U.S. patent application number 12/484838 was filed with the patent office on 2009-12-10 for integrated computer equipment container and cooling unit.
Invention is credited to IIye Meldrum, Brian Monk.
Application Number | 20090301123 12/484838 |
Document ID | / |
Family ID | 41265269 |
Filed Date | 2009-12-10 |
United States Patent
Application |
20090301123 |
Kind Code |
A1 |
Monk; Brian ; et
al. |
December 10, 2009 |
Integrated Computer Equipment Container and Cooling Unit
Abstract
A shipping container having an interior and a plurality of
electronic equipment modules disposed within the interior of the
container is cooled by an air conditioning unit adapted to be
disposed within the interior of the container. The cooling can be
assisted or assumed by use of an air side economizer cycle, or by
use of a water side economizer cycle. The electronic equipment may
include computing equipment and electronic data storage
equipment.
Inventors: |
Monk; Brian; (St. Laurent,
CA) ; Meldrum; IIye; (Terrebonne, CA) |
Correspondence
Address: |
MARJAMA MULDOON BLASIAK & SULLIVAN LLP
250 SOUTH CLINTON STREET, SUITE 300
SYRACUSE
NY
13202
US
|
Family ID: |
41265269 |
Appl. No.: |
12/484838 |
Filed: |
June 15, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US09/39873 |
Apr 8, 2009 |
|
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12484838 |
|
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61050502 |
May 5, 2008 |
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Current U.S.
Class: |
62/259.2 ;
165/56; 62/238.1 |
Current CPC
Class: |
H05K 7/1497 20130101;
F24F 11/0001 20130101; H05K 7/20745 20130101 |
Class at
Publication: |
62/259.2 ;
62/238.1; 165/56 |
International
Class: |
F24F 1/04 20060101
F24F001/04; F25B 27/00 20060101 F25B027/00; F24F 13/02 20060101
F24F013/02; F24F 13/08 20060101 F24F013/08 |
Claims
1. A modular computer equipment center comprising: a shipping
container having an interior; a plurality of electronic equipment
modules disposed within the interior of said container; an air
conditioning unit disposed in the interior of said container, said
air conditioning unit having a casing having a forward wall facing
said plurality of electronic equipment modules, a first side wall
extending perpendicularly to the forward wall, and an aft wall
opposite the forward wall, said air conditioning unit having a
width that is less than a corresponding width of said container
whereby an air plenum is formed between the first side wall of said
casing and a side wall of said container; and an air side
economizer circuit associated with said container and coupled to
said air conditioning unit for cooling said interior of said
container in part using air from external said container.
2. The modular computer equipment center as recited in claim 1,
wherein said air side economizer circuit comprises: an exhaust air
vent disposed in a wall of said container; an intake air vent
disposed in a wall of said container; a closeable exhaust air
damper in flow communication between the atmosphere external said
container and the atmosphere internal said container, said flow
communication being through said air exhaust vent; and a closeable
intake air damper in flow communication between the atmosphere
external said container and said air conditioning unit, said flow
communication being through said air intake vent.
3. The modular computer equipment center as recited in claim 2,
wherein said air side economizer circuit further comprises a
recirculation air damper in flow communication with an inlet vent
of said air conditioning unit for restricting airflow from interior
said container to said air conditioning unit.
4. The modular computer equipment center as recited in claim 1,
wherein said container comprises an intermodal container.
5. The modular computer equipment center as recited in claim 2,
wherein said exhaust air damper is in flow communication with a
portion of said container housing said plurality of electronic
equipment modules.
6. The modular computer equipment center as recited in claim 1,
wherein said air side economizer circuit is controlled in part
using data collected by an external temperature sensor positioned
outside said container.
7. The modular computer equipment center as recited in claim 2,
wherein said air side economizer circuit is operable using a supply
fan of said air conditioning unit and does not include a return
fan.
8. The modular computer equipment center as recited in claim 2,
wherein at least one of the exhaust air damper and the intake air
damper is actuated by control of a controller.
9. A modular computer equipment center comprising: a shipping
container having an interior; a plurality of electronic equipment
modules disposed within the interior of said container; an air
conditioning unit disposed in the interior of said container, said
air conditioning unit having a casing having a forward wall facing
the plurality of electronic equipment modules and a first side wall
extending perpendicularly to the forward wall, said air
conditioning unit having a width that is less than a corresponding
width of said container whereby an air plenum is formed between the
first side wall of said casing and a side wall of said container;
and a water side economizer circuit coupled to said air
conditioning unit for providing cooling fluid thereto.
10. The modular computer equipment center as recited in claim 9
wherein said water side economizer circuit comprises: a heat
exchanger coupled to said air conditioning unit; a passive fluid
cooler coupled in flow communication with said heat exchanger for
providing cooling fluid to said air conditioning unit; one or more
valves configured to divert an amount of flow between said passive
fluid cooler and said heat exchanger.
11. The modular computer equipment center as recited in claim 9
wherein said container comprises an intermodal container.
12. The modular computer equipment center as recited in claim 9,
wherein said water side economizer circuit is controlled in part
using data collected by an external air temperature sensor.
13. The modular computer equipment center as recited in claim 9,
wherein said water side economizer circuit is controlled in part
using data collected by a passive fluid cooler temperature
sensor.
