U.S. patent application number 14/665866 was filed with the patent office on 2015-07-09 for modular it rack cooling assemblies and methods for assembling same.
The applicant listed for this patent is Inertech IP LLC. Invention is credited to John Costakis, Earl Keisling, Gerald McDonnell.
Application Number | 20150195958 14/665866 |
Document ID | / |
Family ID | 45852684 |
Filed Date | 2015-07-09 |
United States Patent
Application |
20150195958 |
Kind Code |
A1 |
Keisling; Earl ; et
al. |
July 9, 2015 |
MODULAR IT RACK COOLING ASSEMBLIES AND METHODS FOR ASSEMBLING
SAME
Abstract
A modular server rack cooling structure for cooling at least one
server in at least one server rack of a data center assembly
includes at least a first supporting member and at least a first
heat exchanger. The first heat exchanger is coupled to the first
supporting member, which is configured to position the first heat
exchanger in heat transfer relationship with the at least one
server. The first heat exchanger is not attached to the at least
one server rack. The modular server rack cooling structure is also
applied to a system that includes at least a first rack and at
least a second rack disposed opposite from one another to form a
hot aisle or a cold aisle. A method is disclosed for installing
additional heat exchangers on the support structure of a modular
server rack cooling structure to meet increased cooling capacity
requirements without requiring additional space.
Inventors: |
Keisling; Earl; (Ridgefield,
CT) ; Costakis; John; (Hyde Park, NY) ;
McDonnell; Gerald; (Poughquag, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Inertech IP LLC |
Danbury |
CT |
US |
|
|
Family ID: |
45852684 |
Appl. No.: |
14/665866 |
Filed: |
March 23, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13517092 |
Jun 19, 2012 |
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PCT/US11/67685 |
Dec 28, 2011 |
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14665866 |
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61482070 |
May 3, 2011 |
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61448631 |
Mar 2, 2011 |
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Current U.S.
Class: |
361/679.47 |
Current CPC
Class: |
H05K 7/20736 20130101;
Y10T 29/49826 20150115; H05K 7/20745 20130101; H05K 7/20827
20130101; H05K 7/20781 20130101 |
International
Class: |
H05K 7/20 20060101
H05K007/20 |
Claims
1. A modular server rack cooling structure for cooling at least one
server in at least one rack of a data center, the modular server
rack cooling structure comprising: at least a first supporting
member; and at least a first heat exchanger, the at least a first
heat exchanger coupled to the at least a first supporting member,
the at least a first supporting member configured to position the
at least a first heat exchanger in heat transfer relationship with
the at least one server, wherein the at least a first heat
exchanger is not attached to the at least one rack.
2. The modular server rack cooling structure according to claim 1,
wherein the at least a first supporting member comprises a beam
member, and wherein the at least a first heat exchanger has a
dimension defining an edge of the at least a first heat exchanger
and wherein the edge of the at least a first heat exchanger is
rotatably coupled to the beam member.
3. The modular server rack cooling structure according to claim 2,
wherein the beam member is a horizontal beam member or a vertical
beam member.
4. The modular server rack cooling structure according to claim 1,
wherein the at least a first supporting member comprises at least
first, second and third beam members, the first beam member
substantially orthogonally coupled to the second beam member and
the third beam member substantially orthogonally coupled to the
second beam member to form a substantially U-shaped configuration,
and wherein the at least a first heat exchanger has a dimension
defining an edge of the at least a first heat exchanger and wherein
the edge of the at least a first heat exchanger is rotatably
coupled to the first beam member, the second beam member, or the
third beam member.
5. The modular server rack cooling structure according to claim 4,
wherein the dimension defining the edge of the at least a first
heat exchanger has a substantially longitudinal dimension defining
a longitudinal edge of the at least a first heat exchanger and
wherein the longitudinal edge of the at least a first heat
exchanger is rotatably coupled to the first beam member or the
third beam member.
6. The modular server rack cooling structure according to claim 5,
wherein the at least a second supporting member comprises a beam
member, and wherein the at least a second heat exchanger has a
dimension defining an edge of the at least a second heat exchanger
and wherein the edge of the at least a second heat exchanger is
rotatably coupled to the beam member of the at least a second
supporting member.
7. The modular server rack cooling structure according to claim 6,
wherein the at least a second heat exchanger is disposed
vertically, horizontally or diagonally.
8. The modular server rack cooling structure according to claim 5,
wherein the at least a second supporting member comprises a beam
member, and wherein the at least a second heat exchanger is coupled
to the beam member of the at least a second supporting member.
9. The modular server rack cooling structure according to claim 1,
wherein the data center further includes at least a second rack for
supporting at least one server, wherein the at least a first rack
and the at least a second rack are disposed opposite one another to
form a hot aisle or a cold aisle between the at least a first rack
and the at least a second rack, the modular server rack cooling
structure further comprising: at least a second supporting member;
and at least a second heat exchanger, the at least a second heat
exchanger coupled to the at least a second supporting member, the
at least a second supporting member configured to position the at
least a second heat exchanger in heat transfer relationship with
the at least one server of the at least a second rack, wherein the
at least a second heat exchanger is not attached to the at least a
second rack.
10. The modular server rack cooling structure according to claim 1,
further comprising at least one forced fluid-flow device configured
and disposed with respect to the at least a first heat exchanger to
provide a flow of fluid between the at least one server and the at
least a first heat exchanger.
11. A modular data center system, comprising: at least a first rack
and at least a second rack disposed opposite one another to form a
hot aisle or a cold aisle between the at least a first rack and the
at least a second rack, each rack supporting at least one server; a
modular server rack cooling structure comprising: at least a first
supporting member; and at least a first heat exchanger, the at
least a first heat exchanger coupled to the at least a first
supporting member, the at least a first supporting member
configured to position the at least a first heat exchanger in heat
transfer relationship with at least one server of the at least a
first rack, wherein the at least a first heat exchanger is not
attached to the at least a first rack; at least a second supporting
member; and at least a second heat exchanger, the at least a second
heat exchanger coupled to the at least a second supporting member,
the at least a second supporting member configured to position the
at least a second heat exchanger in heat transfer relationship with
at least one server of the at least a second rack, wherein the at
least a second heat exchanger is not attached to the at least a
second rack.
12. The modular data center system according to claim 11, wherein
the at least a first supporting member comprises a beam member, the
at least a first heat exchanger has a dimension defining an edge of
the at least a first heat exchanger, the edge of the at least a
first heat exchanger is rotatably coupled to the beam member of the
at least a first supporting member, the at least a second
supporting member comprises a beam member, the at least a second
heat exchanger has a dimension defining an edge of the at least a
second heat exchanger, and the edge of the at least a second heat
exchanger is rotatably coupled to the beam member of the at least a
second supporting member.
13. The modular data center system according to claim 12, further
comprising at least one forced fluid-flow device configured to
provide a flow of fluid between the servers and the heat
exchangers.
14. The modular data center system according to claim 12, wherein
the beam members are vertical beam members disposed adjacent to the
at least a first rack and the at least a second rack.
15. The modular data center system according to claim 12, further
comprising: at least a third supporting member; and at least a
third heat exchanger, the at least a third heat exchanger coupled
to the at least a third supporting member, the at least a third
supporting member configured to position the at least a third heat
exchanger in heat transfer relationship with the at least one
server of the at least a first rack or the at least one server of
the at least a second rack.
16. The modular data center system according to claim 15, wherein
the at least a third supporting member comprises a beam member, and
wherein the at least a third heat exchanger has a dimension
defining an edge of the at least a third heat exchanger and wherein
the edge of the at least a third heat exchanger is rotatably
coupled to the beam member of the at least a third supporting
member.
17. The modular data center system according to claim 15, wherein
the at least a third supporting member comprises a beam member, and
wherein the at least a third heat exchanger is coupled to the beam
member of the at least a third supporting member.
18. The modular data center system according to claim 17, wherein
the at least a second heat exchanger is disposed vertically,
horizontally or diagonally.
19. The modular data center system according to claim 15, further
comprising: at least one forced fluid-flow device configured to
provide a flow of fluid between the servers and the heat
exchangers; at least a fourth supporting member; and at least a
fourth heat exchanger, the at least a third heat exchanger coupled
to the at least a fourth supporting member, the at least a fourth
supporting member configured to position the at least a fourth heat
exchanger adjacent to the at least one forced fluid-flow
device.
20. A method of installing a modular server rack cooling structure
for cooling at least a first server installed in at least a first
rack and at least a second server installed in at least a second
rack, the at least a first rack and the at least a second rack
disposed opposite from each other to form at least a portion of a
hot aisle or a cold aisle, the method comprising: positioning at
least a portion of a modular support structure in the hot aisle or
the cold aisle, the modular support structure comprising at least a
first support member, a second support member, and a third support
member; coupling at least a first heat exchanger to the at least a
first supporting member so that the at least a first heat exchanger
is positioned adjacent to the at least a first server of the at
least a first rack; coupling at least a second heat exchanger to
the at least a second supporting member so that the at least a
second heat exchanger is positioned adjacent to the at least a
second server of the at least a second rack; and coupling at least
a third heat exchanger to the at least a third supporting member so
that the at least a third heat exchanger is positioned within the
hot aisle or the cold aisle, wherein the coupling at least a third
heat exchanger to the at least a third supporting member is
performed after at least a third server is installed in the at
least a first rack or the at least a second rack.
Description
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure generally relates to computing or
information technology (IT) data centers. More particularly, the
present disclosure relates to structures, systems and methods for
installing heat exchangers in IT data centers.
[0003] 2. Background of Related Art
[0004] Over the past several years, computer equipment
manufacturers have expanded the data collection and storage
capabilities of their servers. The expansion of server capabilities
has led to an increase in total power consumption and total heat
output per server and per server rack assembly in data centers. It
has also led to an increase in power and temperature control
requirements for computer data collection and storage. As a result,
the data collection and storage industry has sought and is seeking
new, innovative equipment, systems, and design strategies to handle
the tremendous and continued growth in capacity of computer data
collection and storage.
[0005] Cooling systems for computer server racks have been
struggling to keep pace with the ability to cool ever increasing
computer server heat loads in data centers. The increase of
computer server heat loads (measured in kilowatts (kW)) has
required that more space be allotted for the cooling infrastructure
within the data rooms or that the cooling systems are concentrated
at the heat source, i.e., the computer server racks. Recently,
cooling systems have been designed to concentrate the cooling at
the computer server racks. These cooling systems include rear-door
heat exchangers and rack-top coolers.
[0006] Certain cooling system designs have incorporated de-ionized
water while others use R-134a (i.e., 1,1,1,2-Tetrafluoroethane)
refrigerant in a mostly liquid state. The latest designs are
limited in their ability to be scaled to cooling requirements of
increasingly high density data centers. The output capacity of
rear-door exchangers is limited to the physical size of the
computer rack exterior perimeter and the amount of fluid (measured
in gallons per minute (gpm)) that can be applied to a rear-door
exchanger without excessive pressure drops. The rear-door
exchangers can produce up to approximately 12-16 kW of concentrated
cooling to computer server racks. The overhead rack coolers can
produce up to 20 kW of cooling output using R-134a refrigerant
liquid. This is based on a cooling system design that does not
change the state of the refrigerant. Therefore, the total capacity
is limited to the physical size of the coils as well as the size of
the enclosure for the computer server racks. This equates to
approximately 41,000 to approximately 55,000 BTUs per hour (about
12 KW to about 16.1 KW) of total heat rejection capabilities per
rack assembly.
[0007] Some computer servers can now produce outputs in excess of
35 kW similar to the IBM Blue Jean Server. The rear-door heat
exchangers and other similar cooling products on the market cannot
handle the cooling requirements of these high-density computer
servers.
[0008] Many existing data centers have been constructed with in-row
rack cooling systems and integral hot and cold aisle containment.
These data centers, however, waste a significant amount of space.
Also, it is difficult to increase the cooling capacity of the
in-row rack cooling systems when servers are added to the server
racks or existing servers are replaced with servers requiring more
cooling capacity. Furthermore, it is difficult for many existing
data centers to upgrade their cooling systems to comply with future
government regulations that require reductions in energy
consumption. Thus, the data center industry has been seeking energy
efficient modular cooling solutions for new and existing white
space in data centers, as well as "just-in-time" and modular
cooling expansion capabilities both at the server level as well as
at the overall rack level.
SUMMARY
[0009] In one aspect, the present disclosure features a modular
server rack cooling structure for cooling at least one server in at
least one rack of a data center. The modular server rack cooling
structure for cooling at least one server in at least one rack of a
data center includes at least a first supporting member and at
least a first heat exchanger that are coupled to each other. The
first supporting member is configured to position the first heat
exchanger in heat transfer relationship with the server, where the
first heat exchanger is not attached to the rack.
[0010] In some embodiments, the first supporting member includes a
beam member, the first heat exchanger has a dimension defining an
edge of the first heat exchanger, and the edge of the first heat
exchanger is rotatably coupled to the beam member. In some
embodiment, the beam member is a horizontal beam member or a
vertical beam member.
[0011] In some embodiment, the first supporting member includes at
least a first, second, and third beam members. The first beam
member is substantially orthogonally coupled to the second beam
member and the third beam member is substantially orthogonally
coupled to the second beam member to form a substantially U-shaped
configuration. The first heat exchanger has a dimension defining an
edge of the first heat exchanger and the edge of the first heat
exchanger is rotatably coupled to the first beam member, second
beam member, or third beam member.
[0012] In some embodiments, the dimension defining the edge of the
first heat exchanger has a substantially longitudinal dimension
defining a longitudinal edge of the first heat exchanger and the
longitudinal edge of the first heat exchanger is rotatably coupled
to the first beam member or the third beam member.
[0013] In some embodiments, the second supporting member includes a
beam member, the second heat exchanger has a dimension defining an
edge of the second heat exchanger, and the edge of the second heat
exchanger is rotatably coupled to the beam member of the second
supporting member. In some embodiments, the second heat exchanger
is disposed vertically, horizontally, or diagonally. In some
embodiments, the second supporting member includes a beam member
and the second heat exchanger is coupled to the beam member of the
second supporting member.
[0014] In some embodiments, the data center further includes at
least a second rack for supporting at least one server, where the
first rack and the second rack are disposed opposite one another to
form a hot aisle or a cold aisle between the first rack and the
second rack. The modular server rack cooling structure may further
include at least a second supporting member and at least a second
heat exchanger coupled to each other. The second supporting member
is configured to position the second heat exchanger in heat
transfer relationship with the server of the second rack, where the
second heat exchanger is not attached to the second rack. In some
embodiments, the modular server rack cooling structure further
includes at least one forced fluid-flow device configured and
disposed with respect to the first heat exchanger to provide a flow
of fluid between the server and the first heat exchanger.
