Information
-
Patent Grant
-
6370899
-
Patent Number
6,370,899
-
Date Filed
Wednesday, July 28, 199925 years ago
-
Date Issued
Tuesday, April 16, 200222 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Doerrler; William
- Jiang; Chen-Wen
Agents
-
CPC
-
US Classifications
Field of Search
US
- 062 263
- 062 2591
- 062 297
- 062 298
-
International Classifications
-
Abstract
A single package wall mounted HVAC unit comprising a cabinet assembly including a primary cabinet subassembly, a back panel subassembly adapted to close the open back of the back panel subassembly, and cabinet connection means for removably attaching the primary cabinet subassembly to the back panel subassembly so that the back panel subassembly can be attached to the wall of a structure and then the primary cabinet subassembly can be positioned on and attached to the back panel subassembly. Also disclosed is a blower mounting arrangement for selectively mounting the air circulation blower within the cabinet subassembly in different positions to attenuate the blower noise transmitted to the conditioned space. An interlock is disclosed for the control box to prevent the control box cover from being removed without disconnecting the HVAC unit from the power supply. The outdoor coil assembly is arranged diagonally across the outdoor chamber in the cabinet assembly and the oudoor fan assembly is mounted directly on the cabinet panel covering the front of the outdoor chamber.
Description
BACKGROUND OF THE INVENTION
This invention relates generally to heating, ventilating and air conditioning (HVAC) equipment and more particularly to single package HVAC equipment adapted to be mounted on the wall of a structure to condition the air in an enclosed space within the structure.
Single package wall mounted HVAC equipment is well known. Cost, serviceability, safety, and reliability are several factors that contribute to successful wall mounted HVAC units. Manufacturing cost and installation cost contribute to the overall cost of the equipment. Moreover, noise generated in the air supply from the HVAC units is limited by application and governmental regulations.
In the past, wall mounted HVAC units have been made with a preassembled cabinet which must be maintained intact during installation to prevent damage to the unit. This has necessitated supporting and positioning of the unit against the wall of the structure while at the same time attempting to insure that the air return and air supply duct flanges on the back of the cabinet align with the air return and air supply passages through the wall. Because the workmen could not see the duct flanges sufficiently while supporting the unit in position against the wall and because of the weight of the unit required auxiliary lift equipment to support the unit while it was being positioned on the wall, these prior art units were frequently installed with the duct flanges improperly aligned with the air return and supply passages through the wall. This has resulted in damaging the duct flanges so as to leave cracks at the wall/duct flange interface. These cracks allowed dust and small debris from the wall structure to enter the air passage through the unit and also allow air being forced out the air supply passage in the unit to escape. Moreover, the wall structure behind the cracks was exposed directly to the radiant heat from the electric resistance heater just inside the air supply duct flange. Since both the debris and wall structure were exposed to the high temperature from the heater, the heaters in these prior art units sometimes caused fires. Moreover, the efficiency of the unit was frequently reduced due to this air leakage through the cracks around the damaged duct flanges. Because the entire weight of these prior art units had to be supported by the auxiliary lift devices while the unit was positioned on the structure, the likelihood of injury and the cost of installation has been relatively high.
Some prior art wall mounted HVAC units have attempted to move the electric resistance heater away from close proximity to the air supply outlet so as to reduce the likelihood of fire from the heater. As a result, the air circulation blower was moved downstream of the indoor refrigerant coil and the heater was moved upstream of the air circulation blower. While the positioning of the heater reduced the likelihood of fires, the air circulation blowers discharged directly out of the air supply opening from the unit producing an unacceptably high noise level when no noise attenuation duct structure was located downstream of the air circulation blower. Moreover, when the air circulation blower was moved downstream of the indoor refrigerant coil, fresh air was typically introduced into the circulating air stream to the space being conditioned downstream of the indoor refrigerant coil also. This has resulted in making it more difficult to accurately control the temperature in the conditioned air being supplied back to the enclosed space.
Prior art single package wall mounted HVAC units have typically located the control box within the cabinet assembly so that the front service panel had to be removed while the service personnel gained access to the electrical and refrigerant check points in the control box for servicing the unit. This has made it difficult for the unit to be operated in the manner necessary for accurate servicing by the service personnel because the air passage through the unit had to be left open to the outside air. As a result it was difficult to accurately service the unit.
Prior art single package wall mounted HVAC units frequently have power disconnect devices that allow the power to be disconnected from the electrical components of the unit. However, these prior art units were constructed so that the disconnect devices did not have to disconnect power from the electrical components before the control box cover was removed. As a result, removal of the control box cover while power was still supplied the electrical components increased the danger of shock and damage to the electrical components of the unit.
These prior art single package HVAC units were typically manufactured with the back panel first attached to at least one of the side panels. In order to install the system components, it was necessary to temporarily support the other side of the various divider plates and other support structure eventually supported by the other side panel. This has not only made manufacturing tolerances difficult to maintain in order to insure proper cabinet alignment and also made access to the various components within the cabinet for electrical and refrigerant connections more difficult due to the presence of the back panel early in the manufacturing process.
Examples of prior art HVAC unit constructions are illustrated in the following prior art patents:
|
U.S. Pat. No.
Inventor
Issue Date
|
|
3,871,188
Vold, et al.
March, 1975
|
4,733,543
Blair
March, 1988
|
5,140,830
Sawyer
August, 1992
|
5,301,744
Derks
April, 1994
|
5,444,990
McGill, et al.
August, 1995
|
|
SUMMARY OF THE INVENTION
These and other problems and disadvantages associated with the prior art are overcome by the invention disclosed herein by providing a single package HVAC unit which can be easily mounted on the wall of the structure, which is easily serviced, inexpensive to manufacture and install, and which is safe to operate and maintain. The single package HVAC unit incorporating the invention has a first lightweight cabinet subassembly that can be mounted on the wall of a structure so that the air return and air supply duct flanges on the first cabinet subassembly can be easily visually aligned with the air return and air supply openings through the wall and a second heavier cabinet subassembly mounting all of the mechanical and electrical components of the unit that is installed on the first cabinet subassembly after it is installed on the wall. A hook means is provided that permits the second cabinet subassembly to engage the first cabinet subassembly in an initial tilted position and then pivot on the first cabinet subassembly to the final position overlying the first cabinet subassembly to facilitate alignment between the cabinet subassemblies during installation. The hook means may be at the top of the cabinet subassemblies so that the weight of the second cabinet subassembly causes it to pivot toward the final overlying position on the first cabinet subassembly. The invention further includes a blower assembly repositionable in the air circulation passage through the cabinet assembly so as to attenuate the noise transmitted to the space in the structure being conditioned yet maintain the required volumetric air supply output from the HVAC unit. The cabinet assembly is sized so that the blower assembly can discharge air into the air circulation passage downstream of the indoor refrigerant coil and out of alignment with the air supply outlet from the HVAC unit. The invention also includes a heater means repositionable within the air circulation passage through the cabinet assembly so as to maintain the desired orientation of the heater means to meet the operational design of the heater means. The invention includes a fresh air damper construction located in the vicinity of the air return opening into the HVAC unit and immediately downstream of the indoor refrigerant coil so that fresh air is induced into the air stream passing through the HVAC unit downstream of the indoor refrigerant coil. Likewise, the invention includes a safety interconnect means between the control box cover and the electrical disconnect in the control box to prevent removal of the control box cover without disconnecting the electrical controls in the HVAC unit from the power source. The invention also includes using a straight outdoor coil oriented diagonally of the outdoor chamber in the single package HVAC unit to minimize manufacturing cost and maximize air flow uniformity through the outdoor coil.
The invention is incorporated in a single package HVAC unit adapted to be mounted on a structure over the air return and air supply passages through the structure wall and condition the air for an interior space in the structure comprising conditioning means for conditioning the air for the interior space and a cabinet assembly housing said conditioning means including a first cabinet subassembly adapted to be attached to the wall of the structure with air return and air supply duct flanges projecting into the air return and air supply passages, a second cabinet subassembly adapted to be removably mounted on the first cabinet subassembly, and prepositioning means adapted to preposition the second cabinet subassembly with respect to the first cabinet subassembly and support the second cabinet subassembly on the first cabinet subassembly while the second cabinet assembly is moved from an initial tilted position into a final seated position in registration with the first cabinet subassembly. The prepositioning means may comprise first hook means mounted on the first cabinet subassembly and second hook means mounted on the second cabinet subassembly where the first and second hook means are constructed and arranged for the second hook means to engage the first hook means and support the second cabinet subassembly on the first cabinet subassembly. The first and second hook means may be constructed and arranged so that the second hook means can slide on the first hook means for a limited distance so that the second cabinet subassembly can be slipped into the final seated position in registration with the first cabinet subassembly and may be mounted at the top of the first and second cabinet subassemblies so that the weight of the HVAC unit causes the second cabinet subassembly to pivot toward the final seated position when the second hook means supports the second cabinet subassembly on the first hook means.
The invention may further include air circulation blower means for discharging air therefrom along a prescribed air discharge path and blower mounting means adapted to selectively mount the blower means in a first blower discharge position in the cabinet assembly with the air discharge path is generally axially aligned with the axis of the air supply outlet from the HVAC unit and a second blower discharge position so that the air discharge path is out of alignment with the axis of the air supply outlet to reduce the noise level transmitted out of the air supply outlet. The blower mounting means may include a blower mounting plate corresponding in size and shape to the cross-sectional size and shape of said air circulation passage through the cabinet assembly and fixedly mounting the blower means thereon with the blower intake opening on one side thereof and the blower discharge opening on the other side thereof, and blower plate mounting means for selectively mounting the blower mounting plate in the cabinet assembly within the air circulation passage in the first discharge position so that the blower plate is adjacent the air supply outlet and the discharge outlet opening on the blower means is axially aligned with the air supply outlet, and alternatively in the second position so that the blower plate is spaced away from the air supply outlet and the discharge outlet opening on the blower means is out of alignment with the air supply outlet and a plenum space is defined in the air circulation passage downstream of the blower mounting plate into which the air is discharged from the blower means to reduce the noise transmitted out of the air supply opening. The heater mounting means may selectively mount the heater means adjacent the air intake opening so that air passes into the blower air intake opening through the heater means to be selectively heated in a first orientation relative to the blower means when the blower means is located in the first blower discharge position and in a second orientation relative to the blower means when the blower means is in the second discharge position. The heater means may include a temperature responsive limit switch means located at a prescribed position within the heater means, and the heater mounting means may movably mount the heater means adjacent the air intake opening so that the temperature responsive limit switch means is positioned in the uppermost portion of the heater means relative to the horizontal when the blower means is positioned in the first discharge position and the second discharge position.
The apparatus of the invention may also include the indoor coil of the refrigeration circuit being generally vertically oriented and aligned with the air return opening in the cabinet assembly, a fresh air damper subchamber forming assembly positioned in the cabinet assembly between the inlet side of the indoor coil and the air return opening to define a fresh air damper subchamber sealed to the air return opening at one end thereof and to the indoor coil at the opposite end thereof so that air returning through the air return opening in the cabinet assembly passes through the fresh air damper subchamber to the indoor coil where the fresh air damper subchamber extends between opposite sides of the cabinet assembly and the cabinet assembly defines at least one fresh air inlet opening therethrough in communication with the fresh air damper subchamber; and, a fresh air damper assembly mounted in the fresh air damper subchamber adjacent the fresh air inlet opening for controlling the amount of outside air drawn into the fresh air damper subchamber through the fresh air inlet opening upstream of the indoor coil. The fresh air damper assembly may comprise a damper frame assembly mounted in the fresh air damper subchamber and defining a fresh air damper opening therethrough, a damper door pivotally mounted on the damper frame assembly and adapted to selectively close the fresh air opening through the damper frame assembly, and damper positioning means for selectively maintaining the damper door in a plurality of pivotal positions relative to the fresh air damper opening so as to control the amount of fresh air induced into the air from the space to be conditioned passing through the fresh air damper subchamber.