14. The modular computer equipment center as recited in claim 9,
wherein said water side economizer circuit is controlled in part
using data collected by an external humidity sensor.
15. The modular computer equipment center as recited in claim 9,
wherein said passive cooler includes one of a water tower, a river,
a lake, and a reservoir.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part of International
Patent Application No. PCT/US09/39873, filed Apr. 8, 2009, which
claims the benefit of U.S. Provisional Application No. 61/050,502,
filed May 5, 2008. International Patent Application No.
PCT/US09/39873 is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates generally to transportable modular
computer and information technology equipment centers, more
particularly, to a transportable modular computer and information
technology center having a cooling unit integrated therewith.
BACKGROUND OF THE INVENTION
[0003] Portable modular data centers are increasingly being used to
provide additional computing and electronic storage data capability
without the cost and time delay associated with the construction of
a stationary data center. Such modular data centers typically house
a plurality of electronic modules, either rack-mounted or
shelf-mounted, within a transportable container. The electronic
modules may be disposed on both sides of a central aisle extending
the length of the container so that humans may access the
equipment. Examples of the electronic modules include computer
processors, storage modules such as random access memory, disc
drives, compact discs, video disks and other computer equipment and
electronic information storage devices. The transportable container
may be an intermodal shipping container capable of being
transported by truck, by rail car or by ship, or even by plane. To
facilitate global portability, the container may conform to
International Standard Organization (ISO) container manufacturing
standards.
[0004] For example, U.S. Pat. No. 7,278,273 discloses a modular
data center housed in an ISO compliant intermodal shipping
container. The modular data center includes at least one computing
module including a shipping container and a plurality of computing
systems mounted on racks or shelves within the shipping container
and configured to be shipped and operated within the shipping
container. The modular data center also includes an additional
shipping container housing a temperature control system for
providing chilled air to one or more of the containers housing the
computer modules.
[0005] The multitude of electronic modules disposed on racks or
shelves housed within a data center enclosure collectively generate
a significant amount of heat, for example, between 50 kW and 400 kW
of sensible (dry) heat, during operation. Release of this heat
into, and subsequent accumulation of the heat in the environment
within the enclosure results in temperatures that could adversely
impact the performance, reliability and useful life of the
electronic modules and components thereof. Therefore, it is
desirable to remove the heat produced by the electronic modules
from the environment within the data center enclosure. For example,
U.S. Pat. No. 7,365,973 discloses a cooling system for a data
center wherein chilled coolant from an external source, such as a
chiller unit, is circulated through a plurality of cooling racks
positioned at selected locations within the data center enclosure
for cooling air within the enclosed environment by circulating that
air via fans mounted in the cooling racks through heat exchangers,
also mounted in the cooling racks, in heat exchange with the
chilled coolant.
SUMMARY OF THE INVENTION
[0006] An air conditioning unit is adapted to be installed in a
shipping container having an interior and a plurality of electronic
equipment modules disposed within the interior of the container.
The air conditioning unit includes a casing having dimensions sized
to be disposed within the interior of the shipping container. The
casing has a forward wall facing the plurality of electronic
equipment modules and a first side wall extending perpendicularly
to the forward wall, and defines an interior chamber. An air inlet
is provided in the first side wall opening in flow communication to
the interior chamber and an air outlet in the forward wall, which
is perpendicular to the first side wall, opening in flow
communication to the interior chamber. An air mover is disposed
within the interior chamber. The air mover has an inlet in flow
communication with the air inlet and an outlet in flow
communication with the air outlet. A heat exchanger is disposed
within the interior chamber upstream with respect to air flow of
the air mover for cooling the air flow passing through the interior
chamber. In an embodiment, a mist eliminator may be disposed within
the interior chamber downstream with respect to air flow of the
heat exchanger. The mist eliminator may include a steel mesh
screen.
[0007] To facilitate the return of air flow from the interior of
the container, the casing of the air conditioning unit has a width
that is less than a corresponding width of the container whereby an
air plenum is formed adjacent the first side wall of the casing of
the air conditioning unit when the air conditioning unit is
disposed within the container. In an embodiment, the air
conditioning unit is disposed within an intermodal ISO container.
In an embodiment, the ISO container has a width of about 8 feet and
the casing of the air conditioning unit has a width of about 6
feet.
[0008] At least one flow balancing plate may be disposed at the air
inlet to the air conditioning unit upstream with respect to air
flow of the heat exchanger for selectively distributing the air
flow pass into the heat exchanger. In an embodiment, the perforated
plate has a plurality of selectively sized and selectively arrayed
openings therein. An air filter rack may be disposed at the air
inlet to the air conditioning unit upstream with respect to air
flow of the heat exchanger.
[0009] Economizer cycles can reduce the cooling burden of the air
conditioning unit by using passive cooling sources. In one
embodiment, an air side economizer circuit circulates external air
through the container 20. In another embodiment, a water side
economizer circuit is utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a further understanding of the invention, reference will
be made to the following detailed description of the invention
which is to be read in connection with the accompanying drawing,
where:
[0011] FIG. 1 is a perspective view, partly in section, of a
modular data center and air conditioning unit housed in a shipping
container;
[0012] FIG. 2 is a first perspective view of an exemplary
embodiment of the air conditioning unit shown in FIG. 1;
[0013] FIG. 3 is a second perspective view of an exemplary
embodiment of the air conditioning unit shown in FIG. 1;
[0014] FIG. 4 is a plan view looking down upon the air conditioning
unit of FIG. 2;
[0015] FIG. 5 is a side elevation view taken along line 4-4 of FIG.