[0015] In another aspect, the present disclosure features a modular
data center system including at least a first rack and at least a
second rack disposed opposite one another to form a hot aisle or a
cold aisle between the first rack and the second rack, each of
which supports at least one server. The modular data center system
also includes a modular server rack cooling structure including at
least a first supporting member and at least a first heat exchanger
coupled to each other. The first supporting member is configured to
position the first heat exchanger in heat transfer relationship
with at least one server of first rack so that the first heat
exchanger is not attached to the first rack. The modular data
center system also includes at least a second supporting member and
at least a second heat exchanger coupled to each other. The second
supporting member is configured to position the second heat
exchanger in heat transfer relationship with at least one server of
the second rack so that the second heat exchanger is not attached
to the second rack.
[0016] In some embodiments, the first supporting member includes a
beam member, the first heat exchanger has a dimension defining an
edge of the first heat exchanger, the edge of the first heat
exchanger is rotatably coupled to the beam member of the first
supporting member, the second supporting member includes a beam
member, the second heat exchanger has a dimension defining an edge
of the second heat exchanger, and the edge of the second heat
exchanger is rotatably coupled to the beam member of the second
supporting member.
[0017] In some embodiments, the modular data center system further
includes at least one forced fluid-flow device configured to
provide a flow of fluid between the servers and the heat
exchangers. In some embodiments, the beam members are vertical beam
members disposed adjacent to the first rack and the second
rack.
[0018] In some embodiments, the modular data center system further
includes at least a third supporting member and at least a third
heat exchanger coupled to each other. The third supporting member
is configured to position the third heat exchanger in heat transfer
relationship with the server of the first rack or the server of the
second rack.
[0019] In some embodiments, the third supporting member includes a
beam member, and the third heat exchanger has a dimension defining
an edge of the third heat exchanger, and the edge of the third heat
exchanger is rotatably coupled to the beam member of the third
supporting member. In some embodiments, the third supporting member
includes a beam member and the third heat exchanger is coupled to
the beam member of the third supporting member. In some
embodiments, the second heat exchanger is disposed vertically,
horizontally or diagonally.
[0020] In some embodiments, the modular data center system further
includes at least one forced fluid-flow device configured to
provide a flow of fluid between the servers and the heat
exchangers, at least a fourth supporting member, and at least a
fourth heat exchanger in which the third heat exchanger is coupled
to the fourth supporting member and the fourth supporting member is
configured to position the fourth heat exchanger adjacent to the
forced fluid-flow device.
[0021] In yet another aspect, the present disclosure features a
method of installing a modular server rack cooling structure for
cooling at least a first server installed in at least a first rack
and at least a second server installed in at least a second rack in
which the first rack and the second rack are disposed opposite from
each other to form at least a portion of a hot aisle or a cold
aisle. The method includes positioning at least a portion of a
modular support structure in the hot aisle or the cold aisle where
the modular support structure including at least a first support
member, a second support member, and a third support member. The
method also includes coupling at least a first heat exchanger to
the first supporting member so that the first heat exchanger is
positioned adjacent to the first server of the first rack. The
method also includes coupling at least a second heat exchanger to
the second supporting member so that the second heat exchanger is
positioned adjacent to the second server of the second rack and
coupling at least a third heat exchanger to the third supporting
member so that the third heat exchanger is positioned within the
hot aisle or the cold aisle, where coupling the third heat
exchanger to the third supporting member is performed after at
least a third server is installed in the first rack or the second
rack.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Various embodiments of the present disclosure are described
herein with reference to the drawings. The drawings are not
necessarily to scale, emphasis instead being placed upon
illustrating the principles of the present disclosure wherein:
[0023] FIG. 1 is a perspective view of a data center assembly for
information technology servers in a data center assembly that
includes a plurality of modular support structures, each of which
supports at least one heat exchanger according to embodiments of
the present disclosure;
[0024] FIG. 2 is an elevation view of a modular support structure
for supporting at least one heat exchanger in the data center
assembly of FIG. 1 according to embodiments of the present
disclosure;
[0025] FIG. 3 is a detailed elevation view of the data center
assembly of FIG. 2 showing the position of the heat exchangers with
respect to the servers and server rack according to embodiments of
the present disclosure;
[0026] FIG. 4A is an elevation view of the data center assembly as
taken along section line 4A-4A in FIG. 2 according to embodiments
of the present disclosure;
[0027] FIG. 4B is an elevation view of the data center assembly as
taken along section line 4B-4B in FIG. 2 according to embodiments
of the present disclosure;
[0028] FIG. 5A is a plan view of the data center assembly of FIG. 1
as seen in the direction of the arrows 5A-5B in FIG. 4A
illustrating the plurality of modular support structures in the
data center assembly according to embodiments of the present
disclosure;
[0029] FIG. 5B is a plan view of the data center assembly of FIG. 1
as seen in the direction of the arrows 5B-5B in FIG. 4B
illustrating the plurality of modular support structures in the
data center assembly according to embodiments of the present
disclosure;
[0030] FIG. 6 is a plan view of a data center assembly according to
embodiments of the present disclosure;
[0031] FIG. 7 is a plan view of a data center assembly according to
embodiments of the present disclosure illustrating the fluid
circuits between refrigeration heat exchanger skids and the heat
exchangers supported by the modular support structures;
[0032] FIG. 8 is an operational end view of the data center
assembly of FIG. 7 having at least one modular support structure
and associated heat exchangers for "Day One" low density operation
according to embodiments of the present disclosure;
[0033] FIG. 9 is an operational end view of the data center
assembly of FIG. 8 having at least one modular support structure
and associated heat exchangers for "Day Two" increased density
operation according to embodiments of the present disclosure;
[0034] FIG. 10 is an operational end view of the data center
assembly of FIG. 9 having at least one modular support structure
and associated heat exchangers for "Day Three" increased density
operation according to embodiments of the present disclosure;
[0035] FIG. 11 is an operational end view of the data center
assembly of FIG. 10 having at least one modular support structure
and associated heat exchangers for high density operations
according to embodiments of the present disclosure;
[0036] FIG. 12 is an exemplary embodiment of a flow diagram for a
close-coupled cooling system for chillerless operation in high wet
bulb temperature applications according to the present
disclosure;
[0037] FIG. 13 illustrates a modular data pod that includes a
separate cooling circuit that forms an "A-Frame" heat exchanger
assembly according to one embodiment of the present disclosure;
[0038] FIG. 14 is an upper plan view of the modular data pod of
FIG. 13 that includes the separate cooling circuit that forms an
"A-Frame" heat exchanger assembly according to one embodiment of
the present disclosure;
[0039] FIG. 15 is a lower plan view of the modular data center pod
assembly of FIG. 14 illustrating forced-flow cooling devices that
force air vertically through a sump below the central aisle of the
modular data center pod assembly;
[0040] FIG. 16 is a schematic flow diagram of a cooling system for
a data center assembly including the close-coupled cooling system
of FIG. 12 according to embodiments of the present disclosure;
[0041] FIG. 17 is an enlarged view of cooling cycle skids that are
illustrated as part of the modular data pod assembly of FIGS.
14-16; and
[0042] FIG. 18 is a perspective view of a data center assembly
illustrating a building enclosure over the hot aisle of the data
center assembly according to embodiments the present
disclosure.
DETAILED DESCRIPTION
[0043] Embodiments of the presently disclosed heat exchanger
support structures, heat exchanger support systems and installation
methods will now be described in detail with reference to the
drawings, in which like reference numerals designate identical or
corresponding elements in each of the several views.
[0044] The presently disclosed heat exchanger support structures,
heat exchanger support systems and installation method advance the
state of the art of data center cooling by providing additional
cooling capacity within the same floor space of an existing or
planned data center, thus reducing the cooling capacity foot print
of the data center and increasing the cooling capacity per unit
area. The presently disclosed heat exchanger support structures,
heat exchanger support systems and installation method can be
retrofitted into existing data centers or planned as part of new
installations.
[0045] FIG. 1 illustrates a modular unified racking system
installation 100 for IT servers in a data center assembly 10 that
includes a plurality of support structures of the modular server
rack cooling structures, each of which supports at least one heat
exchanger according to one embodiment of the present disclosure.
More particularly, the data center assembly 10 includes a plurality
of IT server racks 1001a, . . . , 1001n positioned adjacent to one
another to form a first row 1001' of IT server racks. A second row
1002' of adjacent IT server racks 1002a, . . . , 1002n is formed
opposite to the first row 1001' to form a hot aisle 12 between the
first row 1001' and the second row 1002'.
[0046] Those skilled in the art will recognize that the first row
1001' of IT server racks and an adjacent wall (not shown) of a data
center facility or an adjacent row of IT server racks define a
first cold aisle. Similarly, the second row 1002' of IT server
racks and an adjacent outer wall (not shown) of the data center
assembly 10 or an adjacent row of IT server racks define a second
cold aisle.
[0047] Those skilled in the art will recognize that, in some
embodiments, the first row 1001' of IT server racks and the second
row 1002' of IT server racks can form a cold aisle between the
first row 1001' and the second row 1002'.
[0048] Turning to FIG. 3 in conjunction with FIGS. 1 and 2, each
server rack 1001a, . . . , 1001n and 1002a, . . . , 1002n includes
a plurality of slots that are each configured to receive one
server. As is known in the art, first server rack 1001a of first
row 1001' has a plurality of IT servers 101a.sub.1, . . . ,
101a.sub.n in different slots of server rack 1001a. Similarly,
server rack 1002a of second row 1002' has a plurality of IT servers
102a.sub.1, . . . , 102a.sub.n in different slots of server rack
1002a. Each IT server 101a.sub.1, . . . , 101a.sub.n has at least
one heat transfer path 103a.sub.1, . . . , 103a.sub.n,
respectively, which can include one or more exhaust fans and ports
positioned at the rear end of each IT server 101a.sub.1, . . . ,
101a.sub.n as shown, or which can be upper, lower and/or side
surfaces of each IT server 101a.sub.1, . . . , 101a.sub.n, or other
heat transfer paths that are known in the art.
[0049] As used herein throughout the specification and figures, the
letter "n" in the certain reference numerals represents a variable
quantity. The use of the quantity "n" in the reference numerals,
such as "1001n" or "101a.sub.n," does not necessarily mean that the
quantity "n" is always equal in each instance where the letter "n"
is used. Those skilled in the art will recognize that the value of
"n" may differ for practical applications of the embodiments of the
present disclosure, and that "n" is applied to convey the
description of multiple or "a plurality of" components or
items.
[0050] As with IT servers 101a.sub.1, . . . , 101a.sub.n, each IT
server 102a.sub.1, . . . , 102a.sub.n has at least one heat
transfer path 104a.sub.1, . . . , 104a.sub.n, respectively, which
can include one or more exhaust fans and ports positioned at the
rear end of each IT server 102a.sub.1, . . . , 102a.sub.n, as
shown, or which can also be upper, lower and/or side surfaces of
the IT servers 102a.sub.1, . . . , 102a.sub.n, or other heat
transfer paths that are known in the art.
[0051] The modular server rack cooling structure 2001 includes at
least a first supporting member 201a which is exemplarily
illustrated as a vertically positioned beam positioned adjacent to
the server rack 1001a at the rear end of the plurality of IT
servers 101a.sub.1, . . . , 101a.sub.n, which as noted above, are
disposed in different slots of the server rack 1001a.
[0052] In one embodiment of the present disclosure, as shown in
FIG. 3, the modular server rack cooling structure 2001 is
configured and disposed to support at least one forced-flow cooling
device 1051a, e.g., a motorized fan, to provide forced-flow
circulation from the hot aisle 12 directed toward the first cold
aisle. The forced-flow cooling device 1051a is configured and
disposed to define a region of separation between the hot aisle 12
and the first cold aisle. The first forced-flow cooling device
1051a includes a suction side 15a and a discharge side illustrated
by the arrow 17a, which indicates the direction of air flow. Since
the first forced-flow cooling device 1051a is illustrated as being
positioned vertically above the IT server rack 1001a, the region of
separation is defined along the height of the first forced-flow
cooling device 1051a above the IT server rack 1001a and therefore
the region of separation occurs between the hot aisle 12 and the
volume of space above the first row 1001' of IT server racks
leading into the first cold aisle.
[0053] In one embodiment (not shown), the first forced-flow cooling
device 1051a is positioned horizontally across the hot aisle 12 in
proximity to the top of the IT server rack 1001a.
[0054] In some embodiments, the modular server rack cooling
structure 2001 includes at least one heat exchanger. The first heat
exchanger 1101a is configured and disposed with respect to the
suction side 15a of the forced-flow cooling device 1051a to provide
forced-flow cooling of the first heat exchanger 1101a.
[0055] In one embodiment, the first heat exchanger 1101a is a
serpentine coil microchannel design having a thin rectangular
configuration forming two large substantially flat sides such as a
Model SX-2 Serpentine Coil heat exchanger manufactured by MBA
Manufacturing and Supply Co. of Mundelein, Ill., USA or similar.
The first heat exchanger 1101a has a first substantially flat side
1103a and a second substantially flat side 1105a. As illustrated in
the exemplary embodiment of FIG. 3, the first heat exchanger 1101a
is disposed in proximity to the suction side 15a of the first
forced-flow cooling device 1051a. The first forced-flow cooling
device 1051a is configured and disposed to maintain the region of
separation between the hot aisle 12 and the first cold aisle 141
and to enable cooling of the hot air in the hot aisle 12 that
emanates from the servers in the server racks and which flows
across the serpentine coils of the first heat exchanger 1101a for
cooling.
[0056] In one embodiment, the modular server rack cooling structure
2001 is also configured and disposed to support at least a second
forced-flow cooling device 1052a, e.g., a motorized fan, to provide
forced-flow circulation from the hot aisle 12 directed towards the
second cold aisle 142. The second forced-flow cooling device 1052a
is configured and disposed to define a region of separation between
the hot aisle 12 and the second cold aisle 142 of the data center
assembly 10. The second forced-flow cooling device 1052a includes a
suction side 16a and a discharge side shown by the arrow 18a, which
indicates the direction of air flow. As with the first forced-flow
cooling device 1051a, since the second forced-flow cooling device
1052a is positioned vertically above the IT server rack 1002a, the
region of separation between the hot aisle 12 and the second cold
aisle 142 is defined along the height of the second forced-flow
cooling device 1052a.
[0057] In one embodiment (not shown), the second forced-flow
cooling device 1052a is positioned horizontally across the hot
aisle 12 in proximity to the top of the IT server rack 1002a.
[0058] In some embodiments, the second heat exchanger 1102a is
configured and disposed with respect to the suction side 16a of the
forced-flow cooling device 1052a to provide forced-flow cooling of
the second heat exchanger 1102a. In one embodiment, the second heat
exchanger 1102a is again a serpentine coil microchannel design
having a thin rectangular configuration forming two large
substantially flat sides such as the Model SX-2 Serpentine Coil
heat exchanger manufactured by MBA Manufacturing and Supply Co. of
Mundelein, Ill., USA or similar, mentioned above. The second heat
exchanger 1102a has a first substantially flat side 1104a and a
second substantially flat side 1106a. As illustrated in the
exemplary embodiment of FIG. 3, the second heat exchanger 1102a is
disposed in proximity to the suction side 16a of the second
forced-flow cooling device 1052a. The second forced-flow cooling
device 1052a is configured and disposed to maintain the region of
separation between the hot aisle 12 and the second cold aisle 142
and to enable cooling of the hot air in the hot aisle 12 that
emanates from the IT servers in the server racks and which flows
across the serpentine coils of the second heat exchanger 1102a for
cooling.