The apparatus of the invention may likewise include disconnect means mounted in an open front control box in the cabinet assembly with a base element in the control box and a connecting element that removably insertable into the base element to connect the electrical controls for the unit to a power source, a control box cover removably covering the open front of the control box, and interconnect means on the control box cover operatively engaging the disconnect means so as to prevent removal of the control box cover from the control box without removal of the connecting element from the base element of the disconnect means. The interconnect means may include an insertable body on the connecting element with a projecting flange and a disconnect cover member constructed and arranged to overlie the base element with an opening allowing the insertable body to pass therethrough but not the flange on the insertable body.
The apparatus of the invention may also include a front service panel sized to cover the front access opening in the cabinet assembly, a control box assembly along one side of the front access opening with the interior thereof sealed with respect to the air circulation passage through the cabinet assembly, and front service panel attachment means for selectively attaching the front service panel to the cabinet assembly in a first sealing position so that the front service panel closes the front access opening and the control box assembly, and in a second sealing position so that the front service panel closes the front access opening while leaving the control box assembly uncovered whereby the interior of the control box assembly is accessible from outside the cabinet assembly for service while the air circulation passage remains sealed to allow the HVAC unit to operate as designed during servicing. The control box assembly may include an open front control box defining a sealing lip thereon extending across the access opening and coplanar with the periphery of the access opening and the front panel attachment means may include a first set of holes in the front access panel, a second set of holes in the cabinet assembly in registration with the first set of holes when the access panel is in the first sealing position, a third set of holes in the cabinet assembly in registration with the first set of holes in the access panel when the access panel is in the second sealing position.
The apparatus of the invention may also include a straight outdoor coil assembly mounted in the outdoor chamber of the cabinet assembly and extending diagonally across the outdoor chamber where inlet openings through the side and bottom of the cabinet assembly supply outdoor air to one side of the coil assembly and a discharge opening in the front of the cabinet assembly provides a discharge of air from the opposite side of the coil assembly, and an outdoor air circulation means for moving the air through the outdoor coil assembly. The refrigerant compressor may be mounted in the outdoor compartment downstream of the outdoor coil assembly. The cabinet may define an outdoor chamber access opening to the front of the outdoor chamber with the outdoor air circulation means including an outdoor air fan mounting panel removably mounted on the cabinet assembly to close the front of the outdoor chamber and defining the front outdoor air discharge opening from the outdoor chamber therethrough, and an outdoor air fan assembly directly mounted on the outdoor air fan mounting panel and overlying the front outdoor air discharge opening to draw outdoor air through the outdoor coil assembly and force the outdoor air out of the outdoor air chamber through the front outdoor air discharge opening. The outdoor air circulation means may further include a spun single piece venturi member attached directly to the outdoor air fan mounting panel around the front opening to form a venturi around the outdoor air fan assembly and stiffen the outdoor air fan mounting panel.
These and other features and advantages of the invention will become more clearly understood upon consideration of the following detailed description and accompanying drawings wherein like characters of reference designate corresponding parts throughout the several views and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a front view of one embodiment of the invention;
FIG. 2
is a right side view of the invention seen in
FIG. 1
;
FIG. 3
is a rear view of the invention;
FIG. 4
is a perspective view of the back panel subassembly of the cabinet assembly of the invention;
FIG. 5
is an exploded view illustrating the mounting of the back panel subassembly of the invention;
FIG. 6
is a perspective view of the primary cabinet subassembly of the cabinet assembly of the invention;
FIG. 7
is a side view illustrating the primary cabinet subassembly supported on the back panel subassembly in the initial tilted position;
FIG. 8
is an enlarged portion of
FIG. 7
taken along line
8
—
8
in
FIG. 7
;
FIG. 9
is a side view illustrating the primary cabinet subassembly supported on the back panel subassembly in the final seated position;
FIG. 10
is an enlarged portion of
FIG. 9
taken along line
10
—
10
in
FIG. 9
;
FIG. 11
is an enlarged transverse cross-sectional view of the cabinet assembly taken generally along line
11
—
11
in
FIG. 1
with portions thereof broken away to illustrate the internal construction of the invention;
FIG. 12
is an enlarged transverse cross-sectional view of the cabinet assembly taken generally along line
12
—
12
in
FIG. 1
;
FIG. 13
is an enlarged cross-sectional view showing the construction of the hook means on the upper end of the back panel subassembly;
FIG. 14
is an enlarged cross-sectional view showing the construction of the hook means on the upper end of the primary cabinet subassembly;
FIG. 15
is an enlarged cross-sectional view taken generally along line
15
—
15
in
FIG. 1
illustrating the indoor blower means in the ducted position;
FIG. 16
is an enlarged cross-sectional view taken generally along line
15
—
15
in
FIG. 1
illustrating the indoor blower means in the free blow position;
FIG. 17
is an enlarged front view of the indoor blower means, blower mounting means, heater means, and heater mounting means;
FIG. 18
is an exploded top view of the indoor blower means, blower mounting means, heater means, and heater mounting means as seen in
FIG. 17
;
FIG. 19
is an enlarged side view of the indoor blower means and blower mounting means;
FIG. 20
is an enlarged front view of the outdoor fan means and outdoor fan mounting panel;
FIG. 21
is an enlarged cross-sectional view taken generally along line
21
—
21
in
FIG. 1
with portions thereof broken away to illustrate the outdoor section;
FIG. 22
is a front view similar to
FIG. 1
with the front access cover assembly shifted on the primary cabinet subassembly for servicing;
FIG. 23
is an enlarged exploded cross-sectional view taken generally along line
23
—
23
in
FIG. 2
showing the interconnection with the quick disconnect means and control box cover;
FIG. 24
is an enlarged front view of the upper left corner portion of the back panel assembly;
FIG. 25
is an enlarged top view with the top panel assembly removed of a portion of the upper left back corner portion of the primary cabinet subassembly;
FIG. 26
is an enlarged elevational view of the damper assembly of the invention;
FIG. 27
is an enlarged top view of the damper assembly of the invention; and
FIG. 28
is an enlarged bottom view of the damper assembly of the invention.
These figures and the following detailed description disclose specific embodiments of the invention, however, it is to be understood that the inventive concept is not limited thereto since it may be embodied in other forms.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
Referring generally to
FIGS. 1-3
, it will be seen that the invention is incorporated in a single package HVAC unit
10
adapted to be mounted on an exterior wall EW (
FIG. 5
) of a structure that is provided with an air return passage ARP and air supply passage ASP through the wall, usually vertically aligned and spaced apart. The unit
10
includes a cabinet assembly
11
which is mounted on the wall EW over the air return and supply passages ARP and ASP. The cabinet assembly
11
houses the rest of the components of the unit. The cabinet assembly
11
defines an indoor air circulation passage
12
therethrough (
FIGS. 6
,
15
and
16
) in communication with the air return and air supply passages ARP and ASP through the wall when the cabinet assembly is mounted on the wall, and an outdoor air circulation passage
14
therethrough (
FIGS. 6 and 14
) for circulating outdoor air through the cabinet assembly. Conditioning means
15
(
FIG. 6
) is provided to condition the air as it passes through the indoor air circulation passage
12
in the cabinet assembly
11
to be supplied back to the space in the structure to be conditioned. Indoor air circulation blower means
16
(
FIGS. 6
,
15
and
16
) is mounted in the cabinet assembly
11
to move the air through the indoor air circulation passage
12
and an outdoor air circulation fan means
18
(
FIGS. 6 and 12
) is provided to move outdoor air through the outdoor air circulation passage
14
.
The cabinet assembly
11
is fabricated in two self-supporting subassemblies, a primary cabinet subassembly
20
(
FIG. 6
) and a back panel subassembly
21
(
FIGS. 4 and 5
) to facilitate the mounting of the unit
10
on the wall while at the same time minimizing the manufacturing cost of the unit
10
. As will become more apparent, the fact that the cabinet subassemblies are self-supporting allows lightweight back panel subassembly
21
to be mounted on the wall EW while removed from the primary cabinet subassembly
20
and then the heavier primary cabinet subassembly to be mounted on the wall mounted back panel subassembly
21
while the correct fit between the subassemblies
20
and
21
is assured. Also, since each of the subassemblies
20
and
21
are self-supporting, they can be fabricated separately so that access for fabrication is improved without loss of fit between the two subassemblies.
The primary cabinet subassembly
20
mounts conditioning means
15
, indoor air circulation blower means
16
and the outdoor air circulation fan means
18
therein so that most of the weight of the unit
10
is in the subassembly
20
and has an open back thereto closed by the back panel subassembly
21
. When the back panel subassembly
21
is fitted in the open back of the primary cabinet subassembly
20
, it closes same to form the air passages
12
and
14
. The back panel subassembly
21
is mounted on the wall over the air return and supply passages ARP and ASP while removed from the primary cabinet subassembly
20
as seen in FIG.
5
. The subassembly
21
is provided with air return duct flange
22
that fits into the air return passage ARP through the wall EW and an air supply duct flange
24
that fits into the air supply passage ASP to pneumatically couple the unit
10
to the conditioned space in the structure. This facilitates the mounting of the unit
10
since the installing personnel can easily see the air return and supply passages through the wall and the duct flanges
22
and
24
while the subassembly
21
is being attached to the wall to insure that the air return and supply duct flanges
22
and
24
on back panel subassembly
21
fit within the wall passages. Thus, fire safety and operationally efficiency are assured with the proper fit of the flanges
22
and
24
within the air return and supply passages ARP and ASP respectively. When the back panel subassembly
21
is mounted on the wall EW, the central axis A
1
of the air supply duct flange
24
is aligned with the central axis A
S
of the air supply passage ASP through the wall EW. Since the system components are mounted in the primary cabinet subassembly
20
, only the much lighter back panel subassembly
21
has to be accurately supported on the wall while the attaching fasteners
25
are installed through the back panel subassembly
21
to mount it on the wall.
By having the back panel subassembly
21
seal the open back of the primary cabinet subassembly
20
so as to form the air passages
12
and
14
through the unit
10
, the part count for the cabinet assembly
11
is minimized to reduce manufacturing costs. The primary cabinet subassembly
20
is accessible from both the front and back during manufacture to facilitate the assembly of the unit with the result being reduced manufacturing cost.
Prepositioning means
26
(
FIGS. 4
,
5
,
13
, and
14
) is provided for interconnecting the primary cabinet subassembly
20
and the back panel subassembly
21
while the primary cabinet subassembly
20
is being installed on the already mounted back panel subassembly
21
to facilitate the alignment of the subassemblies
20
and
21
and to support the primary cabinet subassembly
20
on the back panel subassembly
21
during installation. After the back panel subassembly
21
is mounted on the wall EW, the primary cabinet subassembly
20
is tilted toward the back panel subassembly
21
as seen in
FIGS. 7 and 8
at an angle A
2
therebetween so that the prepositioning means
26
interconnects the subassemblies
20
and
21
with the subassembly
20
in vertical and lateral alignment with the back panel subassembly
21
. The primary cabinet subassembly
20
is then pivoted from the initial tilted position ITP seen in
FIG. 7
to the final seated position FSP seen in
FIGS. 9 and 10
while the subassembly
20
is supported on the back panel subassembly
21
through the prepositioning means
26
. The prepositioning means
26
is constructed such that lateral adjustment of the position of the primary cabinet subassembly
20
relative to the back panel subassembly
21
can be made to insure accurate registration of the primary cabinet subassembly
20
relative to the back panel subassembly
21
in the final seated position FSP. Cabinet connection means
28
(
FIG. 2
) is provided to connect the primary cabinet subassembly
20
to the back panel subassembly
21
while in the final seat position FSP to seal the subassemblies
20
and
21
to each other and define the air circulation passages
12
and
14
therebetween.
