1. Field of the Invention
The subject invention generally pertains to refrigerant systems and more specifically to a refrigerant circuit that offers a reheat mode of operation.
2. Description of Related Art
Conventional refrigeration systems comprising a compressor, a condenser, an expansion valve and an evaporator can be used to meet the sensible and latent cooling demands of a room or area in a building when the room temperature is appreciably above a target temperature. In some circumstances, however, high humidity can leave a room feeling uncomfortable even though the room temperature might be at or even below the target temperature. Although further cooling of the room can reduce the humidity, the additional cooling can make the air in the room feel cold and dank.
To avoid this problem, many refrigerant systems include a reheat mode where a heater downstream of the evaporator raises the temperature of the supply air after the evaporator cools the air to reduce the humidity. Such systems can effectively address the latent cooling or dehumidifying demand without subcooling the room. Although the reheat mode can be provided by electric heat or combustion, the system can be less expensive to operate if the reheat is provided by the refrigerant circuit itself. In some cases, for instance, the compressor discharges relatively hot refrigerant gas into an additional heat exchanger that reheats the air that was previously cooled by the evaporator.
Using an additional heat exchanger in such a manner, however, can create a problem regarding the system's refrigerant charge. Air conditioning systems typically require less refrigerant during a reheat mode than during a cooling-only mode. Unless the system has some means for adjusting its refrigerant charge, the system might have an excessive amount of refrigerant during the reheat mode or an insufficient supply during the cooling mode. Thus, the system's efficiency might suffer in the cooling and/or reheat mode.
Previous systems addressing reheat and charge control include those shown in U.S. Pat. No. 6,122,923 to Sullivan; U.S. Pat. No. 6,170,271 to Sullivan; U.S. Pat. No. 6,381,970 to Eber et al.; and, U.S. Pat. No. 6,612,119 to Eber et al.; all of which are commonly assigned to the assignee of the present invention and all of which are hereby incorporated by reference. Although some systems include a liquid receiver for storing excess refrigerant during the reheat mode, such systems can be expensive due to the cost of the added receiver and associated control valves. Consequently, a need exists for a simpler, more cost effective refrigerant reheat system.
It is an object of the present invention to provide a simpler, more cost effective refrigerant system with a reheat mode.
Another object of some embodiments is to adjust a refrigerant system's effective charge without using a liquid receiver dedicated for that purpose.
Another object of some embodiments is to monitor and control the amount of subcooling occurring in a reheat coil.
Another object of some embodiments is to adjust a refrigerant system's effective charge by using the auxiliary side connector of an expansion valve, wherein the auxiliary side connector is downstream of the valve's flow restriction and upstream of the valve's multi-line flow distributor.
Another object of some embodiments is to control the amount of subcooling in a reheat coil by adjusting a system's effective refrigerant charge.
Another object of some embodiments is to determine the level of subcooling in a reheat coil by sensing the temperature of the refrigerant leaving the coil and sensing the temperature of the refrigerant at a strategic intermediate point within the coil.
Another object of some embodiments is to switch the operation of a refrigerant system between a cooling-only mode and a reheat mode by selectively deactivating a main condenser or a reheat coil.
Another object of some embodiments is to store liquid refrigerant in an inactive condenser during a reheat mode.
Another object of some embodiments is to use a plurality of simple check valves to minimize the use of solenoid valves and other externally actuated control valves in switching a refrigerant system between a cooling-only mode and a reheat mode.
Another object of some embodiments is to use a combination evaporator and reheat coil that share a common set of heat exchanger fins rather than using two individual heat exchangers for cooling and reheat functions.
Another object of some embodiments is to reverse a refrigerant's direction of flow through a reheat portion of a heat exchanger while leaving the refrigerant's direction of flow through an evaporator the unchanged.
Another object of some embodiments is to deactivate a condenser during a reheat mode of operation.
Another object of some embodiments is to use a reheat coil in both a reheat mode and a cooling-only mode, wherein the reheat coil provides heat in the reheat mode and provides cooling in the cooling-only mode.