4;
[0016] FIG. 6 is a side elevation view taken along line 5-5 of FIG.
5; and
[0017] FIG. 7 is a schematic diagram of an exemplary control system
associated with the air conditioning unit.
[0018] FIG. 8 is a plan view looking down upon an alternate
embodiment of the modular data center and air conditioning unit
housed in a shipping container, illustrating apparatus associated
with an air cooling economizer cycle.
[0019] FIG. 9 is a simplified schematic diagram illustrating
apparatus associated with a water cooling economizer cycle,
according to an alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to FIGS. 1 and 2, there is depicted an exemplary
embodiment of a modular data center 10 including a plurality of
electronic equipment 12 disposed on shelves or racks housed in a
shipping container 20 and an air conditioning unit (ACU) 30 housed
in an aft portion of the shipping container 20. The electronic
equipment may, for example include, but is not limited to, computer
servers, computer processors, storage modules such as random access
memory, disc drives, compact discs, video discs and other computer
equipment and electronic information storage devices. The
electronic equipment may be organized in electronic modules 14 that
may be arranged in rows 16 disposed on both sides of a central
aisle extending the length of the container or in any other desired
arrangement permitting human access to the equipment. A container
access door 15 may be provided in the aft wall of the container 20.
Additional container access doors may be provided in other walls of
the container if desired.
[0021] The shipping container 20 may be an intermodal shipping
container capable of being transported by truck trailer, rail car
or ship. In an embodiment, the container 20 may conform to
International Standardization Organization (ISO) container
manufacturing standards. Typically, ISO containers have a width of
8 feet, a height of 81/2 feet, and a length of 40 feet, although
other lengths, shorter and longer, are common. However, containers
of various other combinations of height, width and length may be
used.
[0022] The ACU 30 has a casing having a first side wall 32 on the
air inlet side of the ACU 30, a forward wall 34, a second side wall
36 opposite the first side wall, and an aft wall 38 opposite the
forward wall 34, and defines an interior chamber 33 therein. The
ACU casing has a height, h, compatible with the height, H, of the
container 20 and a depth, d, substantially less than the length of
the container 20. However, the ACU casing has a width, w, that is
less than the width, W, of the container 20, such that when the ACU
30 is positioned within the interior of the container 20, a return
air plenum 25 is formed between the air inlet side wall 32 of the
ACU 30. As will be explained in further detail hereafter, to remove
heat from the environment within the interior of the container 20,
air from within the interior of the container 20 is drawn by air
movers within the ACU 30 through the air plenum 25 into and through
the ACU 30 and discharged therefrom through the louvered air
outlets 35 in the forward wall 34 of the ACU 30. In passing through
the ACU 30, the air passes in heat exchange relationship with a
chilled coolant provided from a source (not shown) external of the
container 20, whereby the air is cooled, typically to a temperature
in the range of about 55.degree. F. (about 12.8.degree. C.) to
about 75.degree. F. (about 23.9.degree. C.), and the heat removed
from the air is transferred to the coolant and discharged
externally of the environment within the interior of the container
20.
[0023] Referring now to FIGS. 2-6, in particular, the air
conditioning unit 30 includes an upper ACU module 30U and a lower
ACU module 30L disposed in a stacked array. Each ACU module
includes at least one air mover 40, a heat exchanger 50 and a mist
eliminator 60. The ACU module may also include an air filter 70.
The stacked array of ACU modules 30U and 30L is, as noted
previously, disposed in the aft portion of the container 20 with
the air inlet side wall 32 of the ACU 30 facing the inlet air
plenum 25 defined between the air inlet side 30 and the opposed
inside surface of the container 20.
[0024] The air movers 40 of the upper and lower ACU modules 30U,
30L are disposed in the chamber 33 extending along the side 36 of
the ACU 30 opposite the air inlet side wall 32 of the ACU 30. Each
of the air movers 40 may include at least one plenum blower, such
as, for example, a centrifugal fan, having its inlet in flow
communication with the air inlet plenum 25 and its outlet in flow
communication with a respective one of the air outlets 35 in the
forward wall 34 of the ACU 30. Each plenum blower 40 may be driven
by an electric motor 42 operatively associated therewith, either
through a belt drive or a direct mechanical connection. Each
electric motor 42 is driven via a motor drive 44, which may be
fixed frequency drive or a variable frequency drive 44 associated
with an electric service/supply panel 46 adapted to be connected to
an external electric power source.
[0025] If driven by a variable frequency drive, each motor 42 may
be a variable speed motor whereby the speed of the motor 42 may be
selectively varied to vary the air flow capacity of its associated
blower 40 to match the cooling demand. In this case, each plenum
blower 40 may be sized to provide 100 percent of the required
cooling capacity at maximum design demand. By over sizing each
blower 40 and providing variable speed capability, air mover
redundancy is provided. In the event that one (or more) blower(s)
is out of operation, maximum design cooling operation may still be
met by the remaining active blowers. A shutoff damper assembly 48
may be provided in operative association with each of the plenum
blowers 40 to permit a failed blower 40 to be isolated by closing
the dampers of the shutoff damper assembly 48 to prevent air flow
into the failed blower.