While the prepositioning means
26
is illustrated applied to the top of the subassemblies
20
and
21
, it will be appreciated that The primary cabinet subassembly
20
as seen in
FIGS. 1
,
2
, and
6
includes a base pan assembly
30
forming the bottom thereof, a right side panel assembly
31
mounted on the right side of the base pan assembly
30
, a left side panel assembly
32
mounted on the left side of the base pan assembly
30
opposite the side panel assembly
31
, and a top panel assembly
34
joining the upper ends of the side panel assemblies
31
and
32
. A cabinet divider plate assembly
35
joins the side panel assemblies
31
and
32
a prescribed height above the base pan assembly
30
so as to divide the primary cabinet subassembly
20
into an indoor space between the divider plate assembly
35
and the top panel assembly
34
and an outdoor space between the divider plate assembly
35
and the base pan assembly
30
. Both of these spaces are open at the front and back of the cabinet subassembly
20
. The back panel subassembly
21
closes the open back of the primary cabinet subassembly
20
. That portion of the front of the cabinet subassembly
20
above the cabinet divider plate assembly
35
is selectively closed by a front access panel assembly
36
while that portion of the front of the cabinet subassembly
20
below the cabinet divider plate assembly
35
is selectively closed by the outdoor air fan mounting panel
38
. When the primary cabinet subassembly
20
is mounted on the back panel assembly
21
and the front access panel assembly
36
and the outdoor air fan mounting panel
38
are in place, the indoor air passage
12
is defined in the cabinet assembly
11
above the cabinet divider plate assembly
35
as best seen in
FIGS. 15 and 16
and the outdoor air passage
14
is defined below the divider plate assembly
35
as best seen in
FIGS. 6 and 11
.
The back panel subassembly
21
seen in
FIGS. 3-5
includes a rectilinear back panel
40
with a size and shape corresponding to the open back of the primary cabinet subassembly
20
with insulation
41
on the front side of panel
40
facing the subassembly
20
and extending from just below the level of the cabinet divider plate assembly
35
to the top of the panel
40
. The back panel
40
has rearwardly directed vertical side flanges
42
integral with opposite sides thereof and defines an air return opening
44
and air supply opening
45
therethrough having the same spacing and alignment as the air return and supply passages ARP and ASP in the wall EW.
A stiffener framework
46
is mounted on the backside of the back panel
40
to maintain the back panel subassembly
21
substantially flat when it is attached to the wall EW so that the primary cabinet subassembly
20
will properly fit on the back panel subassembly
21
. The framework
46
includes a bottom U-shaped channel
48
attached to the lower edge of the back panel
40
on the back side thereof and extending across the full width of the back panel. The framework
46
also includes a return duct flange assembly
49
mounted on the back side of the back panel
40
around the air return opening
44
and an air supply duct flange assembly
50
mounted on the back side of the back panel
40
around the air supply opening
46
. Each of the flange assemblies
49
and
50
include horizontally extending upper and lower U-shaped channels
51
that extend across the full width of the back panel
40
just above and below the air return or supply opening
44
or
45
associated therewith and a pair of vertically extending L-shaped angles
52
immediately outside the opening
44
or
45
associated therewith. That leg of the channels
51
in registration with the opening
44
or
45
associated therewith has a flange projection
54
thereon that projects out behind the back panel subassembly
21
to form the air return and supply duct flanges
22
and
24
together with the projecting legs
56
on the angles
52
. All of the channels
48
and
51
as well as the angles
52
are attached to the back panel
40
and the vertical L-shaped angles
52
are also attached to the channels
51
to stiffen and strengthen the back panel assembly
21
to keep it flat when installed on the wall. The stiffener framework
46
reinforces the back panel subassembly sufficiently to support the weight of the primary cabinet subassembly
20
thereon. Appropriate mounting holes
58
are provided through the back panel
40
and the channels
48
and
51
for the attaching fasteners
25
to extend into the wall EW to mount the back panel subassembly
21
on the wall. The installer can look through the openings
44
and
45
to visually insure that the flanges
22
and
24
are in registration with the passages ARP and ASP in the wall EW as the subassembly
21
is being installed. Moreover, since the back panel assembly
21
is relatively light as compared with the weight of the entire unit, the installers can easily manually position the subassembly
21
and hold it in place while the fasteners
25
are installed to mount the back panel subassembly
21
.
When the back panel subassembly
21
is installed as seen in
FIGS. 7 and 9
, it will be seen that it projects out from the wall the distance D
1
seen in
FIG. 13
which is the depth of the side flanges
42
so that the back panel
40
is spaced forwardly of the outside surface of the wall EW this distance. The uppermost U-shaped channel
51
of the air supply duct flange assembly
50
is spaced below the upper edge of the back panel
40
the distance D
2
also seen in
FIG. 13
to form a clearance space
59
behind the back panel
40
and above the uppermost channel
51
that permits the prepositioning means
26
to interconnect the subassemblies
20
and
21
as will become more apparent. The primary cabinet subassembly
20
is installed over the back panel subassembly
21
so that the rear edges of the side panel assemblies
31
and
32
overlie the side flanges
42
of the subassembly
21
.
The side flanges
42
are appropriately slotted to receive appropriate high strength clip nut members
55
such as Tinnerman nuts seen in
FIGS. 4
,
5
, and
13
that are adapted to be threadedly engaged by the cabinet connection means
28
, usually threaded fasteners, to fasten the primary cabinet subassembly
20
to the back panel subassembly
21
and seal the open back of the subassembly
20
. The strength of the clip nut members
55
is such that sufficient clearance can be provided between the side panels
70
of the side panel assemblies
31
and
31
and the side flanges
42
on the back panel
40
for the primary cabinet subassembly
20
to easily fit over the back panel subassembly
21
yet the connection means
28
can force the side panels
70
and side flanges
42
together to form a seal between the back panel subassembly
21
and the primary cabinet subassembly
20
without damage to the side panels
70
or side flanges
42
.
The base pan assembly
30
seen in
FIGS. 6
,
11
, and
12
includes a rectilinear base pan member
60
provided with downturned L-shaped flanges
61
along the front and back edges of the base pan member
60
to reinforce it and downturned side flanges
62
used to connect the base pan assembly
30
to the lower edges of the side panel assemblies
31
and
32
. The base pan member
60
defines the bottom outdoor air inlet
64
therethrough illustrated as a plurality of slots
65
. The slots
65
extend through a triangular portion of the base pan member subtended by a diagonal path P
1
extending across the member
60
to one end thereof (the right end as viewed from the front of the unit) as best seen in FIG.
11
. Compressor mounting nuts
66
(
FIGS. 11 and 12
) are provided on the base pan member
60
on that side of the path P
1
opposite the slots
65
.
The right side panel assembly
31
best seen in
FIGS. 2
,
11
and
12
includes a side panel
70
provided with an integral front inturned flange
71
and an integral back outturned flange
72
. The flanges
71
and
72
serve to stiffen the side panel with the front flange serving to mount one side of the front access panel assembly
36
and the outdoor air fan mounting panel
38
. The top edge of the side panel
70
is stepped as best seen in
FIG. 16
so that the top panel assembly
34
can slope downwardly from the back to the front of the cabinet assembly
11
. The lower portion of the right side panel
70
extending from just below the divider plate assembly
35
to just above the base pan assembly
30
is provided with a side outdoor air inlet opening
74
which is covered by an air inlet grill
75
seen in
FIGS. 2 and 12
. The rear portion of the side panel
70
just above the divider plate assembly
35
is provided with a fresh air inlet opening
76
illustrated in the form of louvers
78
seen in FIG.
2
. The inside of the side panel
70
is covered with insulation
79
extending from the divider plate assembly
35
to the top of the panel as best seen in
FIGS. 6 and 15
except over the fresh air inlet opening
76
.
The left side panel assembly
32
seen in
FIGS. 6
,
7
and
9
is a mirror image of the right side panel assembly
31
except that no side outdoor air inlet opening is present in the assembly
32
. The same reference numbers are applied to those portions of the left side panel assembly
32
corresponding to those of the right side panel assembly
32
.
The top panel assembly
34
seen in FIGS.
6
and
14
-
16
includes a top panel
80
with downturned side flanges
81
on opposite ends thereof used to connect the top panel assembly
34
to the side panels
70
so that the top panel
80
slopes downwardly from the back to the front of the primary cabinet subassembly
20
when it is installed on the structure wall. This insures that rain will flow off of the top of the unit. The top panel
80
has a downturned front flange
82
along the front edge thereof which overlaps the top of the front access panel assembly
36
and a downturned rear flange
83
along the back edge thereof which is coplanar with the back edge of the side panels
70
. The rear flange
83
will project down into the upwardly opening space
59
in the top of the back panel subassembly
21
as best seen in
FIGS. 8 and 10
when the primary cabinet subassembly
20
is installed on the back panel subassembly
21
. The interior of the top panel
80
is covered with insulation
87
(FIGS.
14
and
15
).
The divider plate assembly
35
best seen in
FIGS. 6 and 15
includes a rectilinear divider plate
84
provided with integral downturned side flanges
85
across the opposite end edges thereof used to attach the divider plate assembly
35
to the side panels
70
, an integral downturned L-shaped front flange
86
across the front edge thereof used to connect the top edge of the outdoor fan mounting panel
38
and the bottom edge of the front access panel assembly
36
in place, and an integral downturned L-shaped back flange
88
across the back edge thereof which abuts the back panel subassembly
21
. The front flange
86
and the rear flange
88
serve to reinforce the plate assembly
35
while the rear flange
88
provides a smooth sealing surface thereon to abut the insulation
41
on the back panel subassembly
21
as will become apparent. The divider plate
84
is sized so that the rearwardly facing sealing surface on the back flange
88
is located a prescribed distance D
3
(
FIG. 15
) forward of the back edge of the side panels
70
where the prescribed distance D
3
is selected to be slightly greater than the projecting distance D
1
of the side flanges
42
on the back panel subassembly
21
but less that the cumulative projecting depth D
4
of flanges
42
and the thickness of the insulation
41
as seen in FIG.
13
. In this way, the back flange
88
on the divider plate assembly
35
will be pressed into the insulation
41
to form a seal therewith even though the back flange
88
is not attached to the back panel
40
. The top surface of the divider plate
84
is also covered with insulation
89
.
It will be appreciated that, when the side panel assemblies
31
and
32
are connected to the base pan assembly
30
, the top panel assembly
34
, and the divider plate assembly
35
, the primary cabinet subassembly
20
is open from the front and the back. This gives maximum access for the installation of components in the primary cabinet subassembly
20
during manufacture without requiring any special jigs or supports to temporary hold the components in place as manufacture progresses. As a result, assembly time and manufacturing cost are minimized.
The prepositioning means
26
includes a reinforcing hook member
92
mounted at the top back of the primary cabinet subassembly
20
and a cooperating hook member
94
mounted at the top of the back panel subassembly
21
. The hook member
92
also serves as a reinforcing member to help keep the primary cabinet subassembly
20
in a square condition, that is, with the base pan
60
, divider plate
84
, and the top panel
80
normal to the side panels
70
even though the back panel subassembly
21
is not in place on the back of the primary cabinet subassembly
20
.
The reinforcing hook member
92
best seen in
FIGS. 14 and 25
includes a generally horizontal central support section
95
extending between the side panels
70
and is provided with downturned end mounting flanges
96
at opposite ends thereof that are fastened to the top of the side panels
70
just under the top panel
80
adjacent the rear edge of the panels
70
. The back edge of the central support section
95
is provided with a downturned hook flange
98
. The hook member
92
is mounted between the side panels so that the support section
95
lies juxtaposed underneath the rear portion of the top panel
80
while the downturned hook flange
98
lies against the front side of the rear flange
83
on the top panel
80
as seen in FIG.
14
. The end flanges
96
are provided with clearance cutouts
93
adjacent the back edge of the side panels
70
to clear the upper ends of the back panel subassembly
21
as best seen in FIG.
14
. The hook flange
98
is slightly shorter than the central support section
95
and the inside distance between the side flanges
42
on the back panel
40
and is centered on the support section
95
so as to define a clearance space
97
at opposite ends of the flange
98
as seen in
FIG. 25
to clear the side flanges
42
when the flange
98
is inserted into the upwardly opening space
59
behind the top of the back panel
40
. The clearance spaces
97
are sized to permit the primary cabinet subassembly
20
to be moved slightly from side-to-side to allow the side panels
70
to be aligned with the back panel
40
without the hook flange
98
interfering with the side flanges
42
.