One or more of these and/or other objects of the invention are provided by a refrigerant system that is selectively operable in cooling mode and a reheat mode, wherein a main condenser is deactivated in the reheat mode and in some cases excess liquid refrigerant is stored therein.
A refrigerant system 10 includes a directional valve 12 that can configure system 10 in a cooling mode as shown in
For the embodiment of
In the cooling mode, directional valve 12 directs relatively high-pressure, high-temperature refrigerant discharged from compressor 14 to condenser 16, and reheat coil 20 is generally inactive. An outdoor fan 32 can be energized to force outside air 34 across condenser 16 so that air 34 cools and condenses the refrigerant in condenser 16. From condenser 16, the refrigerant flows sequentially through check valve 24 and expansion device 22. Upon passing through expansion device 22, the refrigerant cools by expansion before entering evaporator 18. The refrigerant flowing through evaporator 18 can cool a stream of air 36 that an indoor fan 38 forces across evaporator 18 and the currently inactive reheat coil 20. After passing through evaporator 18, the refrigerant returns to compressor 14 to perpetuate the cooling cycle.
In the cooling mode, check valve 26 inhibits liquid refrigerant from bypassing expansion device 22 thereby preventing the flooding of the inactive reheat coil 20. Solenoid valve 28 is closed to inhibit refrigerant from bypassing check valve 24 and expansion device 22. Solenoid valve 30 is normally kept open continuously. When open, solenoid valve 30 can convey refrigerant from reheat coil 20 to a point 40 between expansion valve 22 and evaporator 18.
In a currently preferred embodiment, point 40 is an auxiliary side port of expansion device 22, wherein expansion device 22 in this case comprises a Sporlan expansion valve p/n OZE-25-ZGA, a Sporlan multi-line distributor p/n 1117-13-¼″-C17, and a Sporlan auxiliary side port connector p/n ASC-11-7. Sporlan is based in Washington, Missouri and is a division of Parker Hannifin Corporation. Point 40 is downstream of Sporlan expansion valve p/n OZE-25-ZGA and upstream of Sporlan multi-line distributor p/n 1117-13-¼″-C17. Although the Sporlan assembly is currently preferred, other examples of expansion device 22 are well within the scope of the invention.
In the reheat mode, as shown in
During the reheat mode, check valve 24 inhibits liquid refrigerant from backflowing into inactive condenser 16. Directional valve 12 and solenoid valves 28 and 30 are controlled to maintain a desired level of subcooling in reheat coil 20. To do this, a system controller 42 determines and monitors the level of subcooling in reheat coil 20 and compares the level to an established subcooling target. The subcooling target can be a predetermined range of acceptable values, wherein the range lies between certain upper and lower limits.
In some embodiments, controller 42 (e.g., computer, programmable logic controller, or suitable electrical circuit) determines the level of subcooling in reheat coil 20 based on the difference between a first refrigerant temperature and a second refrigerant temperature, wherein a first sensor 44 monitors the first temperature at a first point that is between an inlet 46 and an outlet 48 of reheat coil 20, and a second sensor 50 monitors the second temperature at a second point that is downstream of the first point. The location of the first point can be about twice as far from inlet 46 than from outlet 48 so that the first temperature reflects the refrigerant's saturated temperature within reheat coil 20. The second point is preferably near outlet 48 so that the difference between the first and second temperatures, as determined by controller 42, reflects the level of subcooling in reheat coil 20.
If the level of subcooling is substantially at the subcooling target (e.g., within the predetermined acceptable range), controller 42 leaves solenoid valves 28 and 30 closed. Valve 28 being closed generally traps a substantially fixed amount of liquid refrigerant within condenser 16, and valve 30 being closed prevents subcooled liquid refrigerant within reheat coil 20 from bypassing expansion device 22 and rushing into evaporator 18.
