus be appreciated that the system of the present invention provides cooling to a conditioned space that manages both dry bulb temperature and moisture content to enhance occupant comfort.

In one preferred form described above, the system ideally utilizes ambient dry bulb, ambient vapour pressure and reclaim of space latent cooling to reduce the condensing temperature associated with low pressure expansion to extend the refrigeration effect of the compressor mass flow rate.

In another preferred form described above, the system alternatively or in addition utilizes a liquid receiver to de-couple compressor mass flow from variable heat load requirements, thereby reducing compressor discharge pressure and permitting enhanced utilization of refrigerant gas super heat within the evaporators.

In yet another preferred form described above, the system alternatively or in addition utilizes a two stage compressor oil separation process to enhance heat transfer of both the condenser and evaporators, and alternatively or in addition utilizes ambient and conditioned space sensors to regulate the rate of introduction of outdoor air for amenity and the rate of supply air circulation to deliver cooling to the space.

The adoption of some or all of these preferred forms in a direct expansion air conditioning system broadly in accordance with the present invention reduces energy consumption associated with providing the required levels of comfort and amenity (particularly with regard to ventilation) for occupants of a conditioned space.

BRIEF DESCRIPTION OF DRAWINGS

Having briefly described the general concepts involved with the present invention, a preferred embodiment of a direct expansion air conditioning system will now be described that is in accordance with the present invention. However, it is to be understood that the following description is not to limit the generality of the above description.

FIG. 1A is a flow diagram of a preferred embodiment of a direct expansion air conditioning system in accordance with the present invention.

FIG. 1B is a chart highlighting the various elements illustrated in FIG. 1A.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

For ease of understanding, the following description will first provide a general overview of the flow diagram of FIG. 1A, followed by a more detailed explanation (in a table) of the different elements of the flow diagram.

In general terms, shown in the flow diagram of FIG. 1A is a direct expansion air conditioning system where return air Y from the conditioned space O is psychrometrically treated separately (and thus in parallel) from the outdoor air X (for ventilation) to achieve independent control of latent and sensible cooling. Following this separate treatment of the return air Y and the outdoor air X, the two air streams are then mixed to provide a single conditioned space supply air stream Z to be delivered to the conditioned space O.

The cooling process for the return air stream Y is principally sensible cooling, which is conducted in the return air sensible cooling treatment stage represented in this embodiment by a sensible evaporator H placed in the return air stream Y. The cooling process for the outdoor air stream X is principally latent cooling, which is conducted in the outdoor air latent cooling treatment stage represented in this embodiment by a dehumidification evaporator G placed in the outdoor air stream X.

As will be outlined in the following tabular description of the various components in the preferred embodiment, the thermal capacity of the dehumidification evaporator G is regulated in response to a desired conditioned space humidity set point, together with a load driven variance from that set point. Also, the thermal capacity of the sensible evaporator H is regulated in response to a desired conditioned space dry bulb temperature set point, together with a load driven variance from that set point.

The following table (Table 1) provides a more detailed explanation of the various elements illustrated in the flow diagram of FIG. 1A and corresponds with the table in FIG. 1B, noting that the following schematic designations have been used for various of the control and sensor functions in the flow diagram:

- M—Motor operated valves
- VF—Variable fan control
- S—Solenoid valves
- AS—Ambient air sensors
- CS—Combined air sensors (also referred to as supply air sensors)
- RS—Room air sensors
- VS—Velocity sensors (also referred to as air velocity sensors)
- SS—Sump sensors (also referred to as reservoir sensors)
- LS—Level sensors (also referred to as liquid refrigerant sensors)
- RFS—Refrigeration sensors.

TABLE 1

Identification of Components in Figures 1A and 1B

Ref
Function

A
The component compresses the gaseous refrigerant and provides

refrigerant mass flow through the system. The variable performance

drive increases or decreases the compressor refrigerant mass flow.

J
The component measures refrigerant pressure and temperature.

K
The component permits fluid or gas flow in only one direction.

B
The component is a mechanical device that separates oil from the

refrigerant flow to return it to the compressor and to reduce oil

flow through the evaporators.

C
The component acts as a heat exchanger to reject a portion of the

sum of the heat of compression and the refrigeration effect into the

local ambient air. It incorporates a fan to move air through the heat

exchanger, a refrigerant temperature sensor and a variable

performance drive to regulate the air mass flow rate of the fan.

