Zoning system for air conditioning (HVAC) equipment

Abstract

Variable air flow air conditioning (HVAC) systems including a method of cooling or heating a structure having at least two zones. In example embodiments, individual air flow rates of the at least two zones are measured, and a control system adjusts the individual air flow rates to maintain an instantaneous measured net volumetric air flow rate at a preset volumetric air flow rate as if there was a single fan operating the system.

Claims

1. A method of cooling or heating a structure having at least two zones, the structure including an outdoor compressor, an indoor heat transfer unit and heat pump, the structure having ducts connected between the indoor heat transfer unit and the zones, each of the ducts having an individual fan in communication therewith to draw air from the indoor heat transfer unit and across a coil to the desired zone at a desired rate, so long as the sum of the volumetric air flows through the ducts remains at a preset volumetric air flow rate, the method comprising: drawing air across the heat transfer coil of the indoor heat transfer unit at the preset volumetric air flow rate; measuring individual air flows rates of the at least two zones within at least a portion of the ducts such that air flow signals generated by the measuring of the individual air flow rates are sent to a control system for processing; summing the individual zone air flow signals in the control system to generate an instantaneous measured net volumetric air flow rate for the entire air volume moving across the coil of the indoor heat transfer unit; comparing the measured net volumetric air flow rate to the preset volumetric air flow rate; proportionally adjusting the individual air flow rates to maintain the instantaneous measured net volumetric air flow rate at the preset volumetric air flow rate as if there was a single fan operating the system.

2. The method of claim 1, wherein the control system comprises a distributed control system comprising individual zone controllers connected to a central controller.

3. The method of claim 2, wherein the individual zone controllers act as an intermediary between the corresponding zones and and the central controller.

4. The method of claim 1, further comprising distributing conditioned air to one or more zones of the at least two zones to satisfy any loads while also ensuring that measured net volumetric air flow rate over the coil of the indoor heat transfer unit remains within the preset volumetric air flow rate predetermined by the system's thermal capacity and user performance goals.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic block diagram of a conventional heating and air conditioning system, as is known in the art.

(2) FIG. 2 is a schematic diagram of a conventional single-zone variable air volume system, as is known in the art.

(3) FIG. 3 is a schematic block diagram of a variable air flow heating and air conditioning system, according to an example embodiment of the present disclosure.

(4) FIG. 4 is a schematic diagram of the variable air flow heating and air conditioning system shown in FIG. 3, as used in a structure.

(5) FIG. 5 is a plan view of a schematic diagram of a variable air flow heating and air conditioning system according to another example embodiment of the present invention, showing the system used in a structure such as a residential home.

(6) FIG. 6 is a detailed isometric view of the variable air flow heating and air conditioning system of FIG. 5.

(7) FIG. 7 is a schematic diagram of the variable air flow heating and air conditioning system of FIG. 5.

(8) FIG. 8 is a detailed schematic diagram showing only a single zone of the system of FIG. 5.

(9) FIG. 9 is a flowchart showing the order of operations of the system of FIG. 5 according to an example embodiment of the present invention.

(10) FIG. 10 is a table listing multiple parameters, inputs, outputs and numerical values to be used with the system of FIG. 5 according to an example embodiment of the present invention.

(11) FIG. 11 shows charts including example parameters to be used in first thru third example calculations according to the system of FIG. 5.

(12) FIG. 12 is a schematic diagram of a variable air flow heating and air conditioning system according to another example embodiment of the present invention.

(13) FIG. 13 is a detailed schematic diagram showing only a single zone of the system of FIG. 12.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

(14) The present invention may be understood more readily by reference to the following detailed description of example embodiments taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.

(15) Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.

(16) Common HVAC systems, for example as illustrated in FIG. 1, circulate conditioned air to a single zone inside a structure. The example system 10 also includes an indoor unit 20 and an outdoor unit 14. A thermostat control 16 is commonly located in the conditioned space in the air path near the return grille. The outdoor unit 14 can include a condensing unit and/or a heat pump unit. The heat transfer fluid (typically Freon, water, glycol, etc.) is transferred by piping line 18 from outdoor unit 14 to indoor unit 20.

(17) Outside air supplied to the indoor unit 20 is commonly limited with a manual damper, but can also include an outside air control 26, such as a motor operated damper (not shown). In some examples, an outside air intake 12 can optionally be provided, particularly for newer code compliant installations. The indoor unit 20 can also include a filter (not shown), a heating-and-cooling coil 24 and a fan 22. Conventional indoor units 20 include the fan 22 positioned very close to the heating-and-cooling coil, commonly within the same housing or a directly connected housing forming an indoor unit, also called an evaporator or air handler. The indoor unit 20 is operably connected to an air path 28, such as a plenum and/or ductwork. The fan 22 directs hot or cool conditioned air from the indoor unit 20 into the air path 28. The air path 28, through the duct work and/or plenum, continues between the indoor unit 20 and a remote zone 30. The remote zone 30 includes a thermostat 32, which operably manipulates the desired temperature in the zone. In use, the heating-and-cooling coil in the indoor unit 20 adjusts the temperature of the air delivered to the supply air path 28 as the outdoor unit 14 cycles on and off under the control of the thermostat. The system 10 then includes a common return air path 34 to direct air from the remote zone 30 back to the indoor unit 20. The return air path 34 can include structures for directing air, such as grilles, ductwork and filters.