If the level of subcooling is below the subcooling target, controller 42 opens solenoid valve 28 while leaving solenoid valve 30 closed. This allows solenoid valve 28 to convey liquid refrigerant from condenser 16 to evaporator 18 and ultimately to reheat coil 20 as compressor 14 forces gaseous refrigerant from evaporator 18 to reheat coil 20. Once the subcooling level increases to the subcooling target, controller 42 closes valve 28 while valve 30 is already closed.
If the level of subcooling is above the subcooling target, controller 42 temporarily shifts directional valve 12 to its position of
To carry out the operations just described with respect to the cooling and reheat modes, controller 42 can provide one or more various output signals 52 in response to one or more various input signals 54. Examples of inputs 54 might include, but are not limited to, an input 54a from temperature sensor 44 and an input 54b from temperature sensor 50. Examples of outputs 52 might include, but are not limited to, an output 52a to control fan 32, an output 52b to control fan 38, an output 52c to control compressor 14, an output 52d to control directional valve 12, an output 52e to control solenoid valve 28, and an output 52f to control solenoid valve 30. In cases where expansion device 22 is an electronic expansion valve, controller 42 controls device 22 via an output signal 52g in response to a leaving refrigerant evaporator temperature input 54c from a temperature sensor 56. In cases where expansion device 22 is a thermal expansion valve, signal 54c might control expansion device 22 directly. If expansion device 22 has a fixed flow restriction as opposed to having an adjustable one, signal 52g might be eliminated.
In an alternate embodiment, shown in
In the cooling mode, directional valve 60 directs refrigerant from compressor 14 to condenser 16 where air 34 cools and condenses the refrigerant therein. From condenser 16, the refrigerant flows sequentially through check valve 62 (first check valve) and expansion device 22. Upon passing through expansion device 22, the refrigerant cools by expansion. After passing through expansion device 22, a first portion of the cooled refrigerant enters evaporator 18 while a second portion passes through check valve 64 (second check valve) to enter reheat coil 20 now functioning as a supplemental evaporator. Check valve 66 (third check valve) prevents liquid refrigerant leaving condenser 16 from bypassing expansion device 22. The refrigerant in evaporator 18 and reheat coil 20 cool air stream 36. After passing through their respective heat exchangers, both portions of the refrigerant return to the suction side of compressor 14 to perpetuate the cooling cycle.
In the reheat mode, shown in
In the cooling mode, the refrigerant flows in a forward direction through reheat coil 20, but in the reheat mode, the refrigerant flows in a reverse direction through reheat coil 20. The refrigerant passing through evaporator 18, however, flows in the same predetermined direction regardless of whether system 58 is operating in the cooling or reheat mode.
In another embodiment, shown in
In the cooling mode, directional valve 60 directs refrigerant from compressor 14 to condenser 16 where air 34 cools and condenses the refrigerant therein. From condenser 16, the refrigerant flows sequentially through check valve 62 and expansion device 22. Upon passing through expansion device 22, the refrigerant cools by expansion. After passing through expansion device 22, the cooled refrigerant passes through evaporator 18. From evaporator 18, check valve 64 conveys the refrigerant through reheat coil 20 (functioning as a supplemental evaporator). Solenoid valve 70 is closed to prevent refrigerant leaving evaporator 18 from bypassing reheat coil 20, and check valve 66 prevents liquid refrigerant leaving condenser 16 from bypassing expansion device 22. The refrigerant in evaporator 18 and reheat coil 20 cool air stream 36. After passing sequentially through evaporator 18 and reheat coil 20, the refrigerant returns to the suction side of compressor 14 to perpetuate the cooling cycle.
In the reheat mode, shown in
In the cooling mode, the refrigerant flows in a forward direction through reheat coil 20, but in the reheat mode, the refrigerant flows in a reverse direction through reheat coil 20. The refrigerant passing through evaporator 18, however, flows in the same predetermined direction regardless of whether system 68 is operating in the cooling or reheat mode.
Although the invention is described with respect to a preferred embodiment, modifications thereto will be apparent to those of ordinary skill in the art. The scope of the invention, therefore, is to be determined by reference to the following claims.