[0059] As illustrated in FIG. 4A, the first supporting member 201a
includes at least first, second and third beam members, 201a.sub.1,
201a.sub.2, and 201a.sub.3, respectively. The first beam member
201a.sub.1 is substantially orthogonally coupled to the second beam
member 201a.sub.2, and the third beam member 201a.sub.3 is
substantially orthogonally coupled to the second beam member
201a.sub.2 to form a substantially U-shaped configuration.
[0060] The modular server rack cooling structure 2001 further
includes at least a second supporting member 202a which, as with
first supporting member 201a, is exemplarily illustrated as a
vertically-oriented beam positioned adjacent to the server rack
1002a at the rear end of the plurality of IT servers 102a.sub.1, .
. . , 1012.sub.n, which as noted above, are positioned in different
slots of the server rack 1002a.
[0061] As illustrated in FIG. 4B, and like the first supporting
member 201a described with respect to FIG. 4A, the second
supporting member 202a includes at least first, second and third
beam members, 202a.sub.1, 202a.sub.2, and 202a.sub.3, respectively.
The first beam member 202a.sub.1 is substantially orthogonally
coupled to the second beam member 202a.sub.2, and the third beam
member 202a.sub.3 is substantially orthogonally coupled to the
second beam member 202a.sub.2 to form a substantially U-shaped
configuration.
[0062] As illustrated in FIG. 3, when the modular server rack
cooling structure 2001 includes the second supporting member 202a
to provide stability and to enable practically simultaneous
insertion of both the first heat exchanger 1101a and the second
heat exchanger 1102a when the modular server rack cooling structure
2001 is installed in between the server racks 1001a and 1002a, the
modular server rack cooling structure 2001 further includes at
least a third supporting member 203a. In one embodiment, the third
supporting member 203a couples the first supporting member 201a to
the second supporting member 202a at upper ends 201a' and 202a' of
the supporting members 201a and 202a, respectively.
[0063] As illustrated in FIG. 5A, the third supporting member 203a
includes at least two beam members 203a.sub.1 and 203a.sub.2 that
are each configured and disposed to span across the hot aisle 12 to
couple the first supporting member 201a to the second supporting
member 202a and to couple second supporting beam 201a.sub.2 of the
first supporting member 201a to second supporting beam 202a.sub.2
of the second supporting member 202a.
[0064] As illustrated in FIG. 3, the third supporting member 203a
includes at least one heat exchanger configured to transfer heat to
or from the hot aisle following insertion of the modular server
rack cooling structure 2001 in between the server racks 1001a and
1002a. More particularly, the third supporting member includes a
third heat exchanger 301a supported substantially horizontally
across and above the hot aisle 12.
[0065] The third heat exchanger 301a is a serpentine coil
microchannel design similar to the first heat exchanger 213a and
the second heat exchanger 214a has a thin rectangular configuration
forming two large substantially flat sides such as the Model SX-2
Serpentine Coil heat exchanger manufactured by MBA Manufacturing
and Supply Co. of Mundelein, Ill., USA or similar, described
previously above. The horizontal positioning of third heat
exchanger 301a across and above the hot aisle 12 enables
significantly increased cooling capacity per unit area without an
increase in the size of the cooling capacity footprint. The air
exhausted horizontally from the IT servers in the server racks
1001a and 1002a into hot aisle 12 is forced to rise in the hot
aisle 12 and is passed vertically through the serpentine coils of
the third heat exchanger 301a.
[0066] As described below with respect to FIG. 9, to enable access
to the space above the horizontal heat exchanger 301a, particularly
for maintenance activities, in some embodiments, the horizontal
heat exchanger 301a is rotatably coupled to the second beam member
201a.sub.2 via a hinged connection 303a so that the horizontal heat
exchanger 301a can be rotated downwardly into the upper portion of
the hot aisle 12.
[0067] In one embodiment, at least a first heat exchanger 213a is
coupled to the first supporting member 201a. In one embodiment, the
first heat exchanger 203a is a serpentine coil microchannel design
having a thin rectangular configuration forming two large
substantially flat sides such as a Model SX-2 Serpentine Coil heat
exchanger manufactured by MBA Manufacturing and Supply Co. of
Mundelein, Ill., USA or similar.
[0068] The first heat exchanger 213a has a first substantially flat
side 215a and a second substantially flat side 217a through which
hot air from the servers in the server racks can flow across the
serpentine coils for cooling. Consequently, the first supporting
member 201a is configured to position the first heat exchanger 213a
in proximity to the heat transfer path 103a.sub.1 of at least
server 101a.sub.1 via the first substantially flat side 215a
following insertion of the modular server rack cooling structure in
between the server racks 1001a and 1002a. In some embodiments,
there may be no or minimal contact between the modular server rack
cooling structure 2001 and the server racks 1001a and 1002a.
[0069] The first substantially flat surface 215a is positioned to
interface with, and is in proximity to, the heat transfer path 103a
of at least server 101a.sub.1 following insertion of the modular
server rack cooling structure 2001 in between the server racks
1001a and 1002a. Air flow exhausted through the heat transfer path
103a.sub.1 of at least server 101a.sub.1 therefore flows to the
first substantially flat side 215a of the first heat exchanger 213a
across the coils to the second substantially flat side 217a into
the hot aisle 12. In other words, at least the first supporting
member 201a is configured to position at least the first heat
exchanger 213a in heat transfer relationship with the one or more
servers 101a.sub.1, . . . , 101a.sub.n. Also, at least the first
heat exchanger 213a is not attached to the one or more IT server
racks 1001a, . . . , 1001n.
[0070] As can be appreciated, the first heat exchanger 213a is
configured and sized such that the substantially flat surfaces 215a
and 217a at least partially, if not entirely, overlap the heat
transfer paths 103a.sub.1, . . . , 103a.sub.n of each of the
plurality of IT servers 101a.sub.1, . . . , 101a.sub.n,
respectively, that are positioned in different slots of the server
rack 1001a.
[0071] In one embodiment, the first heat exchanger 213a has a
dimension defining an edge 219a.sub.1 substantially interfacing
with the first beam member 201a.sub.1, an edge 219a.sub.2
substantially interfacing with second beam member 201a.sub.2, and
an edge 219a.sub.3 substantially interfacing with third beam member
201a.sub.3. One of the edges 219a.sub.1, 219a.sub.2 or 219a.sub.3
is rotatably coupled to the respective beam member 201a.sub.1,
201a.sub.2 or 201a.sub.3 such as by hinges 211a.sub.1 illustrated
for beam member 201a.sub.1 and edge 219a.sub.1. (The hinges for
beam members 201a.sub.2 and 201a.sub.3 and edges 219a.sub.2 and
219a.sub.3 are not shown). Thus, the first heat exchanger 213a may
be rotated into the hot aisle 12 to enable access to the IT servers
101a.sub.1, . . . , 101a.sub.n from the hot aisle 12 (as shown by
the dashed line designated by reference numeral 213a).
[0072] As can be appreciated, the dimensions defining edges
219a.sub.1 and 219a.sub.3 are substantially longitudinal to
coincide with the orientation of first beam member 201a.sub.1 and
third beam member 201a.sub.3, respectively. Similarly, the
dimension defining edge 219a.sub.2 is substantially lateral to
coincide with the orientation of second beam member 201a.sub.2.
[0073] In one embodiment, the modular server rack cooling structure
2001 further includes at least a second supporting member 202a
which, like the first supporting member 201a, is exemplarily
illustrated as a vertically-positioned beam positioned adjacent to
the server rack 1002a at the rear end of the plurality of IT
servers 102a.sub.1, . . . , 1012.sub.n, which as noted above, are
positioned in different slots of the server rack 1002a.
[0074] As with the first supporting member 201a, at least a second
heat exchanger 214a is coupled to the second supporting member
202a. Again, in some embodiments, the second heat exchanger 214a is
a serpentine coil microchannel design having a thin rectangular
configuration forming two large substantially flat sides such as
the Model SX-2 Serpentine Coil heat exchanger manufactured by MBA
Manufacturing and Supply Co. of Mundelein, Ill., USA or
similar.
[0075] The second heat exchanger 214a has a first substantially
flat side 216a and a second substantially flat side 218a through
which hot air from the servers in the server racks can flow across
the serpentine coils for cooling. Consequently, the second
supporting member 202a is configured to position the second heat
exchanger 214a in proximity to the heat transfer path 104a.sub.1 of
at least server 102a.sub.1 following insertion of the modular
server rack cooling structure 2001 in between the server racks
1001a and 1002a. In some embodiments, there may be no or little
contact between the modular server rack cooling structure 2001 and
the server racks 1001a and 1002a.
[0076] The first substantially flat surface 216a is positioned to
interface with, and is in proximity to, the heat transfer path
104a.sub.1 of at least server 102a.sub.1 following insertion of the
modular server rack cooling structure 2001 in between the server
racks 1001a and 1002a. Air flow exhausted through the heat transfer
path 104a.sub.1 of at least server 102a.sub.1 therefore flows to
the first substantially flat side 201a of the second heat exchanger
214a across the coils to the second substantially flat side 218a
into the hot aisle 12. In other words, at least the second
supporting member 202a is configured to position at least the
second heat exchanger 214a in heat transfer relationship with the
one or more servers 102a.sub.1, . . . , 102a.sub.n. Also, at least
the second heat exchanger 214a is not attached to the one or more
IT server racks 1002a . . . 1002n.
[0077] Again, as can be appreciated, second heat exchanger 214a
generally is configured and sized such that the substantially flat
surfaces 216a and 218a at least partially, if not entirely, overlap
the heat transfer paths 104a.sub.1, . . . , 104a.sub.n of each of
the plurality of IT servers 102a.sub.1, . . . , 102a.sub.n,
respectively, that are positioned at different elevation levels in
server rack 1002a.
[0078] Those skilled in the art will recognize that the second heat
exchanger 214a can also be rotatably mounted on hinges to be
rotated into the hot aisle 12 to enable access to the IT servers
102a.sub.1, . . . , 201a.sub.n from the hot aisle 12.
[0079] In one embodiment, as illustrated in FIG. 4B, in a similar
manner as with respect to the first supporting member 201a
described with respect to FIG. 4A, the second supporting member
202a includes at least first, second and third beam members,
202a.sub.1, 202a.sub.2, and 202a.sub.3, respectively. The first
beam member 202a.sub.1 is substantially orthogonally coupled to the
second beam member 202a.sub.2, and the third beam member 202a.sub.3
is substantially orthogonally coupled to the second beam member
202a.sub.2 to form a substantially U-shaped configuration.
[0080] As illustrated in FIG. 3, in one embodiment, when the
support structure of the first modular server rack cooling
structure 2001 includes the second supporting member 202a, to
provide stability and to enable practically simultaneous insertion
of both the first heat exchanger 213a and the second heat exchanger
214a when the modular server rack cooling structure 2001 is
installed in between the server racks 1001a and 1002a, the support
structure of the modular server rack cooling structure 2001 further
includes at least a third supporting member 203a. In one
embodiment, the third supporting member 203a couples the first
supporting member 201a to the second supporting member 202a at
upper ends 201a' and 202a' of the supporting members 201a and 202a,
respectively.
[0081] As illustrated in FIG. 5A, the third supporting member 203a
includes generally at least two beam members 203a.sub.1 and
203a.sub.2 that are each configured and disposed to span across the
hot aisle 12 to couple the first supporting member 201a to the
second supporting member 202a and generally to couple second
supporting beam 201a.sub.2 of the first supporting member 201a to
second supporting beam 202a.sub.2 of the second supporting member
202a.
[0082] Thus, the support structure of the first modular server rack
cooling structure 2001 is configured to position the first heat
exchanger 213a in proximity to at least the heat transfer path
103a.sub.1 of the at least first server 101a.sub.1 of the at least
first rack 1001a following insertion of the modular server rack
cooling structure 2001 in between the server racks 1001a and 1002a.
In other words, at least the third supporting member 203a is
configured to position at least the first heat exchanger 213a in
heat transfer relationship with the one or more servers 101a.sub.1
. . . 101a.sub.n. Also, at least the first heat exchanger 213a is
not attached to the one or more IT server racks 1001a . . .
1001n.
[0083] At the same time, the support structure of the first modular
server rack cooling structure 2001 is configured to position the
second heat exchanger 214a in proximity to at least the heat
transfer path 104a.sub.1 of the at least first server 102a.sub.1 of
the at least second rack 1002a following insertion of the support
structure of the modular server rack cooling structure 2001 in
between the server racks 1001a and 1002a. In other words, at least
the second supporting member 202a is configured to position at
least the second heat exchanger 214a in heat transfer relationship
with the one or more servers 102a.sub.1 . . . 102a.sub.n. Also, at
least the second heat exchanger 214a is not attached to the one or
more IT server racks 1002a . . . 1002n.
[0084] As illustrated in FIG. 3, the third supporting member 203a
supports at least one heat exchanger configured to transfer heat to
or from the aisle following insertion of the modular server rack
cooling structure 2001 in between the server racks 1001a and 1002a.
More particularly, the third supporting member supports the third
heat exchanger 301a substantially horizontally across and above the
hot aisle 12.
[0085] Again, third heat exchanger 301a may be a serpentine coil
microchannel design (similar to the first heat exchanger 213a and
the second heat exchanger 214a) having a thin rectangular
configuration forming two large substantially flat sides such as
the Model SX-2 Serpentine Coil heat exchanger manufactured by MBA
Manufacturing and Supply Co. of Mundelein, Ill., USA or similar.
The horizontal positioning of third heat exchanger 301a across and
above the hot aisle 12 enables significantly additional cooling
capacity per unit area without an increase in the size of the
cooling capacity footprint. In this embodiment, the air exhausted
horizontally from the first and second heat exchangers 213a and
214a into hot aisle 12 is forced to rise in the hot aisle 12 and
pass vertically through the serpentine coils of the third heat
exchanger 301a.
[0086] In one embodiment, the third supporting member 203a may
support the third heat exchanger 301a and/or a fourth heat
exchanger 401a that is similar to the types described above with
respect to the first, second and third heat exchangers 213a, 214a
and 301a. The fourth heat exchanger 401a has a dimension defining a
first edge 411a and an opposing second edge 412a wherein the fourth
heat exchanger 401a is rotatably coupled to, and supported by,
either the third supporting member 203a, or is rotatably coupled to
second beam member 201a.sub.2 of the first supporting member 201a.
The fourth heat exchanger 401a thus at least partially extends over
the hot aisle 12 at an angle .theta..sub.1 to the horizontal.