D
The component acts as a sub-cool heat exchanger to reject heat into

the local ambient air to sub-cool liquid refrigerant. It can

incorporate an adiabatic pre-cooling media or a progressive indirect

adiabatic cooling process, a fan to move air through the heat

exchangers, a refrigerant temperature sensor and a variable

performance drive to regulate the mass flow rate of the fan.

E
The component acts as a liquid refrigerant receiver for the storage

and regulation of liquid flow through the system. It incorporates

liquid level sensing, automated pressure equalization valve and

automated oil return valves.

F
The component acts as a sub-cool heat exchanger to sub-cool liquid

refrigerant utilizing condensate collected from the evaporators'

latent cooling effect.

G
This is the air mixer. The component acts as a dehumidification

evaporator to provide latent cooling to the outdoor air used to

ventilate the conditioned space. Air is induced by the system supply

air fan. Airflow is regulated by an automated damper. Liquid

refrigerant flow is regulated through the evaporator by automated

stop and metering valves. The ambient air sensor incorporates

carbon dioxide, dry bulb and humidity sensing. The ambient

airflow volume is measured by a differential pressure sensor.

H
The component acts as a sensible evaporator to provide sensible

cooling to the conditioned space return air. Air is induced by the

system supply air fan. Liquid refrigerant flow is regulated through

the evaporator by automated stop and metering valves. The return

airflow volume is measured by differential pressure sensor.

L
The component provides air movement through the system and the

conditioned space. Sensors monitor the dry bulb and humidity of

the return air and outdoor air exiting the evaporators. A mixed air

space collects conditioned air from the dehumidification evaporator

G and the sensible evaporator H. The supply airflow Z is regulated

by variable performance control of the supply air fan.

I
The component receives gaseous refrigerant and oil and regulates

the flow of gas and liquid for return to the compressor. Suction

pressure and temperature is measured.

M
The component receives condensate via a condensate tray from the

latent cooling process and transfers energy from the sub-cool heat

exchanger F to the condensate. The condensate return is automated

to maintain condensate volume within the tray and condensate

transfer is automated to divert flow to the sub-cool heat

exchanger D.

N
The component adiabatically cools ambient air to provide sub-

cooling to the liquid refrigerant. Condensate is received from the

latent cooling process or from an automated water feed. Water is

recirculated over the cooling media by a circulating pump. A sensor

in the water reservoir detects water level.

O
The conditioned space accepts supply air Z and permits air to

circulate through to relieve sensible and latent heat from the space

to recirculate to the sensible evaporator H. Space conditions are

measured by dry bulb, humidity and carbon dioxide sensors.

P
The component controls the system through the input sensors,

operator set points, logic algorithms and controlled devices.

The system is managed through an operator interface and

monitored through an external interface.

It will be appreciated that Table 1 above describes the different air conditioning componentry that makes up the physical form of the preferred embodiment. The following table (Table 2) describes the logic algorithms that form the basis of the control of the preferred embodiment.

TABLE 2

Logic Algorithms for Control of Components in FIG. 1A

Strategy
Functionality

Sensible cooling
If the space dry bulb temperature is 0.1 degrees or greater

control strategy
than set point, initiate the outdoor air economy cycle

increasing deviation
strategy and incrementally increase the outdoor airflow

above set point
economy cycle set point.

If the space dry bulb temperature is 0.1 degrees or greater than set

point, energize the return air evaporator liquid refrigerant stop valve

to open.

If the space dry bulb temperature 0.5 degrees greater than set point,

commence incremental opening of the return air evaporator liquid

refrigerant metering valve.

If the return air evaporator liquid refrigerant metering valve

opens to a position greater than 50%, commence

incrementally increasing the supply air flow set point.

If the supply air flow set point increases to greater than

70% output, energize the outdoor air evaporator liquid

refrigerant stop valve to open and commence incremental

drive of the outdoor air evaporator liquid refrigerant

metering valve.

If the outdoor air evaporator liquid refrigerant metering

valve position actuator valve opens to a position greater

than 50%, commence incrementally decreasing the

compressor suction pressure set point.

Sensible cooling
If the space dry bulb temperature is 0.1 degrees or greater

control strategy
below set point, commence incrementally increasing the

increasing deviation
compressor suction set point.

below set point
If the space dry bulb temperature is 0.5 degrees or greater

less than set point, commence incremental drive of the

outdoor air evaporator liquid refrigerant metering valve

position actuator valve to close.

If the space dry bulb temperature is 0.5 degrees or greater

less than set point, and the outdoor air evaporator liquid

refrigerant metering valve has been driven closed,

de-energize the outdoor air evaporator liquid refrigerant stop

valve to close and commence incremental drive of the

return air evaporator liquid refrigerant metering valve to close.