(18) Systems such as the example illustrated in FIG. 1 can be reconfigured as a multi-zone system 100 in a structure such as a house 150, as illustrated in FIG. 2. The illustrated multi-zone system 100 includes an outdoor unit 104, and outside air control 126, an indoor unit 120 with a heating-and-cooling coil 124, a fan 122 and can optionally include an outside air intake 102. The heated or cooled air directed from the fan 122 is managed by a series of motor operated control dampers. The example dampers can be mounted in terminal units, also called VAV boxes 140a-c, which limit the air flow to individual air paths 128a-c. Each air path 128a-c extends between a respective VAV box 140a-c and a respective zone 130a-c. Each VAV box 140a-c controls the amount of heated or cooled air entering an air path 128a-c from the fan 122.

(19) A thermostat can be located in the space for each zone which provides control for each VAV box 140a-c. An example thermostat located in the space for each zone can limit the amount of air directed through the air paths, thus providing a distinct temperature control for the three separate zones 130a-c.

(20) For this example, a common return is shown to provide an intake to ductwork, which returns the air path 142 from the zones 130a-c to the indoor unit 120. Alternatively, individually ducted return air path schemes (not shown) can function similarly.

(21) A VAF (variable air flow) system eliminates fans from the central air handler and also eliminates dampers, which creates conditioning zones. Each zone in the VAF system has a thermostat and is served by its own variable speed fan which pushes the air to its designated area through a standard system of ducts and diffusers. This distributed network of fans is controlled by a central controller which adjusts the speed of each individual fan to provide the volume of air flow to match the load of the zone it serves and it also maintains the net air flow through the heat transfer element of the air conditioning system which often has a specific range of operation. This VAF system moves the higher-pressure air flow downstream of the control mechanism to allow the system to overcome limitations imposed by the layout/geometry/configuration of conditioned space and provide for a more responsive system with less fan energy.

(22) The VAF system includes a network of fans and an arrangement of ductwork to allow air to be pulled from an indoor heat transfer unit (IHTU) and distribute by a specific fan to the zone it serves. Essentially, the IHTU functions as an indoor unit without a fan. The fans are driven with variable speed motors to adjust the volume of air being provided to the zones. The fans have features and instrumentation to measure the volume of air being provided to the zones. Each zone has a thermostat which measures the temperature of the space and allows the occupant to enter the target (or set-point) temperature for the space. In addition to thermal inputs, the control system can account for schedule, occupancy, priority, relative humidity, and ventilation requirements (with instrumentation sensing items such as: Humidity, Occupancy, CO2, Indoor Air Quality, VOC, CO, etc.). The control system also maintains the total volume of air through the IHTU within the acceptable range of operation of the equipment. This air volume is further adjusted for system priorities such as humidity control, thermal accuracy, and energy efficiency.

(23) An example VAF system 200 is illustrated in FIGS. 3 and 4. The VAF system 200 includes an outdoor unit 204 and an indoor heat transfer unit 205 (IHTU). The VAF system 200 can include a ventilation fan 203 drawing air from an outside air intake 202 and directing the outside air toward the IHTU 205. The ventilation fan 203 can have variable speed control, can measure air volume and can include CO.sub.2 instrumentation and can form a part of an energy recovery scheme.

(24) The VAF system 200 can connect the outdoor unit 204 to the IHTU 205 through at least one heat transfer fluid (typically Freon, water, glycol, etc.) transferred by piping line 211. The outdoor unit 204 can include a condensing unit and/or a heat pump, as well as a thermostat control.

(25) The IHTU 205 can include a heating-and-cooling coil and a filter (not shown). The IHTU 205 does not include a fan. The VAF system 200 is divided into separate remote zones 230a-c, for example three zones as illustrated in the example shown in FIGS. 3 and 4.

(26) Each zone 230a-c has a separately-operable thermostat 232a-c. In use, within the single VAF system 200 and the single IHTU 205, each separate zone 230a-c can use a separate thermostat 232a-c to maintain a different temperature in each zone. Separate air pathways 208a-c, such as ductwork and/or diffusors, connect each zone 230a-c to the IHTU 205. Each supply air pathway 208a-c includes a separate fan 210a-c positioned remote from the IHTU 205 along the air pathway. Each fan 210a-c is activated to draw and direct conditioned air from the IHTU 205 along an air pathway 208a-c to the respective zone 230a-c. The VAF system 200 does not include or use balancing dampers to manage air flow from the IHTU 205.