[0087] In one embodiment, the third supporting member 203a supports
the fourth heat exchanger 401a and a fifth heat exchanger 502a that
is similar to the types described above with respect to the first,
second and third heat exchangers 213a, 214a and 301a, and is
symmetrically identical to the fourth heat exchanger 401a. The
fifth heat exchanger 502a also has a dimension defining a first
edge 511a wherein the fifth heat exchanger 502a is rotatably
coupled to, and supported by, either the third supporting member
203a, or is rotatably coupled to second beam member 202a.sub.2 of
the second supporting member 202a. The fifth heat exchanger 502a
thus at least partially extends over the hot aisle 12 at an angle
.theta..sub.2 to the horizontal.
[0088] In some situations, it may be desirable to transfer heat
into the data center assembly 10 through the hot aisle 12. Those
skilled in the art will recognize that by reversal of the direction
of air flow and by supplying a fluid medium to the heat exchangers
at a temperature above ambient, such heat transfer into the data
center can be achieved.
[0089] Those skilled in the art will recognize that the sequence of
installation of the aforementioned heat exchangers onto the support
structure of the first modular server rack cooling structure 2001
can be varied according to the heat removal capacity requirements
or other factors as desired. Additionally, those skilled in the art
will recognize that a sequence wherein the first heat exchanger
213a and the second heat exchanger 214a are the first heat
exchangers installed on the modular support structure 2001 enables,
at least during initial operation of the data center assembly 10,
elimination of hot aisle 12 since the first heat exchanger 213a and
the first supporting member 201a are configured to enable direct
interface, via the first substantially flat side 215a, of the first
heat exchanger 213a in proximity to the heat transfer path
103a.sub.1 of at least server 101a.sub.1 and since second heat
exchanger 214a and the first supporting member 202a are configured
to enable direct interface, via the first substantially flat side
216a, of the second heat exchanger 214a in proximity to the heat
transfer path 104a.sub.1 of at least server 102a.sub.1 As a result,
only air that has already been cooled by the first and second heat
exchangers 213a and 214a is circulated into the central aisle
designated as hot aisle 12.
[0090] In one embodiment, as can be appreciated from FIGS. 1-5B,
the present disclosure relates also to a system 50 that allows for
the insertion and removal of the plurality of heat exchangers 213a,
. . . , 213n and 214a, . . . , 214n. As described above, the data
center assembly 10 includes at least two racks 1001a, . . . , 1001n
and/or 1002a, . . . , 1002n. Each rack supports at least one server
101a.sub.1, . . . , 101a.sub.n, . . . , 101n.sub.1, . . . ,
101n.sub.n, and/or 102a.sub.1, . . . , 102a.sub.n, . . . ,
102n.sub.1, . . . , 102n.sub.n having at least one heat transfer
path 103a.sub.1, . . . , 103a.sub.n, . . . , 103n.sub.1, . . . ,
103n.sub.n and/or 104a.sub.1, . . . , 104a.sub.n, . . . ,
104n.sub.1, . . . , 104n.sub.n The sequence of installation of the
aforementioned heat exchangers onto the support structure of the
modular server rack cooling structure 2001 can be varied according
to the heat removal capacity requirements or other factors as
desired.
[0091] System 50 includes a support structure of the modular server
rack cooling structure 2001 that is configured and disposed to
support at least one forced-flow cooling device 1051a, e.g., the
motorized fan, to provide forced-flow circulation from the hot
aisle 12 directed toward the first cold aisle 141. The forced-flow
cooling device 1051a is again configured and disposed to define a
region of separation between the hot aisle 12 and the first cold
aisle 141 of the data center assembly 10. The first forced-flow
cooling device 1051a includes suction side 15a and discharge side
shown by the arrow 17a, which indicates the direction of air flow.
Since the first forced-flow cooling device 1051a is illustrated as
being positioned vertically above the IT server rack 1001a, the
region of separation is defined along the height of the first
forced-flow cooling device 1051a above the IT server rack 1001a and
therefore the region of separation occurs between the hot aisle 12
and the volume of space above the first row 1001' of IT server
racks leading into the first cold aisle 141.
[0092] In one embodiment (not shown), the first forced-flow cooling
device 1051a is positioned horizontally across the hot aisle 12 in
proximity to the top of the IT server rack 1001a.
[0093] In one embodiment, the support structure of the modular
server rack cooling structure 2001 is configured and disposed to
support at least one heat exchanger. The first heat exchanger 1101a
is configured and disposed with respect to the suction side 15a of
the forced-flow cooling device 1051a to provide forced-flow cooling
of the first heat exchanger 1101a. In some embodiments, the first
heat exchanger 1101a is a serpentine coil microchannel design
having a thin rectangular configuration forming two large
substantially flat sides such as a Model SX-2 Serpentine Coil heat
exchanger manufactured by MBA Manufacturing and Supply Co. of
Mundelein, Ill., USA or similar.
[0094] The first heat exchanger 1101a has a first substantially
flat side 1103a and a second substantially flat side 1105a. As
illustrated in the exemplary embodiment of FIG. 3, the first heat
exchanger 1101a is disposed in proximity to the suction side 15a of
the first forced-flow cooling device 1051a. The first forced-flow
cooling device 1051a is configured and disposed to maintain the
region of separation between the hot aisle 12 and the first cold
aisle 141 and to enable cooling of the hot air in the hot aisle 12
that emanates from the servers in the server racks and which flows
across the serpentine coils of the first heat exchanger 1101a for
cooling.
[0095] In one embodiment, the support structure of the modular
server rack cooling structure 2001 is configured and disposed to
support at least the second forced-flow cooling device 1052a, e.g.,
a motorized fan, to provide forced-flow circulation from the hot
aisle 12 directed towards the second cold aisle 142. The second
forced-flow cooling device 1052a is configured and disposed to
define a region of separation between the hot aisle 12 and the
second cold aisle 142.
[0096] The second forced-flow cooling device 1052a includes a
suction side 16a and a discharge side shown by the arrow 18a, which
indicates the direction of air flow. As with the first forced-flow
cooling device 1051a, since the second forced-flow cooling device
1052a is illustrated as being positioned vertically above the IT
server rack 1002a, the region of separation is defined along the
height of the second forced-flow cooling device 1052a. In one
embodiment (not shown), the second forced-flow cooling device 1052a
is positioned horizontally across the hot aisle 12 in proximity to
the top of the IT server rack 1002a.
[0097] The second heat exchanger 1102a is configured and disposed
with respect to the suction side 16a of the forced-flow cooling
device 1052a to provide forced-flow cooling of the second heat
exchanger 1102a. In some embodiments, the second heat exchanger
1102a is a serpentine coil microchannel design having a thin
rectangular configuration forming two large substantially flat
sides such as the Model SX-2 Serpentine Coil heat exchanger
manufactured by MBA Manufacturing and Supply Co. of Mundelein,
Ill., USA or similar.
[0098] The second heat exchanger 1102a has the first substantially
flat side 1104a and the second substantially flat side 1106a. As
illustrated in the exemplary embodiment of FIG. 3, the second heat
exchanger 1102a is disposed in proximity to the suction side 16a of
the second forced-flow cooling device 1052a. The second forced-flow
cooling device 1052a is configured and disposed to maintain the
region of separation between the hot aisle 12 and the second cold
aisle 142 and to enable cooling of the hot air in the hot aisle 12
that emanates from the servers in the server racks and which flows
across the serpentine coils of the second heat exchanger 1102a for
cooling.
[0099] The system 50 also includes a support structure of the
modular server rack cooling structure 2001 that includes the first
supporting member 1001a for supporting at least a first heat
exchanger 213a. The first heat exchanger 213a is coupled to the
first supporting member 201a. As described above, the first
supporting member 201a is configured to position the first heat
exchanger 213a in proximity to the one or more heat transfer paths
103a.sub.1, . . . , 103a.sub.n of the one or more servers
101a.sub.1, . . . , 101a.sub.n of the first rack 1001a following
insertion of the modular server rack cooling structure 2001 in
between the server racks 1001a and 1002a.
[0100] In other words, at least the first supporting member 201a is
configured to position at least the first heat exchanger 213a in
heat transfer relationship with the one or more servers 101a.sub.1,
. . . , 101a.sub.n. Also, at least the first heat exchanger 213a is
not attached to the one or more IT server racks 1001a . . .
1001n.
[0101] The system 50 also includes a support structure of the
second modular server rack cooling structure 2002 that is identical
or substantially identical to the support structure of the first
modular server rack cooling structure 2001 described above for
supporting at least one heat exchanger. As with the support
structure of the first modular server rack cooling structure 2001,
the support structure of the second modular server rack cooling
structure 2002 includes a first supporting member 20lb for
supporting the at least a first heat exchanger 213b. The first heat
exchanger 213b is coupled to the first supporting member 201b.
[0102] In a similar manner as described above, the first supporting
member 201b is configured to position the first heat exchanger 213b
in proximity to the one or more heat transfer paths 103b.sub.1, . .
. , 103b.sub.n of the one or more servers 101b.sub.1, . . . ,
101b.sub.n of the second rack 1001b following insertion of the
modular server rack cooling structure 2002 in between the server
racks 1001a and 1002a.
[0103] In other words, at least the first supporting member 201b is
configured to position at least the first heat exchanger 213b in
heat transfer relationship with the one or more servers 101b.sub.1,
. . . , 101b.sub.n. Also, at least the first heat exchanger 213b is
not attached to the one or more IT server racks 1001a, . . . ,
1001n.
[0104] In one embodiment, the system 50 includes a support
structure of the first modular server rack cooling structure 2001
further including at least a second supporting member 202a for
supporting at least the second heat exchanger 214a. Again, the
second supporting member 202a is configured to position the second
heat exchanger 214a in proximity to one or more heat transfer paths
104a.sub.1, . . . , 104a.sub.n of the one or more servers
102a.sub.1, . . . , 102a.sub.n of at least third rack 1002a
following insertion of the modular server rack cooling structure
2001 in between the server racks 1001a and 1002a. In other words,
at least the second supporting member 202a is configured to
position at least the second heat exchanger 214a in heat transfer
relationship with the one or more servers 102a.sub.1, . . . ,
102a.sub.n. Also, at least the second heat exchanger 214a is not
attached to the one or more IT server racks 1002a . . . 1002n.
[0105] In one embodiment, the data center assembly 10 includes at
least a fourth rack 1002b for supporting servers 102b.sub.1, . . .
, 102b.sub.n having heat transfer paths 104b.sub.1, . . .
104b.sub.n, respectively. The support structure of the modular
server rack cooling structure 2002 further includes at least a
second supporting member 202b. In a similar manner as described
above, the second heat exchanger 214b is coupled to the second
supporting member 202b.
[0106] The second supporting member 202b is configured to position
the second heat exchanger 214b in proximity to the one or more heat
transfer paths 104b.sub.1, . . . , 104b.sub.n of the one or more
servers 102b.sub.1, . . . , 102b.sub.n of fourth rack 1002b
following insertion of the second modular server rack cooling
structure 2002 in between the server racks 1001a and 1002a. In
other words, at least the second supporting member 202b is
configured to position at least the second heat exchanger 214b in
heat transfer relationship with the one or more servers 102b.sub.1
. . . 102b.sub.n. Also, at least the second heat exchanger 214b is
not attached to the one or more IT server racks 1002a . . .
1002n.
[0107] In some embodiments, the support structure of the first
modular server rack cooling structure 2001 is coupled to the
support structure of the second modular server rack cooling
structure 2002 and to support structures of succeeding modular
server rack cooling structures 200n via mechanisms known in the art
such as bolting or bracing. In one embodiment, each support
structure is left in a free-standing independent position.
[0108] Again, in a similar manner as described above, the support
structure of the first modular server rack cooling structure 2001
further includes at least a third supporting member, e.g.,
supporting member 203a. The third supporting member 203a couples
the at least first supporting member 201a to the second supporting
member 202a at upper ends 201a' and 202a' of the supporting members
201a and 202a, respectively. The support structure of the first
modular server rack cooling structure 2001 is configured to
position the at least first heat exchanger 213a in proximity to the
one or more heat transfer paths 103a.sub.1, . . . , 103a.sub.n of
the one or more servers 101a.sub.1, . . . , 101a.sub.n of the first
rack 1001a and to position the at least second heat exchanger 214a
in proximity to the one or more heat transfer paths 104a.sub.1, . .
. , 104a.sub.n of the one or more servers 102a.sub.1, . . . ,
102a.sub.n of the second rack 1002a following insertion of the
first modular server rack cooling structure 2001 in between the
server racks 1001a and 1002b.
[0109] In other words, the at least the third supporting member
203a is configured to position at least the first heat exchanger
213a in heat transfer relationship with the one or more servers
101a.sub.1, . . . , 101a.sub.n. Also, at least the first heat
exchanger 213a is not attached to the one or more IT server racks
1001a, . . . , 1001n. Additionally, at least the third supporting
member 203b is configured to position at least the second heat
exchanger 214b in heat transfer relationship with the one or more
servers 102a.sub.1, . . . , 102a.sub.n. Also, at least the second
heat exchanger 214a is not attached to the one or more IT server
racks 1002a, . . . , 1002n.
[0110] In a similar manner as described above, in one embodiment,
the at least third supporting member 203a again includes at least
one heat exchanger 301a configured to transfer heat to or from the
aisle 12 following insertion of the modular server rack cooling
structure 2001 in between the server racks 1001a and 1002a. The
heat exchanger 301a has a dimension defining an edge to which the
heat exchanger 301a is rotatably coupled, e.g., coupled to at least
portions of the edge, to the third supporting member 203a.
[0111] Those skilled in the art will recognize that in one
embodiment, the support structure of the second modular server rack
cooling structure 2002 further includes at least a third supporting
member 203b coupling the first supporting member 201b of the
support structure of the second modular server rack cooling
structure 2002 to the second supporting member 202b of the support
structure of the second modular server rack cooling structure 2002.
The support structure of the second modular server rack cooling
structure 2002 is configured to position the at least first heat
exchanger 213b in proximity to the one or more heat transfer paths
103b.sub.1, . . . , 103b.sub.n of the one or more servers
101b.sub.1, . . . , 101b.sub.n of the first rack 1001b and to
position the at least second heat exchanger 214b in proximity to
the one or more heat transfer paths 104b.sub.1, . . . , 104b.sub.n
of the one or more servers 102b.sub.1, . . . , 102b.sub.n of the
second rack 1002b following insertion of the modular server rack
cooling structure 2002 in between the server racks 1001a and
1002a.
[0112] In other words, the second supporting member 202a is
configured to position at least the second heat exchanger 214a in
heat transfer relationship with the one or more servers 102a.sub.1,
. . . , 102a.sub.n. Also, at least the second heat exchanger 214a
is not attached to the one or more IT server racks 1002a, . . . ,
1002n.