If the return air evaporator liquid refrigerant metering valve

drives to a position less than 70%, commence

incrementally decreasing the supply air flow set point.

If the return air evaporator liquid refrigerant metering valve

has been driven closed to 0%, de-energize the return air

evaporator liquid refrigerant stop valve to close.

If the supply airflow set point has reduced to less than

50%, incrementally decrease the outdoor airflow economy

cycle set point.

Latent cooling control
If the space dew point temperature is 0.1 degrees or

strategy increasing
greater than set point, energize the outdoor air evaporator

deviation above set
liquid refrigerant stop valve to open.

point
If the space dew point temperature is 0.5 degrees greater

than set point, commence incremental drive opening of the

outdoor air evaporator liquid refrigerant metering valve.

If the outdoor air evaporator liquid refrigerant valve opens

to a position greater than 50%, commence incrementally

increasing the outdoor air flow set point.

If the outdoor air flow set point increases to greater than

70%, commence incrementally decreasing the compressor

suction set point.

Latent cooling control
If the space dew point temperature is 0.1 degrees or

strategy decreasing
greater below set point, commence incrementally

deviation below set
increasing the compressor suction set point.

point
If the space dew point temperature is 0.5 degrees or

greater less than set point, commence incremental drive of

the outdoor air evaporator liquid refrigerant metering valve

to close.

If the space temperature is 0.5 degrees or greater less

than set point, and the outdoor air evaporator liquid

refrigerant metering valve position actuator valve has been

driven to less than 50%, commence reducing the outdoor

air flow set point.

If the space temperature is 0.5 degrees or greater less

than set point, and the outdoor air flow set point has

reduced to minimum, and the outdoor air evaporator liquid

refrigerant metering valve has been driven closed to 0%,

de-energize the outdoor air evaporator liquid refrigerant

stop valve to close.

Supply air flow set
The supply airflow set point will be maintained between a

point
minimum set point and a maximum set point. The supply

airflow set point will be adjusted by the sensible cooling

control strategy.

The supply airflow will be calculated by the addition of the

outdoor airflow and the return airflow.

Supply air flow greater
If the supply airflow is greater than the supply airflow set

than set point
point, incrementally decrease the supply air fan speed.

Supply air flow less
If the supply airflow is less than supply airflow set point,

than set point
incrementally increase the supply air fan speed.

Outdoor airflow set
The outdoor airflow set point will be maintained between a

point
minimum ventilation set point, a maximum ventilation set

point and a maximum outdoor airflow set point for economy

cycle operation. The outdoor airflow set point will be adjusted the

greater of any of the latent cooling strategy, the outdoor air

economy strategy or the CO₂concentration strategy.

Outdoor air flow
If the outdoor airflow is greater than the outdoor airflow set

greater than set point
point, incrementally close the outdoor air throttling damper.

Outdoor air flow less
If the outdoor airflow is below the outdoor airflow set point

than set point
incrementally open the outdoor air throttling damper.

CO₂concentration
If the concentration of CO₂within the return air rises above

strategy
set point, increase the outdoor ventilation airflow set point.

If the concentration of CO₂within the return air falls below

set point, decrease the outdoor ventilation airflow set point.

Outdoor air economy
If the ambient dewpoint is less than the space dew point,

strategy
and the ambient dry bulb is less than the space dry bulb,

enable operation of the outdoor air throttling damper

economy cycle.

If the ambient dew point is greater than the space dew

point, and the ambient dry bulb is greater than the space

dry bulb, disable operation of the outdoor air throttling

damper economy cycle.

Return airflow
The return airflow calculation will be determined utilizing

calculation
the return air evaporator coil differential sensor, the

entering return air evaporator coil dew point sensor and the

leaving return air evaporator coil dew point sensor.

The return air coil airflow will be determined in accordance

with a wetted coil dew point calculation.

Outdoor airflow
The outdoor airflow calculation will be determined utilizing

calculation
the outdoor air evaporator coil differential sensor, the

entering outdoor air evaporator coil dew point sensor and

the leaving outdoor air evaporator coil dew point sensor.

The outdoor air coil airflow will be determined in

accordance with a wetted coil dew point calculation.

Compressor start
The compressor variable performance drive will be

energized in response to the low liquid refrigerant level

compressor start sensor, providing there is a minimum of

opening of either the outdoor air evaporator liquid

refrigerant thermal expansion flow metering valve or the

return air evaporator liquid refrigerant thermal expansion

flow metering valve.