The front edge of the central web section
95
is provided with a depending L-shaped reinforcing flange
99
extending across the width of the primary cabinet subassembly
20
to strengthen the hook member
92
and also maintain the subassembly
20
in a square condition. It will be understood that the hook member
92
may be assembled in the primary cabinet subassembly
20
before the top panel assembly
34
is installed to simplify assembly. Once the hook member
92
is installed, the primary cabinet subassembly
20
will be maintained square even though the front and back of the cabinet subassembly
20
remains open so that final assembly of the subassembly
20
can proceed while assuring that manufacturing tolerances will be maintained.
The hook member
94
on top of the back panel subassembly
21
as seen in
FIGS. 3
,
13
, and
24
includes an upstanding flat base section
100
attached to that portion of the back panel
40
adjacent the top edge thereof. The upper edge of the base section
100
is provided with a short support flange
101
integral therewith that projects rearwardly and downwardly from the upper edge of the base section
100
to form an upwardly facing rounded bearing edge
102
thereon adapted to support the hook member
92
on the primary cabinet subassembly
20
. The flange
101
is sufficiently short to leave an opening
104
between the projecting edge of the flange
101
and the wall EW when the back panel subassembly
21
is mounted on the wall through which the depending hook flange
98
on the hook member
92
can project into the clearance space
59
behind the top of the back panel assembly
21
. This lets the bearing edge
102
on the hook member
94
to engage the underside of the central support section
95
to support the primary cabinet subassembly
20
on the back panel subassembly
21
. The hook flange
98
keeps the hook member
92
on the primary cabinet subassembly
20
engaged with the hook member
94
on the back panel subassembly
21
to maintain the interconnection between the subassemblies
20
and
21
after the primary cabinet subassembly
20
is tilted back at its upper end to the initial tilted position ITP and moved so that the hook member
92
is hooked onto the hook member
94
as shown in
FIGS. 7 and 8
. The side flanges
42
on the back panel
40
maintain the hook flange
98
therebetween to keep the primary cabinet subassembly
20
in lateral alignment with the back panel subassembly
21
. If the primary cabinet subassembly
20
is not perfectly centered on the back panel assembly
21
, the bearing edge
102
on the hook member
94
allows the primary cabinet subassembly
20
to be shifted laterally until lateral registration is achieved.
Once registration is achieved in the initial tilted position ITP, support of the primary cabinet subassembly
20
is slowly removed. The weight of the primary cabinet subassembly
20
and the components housed therein inherently causes the primary cabinet subassembly to swing down over the back panel subassembly
21
to the final seated position FSP seen in
FIGS. 9 and 10
so that the back panel subassembly closes the open back of the primary cabinet subassembly
20
. To make sure that the cabinet subassembly
20
is fully seated on the back panel subassembly
21
, the primary cabinet subassembly
20
can be easily manually shifted toward the wall EW because the central support section
95
on the hook member
92
can slide over the bearing edge
102
on the hook member
94
.
Cabinet connection holes
105
seen in
FIGS. 6 and 7
are provided through the side panels
70
adjacent the back edge thereof and are constructed and arranged so that they are in registration with the clip nut members
55
on the back panel subassembly
21
when the primary cabinet subassembly
20
is in its final seated position FSP. The cabinet connection means
28
includes the connection holes
105
, the clip nut members
55
and fasteners
106
(
FIGS. 1 and 9
) that are threaded into the nut members
55
through the holes
105
. The strength of the nut members
55
is sufficient to allow the fasteners
106
to tightly clamp the side panels
70
to the back panel side flanges
42
to seal the primary cabinet subassembly
20
to the back panel subassembly
21
while allowing enough clearance initially between the side flanges
42
and side panels
70
for the primary cabinet subassembly to be easily placed over the back panel subassembly.
A fresh air damper subchamber forming assembly
110
seen in FIGS.
6
,
11
,
15
, and
21
is provided to form a damper subchamber
111
in the air passage
12
through the cabinet assembly
11
immediately downstream of the air return opening
44
in the back panel subassembly
21
. The subchamber forming assembly
110
comprises a rectilinear damper divider plate
112
connected between the side panels
70
just above the fresh air inlet openings
76
through the side panels and oriented parallel to the divider plate
84
of the divider plate assembly
35
. Opposite ends of the divider plate
112
are provided with integral upturned side flanges
114
used to connect the divider
112
in place between the side panels
70
, an integral upstanding front reinforcing flange
115
is provided across the front edge of plate
112
, and an integral upstanding back flange
116
is provided across the back edge of plate
112
. The depth D
5
of the damper divider plate
112
is about 60% of the depth D
6
of the divider plate
84
separating the indoor and outdoor sections of the cabinet assembly
11
as seen in
FIGS. 11 and 15
so that a gap
124
is left between the front of the plate
112
and the front panel assembly
36
for the free flow of the air being recirculated back to the conditioned space is provided as will become more apparent.
The subassembly
110
is mounted between the side panels
70
so that the rearwardly facing sealing surface on the back flange
116
is spaced forwardly of the back edge of the side panels
70
substantially the same prescribed distance D
3
as the sealing surface on the flange
88
of the divider plate subassembly
35
to insure a seal with the back panel subassembly
21
. Thus, when the primary cabinet subassembly
20
is mounted on the back panel subassembly
21
, a seal is formed around the air return opening
44
through the back panel
40
as best seen in
FIG. 15
to define the open front damper subchamber
111
in the air passage
12
bounded by the divider plates
84
and
112
, the end panels
70
, and the back panel
40
. In this way, the air returning from the conditioned space through the air return opening
44
will pass through the damper subchamber
111
, out the open front of the subchamber
111
, and then upwardly through the gap
124
for recirculation.
The subchamber forming assembly
110
also includes an indoor coil mounting assembly
118
best seen in
FIGS. 15 and 21
mounted between the divider plates
84
and
112
at front opening to the damper subchamber
111
. The assembly
118
includes a pair of spaced apart coil mounting angles
119
extending between the divider plates
84
and
112
, each having a base leg
120
oriented parallel to the back panel
40
with a side flange
121
along the outboard edge thereof used to attach the angle
119
to the adjacent side panel
70
, and a mounting leg
122
along the inboard edge of the base leg oriented parallel to the side panel
70
. The flanges
121
are sealingly attached to the side panels
70
just forward of the fresh air inlet opening
76
through the side panel
70
while the mounting legs
122
define a coil opening therebetween to receive the indoor coil as described hereinafter. The mounting angles
119
in combination with the divider plates
84
and
112
form a structure that also helps maintain the primary cabinet subassembly
20
in a square condition to facilitate its installation on the back panel assembly
21
.
A pair of fresh air damper assemblies
125
seen in
FIGS. 6
,
11
,
15
, and
21
are provided to control the amount of fresh air induced into the air stream circulating through the damper subchamber
111
. One of the damper assemblies
125
is positioned in the subchamber
111
just inboard of the fresh air inlet opening
76
in each side panel
70
. Each damper assembly
125
utilizes the same components but can be configured so as to be used as the right side damper assembly
125
R
or the left side damper assembly
125
L
as seen in
FIGS. 11 and 21
as will become more apparent.
Each damper assembly
125
illustrated in detail in
FIGS. 26-28
includes a vertically oriented damper frame assembly
126
pivotally mounting a damper door assembly
128
thereon for selectively controlling the amount of fresh air induced into the circulating air stream through the fresh air inlet opening
76
in the adjacent side panel
70
.
Each damper frame assembly
126
best seen in
FIGS. 26-28
includes spaced apart angle members
270
adapted to be mounted in the subchamber
111
between the divider plates
84
and
112
. Each angle member
270
has a vertically oriented base leg
271
and a vertically oriented sealing leg
272
normal to and integral with the base leg
271
.
One end of sealing leg
272
is provided with a horizontally oriented mounting flange
274
normal to the leg
272
while the opposite end of the leg
272
is provided with a horizontally oriented mounting flange
275
that is a mirror image of the flange
274
. The mounting flanges
274
and
275
are used to attach the damper frame assembly
126
to the divider plates
84
and
112
using fasteners
276
seen in
FIGS. 21 and 26
and thus mount the damper assembly
125
in the damper subchamber
111
.
The projecting corner of the mounting flange
274
opposite the sealing leg
272
has a bendable pivot tab
278
formed therein which is initially coplanar with the mounting flange
274
. Likewise, the projecting corner of the mounting flange
275
opposite the sealing leg
272
has a bendable pivot tab
279
formed therein which is initially coplanar with the mounting flange
275
. As will become more apparent, the damper door assembly
128
can be pivotally mounted between the mounting flanges
274
and
275
on one of the angle members
270
by bending the tab
278
on the mounting flange
274
toward the opposed mounting flange
275
until tab
278
is normal to the mounting flange
274
and by bending the tab
279
on the mounting flange
275
toward the opposed mounting flange
274
until the tab
279
is normal to the mounting flange
275
. Thus, the bent tabs
278
and
279
are coaxially aligned along the common axis A
3
as seen in FIG.
26
. When the pivot tabs
278
and
279
are not used to pivotally mount one side of the door assembly
128
, they are left coplanar with the mounting flanges
274
and
275
as will be explained.
That side of the sealing leg
272
facing the mounting flanges
274
and
275
is provided with a sealing strip
280
adapted to seal the edges of the door assembly
128
to the frame assembly
126
. The sealing strips
280
are constructed to allow either side of the door assembly
128
to be pivoted as will become more apparent.
This construction allows a common angle member
270
to be used both the front and back sides of the damper assembly
126
and for both the right side and left side fresh air damper assemblies
125
R
and
125
L
simply by properly orienting the angle member
270
. An explanation of the orientation of the angle member
270
for the right side assembly
125
R
illustrated in
FIGS. 26-28
will be made for illustrative purposes. For the right side damper assembly
125
R
, the door assembly
128
is to be pivoted on the angle member toward the back of the unit
10
and designated as
270
BR
while the angle member toward the front of the unit
10
is designated
270
FR
. The pivot tabs
278
and
279
on the back angle member
270
BR
are bent normal to the mounting flanges
274
and
275
. The member
270
BR
is oriented so that mounting flange
274
is uppermost and the mounting leg
271
projects outwardly toward the side panel
70
. The front angle member
270
FR
is oriented so that the mounting flange
275
is uppermost and the mounting leg
271
projects outwardly toward the side panel
70
.
The back angle member
270
BR
is mounted in the subchamber
111
with the base leg
271
coplanar with the back sealing surfaces on the back flange
88
of the divider plate
84
and the back flange
116
on the damper divider plate
112
by the fasteners
276
extending through the mounting tab
274
into the damper divider plate
112
and by the fastener
276
extending through the mounting flange
275
into the cabinet divider plate
64
. The front angle member
270
FR
is mounted in the subchamber
111
with the base leg
271
against the back side of the base leg
120
of the coil mounting angle
119
by the fastener
276
extending through the mounting flange
274
into the cabinet divider plate
84
and by the fastener
276
extending through the mounting flange
275
into the damper divider plate
112
. The angles
270
thus seal with the back panel subassembly
21
and the coil mounting angle
119
so that the forwardly projecting sealing leg
272
on the back angle
270
BR
and the rearwardly projecting sealing leg
272
on the front angle
270
FR
define a damper air opening
281
therebetween.
It will be appreciated that the left side damper assembly
125
L
has the angle members
270
arranged so that the left side damper assembly
125
L
is a mirror image of the right side damper assembly
125
R
when viewed from the interior of the unit looking out. Thus, the back angle
270
on the left side damper assembly
125
L
will have the mounting flange
275
uppermost and the pivot tabs
278
and
279
on the back angle
270
will be bent to pivot the door assembly
128
thereon. The front angle
270
will have unbent tabs
278
and
279
with the mounting flange
274
uppermost.