(27) In use, at least one of the thermostats 232a-c creates demand to adjust the temperature in its respective zone 230a-c. This demand for conditioned air causes one or more of the fans 210a-c to activate to draw conditioned air from the IHTU 205 and direct the conditioned air to the respective zone(s) 230a-c. Conditioned air from the IHTU 205 enters a common plenum (duct) 213 from which it then is drawn to a particular air pathway 208a-c by fans 210a-c as activated by the control system. Each thermostat 232a-c causes one of the fans 210a-c to move a measured volume of conditioned air from the IHTU 205 along one air pathway 208a-c to a respective zone 230a-c. As a result, one zone 230a-c can adjust the temperature set-point independent from adjustments being made for the remaining zones while the remaining zones maintain their temperature in a dynamic and adaptive manner as loads and IHTU capacity varies.

(28) The VAF system 200 can also include at least one return air vent 242 positioned in at least one of the zones 230a-c to return air from the zones along a return air pathway to the IHTU 205 to be re-conditioned.

(29) As particularly shown in FIG. 3, the VAF system 200 includes a central control 207, which communicates sensor inputs, including the temperature adjustment request and temperature reading between the thermostat 232a-c in the zones 230a-c and the fans 210a-c. This information communicated through the central control 207 activates or deactivates dynamically increasing or decreasing the volumetric flow rate of the fans. The central control 207 communicates to the fans 210a-c and the thermostats 232a-c through electronic connection, wired or wireless, and can provide power to the fans. The central control 207 also performs the functions of a thermostat in the operational control of the outdoor unit 204 and IHTU 205, which is either in a heating mode or cooling mode. Transitioning from a heating or cooling mode can be determined in controls via a zone voting scheme, as used in some commonly offered VAV systems. The VAF system is not intended to function to provide for simultaneous heating and cooling in different zones. The VAF system functions to optimize the degree of control to each zone as demanded by the thermal loads of individual zones to better decouple the thermal load from the supply capacity of conditioned air provided by the outdoor unit 204 and IHTU 205. The central control 207 can also communicate with an outside air system in any of the schemes previously described and can incorporate input from sensors for humidity, CO.sub.2, air quality providing power and control through electronic connection, wired or wireless. The central control 207 can also communicate with the outdoor unit 204 to activate or deactivate, and provide power through electronic connection, wired or wireless. The central control 207 can be in electronic communication with an operator interface 206, which allows a user to enter information such as set-points, schedules and priorities for the use of the VAF system 200.

(30) The above disclosed system is illustrated, in FIG. 4 in particular, to be used in a house-like structure 250, but can be applicable to mobile as well as stationary installation, i.e. not just residential/commercial but also automotive (cars, buses, etc.), boats/ships, aircraft, etc. The described system can also provide diagnostic and analytic control, incorporating automated commissioning and advanced features which are not normally included in smaller systems.

(31) FIGS. 5-11 show a VAF system 300 according to another example embodiment of the present invention. As depicted, the VAF system 300 is intended to be used in a house-like structure 350 according to at least one example embodiment of the present invention. According to other example embodiments, the VAF system 300 can be provided for HVAC systems installed in residential homes, multi-family housing, hotels, commercial structures, motor homes, any domicile space, recreational vehicles, vessels, aircraft or other structures comprising multiple zones or spaces to be provided with air conditioning.

(32) According to one example embodiment, the system 300 is generally a split system, for example, comprising a heat pump consisting of an indoor cased coil and an outdoor condensing unit 304 that are connected by a direct expansion (DX) refrigerant loop. All indoor air movement within the structure 350 is provided by the systems and components as described herein. Optionally, according to other example embodiments, the system 300 as described herein can preferably be applied and retrofitted with various other heating and/or cooling systems.

(33) According to one example embodiment, an outdoor air intake component 302 (typically a wall cap, roof cap or intake louver) can be provided. According to one example embodiment, an outdoor air control unit can be provided and in communication with the outdoor air intake component 302. According to example embodiments, the outdoor air control unit 303 may be a simple motor-operated damper, a supply fan, or an energy recovery ventilator (ERV). According to one example embodiment as described above, an outdoor unit 304 can be provided, for example, so as to provide functionality to the heat pump or air conditioning. According to one example embodiment, the outdoor unit 304 can comprise a compressor, a reversing valve, a heat rejection fan and a coil for either heat pump or air conditioning. In example embodiments, the outdoor unit 304 is normally operated by a single thermostat in the indoor controlled space. However, according to example embodiments of the present invention, any and all functions, signals, etc. that a thermostat may provide to the compressor and/or the ITHU 305 are controlled by a central controller 307 (as will be described below).

(34) According to the depicted example embodiment, the ITHU 305 is simply a cased coil. For example, typical prior art ITHU systems including an air handler with a fan, however, all air movement of the system 300 are operated by zone fans 310 (as will be described below), and thus, much more variability of the air flows can be provided to a desired zone of the structure 350. For example, according to one example embodiment, the structure 350 comprises multiple rooms (a-f) designating a zone for each of the rooms. For example, as depicted in the first chart of FIG. 11, each of the rooms (a-f) corresponds with a particular room of the structure 350. Accordingly, each zone (a-f) comprises its own separate fan 310 and air duct 308, conduit or other hose or medium by which air may be directed and carried a distance to a desired space/zone.