If the low liquid refrigerant sensor detects an absence of

liquid refrigerant, energize the liquid receiver gas relief stop

valve to open for a time period and energize the compressor

variable performance drive to operate at low speed.

Liquid receiver low
The liquid receiver refrigerant low level will be regulated by

level charging
the low liquid refrigerant level sensor.

If the low liquid refrigerant level sensor detects an absence

of liquid refrigerant, increase the frequency of the

compressor variable performance drive.

Liquid receiver high
The liquid receiver refrigerant high level will be regulated

level charging
by the high liquid refrigerant level sensor.

If the high liquid refrigerant level sensor detects the

presence of liquid refrigerant, decrease the frequency of

the compressor variable performance drive.

Compressor stop
The compressor variable performance drive will be de-

energized in response to the high liquid refrigerant level

compressor stop sensor.

If the high liquid refrigerant level compressor stop sensor

detects the presence of liquid refrigerant, de-energize the

compressor variable performance drive.

Compressor oil return
Oil will be returned to the compressor in response to the

transition liquid refrigerant level sensor.

When the transition liquid refrigerant level sensor detects a

change of state from an absence of liquid refrigerant to a

presence of liquid refrigerant/oil, energize the oil return

stop valve to open and drive the oil return metering valve

open to a fixed position.

After a time duration, de-energize the oil return stop valve

to close and drive closed the oil return metering valve.

Compressor suction
If the liquid refrigerant mass flow rate is not adequate to

pressure set point
satisfy sensible and latent cooling, the compressor variable

frequency drive will be advanced by either the sensible or

latent cooling strategies through detecting the refrigerant

suction pressure. The set point at commencement of a

signal from either the sensible or latent cooling strategies

will be the pressure at commencement.

On receipt of a lowering or raising suction pressure signal

from either the sensible or latent cooling strategies, lower

or raise the refrigerant suction pressure set point. The

lowering of set point adjustment will take precedence over

the raising of set point signal.

Compressor suction
The compressor variable performance drive will increase or

pressure
decrease frequency in response to the compressor suction

pressure set point. The frequency will be increased

incrementally when the suction pressure is higher than the

suction pressure set point. The frequency will be

decreased incrementally when the suction pressure is

lower than the suction pressure set point.

Condenser fan start
The condensing fans will be energized to maintain

condensing liquid temperature near ambient conditions.

If the differential temperature between the sub-cooled high

pressure liquid refrigerant temperature and the entering

outdoor air dry bulb temperature is greater than the start

differential temperature set point, energize the condenser

fan variable frequency drive and commence operation at

minimum frequency.

Condenser fan stop
The condensing fans will be de-energized to conserve

energy when condensing temperature approaches ambient

conditions.

If the differential temperature between sub-cooled high

pressure liquid refrigerant temperature and the entering

outdoor air dry bulb temperature is less than the stop

differential temperature set point, de-energize the

condenser fan variable performance drive.

Condensing
The condensing head pressure will be regulated by the

temperature control
high pressure liquid refrigerant temperature and ambient

dry bulb temperature.

If the differential temperature between the sub-cooled high

pressure liquid refrigerant temperature and the entering

outdoor air dry bulb temperature is greater than the control

differential set point (and rising), increase the condenser

fan variable performance drive frequency.

If the differential temperature between the sub-cooled high

pressure liquid refrigerant temperature and the entering

outdoor air dry bulb temperature is less than the control

differential set point (and falling), decrease the condenser

fan variable performance drive frequency.

Sub-cooler fan start
The sub-cooler fan will be energized to maintain liquid

temperature near ambient wet bulb conditions.

If the differential temperature between the sub-cooled high

pressure liquid refrigerant temperature and the outdoor air

wet bulb temperature is greater than the start differential

temperature set point, energize the sub cooler fan variable

performance drive and commence operation at minimum

frequency, and energize the sub-cooler water circulating

pump..

Sub-cooler fan stop
The sub-cooler fan will be de-energized to conserve

energy when condensing temperature approaches ambient

conditions.

If the differential temperature between sub-cooled high

pressure liquid refrigerant temperature and the entering

outdoor air wet bulb temperature is less than the stop

differential temperature set point, de-energize the

condenser fan variable performance drive and the sub-

cooler water circulating pump.

Sub-cooler reservoir
The sub-cooler reservoir will be water filled at the

fill
commencement of compressor operation daily.