The damper door assembly
128
as seen in
FIGS. 26-28
includes a rectilinear door
282
with a vertical centerline CL
V
. The door
282
is sized to fit over the damper opening
281
and overlap the sealing strips
280
on sealing legs
272
of the angle members
270
. The door
282
is provided with parallel top and bottom flanges
284
and
285
respectively as seen in
FIGS. 26-28
which project out from the door
282
opposite the sealing legs
272
on the angles
270
as well as front and back side flanges
286
to reinforce the door
282
.
A pivot hole
288
is provided through each end of the top flange
284
and a like pivot hole
289
is provided through each end of the bottom flange
285
, all equally spaced from the door centerline CL
V
, so that the pivot hole
288
1
in one end of the top flange
279
is aligned with the pivot hole
289
1
in the corresponding end of the bottom flange
285
about a common centerline CL
1
while the pivot hole
288
2
in the opposite end of the top flange
284
is aligned with the hole
289
2
in the corresponding end of the bottom flange
285
about common centerline CL
2
. It will thus be seen that the centerlines CL
1
and CL
2
are parallel to the door centerline CL
V
and equally spaced the distance D
8
on opposite sides thereof. Either the pivot holes
288
1
and
289
1
or the pivot holes
288
2
and
289
2
may be used to pivot the door
282
about the vertical axis A
3
depending which side of the door
282
needs to be pivoted. Thus, on the right side damper assembly
125
R
as illustrated in
FIGS. 26-28
, the holes
288
1
and
289
1
are used to pivot the door
282
about the axis A
3
. On the other hand, the left side damper assembly
125
L
is pivoted using the holes
288
2
and
289
2
. Likewise, it will be appreciated that the same door
282
is used in both the right and left side damper assemblies.
The top flange
284
on the door
282
is also provided with a pair of positioning pilot holes
290
1
and
290
2
therethrough equally spaced a prescribed distance D
9
from the door centerline CL
V
as best seen in
FIG. 27
while the bottom flange
285
is provided with a pair of positioning holes
291
1
and
291
2
therethrough also equally spaced the prescribed distance D
9
from the door centerline CL
V
as best seen in FIG.
28
. It will thus be seen that the pilot hole
290
2
in the top flange
284
is spaced the radial distance D
10
from the pivot hole
288
1
on the opposite side of the door centerline CL
V
while the pilot hole
290
1
is spaced the same radial distance D
10
from the pivot hole
288
2
as best seen in FIG.
27
. Likewise, the positioning hole
291
2
in the bottom flange
285
is spaced the radial distance D
11
from the pivot hole
289
1
on the opposite side of the door centerline CL
V
while the positioning hole
291
1
is spaced the same radial distance D
11
from the pivot hole
289
2
as best seen in FIG.
28
. The pilot holes
290
or the positioning holes
291
are used to selectively fix the door assembly
128
at different pivoted positions as will become more apparent so that the amount of outside air induced into the circulating air stream can be selectively varied.
To cooperate with the positioning pilot holes
290
in the door assembly
128
, a plurality of positioning holes
292
are provided adjacent opposite ends of the subchamber divider plate
112
(
FIG. 11
) along an arcuate path P
5
centered on the axis A
3
and located the same radial distance D
10
therefrom as the positioning pilot hole
290
2
is from the pivot hole
288
1
or the positioning pilot hole
290
1
is located from the pivot hole
288
2
through top flange
284
. Similarly, a plurality of positioning pilot holes
294
are provided adjacent opposite ends of the cabinet divider plate
84
(
FIG. 21
) along an arcuate path P
6
centered on the axis A
3
and located the same radial distance D
11
therefrom as the positioning hole
291
2
is from the pivot hole
289
1
or the positioning hole
291
1
is located from the pivot hole
289
2
through the bottom flange
285
.
When the door assembly
128
is positioned within the right side of the subchamber
111
as seen in
FIG. 11
with the pivot holes
288
1
and
289
1
will be used to pivot the door assembly
128
, the positioning pilot hole
290
2
is registrable with any one of the positioning holes
292
in the right hand end of the damper divider plate
112
. Also, the positioning hole
291
2
is registrable with any one of the positioning pilot holes
294
in the right hand end of the cabinet divider plate
112
. A locating fastener
129
is used to selectively fix the door assembly
128
in the right damper assembly
125
R
at any of the prescribed positions established by the holes
292
or
294
.
If access for adjustment of the door assembly
128
is to be through the front of the cabinet assembly
11
after the front access panel assembly
36
is removed, then the locating fastener
129
is installed from the top of the damper divider plate
112
through the selected positioning hole
292
and screwed into the pilot hole
290
2
in the top flange
284
on the door
282
as illustrated in FIG.
11
. On the other hand, if the adjustment of the damper assembly
125
R
is to be made through the air return opening
44
, the locating fastener
129
is installed from within the damper subchamber
111
through the positioning hole
291
2
and screwed into the selected positioning pilot hole
294
in the cabinet divider plate
84
seen in FIG.
21
.
The door assembly
128
positioned within the left side of the subchamber
111
will be pivoted on the left side back angle member
270
using the pivot holes
288
2
and
289
2
so that the positioning pilot hole
290
1
in the top flange
284
is registrable with any one of the positioning holes
292
in the left hand end of the damper divider plate
112
and the positioning hole
291
1
is registrable with any one of the positioning pilot holes
294
in the left hand end of the cabinet divider plate
84
. The locating fastener
129
will be installed similarly to that described above for the right damper assembly
125
R
.
To filter the fresh air passing into the damper subchamber through the fresh air inlet opening
76
through the side panel
70
, a filter mounting assembly
130
is provided on the upstream side of the damper frame assembly
126
as seen in
FIGS. 15 and 21
to removably support a filter media
131
such as a hogshair filter so that it can be removed upwardly out of the mounting assembly
129
. An appropriate access cutout
132
is provided through the divider plate
112
over the filter mounting assembly
126
for the filter media
131
to pass for replacement and a filter cover
134
is provided to seal the cutout
132
. The access cutout
132
also allows access to the damper assembly
125
for manually positioning it when adjustment is to be made for the front of the unit
10
as explained hereinbefore.
The front access panel assembly
36
seen in
FIGS. 1
,
15
, and
16
includes a rectilinear front access panel
135
sized to cover the open front of the primary cabinet subassembly
20
and is provided with side flanges that overlap the front vertical corners of the side panels
70
, a top reinforcing flange that extends under the downturned flange
81
on the top panel
80
, and a bottom offset projection
136
that overlaps the top of the outdoor air fan mounting panel
38
. The interior of the front access panel
135
is covered with insulation
138
.
The conditioning means
15
is illustrated as a refrigeration circuit
140
with an indoor coil
141
, an outdoor coil
142
and a compressor
144
seen in FIG.
6
. The indoor coil
141
is mounted in the coil opening at the front of the damper subchamber
111
between the mounting legs
122
of the indoor coil mounting assembly
118
so that the air passing out of the damper subchamber
111
must pass through the indoor coil
141
. It will be appreciated that the coil
141
is spaced from the front of the primary cabinet subassembly
20
so that the air freely passes out of the coil
141
into the rest of the air passage
12
downstream of the coil. Because the longest dimension of the indoor coil
141
is horizontally oriented and the coil sits in a drain pan
145
supported on the divider plate
84
, the space downstream of the coil
141
is maximized as will become more apparent.
The outdoor coil
142
is a straight coil that is mounted in the outdoor space below the divider plate
84
by the outdoor coil mounting assembly
146
so that the coil is oriented along the diagonal path P
1
as seen in
FIGS. 6 and 21
. The mounting assembly
146
seals the bottom of the coil to the base pan member
60
, seals the top of the coil to the divider plate
84
, seals the forwardmost end of the coil to the right side panel
70
just forward of the side outdoor air inlet opening
74
, and, when the primary cabinet subassembly
20
is mounted on the back panel subassembly
21
, seals the rearmost end of the coil to the back panel
40
. Thus, the outdoor coil
142
with the mounting assembly
146
divides the outdoor space into an inlet chamber upstream of the coil
142
and a discharge chamber downstream of the coil
142
. The compressor
144
is mounted on the base pan member
60
through the compressor mounting nuts
55
in the discharge chamber downstream of the coil
142
. Since the outdoor air flows through the coil
142
from the upstream side to the downstream side, the heat generated by the compressor is dissipated in the outdoor air after it passes through the outdoor coil
142
.
The indoor air circulation means
16
best seen in FIGS.
6
and
15
-
19
includes a conventional centrifugal blower
150
with a blower housing
151
defining inlet openings
152
in opposite sides thereof and a discharge outlet opening
154
therefrom to discharge the pressurized air from the housing along a prescribed pressurized air path P
2
. The blower motor
155
is mounted on one side of the housing
151
to drive the blower impeller. The volumetric capacity of the blower
150
is selected to circulate the desired amount of air through the air passage
12
through the cabinet assembly
11
to meet the design criteria of the unit
10
.
The blower
150
is mounted in the air passage downstream of the indoor coil
141
by an indoor blower mounting assembly
160
. The blower mounting assembly
160
is constructed and arranged so that the blower
150
can be mounted in a first blower position POS
1
within the cabinet assembly
11
as seen in
FIG. 15
where the blower
150
is located at the discharge opening
44
through the back panel
40
with the pressurized air path P
2
axially aligned with the central axis A
1
of the air supply duct flange
24
and a second blower position POS
2
within the cabinet assembly
11
seen in
FIG. 16
where the blower is spaced away from the discharge opening
44
with the pressurized air path P
2
directed upwardly out of alignment with the central axis A
1
of the air supply duct flange
24
. The first or ducted blower position POS
1
is used where the air discharged out of the unit
10
is ducted to the space being conditioned while the second or freeblow blower position POS
2
is used where the air is discharged out of the unit
10
directly into the space being conditioned.
The blower mounting assembly
160
includes a rectilinear blower mounting plate
161
defining a blower outlet opening
162
(
FIG. 6
) therethrough corresponding in size to the blower discharge opening
154
. Blower support channels
164
(
FIGS. 17-19
) are mounted on opposite sides of the opening
162
and are connected to the blower housing
151
along opposite sides of the blower discharge opening
154
to mount the blower
150
on the mounting plate
161
with the pressurized air path P
2
extending out of the plate opening
162
generally normal to the surface of the mounting plate
161
. A motor mount assembly
165
is provided to mount the blower motor
115
with the attached blower impeller
156
operatively located within the blower housing
151
.
The front and back edges of the mounting plate
161
are provided with integral front and back sealing flanges
166
projecting from the plate
161
in the same direction as the blower
150
while opposite end edges of the plate
161
are provided with reinforcing flanges
168
projecting from the plate
161
oppositely of the blower
150
.
The mounting plate
161
is selectively mounted in the primary cabinet subassembly
20
with the blower
150
in position POS
1
or POS
2
by a pair of mounting angles
170
seen in
FIGS. 16 and 17
, each having a mounting leg
171
adapted to be attached to the side panel
70
while the other support leg
172
is adapted to be attached to the mounting plate
161
along the side edge thereof. The mounting leg
171
defines a set of pilot holes therethrough seen in
FIG. 16
that align with a first set of mounting holes
174
in the side panel
70
just forward of the back edge thereof along a generally vertical path P
3
when the blower
150
is to be positioned in the first position POS
1
seen in
FIG. 15
or with a second set of mounting holes
175
in the side panel
70
seen in
FIG. 15
located along an almost horizontal path P
4
when the blower
50
is to be positioned in the second position POS
2
seen in FIG.
16
. It will be noted that the path P
4
is spaced below the top panel
80
and that the pressurized air path P
2
is substantially horizontal in position POS
1
and rotated about 84° in position POS
2
so that the pressurized air being discharged from the blower outlet opening along path P
2
will impinge on the underside of the top panel assembly
34
. It will also be noted that one of the mounting holes in the first set
174
is common to one of the mounting holes in the second set
175
. Fasteners
176
(
FIG. 2
) are provided to threadedly engage the pilot holes in the mounting leg
171
and attach the indoor blower mounting assembly
160
to the side panels
70
through either the first set of holes
174
when the ducted position POS
1
is to be used or through the second set of holes
175
when the free blow position POS
2
is to be used.
