U.S. patent number RE42,195 [Application Number 11/594,721] was granted by the patent office on 2011-03-01 for energy efficient crac unit operation using heat transfer levels.
This patent grant is currently assigned to Hewlett-Packard Development Company, LP.. Invention is credited to Cullen E. Bash, Abdlmonem Beitelmal, Ratnesh K. Sharma.
United States Patent |
RE42,195 |
Bash , et al. |
March 1, 2011 |
**Please see images for:
( Certificate of Correction ) ** |
Energy efficient crac unit operation using heat transfer levels
Abstract
A method for controlling one or more computer room air
conditioning (CRAC) units for energy efficient operation, in which,
the temperature of the air returned (Trat) into the one or more
CRAC units and the temperature of the air supplied (Tsat) by the
one or more CRAC units is detected. The caloric heat transfer level
(Q) is calculated based upon the Trat and the Tsat and it is
determined whether the Q is within a predetermined setpoint caloric
heat transfer range. In addition, at least one operation of the one
or more CRAC units is reduced in response to the Q being within the
predetermined setpoint caloric heat transfer range to thereby
increase the efficiencies of the one or more CRAC units.
Inventors: |
Bash; Cullen E. (Los Gatos,
CA), Sharma; Ratnesh K. (Union City, CA), Beitelmal;
Abdlmonem (Los Altos, CA) |
Assignee: |
Hewlett-Packard Development
Company, LP. (Houston, TX)
|
Family
ID: |
34979610 |
Appl.
No.: |
11/594,721 |
Filed: |
November 8, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
Reissue of: |
10853522 |
May 26, 2004 |
07010392 |
Mar 7, 2006 |
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Current U.S.
Class: |
700/276; 62/177;
700/300; 700/278 |
Current CPC
Class: |
F24F
11/62 (20180101); F24F 11/30 (20180101); H05K
7/207 (20130101); F24F 11/83 (20180101); F24F
2110/10 (20180101) |
Current International
Class: |
G05D
23/00 (20060101) |
Field of
Search: |
;700/276,291,293,299,300,278 ;62/173,177,180 ;454/239 ;705/400 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Kasenge; Charles R
Claims
What is claimed is:
.[.1. A method for controlling one or more computer room air
conditioning (CRAC) units for energy efficient operation, wherein
said CRAC units comprise a cooling system and a blower, said one or
more CRAC units being configured to receive return air, and wherein
said cooling system comprises at least one of a refrigerant and a
coolant configured to cool the return air, said method comprising:
detecting a power consumption of the cooling system; detecting a
power consumption of the blower; calculating costs associated with
the cooling system power consumption and the blower power
consumption; comparing the costs associated with increasing the
temperature of the at least one of the refrigerant and the coolant
and the costs associated with decreasing the volume flow rate of
air delivered by the blower; and reducing at least one operation of
the one or more CRAC units in response to the compared
costs..].
.[.2. The method according to claim 1, wherein the step of reducing
at least one operation of the one or more CRAC units comprises
increasing the temperature of the at least one of the refrigerant
and the coolant in response to the costs associated with increasing
the temperature of the at least one of the refrigerant and the
coolant being below the costs associated with decreasing the volume
flow rate of air delivered by the blower; and wherein the step of
reducing at least one operation of the one or more CRAC units
comprises decreasing the volume flow rate of air delivered by the
blower in response to the costs associated with decreasing the
volume flow rate of air delivered by the blower being below the
costs associated with increasing the temperature of the at least
one of the refrigerant and the coolant..].
.[.3. The method according to claim 1, wherein the cooling system
includes at least one of a refrigerant and a coolant configured to
cool the return air, and wherein the step of calculating costs
comprises calculating costs associated with increasing the
temperature of at least one of the refrigerant and the coolant and
decreasing a volume flow rate of air delivered by the blower, the
method further comprising: determining a level of increased
temperature of the at least one of the refrigerant and the coolant
and a level of decreased volume flow rate of air delivered by the
blower that relates to minimized costs associated with increasing
the temperature of the at least one of the refrigerant and the
coolant and with decreasing the volume flow rate of air delivered
by the blower; and wherein the step of reducing at least one
operation of the one or more CRAC units comprises implementing the
determined level of increased temperature of the at least one of
the refrigerant and the coolant and the determined level of the
decreased volume flow rate of the air delivered by the
blower..].