At the commencement of the first compressor operation of

the day, de-energize closed the water discharge stop valve

and energize open the water feed stop valve. When the

reservoir high level water sensor detects water,

de-energize to close the water feed valve and energize the

adiabatic cooler circulating pump in conjunction with the

sub-cooler fan operation. When the reservoir mid-level

water sensor detects an absence of water, energize open

the water feed stop valve.

De-energize the cooler pump when an absence of water is

detected at the reservoir low level sensor.

At the cessation operation of the supply air fan, the water

discharge valve will be energized open and the feed water

valve will be de-energized closed.

Sub-cooler
The sub-cooler temperature will be regulated by the high

temperature control
pressure liquid refrigerant temperature and ambient wet

bulb temperature.

If the differential temperature between the sub-cooled high

pressure liquid refrigerant temperature and the entering

outdoor air wet bulb temperature is greater than the control

differential set point (and rising), increase the sub-cooler

fan variable performance drive frequency.

If the differential temperature between the sub-cooled high

pressure liquid refrigerant temperature and the entering

outdoor air evaporator wet bulb temperature is less than

the control differential set point (and falling), decrease the

sub-cooler fan variable performance drive frequency.

Head pressure safety
If the head pressure safety switch rises above the safe to

operate set point, trip the manual reset switch to open the

start circuit to the compressor contactor.

The head pressure safety switch monitoring relay will

change state from normally open to closed to identify a

head pressure safety switch intervention.

Head pressure safety
If head pressure sensor rises above the head pressure

incident
warning set point, reduce the compressor variable

frequency drive incrementally and increase condenser fan

variable frequency drive incrementally to reduce the head

pressure to a safe operating pressure differential below the

head pressure warning set point and raise a head pressure

safety incident notice.

If head pressure sensor falls below the safe to operate

pressure differential following a head pressure safety

incident, resume compressor, liquid refrigerant and

condenser head pressure control strategies and raise

resumption of automatic head pressure control notice.

Low pressure safety
If suction pressure safety switch falls below a saturated

suction temperature (SST) pressure of 0° C., trip the

manual reset switch to open the start circuit to the

compressor contactor.

The low pressure safety switch monitoring relay will

change state from normally open to closed to identify

a low pressure safety switch intervention.

Low pressure safety
If suction pressure sensor falls below a SST pressure of

incident
4° C., reduce the compressor variable frequency drive

incrementally and raise a suction pressure safety incident notice.

If the suction pressure sensor rises to above a SST

pressure of 8° C. following a suction pressure safety

incident, resume compressor control and raise resumption

of automatic suction pressure control notice.

Low suction
If the suction temperature sensor falls below 6° C., reduce

temperature safety
compressor variable performance drive frequency

incident
incrementally and raise a suction temperature safety

incident notice.

If the suction temperature sensor rises to above 10° C.,

following a suction temperature safety incident resume

compressor control and raise resumption of automatic

suction temperature control notice.

Super-cooler operation
Operation of liquid refrigerant super-cool heat exchanger

will be managed utilizing the condensate tray water level

sensor, the condensate circulating pump, the condensate

return automated shut off valve and the condensate

transfer automated shut off valve.

Operation of the valves and pump will be sequential as

follows:

When the mid level condensate tray water level sensor

indicates the presence of condensate, the condensate

return stop valve will be energized to open and the

condensate circulating pump will be energized.

When the high level condensate tray water level sensor

indicates the presence of condensate, the condensate

transfer stop valve will be de-energized to open and the

condensate return stop valve will be de-energized closed.

When the high level condensate level sensor indicates the

absence of condensate, the condensate return stop valve

will be energized to open and the condensate transfer stop

valve will be de-energized to close.

When the low level condensate level sensor indicates an

absence of condensate, the condensate pump will be de-

energized.

At the cessation operation of the supply air fan, the

condensate transfer valve will be de-energized open, the

condensate return valve will be de-energized closed and

the condensate pump be energized for a time period to

evacuate condensate from the tray.