The support leg
172
is slotted as seen in
FIG. 17
so that the mounting angles
170
can be adjustably connected to the blower mounting plate
161
when the angles
170
are connected to the side panels
70
in order for the mounting angles/blower plate combination to extend completely across the full width of the air passage
12
to form an air seal with the side panel assemblies
30
and
31
. The depth of the blower mounting plate is selected so that the front and back sealing flanges
166
seal against the insulation
41
on the front of the back panel
40
and the insulation
138
on the back of the front access panel
135
when the indoor blower mounting assembly
160
is in the second freeblow position POS
2
.
When the indoor blower mounting assembly
160
is in the first ducted position POS
1
it will be seen that the surface of the blower mounting plate
161
is pressed against the insulation
41
on the front of the back panel
40
to form a seal therewith. In this position, the blower
150
discharges directly out of the air supply opening
45
. On the other hand, when the indoor blower mounting assembly
160
is in the second freeblow position POS
2
, the blower mounting plate
161
forms a pressurized air plenum
180
(
FIG. 16
) between the top panel assembly
34
and the plate
161
with the discharge from the blower
150
upwardly toward the top panel assembly
34
. Thus, in position POS
2
, air is forced out of the air supply opening
45
simply due to the higher pressure inside the plenum
180
. This serves to attenuate the noise of the blower
150
being transmitted out of the air supply opening
45
when the unit
10
is in the freeblow application where the air is supplied directly into the conditioned space. When the air supply is ducted to the conditioned space, the fan noise is attenuated in the supply duct itself so that the fan can discharge directly out of the air supply opening
45
without raising the level of the noise transmitted to the conditioned space but overcoming the pressure loss in the supply duct so as to maintain the desired volumetric air flow to the conditioned space.
It will be appreciated that the cross-sectional size blower outlet opening
162
through the mounting plate
161
is much smaller than the cross-sectional size of the air supply opening
45
from the cabinet assembly as best seen in FIG.
3
. This is because a larger opening is needed to reduce the pressure loss across the air supply opening
45
while still maintaining the volumetric air flow.
A control box assembly
181
seen in
FIGS. 11
,
15
, and
22
is provided to house the electrical controls
182
for the refrigeration circuit
140
, indoor air circulation blower means
16
and outdoor air circulation fan means
18
. The control box assembly
181
includes an inverted L-shaped box member
184
having a width corresponding to the distance between the side panels
70
. The box member
184
is positioned on top of the divider plate
84
adjacent the front of the unit so that the depending vertical leg
185
on the box member
184
seals against the insulation on top of the plate
112
and the horizontal leg
186
of the box member
184
projects forwardly of the leg
184
. The front edge of the horizontal leg
186
is provided with an upstanding lip
187
to seal against the insulation
138
on back of the front access panel
135
as will become apparent. The leg
186
is spaced above the divider plate
112
a prescribed height HT
1
as seen in FIG.
15
and opposite ends of the box member
184
are sealed to the side panels
70
through the insulation
79
thereon to define an open front control space
188
subtended by the control box member
184
, the end panels
70
, and the divider plate
112
along the lower edge of the upper front opening in the primary cabinet assembly
20
which is sealed from the rest of the air passage
12
through the unit
10
.
The open front of the control space
188
is selectively closed by a control box cover assembly
189
(
FIGS. 15 and 23
) that includes a cover member
190
that can be selectively mounted on or removed from the front of the control box member
184
when the front access panel assembly
36
is removed. A disconnect access opening
191
is defined through the cover member
190
adjacent one end thereof and is arranged so as to overlie the electrical disconnect assembly
192
of the electrical controls
182
mounted in the control box member
184
.
The electrical disconnect assembly
192
is of conventional construction with one or more base elements
194
(
FIGS. 15
,
22
, and
23
) fixedly mounted on the vertical leg
185
on the control box member
184
in registration with opening
191
. Each of the base elements is provided with a removable connecting element
195
that seats in the recess
197
in the base element
194
to connect the electrical controls
182
to a conventional outside power source to operate the unit.
The control box cover assembly
189
also includes a disconnect cover member
196
(
FIGS. 15 and 23
) mounted on the backside of the cover member
190
behind the opening
191
and projects a prescribed distance behind the cover member
190
so that the base section
198
of the cover member
196
overlies the forwardly facing end of the base element
194
when the cover
190
is in place on the control box member
184
. A base access opening
199
is defined through the base section
198
with the same cross-sectional size and shape as the opening to the recess
197
in each base element
194
and is in registration with the base element recess when the cover
190
is in place.
The connecting element
195
seen in
FIG. 23
includes an insertable body
200
with a cross-sectional size and shape complementary to the recess in the base element
194
that fits through the opening
199
into the recess in the base element
194
to connect the power source to the unit. A stop flange
201
is provided around the body
200
spaced a prescribed distance from the projecting end of the insertable body such that the flange abuts the base section
198
on the disconnect cover member
196
when the insertable body
200
on the connecting element
195
is fully seated in the recess in the base element
194
. The flange
201
thus serves to prevent the control box cover member
190
from being removed from the front of the control box assembly
181
without the connecting element
195
being first removed from the base element
194
to disconnect the unit from the power source. The disconnect access opening
191
through the cover member
190
and the access recess formed in the disconnect cover member
196
are sized to allow the service personnel to manually reach through the opening
191
and remove the connecting element
195
prior to removal of the front access panel assembly
36
. This reduces the likelihood of electrical short or shock during removal of the cover member
190
and insures that the service personnel will have to reinstall the connecting element
195
after the cover member
190
is removed to operate the unit during servicing. Likewise, if the connecting element
195
is installed during servicing, the disconnect cover member
196
also prevents the cover member
190
from fitting onto the front of the control box assembly
180
until the connecting element
195
is again removed. Access to the connecting elements
195
through the front access panel assembly
36
is provided by a small access door
202
in the front access panel
135
seen in FIG.
1
.
In order to properly diagnose problems and service the unit
10
, it is sometimes necessary to operate the unit under normal operating conditions. To do this, it is necessary to seal the open front of the primary cabinet assembly
20
above the divider plate
84
so that the indoor air passage
12
remains sealed. The unit
10
is designed so that the front access panel assembly
36
can be reattached to the front of the primary cabinet subassembly
20
while leaving the open front control space accessible to connect test equipment to the electrical controls and refrigeration circuit within the control box assembly
181
.
As seen in
FIG. 22
, the front access panel
135
is provided with a base set of mounting holes
205
while the front inturned flanges
71
on the right and left side panel assemblies
31
and
32
are provided with a first set of pilot holes
206
registrable with the mounting holes
205
(
FIG. 22
) when the front access panel assembly
36
is in the position covering the front of the primary cabinet subassembly
20
and extending from the top of the outdoor air fan mounting panel
38
to the top panel assembly
34
so that the front panel fasteners
208
can be screwed into the holes
206
through the holes
205
to removably mount the front access panel assembly
36
on the front of the primary cabinet subassembly
20
for normal use of the unit.
A second set of pilot holes
209
seen in
FIG. 1
is also provided in the front inturned flanges
71
on the side panels
31
and
32
which are also registrable with some of the mounting holes
205
in the front access panel assembly
36
but are displaced upwardly from the first set of pilot holes
205
by the height HT
1
of the control box assembly
181
. Thus, when the unit
10
is being serviced, the service pers on removes the front access panel assembly
36
, removes the control box cover assembly
189
, and then reattachs the front access panel assembly
36
to the front of the primary cabinet assembly
20
using the second set of pilot holes
209
as illustrated in
FIG. 22
so that the front of the unit is closed for it to operate normally but access to the open front control space
188
is available for testing and servicing the unit.
To provide additional heat for the air being supplied to the conditioned space, a heater assembly
210
is provided as seen in
FIGS. 15-18
. The heater assembly
210
is mounted adjacent that blower inlet opening
152
opposite the blower motor
155
by a heater mounting means
211
. Thus, when the centrifugal blower
150
is positioned in positions POS
1
or POS
2
, the heater assembly
210
remains operatively associated with the blower.
The heater assembly
210
includes an open frame
212
defining an air flow passage
214
therethrough with one or more conventional resistance heating elements
215
mounted on the frame
212
so as to locate the heating element
215
within the passage
214
. The frame
212
also mounts the high temperature limit switch
216
thereon so that it projects into the air flow passage
214
. The limit switch
216
is connected to the circuit to power the heating element
215
and opens when the temperature within the passage
214
exceeds the maximum permissible temperature for safe operation. The limit switch
216
needs to be located within that portion of the air flow passage
214
most likely to be at the highest temperature during the operation of the unit
10
. Because heated air rises, the highest temperature position in the air flow passage
214
is thus at the uppermost portion of the passage. Therefore, the frame
212
of the heater assembly
210
needs to be oriented with respect to the blower
150
to position the switch
216
in the uppermost portion of the air flow passage
214
even though the blower
150
can be located at position POS
1
or POS
2
.
The heater frame
212
has a near side
220
adapted to be located against the blower housing
151
and a distal side
221
opposite the near side
220
. The heater frame
212
includes a first side member
222
with the temperature limit switch
216
located thereon adjacent one end thereof so that the limit switch
216
projects interiorly of the side member
222
into the air flow passage
214
. Frame
212
also includes a second side member
224
attached to that end of the first side member
222
opposite the switch
216
and oriented normal thereto, a third side member
225
attached to that end of the second side member
224
opposite the first side member
222
, and a fourth side member
226
attached between those ends of the first and third side members
224
and
225
opposite the second side member
224
.
The heater mounting means
211
includes a first housing mounting flange
230
along the near side
220
of the first side member
222
and a first plate mounting flange
231
along the distal side
221
of the third side member
225
which are adapted to be used to mount the heater assembly
210
to the blower
150
when the blower
150
is in the first position POS
1
. The heater mounting means
211
also includes a second housing mounting flange
232
along the near side
220
of the second side member
224
and a second plate mounting flange
234
along the distal side
221
of the fourth side member
225
which are adapted to be used to mount the heater assembly
210
to the blower
150
when the blower
150
is in the second position POS
2
. The heater mounting means
211
also includes a first set of housing mounting holes
235
(
FIG. 16
) through the first housing mounting flange
230
with a prescribed spacing therebetween and a second set of housing mounting holes
236
(
FIG. 15
) through the second housing mounting flange
232
with the same hole spacing as the holes
235
. A first set of plate mounting pilot holes
238
(
FIG. 16
) is provided through the first plate mounting flange
231
with a prescribed spacing therebetween and a second set of plate mounting pilot holes
239
(
FIG. 15
) is provided through the second plate mounting flange
234
with the same hole spacing as the holes
238
.
The heater mounting means
211
includes a set of housing pilot holes
240
(
FIG. 19
) in the side of the blower housing
151
adapted to be selectively aligned with the first or second set of housing mounting holes
235
or
236
when the central axis A
4
of the air flow passage
214
in the heater assembly
210
is coaxial with the central axis A
5
of the air inlet opening
150
in the housing
151
as seen in
FIGS. 15-17
.
To connect the heater assembly
210
to the blower mounting plate
161
, the heater mounting means
211
further includes a heater mounting angle
241
seen in
FIGS. 15
,
17
and
18
with a base leg
242
adjustably attached to the mounting plate
161
and a mounting leg
244
normal to leg
242
projecting out from plate
161
parallel to the side of the blower housing
151
. The mounting leg
244
defines a set of plate mounting holes therethrough with the same spacing as the first and second sets of plate mounting pilot holes
238
and
239
in the heater assembly
210
. The heater mounting angle
241
is located so that the plate mounting holes in the mounting leg
244
will align with the first or second set of plate mounting pilot holes
238
or
239
when the central axis of the air flow passage
214
in the heater assembly
210
is coaxial with the central axis of the air inlet opening
150
in the housing
151
. Moreover, the holes in the mounting leg
244
align with the first set of pilot holes
238
when the housing pilot holes
240
are aligned with the first set of mounting holes
235
in the heater frame
211
and the holes in the mounting leg
244
align with the second set of pilot holes
239
when the housing pilot holes
240
are aligned with the second set of mounting holes
235
in the heater frame
211
.