.[.4. The method according to claim 1, wherein the cooling system
comprises at least one of a variable capacity compressor and a
constant capacity compressor with a variable frequency drive (VFD),
and wherein the step of reducing at least one operation of the one
or more CRAC units comprises reducing the speed of the at least one
of the variable capacity compressor and the constant capacity
compressor with the VFD..].
.[.5. The method according to claim 1, wherein the cooling system
comprises a three-way valve located upstream of a cooling coil,
said cooling system further comprising a refrigeration circuit
configured to cool a coolant for delivery into the cooling coil,
said three-way valve being configured to control the temperature of
the coolant contained in the cooling coil by controlling coolant
delivery into the cooling coil, wherein the step of reducing a
least one operation of the one or more CRAC units comprises
reducing the coolant delivery into the cooling coil to thereby
reduce the energy consumption of the refrigeration circuit in
cooling the coolant..].
.[.6. The method according to claim 1, wherein the cooling system
comprises a two-way valve located upstream of a cooling coil, said
cooling system further comprising a refrigeration circuit
configured to cool a coolant for delivery into the cooling coil,
said two-way valve being configured to control the temperature of
the coolant contained in the cooling coil by controlling coolant
delivery into the cooling coil, wherein the step of reducing at
least one operation of the one or more CRAC units comprises
reducing the coolant delivery into the cooling coil to thereby
reduce the energy consumption of the refrigeration circuit in
cooling the coolant..].
.[.7. The method according to claim 1, wherein the blower comprises
a variable frequency drive (VFD), and wherein the step of reducing
at least one operation of the one or more CRAC units comprises
operating the VFD to reduce the speed of the blower to thereby
reduce to power consumption of the blower..].
.[.8. A method for controlling one or more computer room air
conditioning (CRAC) units for energy efficient operation, wherein
said CRAC units comprise a cooling system and a blower, said one or
more CRAC units being configured to receive return air, and wherein
said cooling system comprises at least one of a refrigerant and a
coolant configured to cool the return air, said method comprising:
detecting the temperature of the air returned (Trat) into the one
or more CRAC units; determining whether the Trat is below a minimum
set-point temperature level-in calculating costs associated with
decreasing the temperature of at least one of the refrigerant and
the coolant; calculating costs associated with increasing a volume
flow rate of air delivered by the blower; comparing the costs
associated with decreasing the temperature of at least one of the
refrigerant and the coolant and the costs associated with
increasing the volume flow rate of air delivered by the blower; and
operating the one or more CRAC units to at least one of decrease a
temperature of at least one of a refrigerant and a coolant and
increase a volume flow rate of cooling fluid delivered by a blower
of the one or more CRAC units in response to the Trat being above
the minimum setpoint temperature level..].
.[.9. The method according to claim 8 wherein the step of operating
the one or more CRAC units comprises decreasing the temperature of
the at least one of the refrigerant and the coolant in response to
the costs associated with decreasing the temperature of the at
least one of the refrigerant and the coolant being below the costs
associated with increasing the volume flow rate affair delivered by
the blower; end wherein the step of operating the one or more CRAC
units comprises increasing the volume flow rate of air delivered by
the blower in response to the casts associated with increasing the
volume flow rate of air delivered by the blower being below the
costs associated with decreasing the temperature of the at least
one of the refrigerant and the coolant..].
.[.10. The method according to claim 8 wherein the step of
calculating costs comprises calculating costs associated with
decreasing the temperature of at least one of the refrigerant and
the coolant and increasing a volume flow rate of air delivered by
the blower, the method further comprising: determining a level of
decreased temperature of the at least one of the refrigerant and
the coolant and a level of increased volume flow rate of air
delivered by the blower that relates to minimized costs associated
with decreasing the temperature of the at least one of the
refrigerant and the coolant and with increasing the volume flow
rate of air delivered by the blower; and wherein the step of
operating the one or more CRAC units comprises implementing the
determined level of decreased temperature of the at least one of
the refrigerant and the coolant and the determined level of the
increased volume flow rate of the air delivered by the
blower..].
.[.11. The method according to claim 8 further comprising causing
the one or more CRAC units to enter into a reduced power mode in
response to the Trat being below the minimum setpoint temperature
level..].
.[.12. The method according to claim 11 further comprising:
detecting the Trat while the one or more CRAC units are in the
reduced power mode; and causing the one or more CRAC units to exit
from the reduced power mode in response to the Trat exceeding a
predefined temperature level..].