Refrigeration sensors
Compressor head pressure safety switch

Compressor discharge temperature

Compressor discharge pressure

Condenser exiting liquid temperature

Sub-cooler exiting liquid temperature

Liquid receiver temperature

Liquid receiver pressure

Super-cooler exiting liquid temperature

Compressor suction pressure safety switch

Compressor suction temperature

Compressor suction pressure

Ambient air sensors
Entering evaporator dry bulb

Entering evaporator dew point

Carbon dioxide

Evaporator pressure differential

Exiting evaporator dry bulb

Exiting evaporator dew point

Return air sensors
Dry bulb remote space located

Dew point remote space located

Carbon dioxide remote space located

Entering evaporator dry bulb

Entering evaporator dew point

Evaporator pressure differential

Exiting evaporator dry bulb

Exiting evaporator dew point

Supply air sensors
Dry bulb

Dew point

Water sensor
Condensate tray high level

Condensate tray mid level

Condensate tray low level

Sub-cooler reservoir high level

Sub-cooler reservoir mid level

Sub-cooler reservoir low level

Comfort reporting
The comfort of occupants will be evaluated consistent with

ASHRAE PMV calculator.The conditioned space dry bulb,

dew point and a quotient of the supply air quantity will be

used as input. A trend of the notional PMV will be logged.

Energy Efficiency
Compressor COP

calculating
The compressor COP will be calculated at intervals

utilizing the following input devices:

Compressor kW - extract energy consumption from

compressor variable frequency drive high level

interface

Ambient dry bulb

Ambient dew point

Leaving outdoor air evaporator dewpoint

Leaving outdoor air evaporator dry bulb temperature

Return air dry bulb

Return air dew point

Leaving return air evaporator dewpoint

Leaving return air evaporator dry bulb temperature

Outdoor airflow

Return airflow

The compressor refrigeration effect will be

calculated.

Compressor COP will calculated.

The compressor COP will be trend logged.

System COP

The system COP will be calculated at intervals utilizing the

following high level interfaces from the compressor

refrigeration effect calculation and the following variable

performance drive high level interfaces:

Compressor

Supply air fan

Condenser air fans

Sub cooler fans

The system COP will be trend logged.

Trend and event
All input sensors and output events will be trend log

logging
capable.

Alarm events
All input sensors and variable frequency drives will be

alarm event capable.

Operator interface
All controlled devices, input sensors, operator set points,

trend logs and alarm identification and cancelling will be

accessible to for via a tiered access review through a

graphical operator interface.

External interface
The operator interface will be accessible through an

internet web based external connection.

Alarming events will generate internet email messaging to

identified plant operators.

As will be appreciated from Table 1 and Table 2, the use of evaporators to separately manage space dry bulb and space humidity enhances occupant comfort, while the use of control algorithms to regulate liquid refrigerant to the evaporators in response to space load conditions enhances the utilization of evaporator heat transfer capabilities to extend the refrigeration effect of the circulating refrigerant mass flow. Also, the preferred use of sub-coolers and sub-coolers in the heat of rejection condensing process extends the refrigeration effect of the circulating refrigerant mass flow and reduces compressor head pressure, and the preferred use of liquid refrigerant sensing decouples the volumetric dependence of compressor head pressure from compressor suction pressure.

In conjunction with the preferred use of liquid refrigerant metering valves and suction gas set point management, the adoption of these components configured in the manner described enables evaporators to operate at higher saturation temperature, thereby reducing compressor pressure lift requirements for generation of an enhanced refrigeration effect.

Additionally, the preferred use of volumetric calculation of outdoor air flow and supply airflow in response to feedback signals to provide ventilation amenity and space comfort, reduces both heat load and air circulation energy consumption.

A person skilled in the art will understand that there may be variations and modifications other than those specifically described. It is to be understood that the invention includes all such variations and modifications. The invention also includes all components, steps, functions and features referred to, or indicated in this specification, individually or collectively, and any and all combinations of any two or more of those components, steps, functions and features.

Number	Name	Date	Kind
5054542	Young	Oct 1991	A
5228302	Eiermann	Jul 1993	A
6488120	Longsworth	Dec 2002	B1
20020033024	Hebert	Mar 2002	A1
20060218965	Manole	Oct 2006	A1
20100018228	Flammang	Jan 2010	A1
20100065650	Phillips	Mar 2010	A1
20140102665	Sibik	Apr 2014	A1

Number	Date	Country
10027467	Dec 2001	DE
2008061297	May 2008	WO

Direct expansion air conditioning system with separate outdoor air latent cooling and return air sensible cooling arrangements

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

Field of Search

CPC

International Classifications

Term Extension

Abstract

Description

Claims

Priority Claims (1)

PCT Information

US Referenced Citations (8)

Foreign Referenced Citations (2)

Non-Patent Literature Citations (2)

Related Publications (1)

Entry
Written Opinion of the International Searching Authority in PCT/AU2015/000522 dated Nov. 11, 2015.
English Language Abstract of DE10027467 Obtained on Feb. 26, 2017.