(35) In example embodiments, a common supply plenum or other desired duct or conduit 313 for collecting the air leaving the ITHU 305, for example, which is further in communication with the air ducts 308a-f of each zone. As such, the plenum 313 provides an intermediate collection/transfer area where conditioned air is freely drawn (via the corresponding fan 310a-f) to each of the air ducts 308a-f that are demanding conditioned air. In normal operation, the plenum 313 allows for the single flow of conditioned air to be split according to the number of zones the system intends to serve. According to one example embodiment, the plenum 313 comprises one input from the ITHU 305 and six output channels or conduits (or air ducts 308a-f) such that multiple smaller flows of the conditioned air are drawn from the plenum 313, through each respective air duct 308a-f, passing by respective fans 310 a-f, and further being discharged from a vent or register 330a-f that is provided within each of the respective zones (a-f).

(36) According to example embodiments and as will be described in greater detail below, a central control 307 is provided and configured to continuously process data (e.g., temperature, humidity, CO2, air quality, occupancy, or others as described above) obtained from one or more zone sensors 332a-f that are generally positioned along a wall (or other desired location) of the zone (a-f) it is intending to serve, for example, and conduct one or more real-time calculations with the data obtained from the one or more zone sensors 332a-f so that real-time adjustments can be made for each fan 310a-f (e.g., the fan speed) so as to meet the load of the respective zone (a-f) while maintaining a desired net air flow through the heat transfer element of the air conditioning system (within the specific range of operation).

(37) According to example embodiments, the central control 307 comprises a separate operator interface (OI), for example, which can be a hard-wired device, a remote-connected device (e.g., smart device, tablet, electronic device, PC, computer, laptop, etc.) connected wirelessly (e.g., internet, WiFi, Bluetooth®, IR, radio, based in the Cloud or server, other wireless technology, etc.).

(38) In example embodiments, the fans 310a-f are preferably capable of moving air, for example, by rotation of at least one propeller or fan blade. In example embodiments, the fans 310a-f are powered by a hard-wired connection, for example, and are further connected (wired or wireless) and in communication with the central control 307. Preferably, the fans 310a-f are capable of varying their rotation or speed (e.g., and the air flow thereof) so as to provide a desired air flow of conditioned air to each respective zone based on the respective load thereof. In example embodiments, the variable speed fans 310a-f are configured to draw a measured volume of conditioned air through the plenum 313 and direct it to the zones (a-f) based upon what the central control 307 directs them to do. According to example embodiments, each fan 310a-f comprises a flow measuring sensor incorporated therewith, and thus, is capable measuring the air flow entering and/or exiting the fan 310a-f. According to other example embodiments, separate flow measuring sensors can be incorporated with the fan 310a-f and/or the conduit or duct 308a-f that houses the fan 310a-f therein.

(39) According to example embodiments, the system 300 can further comprise a return 342, for example, which comprises at least a conduit or duct to transfer air from the conditioned space back to the IHTU. According to the depicted example embodiment, a single conduit and intake is depicted. Optionally, multiple returns or intakes can be provided, for example, such that a return can be provided for each zone or room of the air conditioned space.

(40) FIGS. 9-11 show the system of operations of the system 300 and several working examples according to example embodiments of the present invention. For example, as depicted in chart 370 of FIG. 11, the system 300 according to one example embodiment is configured for heating and cooling the house-like structure 350, for example, which comprises six zones (a-f) including an entry room, dining room, office, bedroom, living room and kitchen. According to one example embodiment, the system 300 comprises a design CFM (cubic feet per meter), for example, a calculated optimal scheme based upon the number of zones, space to be heated or cooled and specifications and optimal working ranges of the IHTU, which is set at 1,200 CFM. Furthermore, the system 300 can further include maximum and minimum CFM values corresponding to each of the zones (a-f), for example, which can influence the adjustments (if any) made to the speed of each respective fan 310a-f so as to provide conditioned air to each respective zone while maintaining a desired net air flow through the heat transfer element of the air conditioning system (and within the specific range of operation). For example, as depicted in FIG. 10 according to one example embodiment, the system 300 has a nominal capacity of 3 tons, a design CFM of 1,200, a minimum CFM of 1,050, a maximum CFM of 1,350, and multiple other parameters and inputs including a humidity set-point parameter (Hsp), which is set to 50%.

(41) Referring to the flowchart 360 of FIG. 9 and chart 375 of FIG. 11, a first example is shown depicting the system 300 being used for air conditioning without dehumidification. As shown, the system 300 initially begins at a net airflow value (e.g., design CFM) of 1,200 CFM. Then the measured temperature is compared to the target temperature for each of the zones (a-f) to calculate temperature difference values (e.g., ΔT). Next, the temperature difference values are used to influence a proportional integral derivative (PID) controller to determine the extent of the load being demanded by each of the zones (a-f). As depicted, the entry room (zone a) has a measured temperature of 85 degrees F. and a set-point temperature of 75 degrees F. Thus, the calculated ΔT is 10 degrees and the PID scale factor is 77% (e.g., (ΔT×100%)/sum of each zone's (ΔT×100%)). Typically, simultaneously the air flow is measured, for example, which is measuring the same as the design CFM of 1,200 CFM.