.[.13. The method according to claim 11 wherein the one or more
CRAC units comprise a plurality of CRAC units, and wherein the
plurality of CRAC units are configured to communicate with each
other, the method further comprising: signaling a CRAC unit to exit
from the reduced power mode in response to a Trat of another CRAC
unit exceeding a predefined level..].
.[.14. The method according to claim 1, wherein the one or more
CRAC units comprise a plurality of CRAC units, and wherein one or
more of the plurality of CRAC units are configured with at least
one of a three-way valve and a two-way valve to control coolant
delivery into a cooling coil of the one or more of the CRAC units,
the method further comprising: operating the plurality of CRAC
units to enable the one or wore of the plurality of CRAC units to
maintain the at least one of the three-way valve and the two-way
valve substantially at 100% open positions to thereby reduce energy
usage by the one or more of the plurality of CRAC units..].
.[.15. A computer room air conditioning (CRAC) unit comprising: a
return air temperature sensor; and a controller configured to
compare the temperature of the return air (Trat) with a
predetermined setpoint temperature range to determine whether the
Trat is below a minimum setpoint temperature level in response to
the Trat being outside of the predetermined setpoint temperature
range, wherein the controller is further configured to reduce at
least one operation of the CRAC unit by at least one of decreasing
a temperature of cooling fluid delivered by the CRAC unit and
increasing a volume flow rate of c un fluid delivered by the CRAC
unit in response to the Trat being above the minimum setpoint
temperature level and wherein the controller is configured to cause
the CRAC unit to enter into a reduced power mode in response to the
Trat being below the minimum setpoint temperature level and cause
the CRAC unit to withdraw the CRAC unit from the reduced power mode
in response to the detected Trat exceeding a predefined temperature
level..].
.[.16. The CRAC unit of claim 15, further comprising: a cooling
system; a blower; and a power meter configured to detect a power
consumption of the cooling system and the blower, wherein the
controller is configured to calculate costs associated with the
power consumptions of the cooling system and the blower and to base
the reduction of the at least one operation of the CRAC unit on the
costs associated with operating the cooling system and the
blower..].
.[.17. The CRAC unit according to claim 16 wherein the cooling
system comprises at least one of a variable capacity compressor and
a constant capacity compressor with a variable frequency drive
(VFD), and wherein the controller is operable to reduce operations
of the at least one of the variable capacity compressor and the
constant capacity compressor with a VFD in response to the
temperature of the return air being within the predetermined
setpoint temperature range..].
.[.18. The CRAC unit according to claim 16 wherein the cooling
system comprises a three-way valve located upstream of a cooling
coil, said cooling system further comprising a refrigeration
circuit configured to cool a coolant for delivery into the cooling
coil, said three-way valve being configured to control the
temperature of the coolant contained in the cooling coil by
controlling coolant delivery into the cooling coil, wherein the
controller is configured to operate the three-way valve to reduce
the coolant delivery into the cooling coil in response to the
return air being within the predetermined setpoint temperature
range..].
.[.19. The CRAC unit according to claim 16 wherein the cooling
system comprises a two-way valve located upstream of a cooling
coil, said cooling system further comprising a refrigeration
circuit configured to cool a coolant for delivery into the cooling
coil, said two-way valve being configured to control the
temperature of the coolant contained in the cooling coil by
controlling coolant delivery into the cooling coil, wherein the
controller is configured to operate the two-way valve to reduce the
coolant delivery into the cooling coil in response to the return
air being within the predetermined setpoint temperature
range..].
.[.20. The CRAC unit according to claim 16 wherein the blower
comprises a variable frequency drive (VFD), and wherein the
controller is configured to operate the VFD to reduce the speed of
the blower in response to the return air being within the
predetermined setpoint temperature range..].
.[.21. A system for controlling a computer room air conditioning
(CRAC) unit, said system comprising: means for detecting a
temperature of air returned (Trat) into the CRAC unit; means for
determining whether the Trat is within a predetermined setpoint
temperature range, said means for determining also including means
for reducing at least one operation of the CRAC unit in response to
the Trat being within the predetermined setpoint temperature range;
and means for causing CRAC unit to enter into a reduced power mode
in response to the Trat being below the minimum setpoint
temperature level, said means for detecting Trat being configured
to detect the Trat while the CRAC unit is in the reduced power
mode, and wherein the means for determining is further configured
to cause the CRAC unit to exit from the reduced power mode in
response to the Trat exceeding a predefined temperature
level..].