[0026] Each heat exchanger 50 is disposed within the ACU 30 so as
to extend along the air inlet side 32 of the ACU 30, downstream
with respect to air flow of the air inlet opening in the air inlet
side wall 32 of the ACU 30 and upstream with respect to air flow of
the plenum blower 40. Each heat exchanger 50 may include one or
more heat exchanger tube banks arranged in parallel with respect to
coolant flow through the tubes thereof and in series with respect
to the flow of air over the tubes thereof. Each tube bank is
connected in a conventional manner to an external supply of chilled
coolant (not shown), such as, for example, but not limited to,
chilled water from a chiller, or chilled refrigerant from a
refrigerant condensing unit disposed external of the container 20,
or chilled refrigerant cooled in an external water tower condenser.
In operation, chilled coolant is pumped through the tubes of the
heat exchanger 50 to cool and remove heat from air drawn by means
of the plenum blowers 40 from within the compartment of the
container 20 housing the electronic equipment 12, through the air
plenum 25, over the tubes of the heat exchanger 50, and through the
blowers 40 to be discharged therefrom through the louvered air
outlets 35 back into the compartment of the container 20 housing
the electronic equipment 12. In this manner, heat produced within
the container 20 due to operation of the electronic equipment is
removed from the closed environment within the interior of the
container 20 and transferred to the coolant passing through the
tubes of the heat exchanger 50. The warmed coolant having traversed
the tubes of the heat exchanger 50 is returned to the external
source of chilled coolant whereby the heat produced due to the
operation of the electronic equipment is effectively rejected from
the environment within the container 20.
[0027] In an alternative embodiment, the modular data center 10
includes an air side economizer circuit. The air side economizer
circuit, during operation, eases or ceases the burden on the
external supply of chilled coolant (not shown) to cool the air in
the container 20. Referring to FIG. 8, the apparatus for the air
side economizer circuit 11 includes an exhaust air vent 27 and an
associated exhaust air damper 22, and an intake air vent 28 and an
associated intake air damper 24. The exhaust air vent 27 and intake
air vent 28 are each openings in a wall of the container 20 for
allowing air to exit the interior of the container or flow into the
container, respectively. A grill might also be attached at the
vents, for instance, to keep out intruders, such as persons or
non-human animals.
[0028] Each respective damper 22 and 24 is positioned in flow
communication, through the air vents 27 and 28, between the air
internal to the container 20 and the air external to the container
20. This position can be achieved by placing the dampers 22, 24
directly in the respective vent 27, 28, thereby aligning the
dampers 22, 24 with the wall. This position can also be achieved by
attaching the dampers 22, 24 directly to the respective vent 27,
28. Also, this position can be achieved by attaching each of the
dampers 22, 24 to the respective vent 27, 28 indirectly, such as by
using a duct to connect between them.
[0029] Intake air vent 28 is shown in FIG. 8, with its associated
intake air damper 24, situated in the aft wall of the container 20
and/or the aft wall 38 of the air inlet side of the ACU 30, in
order to provide a closeable path to take air external to the
container 20 into the air conditioning unit. Through air vent 28
and air damper 24, blowers 40 can draw air into the ACU 30 and
discharge it therefrom through the louvered air outlets 35 in the
forward wall of the ACU 30. Air circulates through the portion of
the container 20 housing the plurality of electronic equipment 12.
Air is discharged from the container 20 through air vent 27 and its
associated air damper 22, which provide a closeable path from the
container 20 to the outside. The air vent 27 and air damper 22 are
situated at a wall of the container 20 in order to promote air
circulation over the electronic equipment from the ACU 30. In FIG.
8, the placement is at a side wall shared by the plenum 25, except
in the portion of the container 20 housing the plurality of
electronic equipment 12.
[0030] Positioning the intake air vent 28 and its associated damper
24 in this close proximity to blower(s) 40 increases the draw of
outside air into the air conditioning unit 30 and blower 40. When
the damper 24 opens, negative pressure in the plenum 25 is
relieved, causing the air pressure at the exhaust air damper 22 to
change from negative to positive, which creates the pressure
gradient required to exhaust the heated airflow. In this
embodiment, the supply fan(s) (i.e. blowers 40), which supply air
in the air conditioning unit 30 to the rest of the container 20,
are sufficient to circulate external air into the container, around
the container, and out through the exhaust air damper 22 without
the use of any additional return fan, such as one positioned to
assist blowing air out of the container 20.
[0031] A recirculation air damper 71 can optionally be used to
further prevent air recirculation. Preventing air recirculation
using the recirculation air damper 71 also reduces a need to use a
return fan. The recirculation air damper 71 can be positioned at an
ACU inlet vent 73 in order to close the pathway for air flow from
the plenum 25, through the ACU inlet vent 73, into the air
conditioning unit 30. Closing the ACU inlet vent 73 reduces or
prevents air circulated from the air conditioning unit 30 through
the container 20 from being recirculated through the air
conditioning unit 30. In this embodiment, the more air tight the
plenum 25 is, the more efficient is the circuit. For instance,
closing the gap 112 shown in FIG. 8 seals air exiting the air
conditioning unit 30 through the louvered ducts 35 from being back
drawn through a plenum inlet vent 77 and out of the container 20
through the exhaust air damper 22.