(42) Next, the values obtained from the PID controller are used to calculate a first set of flow adjustments (see first adj column of chart 375). For example, referring to zone a, with the measured flow of 100 CFM, the calculation of the PID controller causes the flow of zone a to increase from 100 CFM to 177 CFM (e.g., increasing the flow by 77%). According to the depicted example, the entry room comprises a scale factor of 100 compared to the sum of each zone's scale factor (e.g., 130). Thus, performing the following calculation, (100/130)×100%=77%), the air flow of 100 CFM is increased by 77%, and thus, the first flow adjustment for zone a provides an increase of 77 CFM to 177 CFM. According to example embodiments, one or more control algorithms, feedback and/or logic loops, or other coding or software can be incorporated with the central control 307 (and/or PID controller thereof) so that the system 300 can continuously monitor the zone(s) it is serving and provide a dynamic and directed response based upon the proportionality of the load(s) being demanded while also maintaining a net air flow through the heat transfer element of the air conditioning system.

(43) In example embodiments, the central control 307 processes the data and calculations are performed for each of the zones (a-f) so that the first set of flow adjustments are complete. Next, the humidity of the air that is being returned to the IHTU 305 is measured, and based upon its value compared to the humidity set-point value Hsp, the sum of the zone's air flows is adjusted to a preset air flow parameter value for a second set of flow adjustments (see second adj column of chart 375 of FIG. 11. As shown in FIG. 9, if the measured humidity H is less than or equal to 50%, the design set-point CFM is used as the sum of the second set of flow adjustments. However, if the measured humidity is greater than the humidity set-point Hsp, then the minimum set-point CFM is used as the sum of the second set of flow adjustments. For example, referring to the second adj column of the chart 375 of FIG. 11, the sum of the zone's (a-f) air flows is set to 1,200 CFM as the measured humidity H was less than the humidity set-point Hsp. Then, by taking the sum of the zone's air flows of the second set of flow adjustments and dividing it by the sum of the zone's air flows of the first set of flow adjustments, a proportional scale factor can be applied to the air flow value of each of the zones (a-f). For example, the second flow adjustment for the entry room (zone a) is 161 CFM (e.g., (1,200/1,315)×177).

(44) Next, after calculating the second set of flow adjustments, further processing of the data is provided so as to substitute some of the values thereof when they are not within the range of acceptable minimum/maximum values (see FLmax & FLmin in FIG. 10). As shown in chart 375, all values remain within the range of minimum/maximum values except for the second flow adjustment for the entry room (e.g., calculated as 161 CFM but maximum is set at 130 CFM). Accordingly, the entry room (zone a) is assigned a final air flow adjustment value of 130 CFM, for example, since the second flow adjustment value exceeded the maximum. For example, if a value exceeds the maximum, the replaced flow adjustment value should correspond to the zone's maximum CFM. Similarly, if the value of the second adjustment is less than the minimum, the replaced flow adjustment value should correspond to the zone's minimum CFM.

(45) Finally, the sum of the second set of flow adjustments is divided by the sum of the second flow adjustment values that were within acceptable ranges, which provides a final scale factor that can be applied to each of the zone's airflow values that were within acceptable ranges. For example, the dining room (zone b) had an air flow value of 182 CFM after the second flow adjustment. Accordingly, as chart 370 indicates that the dining room's FLmin-b, FLmax-b range is between 60-260 CFM, the second flow adjustment value of 182 CFM lies within the range, and thus, gets placed in the column of chart 375 titled “pass-thru values in range”. Then, the sum of the second set of flow adjustments (e.g., 1,200 CFM) is divided by the sum of the second flow adjustment values that were within acceptable ranges (e.g., 1,169 CFM) to obtain a final scale factor of 1.0265 (e.g., 1,200/1,169=1.026 or 103%). Thus, with the exception of the entry room flow value exceeding the maximum of 130 CFM, the final flow adjustment values of the other rooms (zones b-f) are scaled according to the new scale factor of 103% to produce a final set of flow adjustments. According to example embodiments, if the value of the volumetric air flow is outside of the minimum/maximum values (e.g., FLmax & FLmin), either the maximum FLmax or minimum FLmin is used to replace the out-of-range value, and the replacement value remains the same for the final set of flow adjustments.

