Hybrid air handler

Abstract

An improved system, apparatus, method for air ventilation having a hybrid air handler system comprising (1) a hydronic air handler fluidly coupled to and functionally integrated with a direct expansion of a heat pump; (2) a pre-water coil refrigerant to air heat exchanger and a post water coil refrigerant to air heat exchanger fluidly coupled to and functionally integrated with the hydronic air handler; and (3) a reversable or straight cool/heat and direct-expansion water-source heat pump fluidly coupled from load loop side water of the hydronic air handler and functionally integrated with the hydronic air handler. The hybrid air handler system disclosed herein is configured to provide enhanced system efficiency and reliability by simultaneously increasing its cooling capacity and lowering the dew point for dehumidification while eliminating the carbon footprint or the need for electric-resistant heat for any reheating of a building heating and cooling system.

1 . An air ventilation system comprising:
 a conditioned water source, wherein the conditioned water source comprises one of a chiller to provide a supply of chilled water and a boiler to provide a supply of heated water;   an air handling unit comprising:   a housing that defines an inlet and an outlet end;   a fan disposed between the inlet end and outlet end to generate and define an airflow from the inlet end to the outlet end;   a compressor, a first heat exchanger, an expansion valve and a second heat exchanger, wherein the first heat exchanger is disposed downstream of the compressor, the expansion valve is dispose downstream of the first heat exchanger and the second heat exchanger is disposed downstream of the expansion valve, wherein the compressor, first heat exchanger, the expansion valve and the second heat exchanger are fluidly coupled in series to the compressor to form a refrigerant closed loop;   an hydronic coil disposed between the first heat exchanger and the second heat exchanger, wherein the hydronic coil is fluidly coupled to the conditioned water source to circulate one of the supply of chilled water and the supply of heated water through the hydronic coil in a water closed loop;   wherein the airflow moving between the inlet end and the outlet end contacts, in series, the first heat exchanger, the hydronic coil and the second heat exchanger such that the compressor, when operated, circulates a refrigerant through the refrigerant closed loop so that (1) the first heat exchanger and the second heat exchanger adjust a temperature and humidity of the airflow and (2) the conditioned water source, when operated, circulates one of the supply of chilled water and the supply of heated water through the hydronic coil in the water closed loop so that the hydronic coil adjusts the temperature and humidity of the airflow; and   a controller connected to and in communication with the conditioned water source and the air handling unit, wherein the controller is configured to operate the conditioned water source and the air handling unit in response to desired operational demands for a conditioned space.   
     
     
         2 . The air ventilation system of  claim 1 , wherein the first heat exchanger and the second heat exchanger comprises a precooling refrigerant to air heat exchanger and a postcooling/reheating refrigerant to air heat exchanger respectively. 
     
     
         3 . The air ventilation system of  claim 1 , wherein the controller is configured to operate in one of the desired modes of heating, cooling and dehumidification. 
     
     
         4 . An air handling unit assembly comprising:
 a housing that defines an inlet and an outlet end;   a fan disposed between the inlet end and outlet end to generate and define an airflow from the inlet end to the outlet end;   a compressor, a first heat exchanger, an expansion valve and a second heat exchanger, wherein the first heat exchanger is disposed downstream of the compressor, the expansion valve is dispose downstream of the first heat exchanger and the second heat exchanger is disposed downstream of the expansion valve, wherein the compressor, first heat exchanger, the expansion valve and the second heat exchanger are fluidly coupled in series to the compressor to form a refrigerant closed loop;   an hydronic coil disposed between the first heat exchanger and the second heat exchanger, wherein the hydronic coil is fluidly coupled to a conditioned water source comprising one of a chiller to provide a supply of chilled water and a boiler to provide a supply of heated water and to circulate one of the supply of chilled water and the supply of heated water through the hydronic coil in a water closed loop;   wherein the airflow moving between the inlet end and the outlet end contacts, in series, the first heat exchanger, the hydronic coil and the second heat exchanger such that the compressor, when operated, circulates a refrigerant through the refrigerant closed loop so that (1) the first heat exchanger and the second heat exchanger adjust a temperature and humidity of the airflow and (2) the conditioned water source, when operated, circulates one of the supply of chilled water and the supply of heated water through the hydronic coil in the water closed loop so that the hydronic coil adjusts the temperature and humidity of the airflow.   
     
     
         5 . The air handling unit assembly of  claim 4 , further comprising a controller connected to and in communication with the conditioned water source and the housing, wherein the controller is configured to operate the conditioned water source in response to desired operational demands for a conditioned space. 
     
     
         6 . The air handling unit assembly of  claim 5 , wherein the controller is configured to operate in one of the desired modes of heating, cooling and dehumidification. 
     
     
         7 . A method for conditioning the air in a space comprising:
 operating an air ventilation system, wherein the air ventilation system comprises an air handling unit integrated with a direct expansion refrigeration system;   providing a conditioned water source, wherein the conditioned water source comprises one of a chiller to provide a supply of chilled water and a boiler to provide a supply of heated water to the air handling unit;   configuring a programmable logic controller integrated with the air handling unit, the controller having a memory and in electronic communication with at least one processor;   wherein the controller is configured to run a control algorithm in order to operate the air ventilation system comprising the steps of:   enabling at least one operational mode based on receiving of an operational call;   reading the outdoor air temperature and the entering water loop temperature;   air to a certain pre-determined set point; and   (a) if the entering water loop temperature can condition the entering air to the certain pre-determined set point, the control algorithm in response to such determination is configured to:
 (1) initiate engagement of a fan; 
 (2) continue measuring the supply air temperature and humidity until the pre-determined set point is achieved; and 
 (3) continue repeating steps (1) and (2) until the operational call is disabled; and 
   (b) if the entering water loop temperature cannot condition the entering air to a certain pre-determined set point, the control algorithm in response to such determination is configured to:
 (1) initiate continuous monitoring and measuring the supply air temperature and humidity; 
 (2) determine if the pre-determined setpoint is achieved and if not, initiate engagement of the refrigeration system and increase modulation to increase refrigeration capacity until the pre-determined set point is achieved. 
   
     
     
         8 . The method of  claim 7 , further comprising the step of shutting down the refrigeration and returning to the start of the water coil operation if the pre-determined setpoint is not achieved. 
     
     
         9 . An air ventilation system comprising:
 a conditioned water source, wherein the conditioned water source comprises one of a chiller to provide a supply of chilled water and a boiler to provide a supply of heated water;   an air handling unit comprising:   a housing that defines an inlet and an outlet end;   a fan disposed between the inlet end and outlet end to generate and define an airflow from the inlet end to the outlet end;   a compressor, a first heat exchanger, an expansion valve, a second heat exchanger and a third heat exchanger, wherein the first heat exchanger is disposed downstream of the compressor, the expansion valve is dispose downstream of the first heat exchanger and the second heat exchanger and the third heat exchanger is disposed downstream of the expansion valve, wherein the compressor, first heat exchanger, the expansion valve, the second heat exchanger and the third heat exchanger are fluidly coupled in series to the compressor to form a refrigerant closed loop;   an hydronic coil disposed between the first heat exchanger and the second heat exchanger, wherein the hydronic coil is fluidly coupled to the conditioned water source to circulate one of the supply of chilled water and the supply of heated water through the hydronic coil in a water closed loop;   wherein the airflow moving between the inlet end and the outlet end contacts, in series, the first heat exchanger, the hydronic coil, the second heat exchanger and the third heat exchanger such that the compressor, when operated, circulates a refrigerant through the refrigerant closed loop so that (1) the first heat exchanger, the second heat exchanger and the third heat exchanger adjust a temperature and humidity of the airflow and (2) the conditioned water source, when operated, circulates one of the supply of chilled water and the supply of heated water through the hydronic coil in the water closed loop so that the hydronic coil adjusts the temperature and humidity of the airflow; and   a controller connected to and in communication with the conditioned water source and the air handling unit, wherein the controller is configured to operate the conditioned water source and the air handling unit in response to desired operational demands for a conditioned space.   
     
     
         10 . The air ventilation system of  claim 9 , wherein the first heat exchanger, the second heat exchanger and the third heat exchanger comprise a precooling refrigerant to air heat exchanger, a subcooling refrigerant to air heat exchanger and a reheating refrigerant to air heat exchanger respectively. 
     
     
         11 . The air ventilation system of  claim 9 , wherein the controller is configured to operate in one of the desired modes of heating, cooling and dehumidification. 
     
     
         12 . An air handling unit assembly comprising:
 a housing that defines an inlet and an outlet end;   a fan disposed between the inlet end and outlet end to generate and define an airflow from the inlet end to the outlet end;   a compressor, a first heat exchanger, an expansion valve, a second heat exchanger, a third heat exchanger wherein the first heat exchanger is disposed downstream of the compressor, the expansion valve is dispose downstream of the first heat exchanger and the second heat exchanger is disposed downstream of the expansion valve, wherein the compressor, first heat exchanger, the expansion valve, the second heat exchanger and the third heat exchanger are fluidly coupled in series to the compressor to form a refrigerant closed loop;   an hydronic coil disposed between the first heat exchanger and the second heat exchanger, wherein the hydronic coil is fluidly coupled to a conditioned water source comprising one of a chiller to provide a supply of chilled water and a boiler to provide a supply of heated water and to circulate one of the supply of chilled water and the supply of heated water through the hydronic coil in a water closed loop;   wherein the airflow moving between the inlet end and the outlet end contacts, in series, the first heat exchanger, the hydronic coil, the second heat exchanger and the third heat exchanger such that the compressor, when operated, circulates a refrigerant through the refrigerant closed loop so that (1) the first heat exchanger, the second heat exchanger and the third heat exchanger adjust a temperature and humidity of the airflow and (2) the conditioned water source, when operated, circulates one of the supply of chilled water and the supply of heated water through the hydronic coil in the water closed loop so that the hydronic coil adjusts the temperature and humidity of the airflow.   
     
     
         13 . The air handling unit assembly of  claim 12 , further comprising a controller connected to and in communication with the conditioned water source and the housing, wherein the controller is configured to operate the conditioned water source in response to desired operational demands for a conditioned space. 
     
     
         14 . The air handling unit assembly of  claim 13 , wherein the controller is configured to operate in one of the desired modes of heating, cooling and dehumidification. 
     
     
         15 . A method for conditioning the air in a space comprising:
 operating an air ventilation system, wherein the air ventilation system comprises an air handling unit integrated with a direct expansion refrigeration system;   providing a conditioned water source, wherein the conditioned water source comprises one of a chiller to provide a supply of chilled water and a boiler to provide a supply of heated water to the air handling unit;   configuring a programmable logic controller integrated with the air handling unit, the controller having a memory and in electronic communication with at least one processor;   wherein the controller is configured to run a control algorithm in order to operate the air ventilation system comprising the steps of:   enabling at least one operational mode based on receiving of an operational call;   reading the outdoor air temperature and the entering water loop temperature;   air to a certain pre-determined set point; and   (a) if the entering water loop temperature can condition the entering air to the certain pre-determined set point, the control algorithm in response to such determination is configured to:
 (1) initiate engagement of a fan; 
 (2) continue measuring the supply air temperature and humidity until the pre-determined set point is achieved; and 
 (3) continue repeating steps (1) and (2) until the operational call is disabled; and 
   (b) if the entering water loop temperature cannot condition the entering air to a certain pre-determined set point, the control algorithm in response to such determination is configured to:
 (1) initiate continuous monitoring and measuring the supply air temperature and humidity; 
 (2) determine if the pre-determined setpoint is achieved and if not, initiate engagement of the refrigeration system and increase modulation to increase refrigeration capacity; 
 (3) measure reheat generated in the system and determine if the reheat is enough to achieve the pre-determined set point and if not, engage and modulate the third heat exchanger to achieve the pre-determined set point; 
 (4) continue determining if the pre-determined setpoint is achieved after modulation and if not, initiate engagement of the refrigeration system and increase modulation to increase refrigeration capacity until the pre-determined set point is achieved. 
   
     
     
         16 . The method of  claim 15 , further comprising the step of shutting down the refrigeration and returning to the start of the water coil operation if the pre-determined setpoint is not achieved. 
     
     
         17 . An air ventilation system comprising:
 a conditioned water source, wherein the conditioned water source comprises one of a chiller to provide a supply of chilled water and a boiler to provide a supply of heated water;   an air handling unit comprising:   a housing that defines an inlet and an outlet end;   a fan disposed between the inlet end and outlet end to generate and define an airflow from the inlet end to the outlet end;   a compressor, a heat exchanger, an expansion valve and a water control valve, wherein the heat exchanger is disposed downstream of the compressor, the expansion valve is disposed downstream of the heat exchanger, wherein the compressor, heat exchanger, the expansion valve are fluidly coupled in series to the compressor to form a refrigerant closed loop;   an hydronic coil disposed upstream of the heat exchanger, wherein the hydronic coil is fluidly coupled to the water control valve and the conditioned water source to circulate one of the supply of chilled water and the supply of heated water through the hydronic coil in a water closed loop;   wherein the airflow moving between the inlet end and the outlet end contacts, in series, the hydronic coil and the heat exchanger such that the compressor, when operated, circulates a refrigerant through the refrigerant closed loop so that (1) the heat exchanger adjust a temperature and humidity of the airflow and (2) the conditioned water source, when operated, circulates one of the supply of chilled water and the supply of heated water through the hydronic coil in the water closed loop so that the hydronic coil adjusts the temperature and humidity of the airflow; and   a controller connected to and in communication with the conditioned water source and the air handling unit, wherein the controller is configured to operate the conditioned water source and the air handling unit in response to desired operational demands for a conditioned space.   
     
     
         18 . The air ventilation system of  claim 17 , wherein the heat exchanger comprises a reheat refrigerant to air heat exchanger or a condenser. 
     
     
         19 . The air ventilation system of  claim 17 , wherein the controller is configured to operate in one of the desired modes of heating, cooling and dehumidification. 
     
     
         20 . An air handling unit assembly comprising:
 a housing that defines an inlet and an outlet end;   a fan disposed between the inlet end and outlet end to generate and define an airflow from the inlet end to the outlet end;   a compressor, a heat exchanger, an expansion valve, a water control valve wherein the heat exchanger is disposed downstream of the compressor, the expansion valve and the water control valve is disposed downstream of the first heat exchanger, wherein the compressor, first heat exchanger and the expansion valve are fluidly coupled in series to the compressor to form a refrigerant closed loop;   an hydronic coil disposed upstream of the heat exchanger, wherein the hydronic coil is fluidly coupled to the water control valve and a conditioned water source comprising one of a chiller to provide a supply of chilled water and a boiler to provide a supply of heated water and to circulate one of the supply of chilled water and the supply of heated water through the hydronic coil in a water closed loop;   wherein the airflow moving between the inlet end and the outlet end contacts, in series, the hydronic coil and the heat exchange such that the compressor, when operated, circulates a refrigerant through the refrigerant closed loop so that (1) the heat exchanger adjusts a temperature and humidity of the airflow and (2) the conditioned water source, when operated, circulates one of the supply of chilled water and the supply of heated water through the hydronic coil in the water closed loop so that the hydronic coil adjusts the temperature and humidity of the airflow.   
     
     
         21 . The air handling unit assembly of  claim 20 , wherein the water control valve is a three-way control valve. 
     
     
         22 . The air handling unit assembly of  claim 20 , further comprising a controller connected to and in communication with the conditioned water source and the housing, wherein the controller is configured to operate the conditioned water source in response to desired operational demands for a conditioned space. 
     
     
         23 . The air handling unit assembly of  claim 22 , wherein the controller is configured to operate in one of the desired modes of heating, cooling and dehumidification. 
     
     
         24 . A method for conditioning the air in a space comprising:
 operating an air ventilation system, wherein the air ventilation system comprises an air handling unit integrated with a direct expansion refrigeration system;   providing a conditioned water source, wherein the conditioned water source comprises one of a chiller to provide a supply of chilled water and a boiler to provide a supply of heated water to the air handling unit;   configuring a programmable logic controller integrated with the air handling unit, the controller having a memory and in electronic communication with at least one processor;   wherein the controller is configured to run a control algorithm in order to operate the air ventilation system comprising the steps of:   enabling at least one operational mode based on receiving of an operational call;   reading the outdoor air temperature and the entering water loop temperature;   air to a certain pre-determined set point; and   (a) if the entering water loop temperature can condition the entering air to the certain pre-determined set point, the control algorithm in response to such determination is configured to:
 (1) initiate engagement of a fan; 
 (2) continue measuring the supply air temperature and humidity until the pre-determined set point is achieved; and 
 (3) continue repeating steps (1) and (2) until the operational call is disabled; and 
   (b) if the entering water loop temperature cannot condition the entering air to a certain pre-determined set point, the control algorithm in response to such determination is configured to:
 (1) open a three-way control valve; 
 (2) initiate engagement of a fan; 
 (3) initiate continuous monitoring and measuring the supply air temperature and humidity; 
 (4) determine if the pre-determined setpoint is achieved and if not, initiate engagement of the refrigeration system and increase modulation to increase refrigeration capacity; 
 (5) continue determining if the pre-determined setpoint is achieved after modulation and if not, initiate engagement of the refrigeration system and increase modulation to increase refrigeration capacity until the pre-determined set point is achieved. 
   
     
     
         25 . The method of  claim 24 , further comprising the step of shutting down the refrigeration and returning to the start of the water coil operation if the pre-determined setpoint is not achieved.