When the blower
150
is positioned in the first ducted position POS
1
as seen in
FIG. 15
, the first set of blower mounting holes
235
are used to attach the frame
211
to the blower housing
151
through the pilot holes
240
using appropriate heater mounting fasteners
248
and the heater mounting holes in the heater mounting angle
241
are used to attach the heater frame
211
thereto through the first set of pilot holes
238
using fasteners
248
. It will thus be seen that the high temperature limit switch
216
will be located in the uppermost portion of the heater air flow passage
214
when the blower
150
is located in the position POS
1
.
When the blower
150
is positioned in the second freeblow position POS
2
as seen in
FIG. 16
, the second set of blower mounting holes
236
are used to attach the frame
211
to the blower housing
151
through the pilot holes
240
using appropriate heater mounting fasteners
248
and the heater mounting holes in the heater mounting angle
241
are used to attach the heater frame
211
thereto through the second set of pilot holes
239
using fasteners
248
. It will thus be seen that the high temperature limit switch
216
will be located in the uppermost portion of the heater air flow passage
214
when the blower
150
is located in the position POS
2
.
The outdoor air circulation fan means
18
best seen in
FIGS. 6
,
20
, and
21
is mounted on the inside of the outdoor air fan mounting panel
38
. The fan mounting panel
38
defines a louvered front outdoor air discharge opening
250
therethrough (
FIGS. 1
,
20
, and
21
) around a fan mounting section
251
in the center thereof. The discharge opening
250
comprises a plurality of radially extending slits formed around the fan mounting section
251
that are formed into louvers
254
with openings therebetween. A circular reinforcing bead
255
is formed in the fan mounting section
251
to reinforce it and a central draw opening
256
is provided through the center of the section
251
to allow for the metal forming operation on the panel
38
without metal wrinkling.
The fan means
18
comprises a outdoor air fan assembly
260
mounted on the back surface of the mounting section
251
. The motor
261
of the fan assembly
260
is mounted directly to the section
251
and the fan blades
262
are mounted directly on the motor shaft so the they are located behind the louvered discharge opening
250
and adapted to force air forwardly out of the opening
250
from within the outdoor air passage
14
. To enhance the efficiency of the fan assembly
260
, a venturi ring
264
is provided that extends around the tips of the fan blades
262
to form a venturi about the blades. The venturi ring
264
is a seamless member and is attached directly on the mounting panel
38
just outboard of the louvered opening
250
and serves to strengthen the panel
38
. The venturi ring
262
is spin formed from a seamless ring of material to minimize the amount of scrap metal produced in the ring forming operation. It will likewise be seen that this construction makes the fan assembly
260
, compressor
144
, and outdoor coil
142
easily accessible for service simply by removing the front access panel
38
.
For ease of manufacturing, the front access panel assembly
36
and outdoor air fan mounting panel
38
are installed after all of the refrigeration and electrical assembly is completed for the primary cabinet subassembly
20
. Because the primary cabinet subassembly
36
is self supporting, the front and back of the subassembly
36
is left open for assembly access. The outdoor fan assembly
260
and venturi ring
264
can be preassembled on the outdoor air fan mounting panel
38
before the panel
38
is installed to further facilitate the assembly of the unit
10
. Likewise, the back panel subassembly
21
can be fabricated separately from the primary cabinet subassembly
20
to further facilitate the assembly of the unit. As a result manufacturing cost is reduced over the prior art assembly techniques.
To install the unit
10
, the back panel subassembly
21
is separated from the primary cabinet subassembly
20
and installed directly on the wall EW using the fasteners
25
. Because the subassembly
21
is lightweight, it is easily supported during placement on the wall EW and access is provided so that the alignment of the duct flanges
22
and
24
with the air supply and return passages ASP and ARP can be assured. The heavier primary cabinet subassembly
20
is then supported on appropriate equipment and moved over to the back panel subassembly
21
where it is tilted back slightly (usually about 5°) so that the hook member
92
on the primary cabinet subassembly
20
will engage the hook member
94
on top of the back panel subassembly
21
in the initial tilted position ITP. As the primary cabinet subassembly
20
is lowered, the hook members
92
and
94
will engage and the primary cabinet subassembly
20
will be supported on the back panel subassembly
21
. As the equipment supporting the primary cabinet subassembly
20
continues to remove support therefrom, the weight of the primary cabinet subassembly
20
will force the primary cabinet subassembly toward the final seated position FSP. To fully seat the primary cabinet subassembly
20
on the back panel subassembly
21
, the installer simply pushes back on the primary cabinet subassembly
20
so that the hook member
92
slides back along the hook member
94
until the final seated position FSP is reached. The installer then installs the fasteners
265
of the cabinet connection means
28
to complete the installation. It will be appreciated that a seal between the wall EW and the periphery of the primary cabinet subassembly
20
is made with an appropriate sealant. The sealant can be preapplied to the side sealing flanges
72
on the side panel assemblies
31
and
32
so that the seal is formed as an incident to the installation.
In the event the unit
10
becomes inoperable and needs to be replaced, it is only necessary that the primary cabinet subassembly
20
be removed and replaced. This is because all of the operating components of the unit
10
are mounted in the subassembly
20
.
It will likewise be appreciated that the prepositioning means
26
is illustrated being located at the top of the primary cabinet subassembly
20
and the back panel subassembly
21
, however, the prepositioning means may be located at different positions on the subassemblies
20
and
21
without departing from the scope of the invention. For instance, the prepositioning means
26
may be configured to interconnect the bottoms of the subassemblies
20
and
21
so that the primary cabinet subassembly
20
may be tilted away from the back panel subassembly
21
at the top, the primary cabinet subassembly
20
supported on the back panel subassembly
21
, and then the top of the primary cabinet subassembly pushed back to seat the primary cabinet subassembly
20
on the back panel subassembly
21
.
Claims
- 1. A single package HVAC unit in heat exchange with the outdoor air and adapted to be mounted on the wall of structure to condition the air for an interior space in the structure, the wall defining an air return and air supply passages therethrough in communication with the interior space, said unit comprising:A) conditioning means for conditioning air; and, B) a cabinet assembly housing said conditioning means and adapted to the attached to the wall of the structure, said cabinet assembly comprising: 1) a first cabinet subassembly including air return and air supply flanges adapted to be attached to the wall of the structure with said air return and air supply flanges projecting into the air return and air supply passages respectively, 2) a separate second cabinet subassembly adapted to be removably mounted on said first cabinet subassembly, and 3) prepositioning means adapted to preposition said second cabinet subassembly with respect to said first cabinet subassembly and support said second cabinet subassembly on said first cabinet subassembly while said second cabinet assembly is moved from an initial tilted position into a final seated position in registration with said first cabinet assembly, said prepositioning means comprising first hook means mounted on said first cabinet subassembly and second hook means mounted on said second cabinet subassembly, said first and second hook means constructed and arranged for said second hook means to engage said first hook means and support said second cabinet subassembly on said first cabinet subassembly.
- 2. The single package HVAC unit of claim 1 wherein said first and second hook means are constructed and arranged so that said second hook means can slide on said first hook means for a limited distance so that said second cabinet subassembly can be slipped into said final seated position in registration with said first cabinet subassembly.
- 3. The single package HVAC unit of claim 1 wherein said first cabinet subassembly defines a first upper end thereon; wherein said first hook means is mounted on said first cabinet subassembly along said first upper end; wherein said second cabinet subassembly defines a second upper end thereon adapted to overlie said first upper end of said first cabinet subassembly when said second cabinet subassembly is in registration with said first cabinet subassembly; and wherein said second hook means is mounted on said second cabinet subassembly along that portion of said second upper end of said second cabinet subassembly overlying said first upper end of said first cabinet subassembly when said second cabinet subassembly in said final seated position so that the weight of said HVAC unit causes said second cabinet subassembly to pivot toward said final seated position when said second hook means supports said second cabinet subassembly on said first hook means.
- 4. A single package, vertically oriented, HVAC unit adapted to be mounted on the wall of structure and condition the air for an interior space in the structure with heat exchange to the outdoor air, the wall defining an air return passage therethrough in communication with the interior space and an air supply passage therethrough in communication with the interior space, and said unit comprising:a) a self supporting primary cabinet subassembly defining a back peripheral edge therearound and an interior space therein opening through said back peripheral edge; b) conditioning means for conditioning air mounted on said primary cabinet subassembly within said interior space; c) air circulation means for circulating air mounted on said primary cabinet subassembly within said interior space; d) a back panel subassembly adapted to the attached to the wall of the structure over the air return and air supply passages independently of said primary cabinet subassembly, said back panel subassembly defining air return and air supply openings therethrough located so as to be in respective registration with the air return and air supply passages through the wall when said back panel subassembly is attached to the wall over the air return and air supply passages, said back panel subassembly including air return and air supply duct flanges respectively around said air return and air supply openings adapted to fit within the wall air return and air supply passages respectively when said back panel subassembly is positioned on the wall whereby said duct flanges are visible through said openings through said back panel subassembly while said back panel subassembly is being attached to the wall while separated from said primary panel subassembly, said back panel subassembly sized to engage said primary cabinet subassembly along said back peripheral edge to close the open back of said primary cabinet subassembly and form an air circulation passage between said primary cabinet subassembly and said back panel subassembly extending from the air return passage to the air supply, said back panel subassembly having sufficient strength to support said primary cabinet subassembly thereon; and c) cabinet connection means for supporting said primary cabinet subassembly on said back panel subassembly while said primary cabinet subassembly is moved into position so that said back panel subassembly closes the back of said primary cabinet subassembly whereby said back panel subassembly can be attached to the wall of the structure while separated from said primary cabinet subassembly to facilitate visual alignment of said air return and air supply duct flanges with the air return and air supply passages through the wall and then said primary cabinet subassembly can be supported on said back panel subassembly and positioned with respect thereto whereby said back panel subassembly engages said back peripheral edge of said primary cabinet subassembly to close the open back of said primary cabinet subassembly and form said air circulation passage in said cabinet assembly.
- 5. A single package HVAC unit adapted to be mounted on the wall of structure and condition the air for an interior space in the structure with heat exchange to the outdoor air, the wall defining an air return passage therethrough in communication with the interior space and an air supply passage therethrough in communication with the interior space, and said unit comprising:a) a self supporting primary cabinet subassembly defining an interior space therein open at the back thereof; b) a back panel subassembly adapted to the attached to the wall of the structure over the air return and air supply passages and including air return and air supply duct flanges adapted to fit within the wall air return and air supply passages respectively whereby said duct flanges are visible while said back panel subassembly is being attached to the wall, said back panel subassembly defining a peripheral edge therearound having a size and configuration adapted to fit in the open back of said primary cabinet subassembly and seal same so as to define an air circulation passage through said primary cabinet subassembly extending from the air return passage to the air supply passage, c) cabinet connection means for removably attaching said primary cabinet subassembly to said back panel subassembly so that said back panel subassembly can be attached to the wall of the structure and then said primary cabinet subassembly can be positioned and attached to said back panel subassembly; d) a top hook assembly fixedly mounted on said primary cabinet subassembly along the upper edge of the open back thereof, said top hook assembly adapted to engage the upper portion of said back panel subassembly to support said primary cabinet subassembly on said back panel subassembly with said back panel subassembly in registration with the open back of said primary cabinet subassembly.
- 6. The HVAC unit of claim 5 further including:e) air circulation blower means having an intake opening and a discharge opening for discharging air therefrom through said discharge opening along a prescribed discharge path for circulating air through said air circulation passage; and, f) blower mounting means adapted to selectively mount said blower means in a first blower discharge position in said primary cabinet subassembly within said air circulation passage so that said prescribed air discharge path from said blower means is generally axially aligned with the axis of said air supply opening through said back panel subassembly whereby air being discharged from said blower means is directed generally axially along the air supply passage, and in a second blower discharge position within said air circulation passage so that said prescribed discharge path from said blower means is out of alignment with said air supply opening whereby the noise level transmitted out of said air supply outlet is reduced in said second blower discharge position relative to said first blower discharge position.