.[.22. The system according to claim 21 further comprising: means
for varying a temperature of cooling fluid supplied by the CRAC
unit; means for varying a volume flow rate of cooling fluid
supplied by the CRAC unit; and means for detecting a power
consumption of the means for varying temperature and the means for
varying volume flow rate, wherein the means for determining
comprises means for calculating costs associated with the power
consumptions of the means for varying temperature and the means for
varying volume flow rate..].
.[.23. The system according to claim 22 wherein the means for
determining further comprises means for comparing the Trat to a
minimum setpoint temperature level, said means for determining
further comprising means for operating at least one of the means
for varying temperature and the means far varying volume flow rate
to operate at reduced energy consumption levels in response to the
Trat being below the minimum setpoint temperature level..].
.[.24. A computer readable storage medium on which is embedded one
or more computer programs, said one or more computer programs
implementing a method for controlling a computer room air
conditioning (CRAC) unit for energy efficient operation, said CRAC
unit being configured to receive return air, said one or more
computer programs comprising a set of instructions for: detecting
the temperature of the air returned (Trat) into the CRAC unit;
determining whether the Trat is within a predetermined setpoint
temperature range; determining whether the Trat is below a minimum
setpoint temperature level in response to the Trat being outside of
the predetermined setpoint temperature range; causing the CRAC unit
to enter into a reduced power mode in response to the Trat being
below the minimum setpoint temperature level; detecting the Trat
while the CRAC unit is in the reduced power mode; and causing the
CRAC unit to exit from the reduced power mode in response to the
Trat exceeding a predefined temperature level..].
.[.25. The computer readable storage medium according to claim 24,
said one or more computer programs further comprising a set of
instructions for: operating the CRAC unit to at least one of
decrease a temperature of cooling fluid delivered by the CRAC unit
and increase a volume flow rate of cooling fluid delivered by the
CRAC unit in response to the Trat being above the minimum setpoint
temperature level..].
.Iadd.26. A method for controlling one or more computer room air
conditioning (CRAC) units for energy efficient operation, said one
or more CRAC units comprising a cooling system having at least one
of a refrigerant and a coolant, and a blower, said one or more CRAC
units being configured to receive return air, cool said received
air and supply the cooled air, said method comprising: detecting
the temperature of the air returned (Trat) into the one or more
CRAC units; detecting the temperature of the air supplied (Tsat) by
the one or more CRAC units; calculating a caloric heat transfer
level (Q) based upon the Trat and the Tsat; determining whether the
Q is within a predetermined setpoint caloric heat transfer range;
detecting a power consumption of the cooling system; detecting a
power consumption of the blower; calculating costs associated with
the cooling system power consumption and the blower power
consumption, wherein the step of calculating costs comprises
calculating costs associated with increasing the temperature of at
least one of the refrigerant and the coolant and calculating costs
associated with decreasing a volume flow rate of air delivered by
the blower; comparing the costs associated with increasing the
temperature of at least one of the refrigerant and the coolant and
the costs associated with decreasing the volume flow rate of air
delivered by the blower; and reducing at least one operation of at
least one of the cooling system and the blower to reduce the costs
associated with operating at least one of the cooling system and
the blower and thereby increase the efficiencies of the one or more
CRAC units. .Iaddend.
.Iadd.27. The method according to claim 26, wherein the step of
reducing at least one operation of the one or more CRAC units
comprises increasing the temperature of the at least one of the
refrigerant and the coolant in response to the costs associated
with increasing the temperature of the at least one of the
refrigerant and the coolant being below the costs associated with
decreasing the volume flow rate of air delivered by the blower; and
wherein the step of reducing at least one operation of the one or
more CRAC units comprises decreasing the volume flow rate of air
delivered by the blower in response to the costs associated with
decreasing the volume flow rate of air delivered by the blower
being below the costs associated with increasing the temperature of
the at least one of the refrigerant and the coolant. .Iaddend.
.Iadd.28. The method according to claim 26, wherein the cooling
system includes at least one of a refrigerant and a coolant
configured to cool the return air, and wherein the step of
calculating costs comprises calculating costs associated with
increasing the temperature of at least one of the refrigerant and
the coolant and decreasing a volume flow rate of air delivered by
the blower, the method further comprising: determining a level of
increased temperature of the at least one of the refrigerant and
the coolant and a level of decreased volume flow rate of air
delivered by the blower that relates to minimized costs associated
with increasing the temperature of the at least one of the
refrigerant and the coolant and with decreasing the volume flow
rate of air delivered by the blower; and wherein the step of
reducing at least one operation of the one or more CRAC units
comprises implementing the determined level of increased
temperature of the at least one of the refrigerant and the coolant
and the determined level of the decreased volume flow rate of the
air delivered by the blower. .Iaddend.