[0113] Those skilled in the art will recognize that the system 50
in various embodiments includes in the above described combinations
the heat exchangers analogous to heat exchangers 213a, 214a, 301a,
401a and 502a, which are incorporated into the second and
subsequent modular server rack cooling structure 2002, 2003, . . .
, 200n. Those skilled in the art will also recognize that the
subsequent modular server rack cooling structures 2003, . . . ,
200n can be constructed in an identical manner as described in
their entirety above and connected in a modular manner one to
another as required depending on the number of servers and server
racks and their cooling (or heating) requirements.
[0114] FIG. 6 illustrates a variation of the embodiments of the
third, fourth and fifth heat exchangers 301a, 401a and 502a mounted
on the modular support structures wherein said heat exchangers are
configured to have a width dimension W.sub.M that generally exceeds
the widths W.sub.R of each server rack 1001a, . . . , 1001n and
1002a, . . . , 1002n and/or of each server 101a.sub.1, . . . ,
101a.sub.n, . . . , 101n.sub.1, . . . , 101n.sub.n, and/or
102a.sub.1, . . . , 102a.sub.n, . . . , 102n.sub.1, . . . ,
102n.sub.n. As illustrated, the third, fourth and fifth heat
exchangers have a width dimension W.sub.M that generally equals
twice the width dimension W.sub.R of each server rack. Accordingly,
the third heat exchangers are designated 301ab, 301cd, . . . ,
301(n-1)(n), the fourth heat exchangers are designated 401ab,
401cd, . . . , 401(n-1)(n), and the fifth heat exchangers are
designated 502ab, 502cd, . . . , 502(n1-1)(n). The forced-flow
cooling devices 1051a through 1051n and 1052a through 1052n retain
their original designation since only one device is shown dedicated
to individual racks 1001a through 1001n and 1002a through 1002n,
respectively. The first heat exchangers 1101a and 1101b are
designated as 1101ab, heat exchangers 1101c and 1101d are
designated as 1101cd and heat exchangers 1101n-1 and 1101n are
designated as 1101(n-1)n.
[0115] Additionally, as illustrated in FIG. 2 and as known in the
art, each heat exchanger has cooling fluid connections, e.g.,
piping conduits, that are coupled by flexible connections, as
described below and as shown in more detail with respect to FIGS.
7-11. As exemplarily illustrated in FIGS. 4A, 5A, 6 and 7 and best
illustrated in FIG. 6 and FIG. 7, the heat exchangers associated
with the first row 1001' are fluidically coupled to a first cooling
cycle skid 3001 while the heat exchangers associated with the
second row 1002' are fluidically coupled to a second cooling cycle
skid 3002. In one embodiment, the first and second cooling cycle
skids 3001 and 3002, respectively, include a cooling cycle, such as
that described in the aforementioned U.S. Provisional Patent
Application No. 61/482,070, which was filed on May 3, 2011, the
entire contents of which is incorporated by reference herein. Other
cycles as known in the art also can be applied to the first and
second cooling cycle skids 3001 and 3002 to fluidically couple to
the heat exchangers. A description of the close-coupled cooling
system as applied to first and second cooling cycle skids 3001 and
3002, respectively, is described below with reference to FIG.
12.
[0116] With respect to the connection of the modular support
structures, referring to FIGS. 1-6, the present disclosure relates
to a method for installing a support structure for supporting a
plurality of heat exchangers in a data center, e.g., modular
support structure 2001 for supporting heat exchangers 213a, 214a,
301a, 401a and/or 502a in data center assembly 10. The data center
assembly 10 includes the plurality of racks 1001a, . . . , 1001n
and 1002a, . . . , 1002n for supporting the plurality of servers
each having at least one heat transfer path as described above. The
method includes the steps of: providing a modular support
structure, e.g., 2001 or 2002 . . . or 200n, including at least two
heat exchangers, e.g., at least heat exchangers 213a and 214a
and/or 213b and 214b and/or 213n and/or 214n, and installing the
modular support structure, e.g., 2001 or 2002 . . . or 200n, to
directly interface the at least two heat exchangers 213a and 214a
and/or 213b and 214b . . . and/or 213n and 214n, with at least two
respective heat transfer paths of the plurality of servers, e.g.,
one or more heat transfer paths 103a.sub.1, . . . , 103a.sub.n and
104a.sub.1, . . . , 104a.sub.n and/or 103b.sub.1, . . . ,
103b.sub.n and 104b.sub.1, . . . , 104b.sub.n . . . and/or
103n.sub.1, . . . , 103n.sub.n and 104n.sub.1, . . . , 104n.sub.n
of the one or more respective servers, e.g., servers 101a.sub.1, .
. . , 101a.sub.n and 102a.sub.1, . . . , 102a.sub.n and/or
101b.sub.1, . . . , 101b.sub.n and 102b.sub.1, . . . , 102b.sub.n .
. . and/or 101n.sub.1, . . . , 101n.sub.n and 102n.sub.1, . . . ,
102n.sub.n of the respective first racks, e.g., racks 1001a, . . .
, 1001n, and second racks, e.g., racks 1002a, . . . , 1002n,
without contact between the respective modular support structure,
e.g., modular support structures 2001, . . . , 200n, and the
plurality of racks, e.g., racks 1001a, . . . , 1001n and 1002a, . .
. , 1002n, and without contact between the respective modular
support structure, e.g., modular support structures 2001, . . . ,
200n, and the plurality of servers, e.g., servers 101a.sub.1, . . .
, 101a.sub.n and 102a.sub.1, . . . , 102a.sub.n and/or 101b.sub.1,
. . . , 101b.sub.n and 102b.sub.1, . . . , 102b.sub.n . . . and/or
101n.sub.1, . . . , 101n.sub.n and 102n.sub.1, . . . ,
102n.sub.n.
[0117] In one embodiment, the method also includes installing the
third, fourth and fifth heat exchangers 301a, . . . , 301n, 401a, .
. . , 401n and 502a, . . . , 502n in the respective support
structures of the modular server rack cooling structures 2001, . .
. , 200n in the manner as described above for the various
embodiments.
[0118] Alternatively, in some embodiment, the present disclosure
relates to a method of installing a modular server rack cooling
structure for cooling at least a first server installed in at least
a first rack and at least a second server installed in at least a
second rack, e.g., modular server rack cooling structure 2001,
2002, . . . , 200n. The at least a first rack 1001a, . . . , 1001n
and the at least a second rack 1002a, . . . , 1002n are disposed
opposite each other to form a hot aisle 12 or a cold aisle. The
method includes positioning at least a portion of the modular
server rack cooling structure 2001, 2002, . . . , 200n in the hot
aisle 12 or the cold aisle. The modular server rack cooling
structure 2001, 2002, . . . , 200n includes at least a first
support member 201a, . . . , 201n, a second support member 202a, .
. . , 202n, and a third support member 203a, . . . , 203n, and
coupling at least a first heat exchanger, e.g., heat exchanger
213a, . . . , 213n, to the at least a first supporting member 201a,
. . . , 201n so that the at least a first heat exchanger 213a . . .
213n is positioned adjacent to the at least a first server
101a.sub.1, . . . , 101a.sub.n of the at least a first rack 1001a;
coupling at least a second heat exchanger, e.g., heat exchanger
214a, . . . , 214n, to the at least a second supporting member
202a, . . . , 202n so that the at least a second heat exchanger
214a, . . . , 214n is positioned adjacent to the at least a second
server 102a.sub.1, . . . , 102a.sub.n of the at least a second rack
1002a; and coupling at least a third heat exchanger, e.g., heat
exchanger 301a, . . . , 301n to the at least a third supporting
member 203a, . . . , 203n after at least a third server 101b.sub.1,
. . . , 101b.sub.n, or 102b.sub.1, . . . , 121b.sub.n is installed
in the at least a first rack 1001a or the at least a second rack
1002a, respectively.
[0119] FIGS. 7-11 are operational schematics for the heat
exchangers associated with the modular server rack cooling
structure 2001, . . . , 200n described above showing a phased
installation of the various heat exchangers added to the modular
support structures as necessary to accommodate increased heat
loads.
[0120] More particularly, FIG. 7 is an operational schematic plan
view of a data center assembly 10' according to one embodiment of
the present disclosure illustrating the fluid circuits between
refrigeration heat exchanger skids and the heat exchangers
supported by the modular server rack cooling structures. Data
center assembly 10' is substantially identical to data center
assembly 10 except that in FIG. 7, as compared to FIGS. 1, 4A and
4B, a single circulating exhaust fan 1051a, 1051b, . . . , 1051n
and 1052a, 1052b, . . . , 1052n is associated with each rack
1001'a, 1001'b, . . . , 1001'n in first row 1001' and 1002'a,
1002'b, . . . , 1002'n in the second row 1002', respectively,
mounted above each rack on respective support structures of the
modular server rack cooling structures 2001, 2002, . . . , 200n, in
contrast to the two exhaust fans per rack illustrated in FIGS. 1,
4A and 4B. Each exhaust fan 1051a, 1051b, . . . , 1051n and 1052a,
1052b, . . . , 1052n is positioned in proximity to respective
primary exhaust heat exchangers 1101a, 1101b, . . . , 1101n and
1102a, 1102b, . . . , 1102n to cause air flow across each heat
exchanger above each respective rack. The primary exhaust heat
exchangers 1101a, 1101b, . . . , 1101n and 1102a, 1102b, . . . ,
1102n again have a thin, rectangular configuration and are mounted
substantially vertically and orthogonally with respect to the top
surfaces of the racks.
[0121] Primary exhaust heat exchangers 1101a, 1101b, . . . , 1101n
are fluidically coupled to first cooling cycle skid 3001 through a
first primary cooling circuit 1111 and primary exhaust heat
exchangers 1102a, 1102b, . . . , 1102n are fluidically coupled to
second cooling cycle skid 3002 through a second primary cooling
circuit 1112.
[0122] In one embodiment, again the third supporting member 203a
includes third heat exchanger 301a supported substantially
horizontally across and above the hot aisle 12. In this embodiment,
the air exhausted horizontally from the first and second heat
exchangers 213a and 214a into hot aisle 12 is forced to rise in the
hot aisle 12 and pass vertically through the serpentine coils of
the third heat exchanger 301a.
[0123] As illustrated in and described above with respect to FIG.
3, fourth heat exchanger 401a and, as illustrated in FIG. 7, an
additional plurality of substantially identical thin, rectangularly
configured heat exchangers 401b, . . . , 401n are positioned on the
respective modular server rack cooling structures 2001, 2002, . . .
, 200n above the hot aisle 12 and straddling the first row 1001' of
racks. Thus, in a similar manner as described above with respect to
FIG. 3, the fourth heat exchangers 401a, . . . , 401n at least
partially extend over the hot aisle 12 at an angle .theta..sub.1 to
the horizontal.
[0124] Similarly, as illustrated in and described above with
respect to FIG. 3, fifth heat exchanger 502a and, as illustrated in
FIG. 7, an additional plurality of substantially identical thin,
rectangularly configured heat exchangers 502b, . . . , 402n are
positioned on the respective modular server rack cooling structures
2001, 2002, . . . , 200n above the hot aisle 12 and straddling the
second row 1002' of racks. Again, in a similar manner as described
above with respect to FIG. 3, the fifth heat exchangers 502a, . . .
, 502n thus at least partially extend over the hot aisle 12 at an
angle .theta..sub.2 to the horizontal.
[0125] The angles .theta..sub.1 and .theta..sub.2 are generally
equal and as illustrated in FIG. 3, and as shown in FIG. 11
discussed in more detail below, the fourth heat exchangers 401a,
401b, . . . , 401n and the fifth heat exchangers 502a, 502b, . . .
, 502n form an "A-Frame" configuration when the second edges 412a,
412b, . . . , 412n of the respective fourth heat exchangers 401a,
401b, . . . , 401n and the second edges 512a, 512b, . . . , 512n of
the respective fifth heat exchangers 502a, 502b, . . . , 502n are
either in direct contact as shown in FIG. 3 or in close proximity
as shown in FIG. 11.
[0126] Fourth heat exchangers 401a, 401b, . . . , 401n are
fluidically coupled to first cooling cycle skid 3001 through a
first "A-Frame" cooling circuit 1131 and fifth heat exchangers
502a, 502b, . . . , 502n are fluidically coupled to second cooling
cycle skid 3002 through a second "A-Frame" cooling circuit
1132.
[0127] FIG. 8 is an operational or installation schematic end view
of the data center assembly 10' having at least one modular support
structure and associated heat exchangers for "Day One" low density
operation. More particularly, the data center assembly 10' forms a
first cold aisle 141 between the outer structural walls of the data
center (not shown) and the first row 1001' of IT server racks and a
second cold aisle 142 between the outer structural walls of the
data center (not shown) and the second row 1002' of the IT server
racks. As illustrated above in FIG. 3, the servers in the server
racks in the first row 1001' and the servers in the server racks in
the second row each transfer heat into the common hot aisle 12.
[0128] In FIG. 8, the modular server rack cooling structures 2001,
2002, . . . , 200n are positioned in the hot aisle 12 with their
associated heat exchangers in proximity to the heat transfer paths
of the servers. Thus, during operation of the data center assembly
10', heat is generated in the servers from one or both rows of
servers. The heat exhausts through the server heat transfer paths
into the hot aisle 12 first passing through the associated
vertically-mounted heat exchangers 213a, 213b, . . . , 213n and
213a, 213b, . . . , 213n of the modular server rack cooling
structures 2001, 2002, . . . , 200n.
[0129] However, in the "low density" operational mode or "low
density" phased installation illustrated in FIG. 8, the circulation
cooling circuits (shown in FIG. 10 below) for the heat exchangers
213a, 213b, . . . , 213n and 214a, 214b, . . . , 214n of the
modular server rack cooling structures 2001, 2002, . . . , 200n are
either not installed or not in operation or both. As defined
herein, "density" refers to a volumetric heat load per unit volume,
such as in KW/m.sup.3 (Kilowatts/cubic meter).
[0130] High temperature server exhaust air A1 and A2 enters the hot
aisle 12 and is circulated vertically upward in the hot aisle and
passes through the primary exhaust heat exchangers 1101a, 1101b, .
. . , 1101n and respective exhaust fans 1051a, 1051b, . . . , 1051n
and through primary exhaust heat exchangers 1102a, 1102b, . . . ,
1102n and respective exhaust fans 1052a, 1052b, . . . , 1052n back
to the respective cold aisles 141 and 142 to flow into the servers
as cold air supplies A3 and A4, respectively.
[0131] As described above with respect to FIG. 7, primary exhaust
heat exchangers 1101a, 1101b, . . . , 1101n are fluidically coupled
to first cooling cycle skid 3001 through the first primary cooling
circuit 1111 and primary exhaust heat exchangers 1102a, 1102b, . .
. , 1102n are fluidically coupled to second cooling cycle skid 3002
through second primary cooling circuit 1112. The first and second
primary cooling circuits 1111 and 1112, respectively, are in full
or partial operation to remove the heat load from the data center
assembly 10', as required. The cooling circuits for the remaining
heat exchangers discussed with respect to FIG. 7 are not in
operation due to the low magnitude of the heat load per unit
volume.