(46) According to an example embodiment and referring back to the dining room of the chart 375, the pass-thru value of 182 is multiplied by the final scale factor of 103% to obtain a final calculated air flow value of 188 CFM. The same is performed for each of the other “pass-thru” values and the final volumetric air flow values can be charted, logged or otherwise presented appropriately within the central control so as to provide one or more speed reference voltages to the corresponding fans. According to example embodiments, speed reference voltages can be generated by the central control and sent to each of the desired fans to initiate rotation of the blade(s) to a speed needed to generate the final calculated volumetric air flow value. Accordingly, as depicted in chart 375 of FIG. 11, zone sensors, flow measuring devices, temperature and humidity sensors, etc. allow for the ability of the system 300 (and central control 307 thereof) to process the data and perform calculations to proportionally scale the individual volumetric air flow values to most effectively, efficiently and economically output conditioned air to the plurality of zones. Furthermore, as disclosed above, the plenum 313 is configured to act as a splitter or temporary housing or pass-by for the ducts 308a-f, and thus with the fans 310a-e interconnected and in communication with the ducts 308a-f (and downstream from the IHTU and coils thereof), the rotation of one or more fan blades in at least one direction causes air to flow therein, and thus, creates a pull or draw effect on the air within the duct 308a-f. As similarly described above, preferably the summation of the volumetric air flow values for each of the zones is within the set maximum CFM/minimum CFM values based on the particulars of the tonnage and manufactures suggestions, and thus, the net volumetric air flow passing through the coil of the IHTU (e.g., being drawn therethrough by the plurality of fans 308a-f communicating within the ducts 308a-f) is maintained within the set or acceptable range.

(47) Thereafter, once the final flow adjustment values are obtained and sent to the fans as reference voltages, the process is repeated (see FIG. 9). Accordingly, for each repetition, the zone temperatures are typically brought closer to their target temperatures, and thus the ΔT for each zone continues to be reduced until each zone is fully satisfied.

(48) According to one example embodiment, the sequence of operations for the VAF system 300 includes steps 0-5 as shown in Operation Outline 1 below. As shown, the steps include: 0) set-up system, pre-program variables, schedules, operator interface 1) start system; 2) measure temperature a. compare to zone temperature set-point; b. calculate zone ΔT; c. generate PID scale factor; 3) increase zone fan speed to set point; a. initial Set point shall be zone design CFM; b. measure zone air flow; c. receive new fan speed reference voltage based on CFM set point; d. call for heating or cooling; 4) run IHTU; a. for majority of zones calling for cooling, enable compressors for AC operation; b. for majority of zones calling for heating, enable heating system; c. verify sufficient flow for heating or cooling operation; d. send new fan speed reference voltage based on CFM set point; 5) repeat process; a. re-evaluate call for heating or cooling; and b. satisfy heating or cooling, disable heating/cooling. Optionally, the process/steps of the sequence of operations of the VAF system 300 can be chosen as desired.

(49) 0) Set-up system, Pre-program variables, schedules, Operator Interface

(50) 1) Start System

(51) 2) Measure temperature a. Compare to Zone Temperature Set-point b. Calculate zone ΔT c. Generate PID scale factor

(52) 3) Increase zone fan speed to set point a. Initial Set point shall be zone design CFM b. Measure zone air flow c. Receive new fan speed reference voltage based on CFM set point d. Call for heating or cooling

(53) 4) Run IHTU a. For majority of zones calling for cooling, enable compressors for AC operation b. For majority of zones calling for heating, enable heating system c. Verify sufficient flow for heating or cooling operation d. Send new fan speed reference voltage based on CFM set point

(54) 5) Repeat process a. Re-evaluate call for heating or cooling b. Satisfy heating or cooling, disable heating/cooling

Operation Outline 1

(55) According to example embodiments, the central control 307 can continuously monitor and measure the air flows distributed to the individual zones (and the temperatures of the individual zones), which can be quantified and manipulated by the central control on a continuous and dynamic basis. According to example embodiments, the individual zone temperatures are compared to individual set-point temperatures of the same respective zones such that scale factors can be created by using classical temperature control algorithms utilizing standard proportional, integral and derivative (PID) techniques. According to example embodiments, the PID scale factors are applied to the zone's individual air flows so as to adjust the same, and for example, the individual air flows are summed together to establish a new air flow sum. According to example embodiments, the individual air flow values are recalculated on a proportional basis such that the individual air flow values add to a sum equal to a predetermined net air flow value. According to some example embodiments, maximum and minimum air flow values are predetermined and fixed, and wherein individual flow values outside of the range of values between the minimum and maximum air flow values are replaced with the closer of the maximum or minimum air flow value. According to example embodiments, the individual air flow values that remain within the range of predetermined maximum and minimum air flow values are adjusted on a prorated basis so that the remaining total sum of air flows equals the prescribed total air flow. According to example embodiments, the final air flow values calculated by the control system are converted to reference voltage signals and applied (e.g. sent or otherwise communicated therewith) to the individual fans 308a-f directing air to the individual control zones in a continuously repeated process to operate an air conditioner.

(56) FIG. 11 shows two other working examples including an air conditioning example with dehumidification (see chart 380) and a heating example (see chart 385). In example embodiments, the process identified in the flowchart of FIG. 9 is repeated for the examples of charts 380, 385. As noted in chart 380, since there is air conditioning with dehumidification, the total flow set-point is 1,050 CFM (for measured humidity above 50%). In example embodiments, working examples of charts 380, 385 are processed similarly and go through a first flow adjustment, a second flow adjustment, an air flow substitution/pass-thru process, and a final flow adjustment.