[0032] Alternatively, the recirculation air damper 71 can be
positioned to close a pathway through a plenum inlet vent 77 for
air flow from the portion of the container 20 housing the plurality
of electronic equipment 12 to the plenum 25. In this latter
position, the recirculation air damper prevents air from exiting
into the plenum 25, thereby eliminating extra area for air to flow
and possibly leak back into a path of recirculation. Closing the
recirculation air damper 71 at either ACU inlet vent 73 or plenum
inlet vent 77 increases the draw of air through the intake air
damper 24 and forces air to exit through the exhaust air vent 27.
Again, however, closing gap 112 will help prevent air exiting the
air conditioning unit 30 through the louvered ducts 35 from short
circuiting its way back to the air intake side of the air
conditioning unit 30 by way of plenum 25. Coordinating the use of
the recirculation damper 71 at both vents 73 and 77 can also
prevent leaking to assure air recirculation is 100% prevented.
[0033] Intake air vent 28 and intake air damper 24 can be
positioned alternatively on a wall of the container to provide flow
communication between the air external to the container 20 and the
plenum 25. In this case, the recirculation air damper 71 can be
positioned to close the air pathway through the plenum inlet vent
77. Closing air flow through the ACU inlet vent 77 increases the
draw of air through the intake air damper 24 and the exhaust of air
through the exhaust air damper 22. Furthermore, this positioning of
the intake air vent 28 and its associated air damper 22 can be
useful when using the air side economizer cycle 11 simultaneously
with the heat exchanger 50. External air that is cooler than the
air exiting the container 20 through the exhaust air vent 27 can be
further cooled as it enters the air conditioning unit 30 at ACU
inlet vent 73 and passes thoroughly over the heat exchanger 50.
[0034] Air dampers 22, 24 and their associated air vents 27, 28 can
be positioned in alternative locations or on alternative walls
within the portion of the container 20 housing the plurality of
electronic equipment 12. For instance, the exhaust air damper 22
and the air vent 27 can alternatively be situated in the forward
wall of the container 20, or in the side wall opposite the one
shown holding the air damper 22 in FIG. 8. In each of these cases,
closing the recirculation damper 71 positioned at either the vent
73 or the vent 77 promotes the flow of air to exit the container 20
through the exhaust air damper 27 and the exhaust air vent 22.
[0035] When the intake air vent 28 and its associated damper 24
intake air directly, or through a duct, to the air conditioning
unit 30, closing the recirculation air damper 71 at either the vent
77 or the vent 73 promotes the flow of air to exit the container 20
through the exhaust air vent 27 and its associated damper 22.
Closing recirculation damper 71 at the vent 73 eliminates the risk
of the blower(s) drawing air from a leak or unsealed path from the
plenum 25 to heated air. Also, in this case, the exhaust air vent
27 and its associated damper 22 can be located in a wall of the
container 20 at the plenum 25 to exhaust air from the plenum 25
rather than the portion of the container 20 housing the plurality
of electronic equipment 12.
[0036] To further help promote air flow exiting the container
through exhaust air vent 27 and exhaust air damper 22, for
instance, when complete recirculation is not achieved, an optional
return fan 75, such as a centrifugal fan, can be used. The return
fan 75 is positioned in flow communication with the exhaust air
damper 22. The return fan 75 may be driven by an electric motor 79
operatively associated therewith, either through a belt drive or a
direct mechanical connection. The electric motor 79 may be driven
by a fixed frequency drive or a variable frequency drive (not
shown) associated with an electric service/supply panel (e.g. the
electric service/supply panel 46 illustrated in FIG. 4) adapted to
be connected to an external electric power source.
[0037] If driven by a variable frequency drive, the motor 79 may be
a variable speed motor whereby the speed of the motor 79 may be
selectively varied to vary the air flow capacity of the return fan
75 to match the cooling demand.
[0038] Each air damper 22, 24, 71 is opened or closed by an
actuator 26 operatively associated therewith. Each actuator 26 is
connected to an external electric power source (not shown),
possibly through an electric service/supply panel (e.g. the
electric service/supply panel 46 illustrated in FIG. 4) adapted to
be connected to the external electric power source.
[0039] In operation, when the air temperature external to the
container 20 is below a predetermined external air temperature set
point, the air dampers 22, 24 open. Air movers 40 draw air into the
ACU 30 through air damper 24, circulate the drawn air amongst the
electronic equipment 12 in the container 20, and expel the drawn
air through the air damper 22. When a return fan 79 is used, it
further blows air out of the container 20 through the exhaust air
damper 22. When a recirculation air damper 71 is used, it operates
in coordination to achieve the desired air flow and the resultant
desired cooling. Generally, damper 71 closes when dampers 22 and 24
are open.