[0132] FIG. 9 is an operational or installation schematic end view
of the data center assembly 10' illustrated in FIG. 8 for "Day Two"
"increased density" operation according to one embodiment of the
present disclosure. The difference between the "increased density"
operation illustrated in FIG. 9 and the "low density" operation
described above with respect to FIG. 8 is that in FIG. 9, cooling
circuit 1121 for horizontal heat exchangers 301a, 301b, . . . ,
301n formed are also installed and in full or partial operation to
further remove heat from the data center assembly 10', as
required.
[0133] As previously described above, to enable access to the space
above the horizontal heat exchanger 301a particularly for
maintenance activities, in one embodiment, the horizontal heat
exchanger 301a is rotatably coupled to the second beam member
201a.sub.2 via a hinged connection 303a such that the horizontal
heat exchanger 301a can be reversibly rotated downwardly into the
upper portion of the hot aisle 12 as shown by the angle .phi. below
the horizontal.
[0134] FIG. 10 is an operational or installation schematic end view
of the data center assembly 10' illustrated in FIG. 9 for "Day
Three" increased density operation according to one embodiment of
the present disclosure. The difference between the "Day Three"
"increased density" operation illustrated in FIG. 10 and the "Day
Two" "increased density" operation described above with respect to
FIG. 9 is that in FIG. 10, the first cooling circuit 1141 and the
second cooling circuit 1142 for the respective first heat
exchangers 213a, 213b, . . . , 213n and second heat exchangers
214a, 214b, . . . , 214n that are positioned in proximity to the
one or more heat transfer paths of the one or more servers as
described above with respect to FIGS. 3-6 are also installed to
further remove heat from the data center assembly 10', as
required.
[0135] FIG. 11 is an operational or installation schematic end view
of the data center assembly 10' illustrated in FIG. 10 for "high
density" operation according to one embodiment of the present
disclosure. The difference between the "high density" operation
illustrated in FIG. 11 and the "Day Two" "increased density"
operation described above with respect to FIG. 10 is that in FIG.
11, as described above with respect to FIGS. 3 and 7, the first and
second cooling circuits 1131 and 1132 for the respective "A-Frame"
fourth heat exchangers 401a, 401b, . . . , 401n and fifth heat
exchangers 502a, 502b, . . . , 502n are installed and in full or
partial operation to further remove heat from the data center
assembly 10', as required. As shown in the exemplary embodiment of
FIG. 11, the second edges 412a, 412b, . . . , 412n of the
respective fourth heat exchangers 401a, 401b, . . . , 401n and the
second edges 512a, 512b, . . . , 512n of the respective fifth heat
exchangers 502a, 502b, . . . , 502n are in close proximity to each
other and separated by a gap G as shown in FIG. 11. The fourth
"A-Frame" heat exchangers 401a, 410b, . . . , 401n thus at least
partially extend over the hot aisle 12 at angle .theta..sub.1 to
the horizontal. Similarly, the fifth "A-Frame" heat exchangers
502a, 502b, . . . , 502n thus at least partially extend over the
hot aisle 12 at angle .theta..sub.2 to the horizontal.
[0136] FIG. 12 illustrates a flow diagram of one embodiment of a
close-coupled cooling system 4000 designed to cool electronic
equipment of an IT data center such as the IT data assemblies 10
and 10' described above with respect to FIGS. 1-11. The system 4000
includes four independent, yet cooperating, fluid circuits
designated as 4100, 4200, 4300, and 4400, respectively.
[0137] The first circuit 4100 interfaces with the electronic
equipment of the IT data center and provides cooling to the
electronic equipment via a first fluid. The first fluid may contain
a liquid refrigerant R134a or similar refrigerants. The first
circuit 4100 includes at least one evaporator coil (not shown in
FIG. 12, but see, e.g., the evaporator coils of FIG. 16 and
corresponding description) that is in thermal communication with
the electronic equipment and extracts heat from the electronic
equipment to the first fluid. As the first fluid flows from an
inlet of the at least one evaporator coil to an outlet of the
evaporator coil, heat is transferred from the electronic equipment
to the first fluid. In one embodiment, the first fluid enters the
at least one evaporator coil at a temperature of approximately
23.degree. C. During heat transfer or exchange, the first fluid
transforms from a liquid state to an at least partially vapor
state.
[0138] The first circuit 4100 includes a fluid supply path 4100a
and a fluid return path 4100b coupled to the inlet and outlet of
the at least one evaporator coil, respectively. The fluid supply
path 4100a delivers the first fluid in a liquid state to the inlet
of the at least one evaporator coil, and the fluid return path
4100b receives the first fluid in an at least partially vapor state
from the outlet of the at least one evaporator coil. The first
circuit 4100 includes a liquid refrigerant pump 4120 that pumps the
first fluid through the fluid supply path 4100a. The first circuit
4100 also includes a variable frequency drive 4125 that regulates
capacity and motor speed of the liquid refrigerant pump 4120.
[0139] The first circuit 4100 further includes a main condenser
1300 that receives the first fluid from the fluid return path
4100b. The main condenser 1300 is a refrigerant-to-water heat
exchanger that cools the first fluid that passes through the main
condenser 1300 and condenses the first fluid from the at least
partially vapor state to the liquid state. In one embodiment, to
fully condense and cool the first fluid, the main condenser 1300 is
maintained at a predetermined condensing temperature of
approximately 23.3.degree. C. or lower.
[0140] Further, the first circuit 4100 may include (1) a fluid path
4100c that carries the first fluid from the main condenser 1300 to
a refrigerant liquid receiver 4128, and (2) a fluid path 4100d that
carries the first fluid from the refrigerant liquid receiver 4128
to a suction side of the liquid refrigerant pump 4120.
[0141] The refrigerant liquid receiver 4128 is configured to detect
and regulate the temperature of the first fluid. Specifically, the
refrigerant liquid receiver 4128 is configured to reduce the
temperature of the first fluid by thermally coupling the first
circuit 4100 to the fourth circuit 4400. In some embodiments, the
refrigerant liquid receiver 4128 maintains the first fluid at a
predetermined temperature between approximately 22.2.degree. C. and
approximately 23.3.degree. C.
[0142] The refrigerant liquid receiver 4128 may also include
components (e.g., a detector and a controller) configured to detect
and regulate the liquid level of the first fluid contained in the
refrigerant liquid receiver 4128. A low liquid level in the
refrigerant liquid receiver 4128 may cause cavitation problems at
the liquid refrigerant pump 4120. To avoid this problem, the
refrigerant liquid receiver 4128 includes a liquid level controller
4127 that detects the liquid level in the receiver 4128 and
triggers an alarm if a low liquid level is detected. Also, the
refrigerant liquid receiver 4128 may collect the first fluid in the
first circuit 4100 when the cooling system 4000 is in an idle or
standby mode.
[0143] The first circuit 4100 also includes a temperature sensor
4126 that is located on the fluid path 4100c at the exit of the
main condenser 1300. The temperature sensor 4126 detects the
temperature of the first fluid when it exits from the main
condenser 1300. The readings of the temperature sensor 4126 reflect
the temperature of the main condenser 1300.
[0144] The second circuit 4200 interfaces with the first circuit
4100 at the main condenser 1300a, where the second circuit 4200
performs heat exchange with the first circuit 4100. Specifically,
the second circuit 4200 has a second fluid flowing through it. The
second fluid removes heat from the first fluid of the first circuit
4100 at the main condenser 1300a. In one embodiment, upon exiting
the main condenser 1300a, the second fluid has a temperature of
approximately 22.8.degree. C.
[0145] The second circuit 4200 includes a fluid path 4200a that
carries the second fluid from a cooling tower, fluid cooler, or dry
cooler (not shown in FIG. 12) to the second circuit 4200. The fluid
path 4200a is fluidly coupled to a fluid path 4200d which delivers
the second fluid to the main condenser 1300. The second circuit
further includes a fluid path 4200h that receives the second fluid
from the main condenser 1300. The fluid path 4200h is fluidly
coupled to a fluid path 4200e which carries the second fluid to a
fluid path 4200m that delivers the second fluid back to the cooling
tower, fluid cooler or dry cooler.
[0146] In some embodiments, the second circuit 4200 includes a pump
to facilitate the flow of the second fluid through the second
circuit 4200. In one embodiment, the second fluid is regulated at a
flow rate of approximately 1192 liters/minute. The pump may be in
any of the following forms: a central pumping and cooling tower,
dry cooler, fluid cooler or other chilled, well water circuit, or
other chilled water circuit.
[0147] Further, the second circuit 4200 may include a mixed water
temperature sensor 4220 that monitors the temperature of the second
fluid before it enters the main condenser 1300. The second circuit
4200 may also include a water regulating valve 4214, which
operatively communicates with the temperature sensor 4126 of the
first circuit 4100. The water regulating valve 4214 is configured
to regulate the flow rate of the second fluid in proportion to the
readings of the temperature sensor 4126.
[0148] For instance, to maintain the main condenser 1300 at or
below a predetermined condensing temperature (e.g., 23.3.degree.
C.), the water regulating valve 4214 adjusts the flow rate of the
second fluid based on the temperature of the main condenser 1300 as
measured by the temperature sensor 4126. For example, if the
temperature sensor 4126 has a reading significantly higher than the
predetermined condensing temperature (e.g., 23.3.degree. C.) of the
main condenser 1300, the water regulating valve 4214 then
significantly increases the flow rate of the second fluid flowing
through the second circuit 4200 to thereby rapidly reduce the
temperature of the main condenser 1300. However, if the temperature
sensor 4126 has a reading slightly higher than the predetermined
condensing temperature (e.g., 23.3.degree. C.), the water
regulating valve 4214 then slightly increases the flow rate of the
second fluid flowing through the second circuit 4200.
[0149] In some embodiments, to maintain the temperature of the main
condenser 1300 at or below the predetermined condensing temperature
(e.g., 23.3.degree. C.), the second fluid is maintained at a
threshold temperature of approximately 18.9.degree. C. or
lower.
[0150] To maintain the second fluid at or below the threshold
temperature (e.g., 18.9.degree. C.), the second circuit 4200 may
include at least one cooling mode to cool the second fluid. For
example, the second circuit 4200 may include a simple free cooling
mode in which the second circuit 4200 relies on the atmosphere to
cool the second fluid via a cooling tower, fluid cooler, or dry
cooler (not shown in FIG. 12). In operation, after heat is
transferred from the first fluid to the second fluid at the main
condenser 1300, the second fluid follows the fluid paths 4200h,
4200e and proceeds to a cooling tower, fluid cooler or dry cooler
(not shown in FIG. 12) to reject its heat into the atmosphere. The
cooled second fluid then follows the fluid paths 4200a and 4200d
back to the main condenser 1300 to cool the first fluid. It is
envisioned that the second fluid may continuously repeat the above
cycle.
[0151] In one embodiment, the simple free cooling mode maintains
the second fluid at or below the threshold temperature (e.g.,
18.9.degree. C.), only when the wet bulb temperature of the IT data
center is below 17.2.degree. C. If the wet bulb temperature is
above 17.2.degree. C., the second fluid may exceed its threshold
temperature.
[0152] Further, the second circuit 4200 may include a mechanical
compressed cooling mode, in which the third circuit 4300 cools the
second circuit 4200 through mechanical compression cycles. A third
fluid flows through the third circuit 4300. The third fluid may
contain a liquid refrigerant, such as R134a, or any other suitable
refrigerant.
[0153] The third circuit 4300 includes an atmospheric sub-cooler
exchanger 1200a to sub-cool the second fluid 4200 before the second
fluid arrives at the main condenser 1300. The atmospheric
sub-cooler exchanger 1200a is a refrigerant-to-water heat exchanger
that trims or cools at least a portion of the second fluid. The
third circuit 4300 may also include a trim condenser 1200b, which
is a refrigerant-to-water heat exchanger that transfers heat in the
third fluid, which is the heat that the third fluid has absorbed
from the second fluid at the atmospheric sub-cooler exchanger
1200a, back to the second fluid. The third circuit 4300 may further
include a sub-cooler compressor 4310 that compresses the third
fluid.
[0154] The third circuit 4300 includes a fluid path 4300a that
carries the third fluid from the atmospheric sub-cooler exchanger
1200a to the sub-cooler compressor 4310 for compression, and a
fluid path 4300b that carries the compressed third fluid to the
trim condenser 1200b. Additionally, the third circuit 4300 includes
a fluid path 4300c that carries the third fluid from the trim
condenser 1200b to a metering device, or a thermal expansion valve
4311, which expands the third fluid back to the atmospheric
sub-cooler exchanger 1200a. It is envisioned that the third fluid
may continuously flow through the third circuit 4300 as long as the
third circuit 4300 is activated.
[0155] In some embodiments, the third circuit 4300 is activated
only when the second fluid exceeds its threshold temperature (e.g.,
18.9.degree. C.), which may occur when the wet bulb temperature is
over 17.2.degree. C. The cooling capacity of the third circuit 4300
may be regulated in direct proportion to the wet bulb temperature
that is in excess of 17.2.degree. C., as illustrated in Table 1
below.
TABLE-US-00001 TABLE 1 WET BULB COOLING CAPACITY OF THE TEMPERATURE
THIRD CIRCUIT 4300 63 wb (17.2.degree. C.) 0 kW 64 wb (17.8.degree.
C.) 45.7 kW 65 wb (18.3.degree. C.) 91.4 kW 66 wb (18.9.degree. C.)
137.2 kW 67 wb (19.4.degree. C.) 182.9 kW 68 wb (20.degree. C.)
228.6 kW 69 wb (20.6.degree. C.) 274.3 kW 70 wb (21.1.degree. C.)
320 kW
[0156] The third circuit 4300 closely controls the temperature of
the second fluid by trimming and cooling the temperature of the
second fluid one degree at a time. For instance, if the second
fluid temperature rises above its threshold temperature by one
degree, the third circuit 4300 then reduces the temperature of the
second fluid by one degree.
[0157] In one embodiment, for efficiency reasons, the second
circuit 4200 directs a small portion of the second fluid to perform
heat exchange with the third fluid, before the second fluid enters
the main condenser 1300. Specifically, the second circuit 4200
includes a splitter tee 4210 on the fluid path 4200d before an
inlet of the main condenser 1300. The splitter tee 4210 diverts a
portion of the second fluid, e.g., approximately one third of the
second fluid, to an inlet of the atmospheric sub-cooler exchanger
1200a. In some embodiments, the portion of the second fluid has a
temperature of 22.2.degree. C. at the inlet of the atmospheric
sub-cooler exchanger 1200a.
[0158] The second circuit 4200 may include another splitter tee
4211 on the fluid path 4200d upstream from the splitter tee 4210.