- 7. The HVAC unit of claim 6 wherein said blower mounting means comprises:a blower mounting plate corresponding in size and shape to the cross-sectional size and shape of said air circulation passage through said cabinet assembly and fixedly mounting said blower means thereon with said blower intake opening on one side thereof and said blower discharge opening on the other side thereof; and blower plate mounting means for selectively mounting said blower mounting plate in said primary cabinet subassembly within said air circulation passage in said first discharge position so that said blower plate is adjacent said air supply outlet through said back panel subassembly and said discharge outlet opening on said blower means is axially aligned with said air supply outlet, and alternatively in said second position so that said blower plate is spaced away from said air supply outlet and said discharge outlet opening on said blower means is out of alignment with said air supply outlet and a plenum space is defined in said air circulation passage downstream of said blower mounting plate into which the air is discharged from said blower means to reduce the noise transmitted out of said air supply opening.
- 8. The HVAC unit of claim 6 further comprising:heater means for heating the air passing through said air passage in said cabinet assembly; and, heater mounting means for selectively mounting said heater means adjacent said intake opening on said air circulation blower means so that air passes into said intake opening through said heater means to be selectively heated, said heater mounting means alternatively mounting said heater means in a first orientation relative to said blower means when said blower means is located in said first blower discharge position and in a second orientation relative to said blower means when said blower means is in said second discharge position.
- 9. The HVAC unit of claim 6 further comprising:heater means for heating the air passing through said air passage in said cabinet assembly, said heater means including temperature responsive limit switch means located at a prescribed position within said heater means; and, heater mounting means movably mounting said heater means adjacent said air intake opening on said blower means so that air passes into said blower air intake opening through said heater means to be selectively heated and so that said temperature responsive limit switch means is positioned in the uppermost portion of said heater means relative to the horizontal when said blower means is positioned in said first discharge position and said second discharge position.
- 10. The HVAC unit of claim 5 further including:e) a refrigeration circuit including an indoor coil having an inlet side and an outlet side mounted in said air circulation passage a prescribed distance downstream of said air return opening, said coil generally vertically oriented and aligned with said air return opening; f) a fresh air damper subchamber forming assembly positioned in said cabinet assembly between the inlet side of said indoor coil and said air return opening to define a fresh air damper subchamber sealed to said air return opening at one end thereof and to said indoor coil at the opposite end thereof so that air returning through said air return opening in said cabinet assembly passes through said fresh air damper subchamber to said indoor coil, said fresh air damper subchamber extending between opposite sides of said primary cabinet subassembly, said primary cabinet subassembly defining at least one fresh air inlet opening therethrough in communication with said fresh air damper subchamber; and, g) a fresh air damper assembly mounted in said fresh air damper subchamber adjacent said fresh air inlet opening for controlling the amount of outside air drawn into said fresh air damper subchamber through said fresh air inlet opening upstream of said indoor coil.
- 11. The single package HVAC unit of claim 10 wherein said fresh air damper assembly comprises a damper frame assembly mounted in said fresh air damper subchamber and defining a fresh air damper opening therethrough, a damper door pivotally mounted on said damper frame assembly and adapted to selectively close said fresh air opening through said damper frame assembly, and damper positioning means for selectively maintaining said damper door in a plurality of pivotal positions relative to said fresh air damper opening so as to control the amount of fresh air induced into the air from the space to be conditioned passing through said fresh air damper subchamber.
- 12. The HVAC unit of claim 5 further including:e) a refrigeration circuit housed in said primary cabinet subassembly; f) an open front control box mounted in said primary cabinet subassembly; g) electrical controls for controlling the operation of said refrigeration circuit housed in said control box, said electrical controls comprising electrical disconnect means for connecting the electrical controls to an electrical power source, said electrical disconnect means including a base element fixedly mounted in said control box and a connecting element removably insertable into said base element to connect said electrical controls to the power source when said connecting element is inserted into said base element and for disconnecting said electrical controls for the power source when said connecting element is removed from said base element; h) a control box cover removably covering the open front of said control box; and, i) interconnect means on said control box cover operatively associated with said disconnect means so as to prevent removal of said control box cover from said control box without removal of said connecting element from said base element of said disconnect means.
- 13. The single package HVAC unit of claim 12 wherein said connecting element of said disconnect means includes an insertable body sized to fit in said base element and an outwardly projecting flange on said insertable body larger than said insertable body; and wherein said interconnect means comprises a disconnect cover member fixedly mounted on said control box cover, said disconnect cover member constructed and arranged to overlie said base element when said control box cover is covering said control box and defining an opening therethrough sized to allow said insertable body to pass therethrough but to prevent said outwardly projecting flange from passing therethrough whereby said connecting element can be installed in said base element after said control box cover is covering said control box to connect said electrical controls to the power source while said disconnect cover member prevents said control box cover from being removed from said control box without removal of said connecting element of said disconnect means.
- 14. The single package HVAC unit of claim 5 wherein said primary cabinet subassembly defines a front access opening to said air circulation passage, said primary cabinet subassembly further including a front service panel sized to cover said front access opening in said primary cabinet subassembly and front service panel attachment means for removably attaching said front service panel to said primary cabinet subassembly so as to close said front access opening, and further comprising:e) a control box assembly mounted in said primary cabinet subassembly within said air circulation passage and extending across one side of said front access opening, said control box assembly mounted in said primary cabinet subassembly so that the interior of said control box assembly is sealed from said air circulation passage, and said front service panel attachment means constructed and arranged to removably attach said front service panel to said cabinet assembly in a first sealing position so that said front service panel closes said front access opening and said control box assembly, and in a second sealing position so that said front service panel closes said front access opening while leaving said control box assembly uncovered whereby the interior of said control box assembly is accessible from outside said primary cabinet subassembly for service while said air circulation passage remains sealed to allow said HVAC unit to operate as designed during servicing.
- 15. The single package HVAC unit of claim 14 wherein said control box assembly comprises an open front control box mounted in said air circulation passage and defining a sealing lip thereon extending across said front access opening, said sealing lip oriented parallel to that side of said access opening adjacent which said control box is mounted and substantially coplanar with the periphery of said access opening so that said front service panel sealingly engages said sealing lip when said front service panel closes said front access opening, and wherein said front panel attachment means includes a first set of panel mounting holes in said front access panel, a second set of complementary panel mounting holes in said cabinet assembly around said front access opening in registration with said first set of panel mounting holes when said front service panel covers said access opening and the open front of said control box, a third set of complementary panel mounting holes in said cabinet assembly around said front access opening in registration with at least some of said first set of said panel mounting holes when said front access panel covers said front access opening while forming a seal with said sealing lip on said control box and exposing the open front of said control box, and panel fastening means for selectively extending through said first set of panel mounting holes and that set of complementary panel holes in said cabinet in registration with said first set of panel mounting holes to removably attach said front service panel to said cabinet assembly in said first and second sealing positions.
- 16. The single package HVAC unit of claim 5 wherein said cabinet assembly defines an outdoor chamber therein when said primary cabinet subassembly is mounted on said back panel subassembly having opposed chamber sides, a chamber top, a chamber back, a chamber bottom and a chamber front; said primary cabinet subassembly defining a side outdoor air inlet opening therethrough through one of said chamber sides, a bottom outdoor air inlet opening therethrough through said chamber bottom, and an front outdoor air discharge opening therethrough through said chamber front; and further comprising:e) a straight outdoor coil assembly mounted in said outdoor chamber and extending diagonally across said outdoor chamber in a sealing relationship with said chamber top, chamber front, chamber back, and chamber bottom so that said side and bottom outdoor air inlet openings communicate with one side of said outdoor coil assembly while said front outdoor air discharge opening communicates with the opposite side of said outdoor coil assembly; and, f) outdoor air circulation means operatively associated with outdoor coil assembly for moving outdoor air into said outdoor chamber through said side and bottom outdoor air inlet openings, through said outdoor coil assembly, and then out of said outdoor chamber through said front outdoor air discharge opening.
- 17. The single package HVAC unit of claim 16 further including a refrigerant compressor mounted in said outdoor chamber on that side of said outdoor coil assembly opposite said side and bottom outdoor air inlet openings so that the heat generated by said compressor is dissipated by the outdoor air flowing through said outdoor air chamber after passage through outdoor coil assembly.
- 18. The single package HVAC unit of claim 16 wherein said primary cabinet subassembly defines an outdoor chamber access opening therethrough to the front of said outdoor chamber; wherein said primary cabinet subassembly further includes an outdoor air fan mounting panel adapted to removably close the front of said outdoor chamber, said outdoor air fan mounting panel defining said front outdoor air discharge opening from said outdoor chamber therethrough, and wherein said outdoor air circulation means further includes an outdoor air fan assembly directly mounted on said outdoor air fan mounting panel and overlying said front outdoor air discharge opening to draw outdoor air through said outdoor coil assembly and force the outdoor air out of said outdoor air chamber through said front outdoor air discharge opening.
- 19. The single package HVAC unit of claim 18 wherein said outdoor air circulation means further includes a spun single piece venturi member attached directly to said outdoor air fan mounting panel around said front outdoor air discharge opening to form a venturi around said outdoor air fan assembly operatively associated therewith and to stiffen said outdoor air fan mounting panel.
- 20. A single package HVAC unit adapted to be mounted on the wall of structure and condition the air for an interior space in the structure with heat exchange to the outdoor air, the wall defining an air return passage therethrough in communication with the interior space and an air supply passage therethrough in communication with the interior space, and said HVAC unit comprising:a cabinet assembly adapted to be mounted on the wall of the structure over the air return and air supply passages through the wall, said cabinet assembly defining an indoor air circulation passage therethrough extending from the air return passage to the air supply passage, and an outdoor air circulation passage therethrough in communication with the outdoor air; a refrigerant circuit for conditioning the air to be supplied to the interior space, said refrigerant circuit including an indoor coil positioned in said indoor air circulation passage and an outdoor coil position in said outdoor air circulation passage; indoor air circulation blower means positioned in said indoor air circulation passage for moving air through said indoor air circulation passage; and outdoor air circulation fan means positioned in said outdoor air circulation passage for moving air through said outdoor air circulation passage, said cabinet assembly comprising: a) a self supporting primary cabinet subassembly including a pair of spaced apart generally vertically extending side panel assemblies having upper and lower ends and defining generally vertically extending rear edges thereon, a bottom pan assembly connecting the lower ends of said side panel assemblies, a top panel assembly connecting the upper ends of said side panel assemblies, a divider wall assembly connecting said side panel assemblies intermediate the ends thereof, said primary cabinet subassembly defining a first space therein subtended between said side panel assemblies, said divider wall assembly and said top panel assembly open at the back thereof, and defining a second space therein subtended between said side panel assemblies, said bottom pan assembly and said divider wall open at the back thereof; b) a back panel subassembly sized to engage said side panel assemblies, said divider wall assembly, said top panel assembly and said bottom pan assembly so as to close the open back of said first and second spaces in said primary cabinet subassembly, said back panel subassembly defining air return and air supply openings therethrough and including air return and air supply duct flanges respectively around said air return and air supply openings adapted to fit within the wall air return and air supply passages respectively when said back panel subassembly is positioned on the wall whereby said duct flanges are visible through said openings through said back panel subassembly while said back panel subassembly is being attached to the wall while separated from said primary panel subassembly, said back panel subassembly having sufficient strength to support said primary cabinet subassembly thereon; and c) cabinet connection means for supporting said primary cabinet subassembly on said back panel subassembly while said primary cabinet subassembly is moved into position whereby said back panel subassembly closes the back of said primary cabinet subassembly so that said back panel subassembly can be attached to the wall of the structure while separated from said primary cabinet subassembly and then said primary cabinet subassembly can be positioned on said back panel subassembly to close the open back of said primary cabinet subassembly.
US Referenced Citations (3)
Number |
Name |
Date |
Kind |
4854376 |
Tunekawa et al. |
Aug 1989 |
A |
4958550 |
Kuroda et al. |
Sep 1990 |
A |
5444990 |
McGill et al. |
Aug 1995 |
A |