[0040] The set point can be adjusted as necessary, depending on the
amount of heat required to be removed. A typical application might
require cooling approximately 300 kW of dry heat, while any amount
in the range from 50 kW to 400 kW might be required. The operating
speed of the air movers 40 is also adjusted as required depending
on the air temperature internal and external to the container 20
and the required amount of heat to be removed from the container
20. As an example, if 300 kW of heat is required to be removed from
the container 20, and the external air temperature is approximately
60 degrees Fahrenheit, then the air cooling economizer cycle must
intake and expel 30,000 CFM of air in order to deliver air at 87
degrees Fahrenheit and avoid using the external supply of chilled
coolant (not shown).
[0041] Referring to FIG. 9, a further embodiment includes a water
cooling economizer cycle, that, during operation, transfers in part
or in whole, the cooling burden from an active coolant chiller 52
to a passive fluid cooler 54. An active chiller synthetically
chills. A refrigerant condensing unit is an example. A passive
fluid cooler allows heat to be removed from the coolant using
natural resources which may be available. Examples of passive fluid
coolers include, but are not limited to, water towers, rivers,
lakes, and reservoirs.
[0042] The active chiller 52 and the passive fluid cooler 54 are
located external to the container 20. The active chiller 52 is
connected to the tube banks of the heat exchanger 50 in each ACU
module 30U, 30L. An active chiller valve 62 exists either inside
the ACU 300, or between the ACU 300 and the passive fluid cooler
54. The passive fluid cooler 54 is also connected to the tube banks
of the heat exchanger 50 in each ACU module 30U, 30L. A passive
fluid cooler valve 64 exists either inside the ACU 300, or between
the ACU 300 and the passive fluid cooler 54. Alternatively, valves
62, 64 can be a series of valves to appropriately achieve the same
function.
[0043] In operation, valves 62, 64 open and close, inversely, to
route the chilled coolant to/from the passive fluid cooler 54 or
the active chiller 52, depending on the temperature of the air, the
temperature of the passively chilled coolant external to the
container 20, the temperature of the coolant in the ACU 300, the
humidity external to the container, and/or the amount of heat
required to be removed from the container 20. By "open and close
inversely", it is meant that when the valve 62 is selectively
opened, the valve 64 is closed, and conversely, when the valve 64
is selectively opened, the valve 62 is closed. When cooling is not
required, both valves 62, 64 may be closed. For example, if the air
temperature external to the container 20 is 58 degrees Fahrenheit,
and the ACU 300 requires an inlet coolant temperature of 65 degrees
Fahrenheit, then it is economical for the valves 62, 64 to route
the coolant exiting the ACU 300 to the passive fluid cooler (e.g.,
a cooling tower) to be naturally cooled before returning to the
container 20. The valves 62, 64 can be self-actuated.
Alternatively, separate actuators (not shown) operatively connected
to the valves 62, 64 can be controlled separately. If necessary,
the self-actuated valves, or each actuator (not shown) can be
connected to an external electric power source (not shown),
possibly through an electric service/supply panel (e.g. the
electric service/supply panel 46 illustrated in FIG. 4) adapted to
be connected to the external electric power source. Further,
separate heat exchangers may be coupled to the active and passive
fluid coolers.
[0044] A mist eliminator 60 may be disposed in the path of the air
flow passing through the ACU 30. Moisture may enter the closed
environment within the container 20 from the outside when humans
make entry into the container 20 to access the electronic equipment
housed therein. Additionally, moisture may condense out of the air
within the closed environment when the air temperature therein
drops, such as when the electronic equipment is shut-down, and
therefore not generating heat, or the outside temperature drops
significantly. Upon start-up of the ACU 30, this condense moisture
will be re-entrained into the sir flow and will be removed
therefrom before the electronic equipment is booted up. In the
exemplary embodiment depicted in the drawing, a mist eliminator 60
is disposed downstream heat exchanger 50 with respect to air flow.
Although most of the moisture in the air flow entering the heat
exchanger 50 will condense on the outside of the tubes and drain
into a condensate pan disposed beneath the heat exchanger 50, the
mist eliminator 60 will collect those moisture droplets that may be
carried over in the air flow passing from the heat exchanger 50.
The mist eliminator 60 will also function to help balance airflow
across the heat exchanger 50. The mist eliminator 60 may of
conventional design. In an embodiment, the mist eliminator 60
comprises a steel mesh screen.
[0045] An air filter rack 70 having a framework supporting one or
more air filters may be disposed at the air inlet in the air inlet
side wall 32 of the casing of the ACU 30 upstream with respect to
air flow of the heat exchanger 50. The air filters function to
remove dust, dirt and other debris that may be entrained in the air
flow from the compartment of the container 20 housing the electric
equipment. Dirt, dust and other debris may be brought into the
closed environment within the container 20 when humans enter
therein to service, maintain or replace the electronic equipment 12
housed therein. The air filter rack 70 may be of conventional
design.
[0046] Additionally, one or a plurality of flow balancing plates 80
may be disposed in the ACU 30 upstream of the heat exchanger 50
either in the filter rack 70 or external to the air inlet to the
ACU 30. The flow balancing plates 80 may comprise perforated sheets
having a plurality of opening therein arrayed in a desired pattern
or non-perforated, solid sheets. Those skilled in the art will
recognize that the distribution of air flow from the air plenum 25
into the heat exchanger 50 may be selectively adjusted to provide a
uniform flow distribution across the face of the air inlet to the
ACU 30 by selective sizing and arrangement of the openings in the
perforated flow balancing plates 80. If desired, the flow balancing
plates 80 may be disposed and supported in the supporting framework
of air filter rack.