In conjunction with a flow balancing or flow control valve 4200g
positioned in fluid path 4200d between splitter tee 4210 and
splitter tee 4211, the splitter tee 4211 allows the portion of the
second fluid to flow from an outlet of the atmospheric sub-cooler
exchanger 1200a back to the fluid path 4200d. At the splitter tee
4211, the portion of the second fluid, e.g., approximately one
third of the second fluid, rejoins the remaining portion of the
second fluid, e.g., approximately two thirds of the second fluid.
The blended second fluid then proceeds to the main condenser 1300.
It is envisioned that the blended second fluid has a temperature of
approximately 18.9.degree. C. before entering the main condenser
1300.
[0159] Alternatively, depending upon the degree or percentage
opening of the flow control or flow balancing valve 4200g, flow
control or flow balancing valve 4200g can allow either complete or
partial divergence of flow from the main condenser 1300 to the
atmospheric sub-cooler exchanger 1200a or force flow in fluid path
4200d entirely through main condenser 1300.
[0160] Additionally, for efficiency reasons, the second circuit
4200 may direct only a small portion of the second fluid to perform
heat exchange with the third fluid, after the second fluid exits
from the main condenser 1300. Specifically, the second circuit 4200
includes a splitter tee 4212 on the fluid path 4200h at the exit of
the main condenser 1300. The splitter tee 4212 diverts a portion of
the second fluid, e.g., approximately one third of the second fluid
via a fluid path 4200i to the trim condenser 1200b to reclaim heat
from the third fluid. In some embodiments, the approximately one
third of the second fluid has a temperature of approximately
27.4.degree. C. at an outlet of the trim condenser 1200b. The
second circuit 4200 may include an additional splitter tee 4213 on
the fluid path 4200h downstream from the splitter tee 4212. In
conjunction with a flow balancing or flow control valve 4200k
positioned in fluid path 4200e between splitter tee 4212 and
splitter tee 4213, the splitter tee 4213 allows the portion of the
second fluid, e.g., approximately one third of the second fluid
exiting from the trim condenser 1200b to join the rest of the
second fluid. At the splitter tee 4213, the portion of the second
fluid, e.g., approximately one third of the second fluid rejoins
the remaining portion of the second fluid, e.g., approximately two
thirds of the second fluid. In some embodiments, the blended second
fluid has a temperature of approximately 26.4.degree. C. at the
splitter tee 4213. The blended second fluid then together follows
the fluid paths 4200e, 4200m towards the exit of the second circuit
4200.
[0161] Alternatively, depending upon the degree or percentage
opening of the flow balancing or flow control valve 4200k, flow
balancing or flow control valve 4200k can allow either partial or
complete divergence of flow from the main condenser 1300 to the
trim condenser 1200b or force flow in fluid paths 4200h and 4200e
entirely through main condenser 1300.
[0162] In some embodiments, the third circuit 4300 does not include
the atmospheric sub-cooler exchanger 1200a or the trim condenser
1200b. Rather, the third circuit 4300 includes a trim chiller which
is configured to cool the entire IT data center.
[0163] In one embodiment, the second circuit 4200 may exclusively
have only one cooling mode, either the simple free cooling mode or
the mechanical compressed cooling mode described above.
[0164] In another embodiment, the second circuit 4200 may have both
of the cooling modes that alternate with each other. For instance,
the second circuit 4200 switches to the simple free cooling mode
when the wet bulb temperature is at or below a threshold
temperature, e.g., 17.2.degree. C., and switches to the mechanical
compressed cooling mode once the wet bulb temperature exceeds the
threshold temperature.
[0165] In other embodiments, the two cooling modes cooperate with
other, and the second circuit 4200 may operate in both cooling
modes concurrently. In these embodiments, the simple free cooling
mode is always on, such that the simple free cooling mode remains
active regardless of the wet bulb temperature. On the other hand,
the mechanical compressed cooling mode, e.g., the third circuit
4300, is activated only when the simple free cooling mode alone
cannot maintain the second fluid at or below the threshold
temperature, e.g., 18.9.degree. C., such as when the wet bulb
temperature is above the threshold temperature, e.g., 17.2.degree.
C. In these embodiments, when the wet bulb temperature is at or
below its threshold temperature, the second circuit 4200 relies
solely on the atmosphere for cooling. Once the wet bulb temperature
reaches beyond its threshold temperature, the third circuit 4300 is
activated and is controlled to generate cooling capacity in
proportion to the wet bulb temperature that is in excess of the
threshold temperature. It is envisioned that the third circuit 4300
can be turned on and off automatically without user intervention.
For instance, the atmospheric sub-cooler exchanger 1200a
automatically becomes active or inactive as the wet bulb
temperature crosses its threshold temperature.
[0166] Statistically, the cooling system 4000 operates exclusively
in the simple free cooling mode for approximately 95% of the
operating time. The mechanical compressed cooling mode is turned on
for approximately 5% of the operating time. In a geographical area
where the wet bulb temperature is about 18.3.degree. C., the
cooling system 4000 may run exclusively in the simple free cooling
mode virtually all year round and turns on the mechanical
compressed cooling mode for less than 0.04% of the operating time.
If the area has a wet bulb temperature of about 20.6.degree. C.,
the mechanical compressed cooling mode is active for about 3% of
the operating time. In all these scenarios, a traditional, large,
oversized cooling electrical infrastructure as in the prior art
would rely on mechanical compression cycles for about 40-60% of its
operating time, thus inducing a much higher operation cost than
that of the cooling system 4000.
[0167] In addition to the second circuit 4200, the fourth circuit
4400 may also perform heat exchange with the first circuit 4100.
Specifically, the fourth circuit 4400 interfaces with the first
circuit 4100 at the refrigerant liquid receiver 4128 where the
fourth circuit 4400 condenses and cools the first fluid via a
fourth fluid that flows through the fourth circuit 4400. The
refrigerant liquid receiver 4128 has a sub-cooler coil 4129, which
is an evaporator thermally coupled to both the first circuit 4100
and the fourth circuit 4400.
[0168] The fourth circuit 4400 includes a sub-cooler compressor
4410 configured to compress the fourth fluid and a sub-cooler
condenser 1300a which transfers heat from the fourth circuit 4400
to the second circuit 4200. Both the sub-cooler compressor 4410 and
the sub-cooler condenser 1300a are fluidly coupled to the
sub-cooler coil 4129 of the refrigerant liquid receiver 4128.
[0169] The fourth circuit 4400 includes a fluid path 4400a that
carries the fourth fluid from the receiver sub-cooler coil 4129 to
a suction side of the sub-cooler compressor 4410 for compression, a
fluid path 4400b that carries the compressed fourth fluid from the
sub-cooler compressor 4410 to the sub-cooler condenser 1300a, and a
fluid path 4400c that carries the fourth fluid from the sub-cooler
condenser 1300a to a thermal expansion valve 4420, which expands
the fourth fluid and provides the expanded fourth fluid to the
sub-cooler coil 4129.
[0170] In some embodiments, the fourth circuit 4400 is
automatically turned on and off based on the conditions detected by
the refrigerant liquid receiver 4128. For instance, the fourth
circuit 4400 becomes active when the liquid level detected by the
refrigerant liquid receiver 4128 drops below a predetermined
threshold. Specifically, the fourth circuit 4400 may be activated
in response to an alarm signal generated by the liquid level
controller 4127 when a low liquid level is detected, and may become
inactive when the liquid level reaches the predetermined threshold.
Further, the fourth circuit 4400 may also controlled based on the
temperature of the first fluid as detected by the refrigerant
liquid receiver 4128. For instance, the fourth circuit 4400 may
become active when the temperature of the first fluid exceeds a
predetermined threshold, and become inactive when the temperature
drops to or below the predetermined threshold.
[0171] The second circuit 4200 removes heat from the fourth circuit
4400 at the sub-cooler condenser 1300a. In some embodiments, the
second circuit 4200 includes a splitter tee 4205 on the fluid path
4200d. The splitter tee 4205 includes a split path 4200b that
diverts a small portion of the second fluid, e.g., approximately 19
liters/minute, to an inlet of the sub-cooler condenser 1300a where
the small portion of the second fluid extracts heat from the fourth
circuit 4400. The remaining, undiverted portion of the second fluid
follows the fluid path 4200d to the main condenser 1300 to remove
heat from the first circuit 4100.
[0172] The second circuit 4200 may also include another splitter
tee 4215 on the fluid path 4200e. The splitter tee 4215 has a split
branch 4200c that carries the small portion of the second fluid
returned from an outlet of the sub-cooler condenser 1300a to the
fluid path 4200e to join the rest of the second fluid proceeding
towards the exit of the second circuit 4200. In one embodiment, the
temperature of the second fluid at the splitter tee 4215 is
approximately 26.4.degree. C. when the fourth circuit 4400 is
active, i.e., when the sub-cooler condenser 1300a is turned on, and
approximately 26.7.degree. C. when the fourth circuit 4400 is
inactive, i.e., when the sub-cooler condenser 1300a is turned
off.
[0173] The close-coupled cooling system 4000 may be installed in an
auxiliary enclosure of a modular data pod (see FIGS. 13-17 and
related discussion below) and may provide chillerless cooling
within a data enclosure of the modular data pod in high wet bulb
temperature applications.
[0174] The operation of the close-coupled cooling system 4000 may
be summarized as follows. In the free cooling mode of operation,
the first cooling circuit 4100 which includes the liquid receiver
4128 and the liquid refrigerant pump 4120 and the second cooling
circuit 4200 which includes the main condenser 1300 are in
operation to transfer heat from the data center assemblies 10 or
10' described above via the fluid supply path 4100a and fluid
return path 4100b and to reject heat to the environment via the low
temperature supply path 4200a and via primary cooling coil cooling
water return connection 4200m.
[0175] When the environmental conditions preclude exclusive
reliance on the free cooling mode of operation, e.g., if the
wet-bulb temperature is at or exceeds a predetermined wet-bulb
temperature limit, or if there is an increase in the heat load
generated within the data center assemblies 10 or 10', the
close-coupled cooling system 4000 is placed into an incremental
mechanical-assist cooling mode of operation. In the incremental
mechanical assist cooling mode of operation, first cooling circuit
4100 and the second cooling circuit 4200 as described above with
respect to the free cooling mode of operation continue to remain in
operation while the third cooling circuit 4300, which includes the
trim condenser 1200b, the sub-cooler exchanger 1200a, and the
sub-cooler compressor 4310, is placed into operation to permit
incremental additional cooling of the data center assemblies 10 or
10' such that the cooling capacities of the first, second and third
cooling circuits 4100, 4200 and 4300, respectively, are adjusted
incrementally depending on the on the change in heat load from the
data center assemblies 10 or 10' and/or any change in environmental
conditions based on the wet bulb temperature.
[0176] In an alternative incremental mechanical-assist cooling mode
of operation, the first cooling circuit 4100 and the second cooling
circuit 4200 as described above with respect to the free-cooling
mode of operation continue to remain in operation while the fourth
cooling circuit 4400, which includes the sub-cooler condenser 1300a
and the sub-cooler compressor 4410, is placed into operation to
permit incremental additional cooling of the data center assemblies
10 or 10' such that the cooling capacities of the first, second and
fourth cooling circuits 4100, 4200 and 4400, respectively, are
adjusted incrementally depending on the on the increase or decrease
in heat load from the data center assemblies 10 or 10' and/or any
change in environmental conditions based on the wet bulb
temperature.
[0177] When the environmental conditions and/or the heat load from
the data center assemblies 10 or 10' preclude exclusive reliance on
the free-cooling mode of operation together with either one of the
incremental mechanical assist modes of operation, the close-coupled
cooling system 4000 is placed into a supplemental incremental
mechanical assist-mode of operation. In the supplemental
incremental mechanical assist mode of operation, the first cooling
circuit 4100, the second cooling circuit 4200 and the third cooling
circuit 4300 as described above with respect to the incremental
mechanical-assist mode of operation continue to remain in operation
while the fourth cooling circuit 4400 is placed into operation to
permit incremental additional cooling of the data center assemblies
10 or 10' such that the cooling capacities of the first, second,
third and fourth cooling circuits 4100, 4200, 4300 and 4400,
respectively, are adjusted incrementally depending on the on the
increase or decrease in heat load from the data center assemblies
10 or 10' and/or any increase in environmental conditions based on
the wet bulb temperature.
[0178] The cooling system 4000 has many significant advantages over
traditional cooling systems, such as chilled water systems, chiller
plants or direct expansion cooling systems. First, the cooling
system 4000 requires far less mechanical-assisted cooling
infrastructure than traditional cooling systems. The cooling system
4000 increases its use of mechanical-assisted cooling
infrastructure only when necessary. Specifically, the cooling
system 4000 has two basic circuits, i.e., the first circuit 4100
and the second circuit 4200, which run constantly, and two backup
circuits, i.e., the third circuit 4300 and the fourth circuit 4400,
which run only when necessary. Specifically, the third circuit 4300
is active only when the wet bulb temperature is above the threshold
temperature, and the fourth circuit 4400 is active only when the
first fluid liquid level is low or the first fluid temperature is
above a certain threshold. Since the two backup circuits operate
only when necessary, e.g., approximately 10-20% of the operating
time, the cooling system 4000 overall relies on less
mechanical-assisted cooling infrastructure than the traditional
cooling system.
[0179] Second, the cooling system 4000 is less prone to failures
than the traditional cooling system. Specifically, the cooling
system 4000 completely avoids a full system swing over process that
is common in the traditional cooling system. A full system swing
over process switches between two systems by shutting down one
system and starting up another, which typically happens when the
traditional cooling system switches between a free cooling system
and a mechanical cooling system. The full system swing over process
is dangerous and prone to failures. The cooling system 4000, on the
other hand, avoids the full system over process. In the cooling
system 4000, the basic circuits and the backup circuits run
independently, yet cooperating with each other. The basic circuits
4100 and 4200 run continuously regardless of the state of the
backup circuits 4300 and 4400. The backup circuits 4300 and 4400
are turned on only when necessary. Accordingly, the cooling system
4000 avoids the failures in the full system swing over process, and
is a safer approach than the traditional cooling system.
[0180] Third, the cooling system 4000 has a higher tolerance for
high wet bulb temperatures than the traditional cooling system. The
traditional cooling system generally has a very high operation cost
when the wet-bulb temperature is above 10.degree. C. For instance,
the maximum wet-bulb temperature that the traditional cooling
system can survive in a free-cooling mode is approximately
10.degree. C. When the wet-bulb temperature exceeds 10.degree. C.,
the traditional cooling system must switch from a free-cooling
system to a mechanical cooling system to provide sufficient cooling
to an IT data center. For about every half degree above 10.degree.
C., the mechanical cooling system has to generate an additional
cooling capacity of 320.6 kW, which demands the traditional cooling
system to acquire sufficient power to generate the additional
cooling capacity.
[0181] On the other hand, the cooling system 4000 of the present
disclosure has a better tolerance for high wet-bulb temperatures.