(57) FIGS. 12-13 show a VAF system 400 according to another example embodiment of the present invention. is intended to be used in a house-like structure 450 according to at least one example embodiment of the present invention. According to other example embodiments, the VAF system 400 can be provided for HVAC systems installed in residential homes, multi-family housing, hotels, commercial structures, motor homes, any domicile space, recreational vehicles, vessels, aircraft or other structures comprising multiple zones or spaces to be provided with air conditioning. According to example embodiments, the VAF system 400 is substantially similar to the VAF system 300 as described above. For example, according to example embodiments, the VAF system 400 comprises the components of the VAF system 300 in addition to individual zone controllers that are connected between the central control 407 and the respective components of the individual zones (e.g., fan 408a-f, zone sensor 432a-f, and flow sensor (see FS)). Thus, the VAF system 400 comprises a distributed control system compared to the central control system of the above-described VAF system 300.

(58) According to example embodiments, a zone controller 407′ is provided for each zone and communicating with the central control 407 through a data bus using standard communication protocol, for example, such as BACnet, LON or Modbus. As such, the individual zone controllers act as an intermediary between the zone it is intending to serve and the central control 407. According to example embodiments, the individual zone controllers can monitor, collect, send, process data and/or make any desired calculations as needed, for example, in addition to the central control connected therewith. In example embodiments, with each zone comprising its own controller 407′, the entirety of the system's 400 control system is more practically implemented, and thus, conditioned air can be efficiently and effectively distributed to the appropriate zones to satisfy any loads while also ensuring that the net volumetric air flow over the coil of the IHTU 405 remains within a fixed volumetric rate predetermined by the system's thermal capacity and user performance goals. Optionally, the central control can be configured so as to maintain the net volumetric flow within a range of the fixed volumetric rate (e.g., between 1,050 and 1,350 according to the examples of FIG. 10). For example, according to one example embodiment, a performance goal to be set by the user could include an adjustable “power on” or “start system” trigger within the “user-adjustable settings” of the control system such that the system would start according to the percentage of zones requesting air conditioning. For example, an “energy efficient” system setting may be where the system would not start until there was a demand of about 75% of the zones. According to other example embodiments, the system can be configured such that the system would initiate or start even if so little as one zone requested air conditioning. According to another example embodiment, the control system could be configured such that 100% of the zones must request air conditioning before the system powers on and begins.

(59) The controls for the VAF system and also the controls found in other ‘smart’ thermostats (such as Nest®, Ecobee®, and others) can be provided and could be enabled to communicate load and location information to a central processing system for purposes of aggregating the data and processing it for presentation in a novel manner. According to example embodiments, data which may be used for processing and presenting includes the location of the structure comprising the VAF system (city, state, county, zip code, etc.), the cooling or heating load (in use per established time increment), which can be calculated from the product of percent run time and listed capacities, or for example, could factor in percent load for variable capacity compressors. Other relevant information or data that could be provided includes the differentiation between commercial and residential occupancies.

(60) According to example embodiments, the information can be stored and processed as meta-data. It can be used to create near-real-time maps displaying constant load and also a neutral line indicating where the heating and cooling capacities are equal. It is envisioned that this would be similar to a weather map with the purpose of informing professional and academic interests as well as general curiosity for anyone wanting additional awareness of heating and cooling demands. The presentation of this data can be provided in multiple ways. According to one example, the presentation of data includes lines of constant percent usage for cooling, a neutral line and percent usage for heating. According to some example embodiments, the data can be presented similarly to isotherm lines on a weather map. According to another example embodiment, lines of total capacity for cooling and heating can be provided, for example, similar to rain fall totals on a weather map. According to example embodiments, more dense areas would indicate higher totals similar to flood events on a weather map.

(61) According to one example embodiment, the sequence of operations for the VAF system 400 includes steps 0-3 as shown in Operation Outline 2 below. As shown, the steps include: 0) set-up system; pre-program variables, schedules, operator interface; 1) start system; a. central control i. polls zone controllers; ii. evaluate call for cooling and heating; iii. for majority of zones calling for cooling, enable compressors for AC operation; iv. for majority of zones calling for heating, enable heating system; v. receive airflow CFM information from each zone; vi. sum (add) all zone airflows (CFM) together and verify required airflow for heating or cooling; vii. calculate fan speed correction factor; viii. send fan speed correction factor to zone controllers based on system CFM set point; ix. receive zone reference only signals from zone controller; x. send system control information to zone controllers; 1. occupied, standby, unoccupied; 2. system mode heating/cooling; 3. zone set point for standby, unoccupied modes and when zone local set-point is disabled; b. zone Control i. measure zone temperature 1. compare to zone temperature set-point; 2. calculate zone ΔT; 3. generate PID scale factor; 4. add+fan speed correction multiplier sent from central controller to PID loop output; 5. send fan speed reference voltage to zone fan; 6. send demand signals to central control a. call for cooling or heating; b. zone airflow CFM; 7. send only reference signals to central controller; a. zone temp; b. zone set-point; ii. start fan (follow ramp-up preset rate at start-up) 1. initial set point shall be zone design CFM; 2. measure zone air flow; 3. receive new fan speed reference voltage based on CFM set point; 2) repeat process; a. re-evaluate call for heating or cooling; and b. satisfy heating or cooling, disable heating/cooling. Optionally, the process/steps of the sequence of operations of the VAF system 400 can be chosen as desired.