[0047] The ACU 30 may also include a controller 90 for controlling
the operation of each of the air conditioning modules 30U and 30L.
The controller 90 may be located within the electrical panel for
ready access via the container doors 15 at the end of the container
20. Referring now to FIG. 7, in particular, the controller 90
monitors each of the respective discharge air temperature sensors
92 associated with the blowers 40. Each discharge air temperature
sensor 92 may be located in the discharge duct of its associated
blower 40. The controller 90 also monitors the temperature of the
coolant entering and the temperature of the coolant leaving each of
the heat exchangers 50 associated with the air conditioning modules
30U and 30L via coolant temperature sensors 98. The controller 90
also controls the variable frequency drives 44 to vary the speed of
the fan motors 42 to vary the air flow delivered by each of the
blowers 40. The controller 90 also controls the flow of coolant
through the respective heat exchangers 50, for example by opening,
closing or modulating a coolant flow control valve 94 disposed in
the coolant supply line 2 to the respective heat exchangers 50 if
the ACU 30 is associated with an external water chiller, or
starting and stopping a compressor 96 in conjunction with
modulating a refrigerant flow control valve 94 if the ACU 30 is
associated with an external refrigerant condensing unit (in which
case the compressor may be located off-board the container) or a
water tower condensing unit (in which case the compressor may be
located on-board). The controller 90 processes the discharge air
and the coolant temperature measurement signals received and in
response thereto varies the air flow and/or water flow as
appropriate to maintain a desired discharge air temperature,
typically in the range of about 55.degree. F. (about 12.8.degree.
C.) to about 75.degree. F. (about 23.9.degree. C.), as well as to
optimize the efficiency of the cooling system, including the
external coolant supply device, for example a water chiller or a
refrigerant condensing unit. It is to be understood that the
controller 90 may vary the air flow delivered by the blower 40 and
water flow through the heat exchanger of one of the modules 30U and
30L independently of the other of the modules 30U and 30L.
[0048] In conjunction with the optional air cooling economizer
cycle, the controller 90 can also monitor the air temperature
external to the container 20 via sensor 100. The controller 90 can
control the selective opening and selective closing of the air
dampers 22, 24, and adjust the speed of each blower 40 to regulate
the air temperature inside the container 20 when the external air
temperature is below. Furthermore, the controller 90 can control
the selective opening and selective closing of recirculation damper
71, as well as the operation of return fan 75, in coordination with
the operation of air dampers 22, 24 and blowers 40.
[0049] In conjunction with the optional water cooling economizer
cycle, the controller 90 can monitor the external air temperature,
or alternatively, the coolant in the passive fluid cooler 54 (e.g.,
water in a lake or river) via sensor 100. The controller 90 can
also monitor external humidity via sensor 102 in order to determine
the outdoor air enthalpy. The controller 90 processes the external
air temperature, the external humidity, the discharge air
temperature, and/or the coolant temperature measurement signals
received and in response thereto routes the water flow as
appropriate between the active chiller 52 and the passive fluid
cooler 54 via active chiller valve 62 and passive fluid cooler
valve 64. Valves 62, 64 of FIG. 9 are represented in FIG. 7 by flow
control valves 94. However, additional valves can be used to
increase the source of coolant and the method of cooling the
coolant. In an example, when the outside temperature drops below a
predetermined external air temperature set point, then the
controller 90 closes the active chiller valve 62 and opens the
passive fluid cooler valve 64. The controller 90 may modulate the
passive fluid cooler valve 64 to maintain the air temperature
desired inside the container 20. If the passive fluid cooler valve
64 is fully open, and the controller 90 receives temperature data
indicating the coolant exiting the ACU 300 exceeds a predetermined
exiting coolant temperature set point, then the controller 90 will
gradually close the passive fluid cooler valve 64 while gradually
opening the active chiller valve 62, as necessary to maintain the
air temperature desired inside the container 20. If the outside
temperature is above the external air temperature set point, or the
air temperature desired inside the container 20 cannot be
maintained, then the controller 90 will turn off the water cooling
economizer cycle by closing the passive fluid cooler valve 64 and
opening the active chiller valve 62.
[0050] The controller 90 may have functional capability to shut
down a blower 40 by deactivating its associated fan motor 42 in the
event of a sudden drop or complete loss of static pressure,
detected by a static pressure sensor (not shown) disposed in
association with each blower, such as may occur as a result of a
fan belt break or other component failure. The controller 90 may
have functional capability to detect condensate build-up in a
condensate drain pan 58 beneath each of the heat exchanger 50 and
the capability to detect a water leak, either from the heat
exchanger itself or from an overflowing condensate drain pan. To do
so, the controller 90 may be programmed to monitor a plurality of
sensors 91, 93, 95 for example electrical resistance sensor tapes,
associated with a condensate drain pan disposed beneath each of the
heat exchangers 50 and with the floor beneath the condensate drain
pan. If an electrical resistance sensor tape becomes wet, the
sensor transmits a signal to the controller 90 indicating the
presence of water. For example, a first sensor tape 91 may be
disposed in the bottom of drain pan 58 to detect if condensate is
present in the drain pan, a second sensor 93 may be disposed near
the top rim of the drain pan 58 to detect if the drain pan is
filled with condensate, and a third sensor tape 95 may be disposed
beneath the drain pan 58 to detect if the condensate has over
flowed the drain pan or the heat exchanger has developed a coolant
leak.
[0051] The controller 90 may also control a reaction to other
events, such as unauthorized or accidental access, smoke, high or
low temperatures and humidities, failure of any moving part, dirty
filters, failure of a part to respond properly to the controller
90, and power failure. Additional sensors, not shown, may be used.
Sensors to collect data to be sent to the controller 90 include,
but are not limited to, smoke detectors, temperature sensors, water
detectors, pressure sensors and mechanical interlock switches.
Reaction events vary depending on the event. Some examples include,
but are not limited to, the following. In the event of a fan
failure, an alert causes other forms of cooling to increase, such
as coolant flow opening to maximum. If a belt breaks, the fan motor
shuts off while operational fans and coolant flow increase speed.
If condensate is detected, it is logged. If excess condensate is
detected or a catastrophic leak is detected, an alert is sent, and
the ACU 30 is shut down. Air dampers 22, 24 can be opened. If a
door is open, the event is logged and cooling increases. A dirty
filter causes an alarm. High air humidity causes a reaction to
promote condensation, including increasing coolant flow and
minimizing fan speeds.
[0052] As noted previously, the air conditioning unit 30 is
designed with a width, w, that is less than the width, W, of the
container 20, such that when the ACU 30 is positioned within the
interior of the container 20, a return air plenum 25 is formed
between the air inlet side 32 of the ACU 30. Additionally, the air
inlet side 32 of the ACU 30 and the air outlet side 34 of the ACU
30 are perpendicular to each other. Thus, as best seen in FIG. 4,
air flow through the ACU 30 is therefore in a general U-shaped
pattern. The ACU 30 draws in air flow at a high velocity, up to
about 600 feet per minute, into the compartment housing the
electronic equipment 12 along one side of the interior of the
container 20, referred to as the "cold side", and receives return
air at a high velocity, up to about 600 feet per minute, from the
compartment housing the electronic equipment 12 along the other
side of the interior of the container 20, referred to as the "warm
side". In this manner, adequate cooling air is provided to all of
the electronic equipment supported of racks or shelves within the
interior of the container 20.
[0053] The air conditioning unit 30 is capable of delivering an
amount of cooled air flow sufficient to meet maximum cooling demand
for a modular data center disposed within a standard ISO shipping
container while still fitting entirely within the interior of a
standard ISO shipping container. The casing of the ACU 30 may have
cutouts and offsets to recess coolant inlet and outlet connections
4 and 6. All protuberances from the ACU 30, such as door handles,
door hinges, power connections and the like are within the
footprint defined by the width and depth of the ACU 30. For
example, the casing of the ACU 30 may have a height, h, of about
81/4 feet, a depth of about 91/2 feet and an overall width of about
6 feet. When installed in a standard ISO container, due to the
limited width of the ACU 30, the air plenum 25 formed between the
air inlet side wall 32 of the casing of the ACU 30 and the facing
wall of the container 20 will have a width of about 20 inches,
which is large enough to also provide access with the air plenum 25
to service and replace the rack of air filters 70 and flow
balancing plates 80.
[0054] Additionally, the ACU 30 may be equipped with lifting lugs
21 mounted to the base frame 31 of the ACU 30 for providing members
to which a crane or other hoisting device may be attached to permit
the ACU 30 to be lifted. The lifting lugs may be removable to
facilitate final installation of the ACU 30 into the container 20.
The ACU 30 may also be equipped with strap holes 23 and forklift
points (not shown) in the base frame 31 of the ACU 30 to facilitate
securing the ACU 30 to a forklift truck and maneuvering the ACU 30
during final installation of the ACU 30 into the container 20. The
ACU 30 may also include an access door 39 in the aft side wall 38
of the casing of the ACU 30, accessible via opening the container
door 15, to provide human access to the plenum blowers 40 and
associated fan motors 42, motor drives 44 and the electric supply
panel 46. Additionally a pair of removable access panels 88 may be
provided in the side wall 36 of the casing of the ACU 30 to permit
access to the bearings, gearing and drive system of the plenum
blowers 40 and associated fan motors 42. A corresponding access
door 18 may be provided in the side of the container to permit
access to the access panels 88.
[0055] The terminology used herein is for the purpose of
description, not limitation. Specific structural and functional
details disclosed herein are not to be interpreted as limiting, but
merely as basis for teaching one skilled in the art to employ the
present invention. While the present invention has been
particularly shown and described with reference to the exemplary
embodiments as illustrated in the drawing, it will be recognized by
those skilled in the art that various modifications may be made
without departing from the spirit and scope of the invention. Those
skilled in the art will also recognize the equivalents that may be
substituted for elements described with reference to the exemplary
embodiments disclosed herein without departing from the scope of
the present invention.
[0056] Therefore, it is intended that the present disclosure not be
limited to the particular embodiment(s) disclosed, but that the
disclosure will include all embodiments falling within the scope of
the appended claims.
* * * * *