In some embodiments, the maximum wet bulb temperature that the
cooling system 4000 can survive in a free cooling mode is
approximately 17.2.degree. C., much higher than that of the
traditional cooling system. Once the wet-bulb temperature exceeds
17.2.degree. C., the cooling system 4000 switches to the mechanical
compressed cooling mode. For every half degree above 17.2.degree.
C., the mechanical compressed cooling mode generates an additional
cooling capacity of 45.7 kW, which, in turn, consumes significantly
less power than the traditional cooling system. Because of its high
tolerance for high wet bulb temperature, the cooling system 4000 is
better suited for a high density IT data center, e.g., 40 kW per
rack, than the traditional cooling system.
[0182] Fourth, the cooling system 4000 is more energy efficient
than the traditional cooling system. The cooling system 4000
maximizes energy savings by having the simple free cooling mode
which relies on atmosphere to assist cooling the IT data center. In
the simple free cooling mode, the cooling system 4000 consumes a
limited of power, which, for instance, is 15% less than what is
required to power the traditional cooling system. Further, the
cooling system 4000 adjusts its power consumption dynamically as a
function of the load in the IT data center. As the load increases,
the cooling system 4000 increases its power consumption level to
cause an increase in the flow rates in the two basic circuits
and/or activate one or both of the backup circuits, which, in turn,
generate more cooling capacity to compensate for the load increase.
By contrast, as the load decreases, the cooling system 4000
decreases its power consumption level which, in turn, reduces its
output of cooling capacity.
[0183] Fifth, the cooling system 4000 is more scalable to the size
of the IT data center and easier deployable than the typical
cooling system. For instance, the cooling system 4000 can be
deployed modularly at specific, targeted locations in an IT data
center, in contrast to the typical cooling system which has to be
deployed as a whole covering the full extent of the IT data center.
Due to its modularity, the cooling system 4000 targets specific
locations in the IT data center and avoids locations that do not
need cooling. Also due to its modularity, the cooling system 4000
can be deployed on existing and retrofit cooling systems which the
typical cooling system fails to do. Further, the number of cooling
systems 4000 deployed in an IT data center may be scaled according
to the dynamic change, e.g., shrink or growth, of the IT data
center.
[0184] Lastly, the cooling system 4000 has a lower overall cost
than that of the traditional cooling system. For instance, the
cooling system 4000 requires a relatively low initial capital and
maintenance. Further, due to its energy efficiency, the cooling
system 4000 has a low operation cost. As a result, the cooling
system 4000 is more cost effective than the traditional cooling
system. Because of its overall low cost, in addition to its high
tolerance for high wet bulb temperature, the cooling system 4000 is
an optimal cooling choice for the high density IT data center,
e.g., 40 kW per rack.
[0185] Thus, a control strategy is employed to enable close system
pressure and flow tolerances utilizing bypass control valves,
temperature and pressure sensors, and receiver safeties and
pressure regulators. This control strategy may be executed in real
time and is relational with dynamic control of all components. The
control strategy incorporates feed back from the IT servers, in
order to better facilitate close coupled cooling based on real time
individual loading of the rack servers and computer loads.
[0186] One of the benefits of the dedicated close-coupled cooling
systems (e.g., 525) is that they can adapt to the different heat
loads that are generated by different servers contained in the
modular data pods. As a result, the dedicated close-coupled cooling
systems can operate efficiently. In contrast, traditional cooling
systems for data centers and data pod modules are typically
designed for, and operate at, the worst case conditions for a
particular computer design. Also, traditional cooling systems cool
all data pod modules according to the data module with the greatest
heat load.
[0187] FIGS. 13-17 illustrate a modular data pod 80'' that includes
an "A-Frame" cooling circuit 2601. In one embodiment, the "A-Frame"
cooling circuit 2601 contains a coolant supplied from a first
cooling cycle skid 3001 as discussed above with respect to FIGS. 6
and 7. For the specific application of the modular data pod 80''
illustrated in FIGS. 13-15 "A-Frame The "A-Frame" cooling circuit
2601 has an "A-Frame" heat exchanger assembly 3400, which is formed
partially of cooling coils 3401a-c and 3502a-c, illustrated in FIG.
14, in conjunction with an air circulator support structure 816
illustrated in FIG. 13.
[0188] With reference to FIG. 13, the air circulator support
structure 816 includes air circulators 816a, 816b and 816c that are
configured and disposed in a manner to induce air circulation in
the following direction. Cold air in the cold aisle 8002' flows
downwardly from the top of each server rack 803a' or 807c' to the
bottom of the server rack. After the air passes through a server,
e.g., 813a' on a server rack, e.g. 803a', the air passes across a
heat exchanger 3214a, and then enters a hot aisle 8001' located
between the server rack, e.g. 803a', and an external wall member
1083'. Subsequently, the air circulates upwardly into a third
volume 8003' to complete one circulation cycle. The air then
recirculates through the "A-Frame" heat exchanger assembly 3400 in
the same order described above.
[0189] The modular data pod 80'' is supported on a support
structure 8000' which includes fluid supply paths 2701a and 2702a
which is part of the first fluid circuit 2071 and fluid return
paths 2702a and 2702b which is part of the second fluid circuit
2702 as explained below with respect to FIGS. 16 and 17.
[0190] The modular data pod 80'' also includes cable trays 340 that
are exemplarily mounted above the server racks, e.g., 803a' and
807c'. In one embodiment, the modular data pod 80'' includes a
dedicated electrical power supply, e.g. one or more batteries 832
located at a lower end 811' of the data pod enclosure 108''.
[0191] External wall members 1083' and 1087' define an aperture
812' at an upper end 811 of data enclosure 108''. A data pod
covering member 812 is configured and disposed in a manner to
substantially cover the aperture 812'.
[0192] FIG. 14 is an upper plan view of the modular data center pod
80'' assembly having a server rack cooling structure disposed
within the cold aisle above the space defined by a plurality of
server racks arranged in a "U"-shape according to other embodiments
of the present disclosure. More particularly, modular octagonal
data pod 80'' includes a data enclosure 108'' including eight
external wall members 1081', 1082', 1083', 1084', 1085', 1086',
1087' and 1088' that are contiguously joined to one another along
at least one edge 88' in the shape of a polygon.
[0193] Contiguous external wall members 1088', 1081' and 1082' form
a first end 88a' of the modular data pod 80' while correspondingly
contiguous external wall members 1084', 1085' and 1086' form a
second end 88b' of the modular data pod 80'.
[0194] Elongated external wall member 1083' includes server racks
803a'-c', and the second end 88'b includes two server racks 804'
and 806'. Elongated external wall member 1087' includes server
racks 807a'-c'.
[0195] The server racks may be arranged in a "U"-shape as
illustrated in FIG. 14, or other shapes as described in commonly
assigned PCT/US2011/41710 by Keisling et al. entitled "SPACE-SAVING
HIGH DENSITY MODULAR DATA PODS AND ENERGY-EFFICIENT COOLING
SYSTEM", filed on Jun. 23, 2011, incorporated by reference herein,
as described above.
[0196] Modular data pod 80'' also includes first heat exchangers
3101a-d mounted above server racks 803a', 803b', 803c' and 804',
respectively. Modular data pod 80'' also includes second heat
exchangers 3102a-d mounted above server racks 807c', 807b', 807a'
and 806', respectively.
[0197] Modular data pod 80'' also includes an auxiliary enclosure
818' adjacent to one of the external wall members 1081' to 1088',
with the auxiliary enclosure 818' illustrated as being adjacent to
external wall member 1081'. Similarly, the auxiliary enclosure 818'
includes one or more close-coupled dedicated cooling systems 2601
and 2602 for chillerless operation in high wet bulb temperature
applications which is further described in detail below with
respect to FIG. 17.
[0198] FIG. 15 is a lower plan view of the modular data center pod
80'' assembly of FIG. 14 illustrating forced-flow cooling devices
that force air vertically through a sump below the central aisle of
the modular data center pod assembly. More particularly, air
circulators 816a and 816b are disposed below central aisle 850 of
the modular data center pod 80'' and are configured to force air
flow vertically upwards through a sump 852. The cable trays 340
exhibit a generally "U-shaped" configuration above the server racks
803a'-c', 804', 806' and 807a'-c'.
[0199] In one embodiment, as illustrated in FIGS. 16-17, the
modular data center pod 80'' may include two "A-Frame" cooling
circuits 2601, 2602. For clarity, odd-numbered reference numerals
refer to components included in the first cooling circuit 2601 and
even-numbered reference numerals refer to components included in
the second cooling circuit 2602. Installation and operation of the
cooling circuits 2601 and 2602 need not take place
concurrently.
[0200] The two cooling circuits 2601, 2602 receive coolants
supplied from a first cooling cycle skid 3001 and a second cooling
cycle skid 3002, respectively.
[0201] As shown in FIG. 17, each cooling circuit 2601, 2602
includes a first fluid circuit 2701, 2702, respectively. The first
fluid circuits 2701 and 2702 are evaporator circuits that utilize
R134a or a similar refrigerant and, in one embodiment, are in
thermal fluidic communication with the various heat exchangers of
the data center assembly 10 or 10'.
[0202] Returning to FIG. 16, each of the first fluid circuits 2701,
2702 includes a fluid supply path 2701a, 2702a and a fluid return
path 2701b, 2702b, both of which are in fluid communication with
heat exchangers, e.g. 3101a-n, by carrying fluid or refrigerant to
and from the heat exchangers. The heat exchangers, e.g., 3101a-n,
are placed in close proximity to IT servers or IT racks in the IT
data center for providing close coupled cooling at the point of
load.
[0203] The first fluid supply path 2701a includes a first branch
path 2702a1 which carries coolant or cooling fluid to the first
heat exchangers 3101a-n via sub branches 2703a-n and to the second
heat exchangers 3102a-n via sub branches 2704a-n. The first fluid
return path 2701b carries coolant from the first heat exchangers
3101a-n via sub branches 2705a-n back to the first cooling circuit
2601, and carries coolant from the second heat exchangers 3102a-n
via sub branches 2706a-n.
[0204] In one embodiment, the first fluid supply path 2701a
includes a second branch path 2702a2 that supplies coolant to
fourth heat exchangers 3401a-n via sub branches 2775a-n, and then
to fifth heat exchangers 3502a-n. The coolant exits the fifth heat
exchangers 3502a-n via sub branches 2776a-n to the first fluid
return path 2701b via a branch path 2701b2. The coolant removes
heat from the fourth and fifth heat exchangers and is converted to
a heated fluid as a result.
[0205] It is envisioned that the second fluid paths 2702a-b have
similar structures and functionalities as that of the first fluid
paths 2701a-b to cool heat exchangers 3301a-n, 3213a-n and 3214a-n.
(Heat exchangers 3301a-n are not illustrated in FIG. 16 but, in one
embodiment, may be installed horizontally at the base of the
"A-Frame" above or below and parallel to the air circulators 816a,
816b, 816c).
[0206] As the coolant leaves each heat exchanger, the coolant
absorbs heat from the heat exchanger and becomes heated fluid,
which is then delivered to the inlet of the main condenser 1300
illustrated in FIG. 12 for cooling.
[0207] As shown in FIG. 17, the first cooling circuit 2601 includes
a cooling system similar to the cooling system 4000 of FIG. 12. The
first fluid supply path 2701a and the first fluid return path 2701b
of the first cooling circuit 2601 are respectively coupled to the
first supply path 4100a and the first return path 4100b of the
first circuit 4100 of the cooling systems 4001 and 4002, which in
turn are in fluid communication with the first row 1001' and the
second row 1002' of server racks as described above and illustrated
in FIGS. 1 and 6-11 with respect to data assemblies 10 and 10' and
to modular data pod 80'' as described above and illustrated in
FIGS. 14-16. In operation, the first fluid return path 2701b
carries the heated fluid to the first return path 4100b, which
delivers the heated fluid to the main condenser 1300 where the
heated fluid is cooled and condensed. For purposes of cooling the
heated fluid, the main condenser 1300 may be assisted by the second
circuit 4200 and the third circuit 4300.
[0208] After the fluid exits from the main condenser 1300, the
fluid flows to the refrigerant liquid receiver 4128 where the
liquid level and temperature of the fluid is measured. If the
liquid level is low or if the temperature is high, the sub cooler
compressor 4410 and the sub cooler condenser 1300a are activated to
increase the liquid level and/or reduce the temperature of the
fluid. After the fluid exits from the refrigerant liquid receiver
4128, the fluid flows to the liquid refrigerant pump 4120 which
pumps the fluid, now the coolant, to the fluid supply path 4100a
which then delivers the coolant to the first fluid supply path
2701a. The coolant would then be reused to cool the heat
exchangers, e.g., heat exchangers 3101a-n.
[0209] Having now received the benefit of the description of
cooling system 4000 described above with respect to FIG. 12, those
skilled in the art will recognize that cooling systems 4001 and
4002 are simplified versions of cooling system 4000.
[0210] For extremely high density applications (e.g., greater than
25 kW per rack), a dual coil (in series) circuit can be utilized.
The secondary coil (e.g., a micro channel) receives the coldest
refrigerant liquid first. This coil may receive inlet air
temperatures less than the inlet temperature to the primary coil
(immediately adjacent to the IT racks). (e.g., approximately
6.2.degree. C. (approximately 6.2.degree. C. less than the inlet
temperature to the primary coil) The liquid and partial vapor
leaving the micro channel then enters a simple serpentine single
row evaporator coil. This serpentine coil is closest to the IT
rack. Therefore the serpentine coil receives the hottest air (e.g.,
approximately 46.6.degree. C.). The remaining liquid can be boiled
off in serpentine coil thereby utilizing the full heat rejection
benefits of latent heat of vaporization principles. There are no
thermal expansion valves or other pressure metering devices ahead
of the coils. Such a dual coil circuit is described in
commonly-owned international application no. PCT/US2011/043893,
which was filed on Jul. 13, 2011, the entire contents of which are
hereby incorporated herein by reference.
[0211] FIG. 18 is a perspective view of one embodiment of a data
center assembly according to the present disclosure illustrating a
hot aisle enclosure 1400. The hot aisle enclosure 1400 includes a
roof 1402 and a shroud 1404 that form a conduit through which air
can flow. The hot aisle enclosure 1400 also includes a plurality of
forced-flow cooling devices 1051a, . . . , 1051n and 1052a, . . . ,
1052n to pull air up through the hot aisle and exhaust it to the
atmosphere outside of the hot aisle enclosure 1400. The hot aisle
enclosure 1400 also includes an access door 1406 in an end wall
1408 through which a person can access the hot aisle and perform
maintenance or upgrades on components of the data center
assembly.
[0212] While several embodiments of the disclosure have been shown
in the drawings, it is not intended that the disclosure be limited
thereto, as it is intended that the disclosure be as broad in scope
as the art will allow and that the specification be read likewise.
Therefore, the above description should not be construed as
limiting, but merely as exemplifications of particular embodiments.
Those skilled in the art will envision other modifications within
the scope and spirit of the claims appended hereto.
* * * * *