(62) 0) Set-up system, Pre-program variables, schedules, Operator Interface

(63) 1) Start System a. Central Control i. polls zone controllers ii. Evaluate call for cooling and heating iii. For majority of zones calling for cooling, enable compressors for AC operation iv. For majority of zones calling for heating, enable heating system v. Receive airflow CFM information from each zone vi. Sum (add) all Zone airflows (CFM) together and verify required airflow for heating or cooling vii. Calculate fan speed correction factor viii. Send fan speed correction factor to zone controllers based on system CFM set point ix. Receive zone reference only signals from zone controller x. Send system control information to zone controllers 1. Occupied, standby, Unoccupied 2. System mode heating/cooling 3. Zone set point for standby, unoccupied modes and when zone local setpoint is disabled b. Zone Control i. Measure zone temperature 1. Compare to Zone Temperature Set-point 2. Calculate zone ΔT 3. Generate PID scale factor 4. Add+fan speed correction multiplier sent from central controller to PID loop output. 5. Send fan speed reference voltage to zone fan. 6. Send demand signals to Central Control a. Call for cooling or heating b. Zone airflow CFM 7. Send reference only signals to central controller a. Zone Temp b. Zone setpoint ii. Start Fan (follow ramp-up preset rate at start-up) 1. Initial Set point shall be zone design CFM 2. Measure zone air flow 3. Receive new fan speed reference voltage based on CFM setpoint

(64) 2) Repeat process a. Re-evaluate call for heating or cooling b. Satisfy heating or cooling, disable heating/cooling

Operation Outline 2

(65) According to another example embodiment, the present invention relates to a method of efficiently and effectively cooling or heating a structure having at least two zones. According to one example embodiment, the structure includes an outdoor compressor, an indoor heat transfer unit and heat pump. Ducts are connected between the indoor heat transfer unit and the zones. The indoor heat transfer unit lacks a central fan and individual fans are placed within the ducts (or positioned to be in communication with the ducts) to draw air from the indoor heat transfer unit (and across the coil) to the desired zone at the desired rate, for example, so long as the sum of the net volumetric air flow remains within a net volumetric air flow range (or for example, remains at a preset volumetric air flow rate lying within the range). According to example embodiments, the method includes including drawing air across the heat transfer coil of the indoor heat transfer unit within the net volumetric air flow range (or preset volumetric air flow rate); measuring individual air flows of the at least two zones within at least a portion of the ducts such that air flow signals generated by the measuring thereof are sent to a control system for processing; summing the individual zone air flow signals in the control system to generate an instantaneous net volumetric air flow rate for the entire air volume moving across the coil of the indoor heat transfer unit; comparing the measured net volumetric air flow rate to the preset volumetric air flow rate to adjust it proportionally to maintain the instantaneous net air flow at the preset volume as if there was a single fan operating the system.

(66) Optionally, according to other example embodiments, the method as described herein, and the systems, components, etc. can be equally applied to packaged-type HVAC systems. Indeed, split systems such as the above-described examples comprising an outdoor compressor and an indoor heat transfer unit and the heat transfer coils thereof are excellent candidates for the systems 200-400 as described herein. However, other HVAC systems such as packaged air conditioning units can similarly be converted or newly built so as to provide seamless operability with the systems as described herein. According to one example embodiment, in a similar manner, the fan is removed from the packaged unit and a common supply plenum is connected to communicate within the indoor heat transfer unit and coils of the packaged unit. Ducts are provided for extending from the supply plenum to two or more zones. The speed or rotation of at least one fan positioned within each duct causes conditioned air to be drawn across the heat transfer coils, through the supply plenum and further along the ducts until being output into the respective zone. In a similar manner, the packaged unit can comprise a central control or can comprise a distributed control system, both of which are described in greater detail above. According to yet other example embodiment, various other heating and cooling equipment can be configured to operate with the systems as described herein.

(67) Although specific embodiments of the disclosure have been described, numerous other modifications and alternative embodiments are within the scope of the disclosure. For example, any of the functionality described with respect to a particular device or component may be performed by another device or component. Further, while specific device characteristics have been described, embodiments of the disclosure may relate to numerous other device characteristics. Further, although embodiments have been described in language specific to structural features and/or methodological acts, it is to be understood that the disclosure is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the embodiments. Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments could include, while other embodiments may not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.

(68) While the invention has been described with reference to example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims.