Variable refrigerant package

Abstract

A variable refrigerant package air conditioner is shown that is easy to install in new construction with a unique base that causes collected mixture that overflows to drain outside the building. A control system is shown that has motors and compressor that are pulse width modulated so the air conditioner is infinitely variable while maintaining the highest possible power factor. Dehumidification of outside air occurs as it is mixed with inside air. By gradually approaching a temperature set point and even reheating after dehumidification, moisture is removed from the room.

What we claim is: 
     
       1. A variable refrigerant package for cooling a room, said variable refrigerant package being located in a closet adjacent an outside wall, said closet being wired for power and connection to a thermostat to set temperature in said room, said variable refrigerant package abutting a plenum through said outside wall and resting on a base, said variable refrigerant package including:
 an outdoor air inlet through said plenum; 
 a condenser; 
 a condenser fan assembly for drawing outside air through said outdoor air inlet and moving said outside air through said condenser and out said plenum to outside said room; 
 a path for indoor entering air; 
 an evaporator and electric heater in said path; 
 a blower assembly for drawing said indoor entering air from said room through said evaporator and electric heater prior to discharge back into said room; 
 an evaporator drain pan below said evaporator for collecting any condensate and discharging collected condensate through a drain tube from said variable refrigerant package; 
 a compressor connected to refrigerant lines connecting said condenser to said evaporator to compress refrigerant flowing there through therethrough; 
 a reversing valve assembly connected to said refrigerant lines for reversing direction of flow of said refrigerant; 
 an improvement in said variable refrigerant package comprising: 
 an electromagnetic interference filter for receiving and filtering electromagnetic interference from said power, said power being an AC signal; 
 an n-phase interleaved active power factor correction for said power, said n-phase interleaved active power factor correction receiving said power filtered by said electromagnetic interference filter, said n-phase interleaved active power factor correction including:
 (a) a full wave rectifier for converting said power to a rectified AC signal; 
 (b) a resistor network comprised of a first plurality of resistors connected to said full wave rectifier, said first plurality of resistors for sensing an input voltage from said full wave rectifier, and a second plurality of resistors for sensing an output voltage from an output capacitor and providing a feedback voltage; 
 (c) a pair of inductors connecting to a pair of current sensors before connecting to respective power switching devices, said pair of current sensors comprised of a current sensor and voltage sensor, said pair of current sensors continually detecting consumption of said power; 
 (d) a controller programmed for monitoring and receiving (1) said input voltage from said full wave rectifier, (2) said output voltage from said output capacitor, and (3) currents from said pair of current sensors, and comparing said input voltage and said output voltage with said currents from said pair of current sensors to trigger said power switching devices to give an increased power factor equal to or substantially close to unity; 
 
 said increased power factor being for power supplied to said compressor, blower assembly and/or condenser fan. 
 
     
     
       2. The variable refrigerant package for cooling a room as recited in  claim 1  wherein said power switching devices are MOSFETs. 
     
     
       3. The variable refrigerant package for cooling a room as recited in  claim 2 , further includes comprising diodes which are configured to allow current flow only to said capacitor from said pair of said inductors and said full wave rectifier. 
     
     
       4. The variable refrigerant package for cooling a room as recited in  claim 3 , further including comprising: 
 an input voltage divider which is configured to give said input voltage; and 
 an output voltage divider which is configured to give said output voltage. 
 
     
     
       5. The variable refrigerant package for cooling a room as recited in  claim 1 , further comprising a reversing valve assembly connected to the refrigerant lines for reversing direction of flow of the refrigerant.  
     
     
       6. The variable refrigerant package for cooling a room as recited in  claim 1 , further comprising an electric heater in the path.  
     
     
       7. The variable refrigerant package for cooling a room as recited in  claim 1 , further comprising an evaporator drain pan below the evaporator.  
     
     
       8. The variable refrigerant package for cooling a room as recited in  claim 7 , further comprising a drain tube connected to the evaporator drain pan, the drain tube being configured to discharge any condensate collected in the drain pan from the refrigerant package.  
     
     
       9. A variable refrigerant package for cooling a room, wherein the variable refrigerant package is configured to be installed in a closet adjacent an outside wall, the closet being wired for power and connection to a thermostat to set a temperature in the room, the variable refrigerant package abutting a plenum through the outside wall, the variable refrigerant package comprising:
 an outdoor air inlet through the plenum;   a condenser;   a condenser fan assembly configured to draw outside air through the outdoor air inlet and move the outside air through the condenser and out the plenum to outside the room;   a path for indoor entering air;   an evaporator in the path;   a blower assembly configured to draw the indoor entering air from the room through the evaporator prior to discharge back into the room;   a compressor connected to refrigerant lines connecting the condenser to the evaporator to compress refrigerant flowing therethrough;   an electromagnetic interference filter for receiving and filtering electromagnetic interference from the power, the power being an AC signal;   an n-phase interleaved active power factor correction for the power, the n-phase interleaved active power factor correction receiving the power filtered by the electromagnetic interference filter, the n-phase interleaved active power factor correction comprising:
 (a) a full wave rectifier configured to convert the power to a rectified AC signal; 
 (b) a resistor network comprised of (i) a first plurality of resistors connected to the full wave rectifier, the first plurality of resistors configured to sense an input voltage from the full wave rectifier, and (ii) a second plurality of resistors configured to sense an output voltage from an output capacitor and to provide a feedback voltage; 
 (c) a pair of inductors connecting to a pair of current sensors before connecting to respective power switching devices, the pair of current sensors comprised of a current sensor and voltage sensor, the pair of current sensors being configured to continually detect consumption of the power; 
 (d) a controller programmed for monitoring and receiving (1) the input voltage from the full wave rectifier, (2) the output voltage from the output capacitor, and (3) currents from the pair of current sensors, and comparing the input voltage and the output voltage with the currents from the pair of current sensors to trigger the power switching devices to give an increased power factor equal to or substantially close to unity, wherein the increased power factor is for power supplied to the compressor, blower assembly and/or condenser fan.