.Iadd.29. The method according to claim 26, wherein the cooling
system comprises at least one of a variable capacity compressor and
a constant capacity compressor with a variable frequency drive
(VFD), and wherein the step of reducing at least one operation of
the one or more CRAC units comprises reducing the speed of the at
least one of the variable capacity compressor and the constant
capacity compressor with the VFD. .Iaddend.
.Iadd.30. The method according to claim 26, wherein the cooling
system comprises a three-way valve located upstream of a cooling
coil, said cooling system further comprising a refrigeration
circuit configured to cool a coolant for delivery into the cooling
coil, said three-way valve being configured to control the
temperature of the coolant contained in the cooling coil by
controlling coolant delivery into the cooling coil, wherein the
step of reducing at least one operation of the one or more CRAC
units comprises reducing the coolant delivery into the cooling coil
to thereby reduce the energy consumption of the refrigeration
circuit in cooling the coolant. .Iaddend.
.Iadd.31. The method according to claim 26, wherein the cooling
system comprises a two-way valve located upstream of a cooling coil
and a mass flow sensor located along a coolant line of the two-way
valve, said cooling system further comprising a refrigeration
circuit configured to cool a coolant for delivery into the cooling
coil, said two-way valve being configured to control the
temperature of the coolant contained in the cooling coil by
controlling coolant delivery into the cooling coil, wherein the
step of calculating a caloric heat transfer level (Q) comprises
calculating the Q based upon the Trat, the Tsat, and a measured
mass flow through the coolant line, and wherein the step of
reducing at least one operation of the one or more CRAC units
comprises reducing the cooling delivery into the cooling coil to
thereby reduce the energy consumption of the refrigeration circuit
in cooling the coolant. .Iaddend.
.Iadd.32. The method according to claim 26, wherein the blower
comprises a variable frequency drive (VFD), and wherein the step of
reducing at least one operation of the one or more CRAC units
comprises operating the VFD to reduce the speed of the blower to
thereby reduce the power consumption of the blower. .Iaddend.
.Iadd.33. The method according to claim 26, further comprising:
determining whether the Q is below a minimum setpoint caloric heat
transfer level in response to the Q being outside the predetermined
setpoint caloric heat transfer range; determining a volume flow
rate of air supplied by the one or more CRAC units; comparing the
volume flow rate of air with a flow rate setpoint; and increasing
the volume flow rate of air supplied by the one or more CRAC units
in response to the flow rate falling below the volume flow rate of
air setpoint. .Iaddend.
.Iadd.34. The method according to claim 33, further comprising:
causing the one or more CRAC units to enter into a reduced power
mode in response to the Q being below the minimum setpoint caloric
heat transfer level; detecting the Trat and the Tsat while the one
or more CRAC units are in the reduced power mode; calculating the Q
while the one or more CRAC units are in the reduced power mode; and
causing the one or more CRAC units to exit from the reduced power
mode in response to the Q exceeding a predefined caloric heat
transfer level. .Iaddend.
.Iadd.35. The method according to claim 34, further comprising:
causing the one or more CRAC units to enter into a reduced power
mode in response to the Q being below the minimum setpoint caloric
heat transfer level; wherein the one or more CRAC units comprise a
plurality of CRAC units, and wherein the plurality of CRAC units
are configured to communicate with each other, the method further
comprising: signaling a CRAC unit to exit from the reduced power
mode in response to a Q of another CRAC unit exceeding a predefined
level. .Iaddend.
.Iadd.36. The method according to claim 26, wherein the one or more
CRAC units comprise a plurality of CRAC units, and wherein one or
more of the plurality of CRAC units are configured with at least
one of a three-way valve and a two-way valve to control coolant
delivery into a cooling coil of the one or more of the CRAC units,
the method further comprising: operating the plurality of CRAC
units to enable the one or more of the plurality of CRAC units to
maintain the at least one of the three-way valve and the two-way
valve substantially at 100% open positions to thereby reduce energy
usage by the one or more of the plurality of CRAC units.
.Iaddend.
.Iadd.37. A computer room air conditioning (CRAC) unit comprising:
a cooling system, a blower, and a power meter configured to detect
a power consumption of the cooling system and the blower, a first
sensor configured to detect a temperature of return air (Trat); a
second sensor configured to detect a temperature of supply air
(Tsat); and a controller configured to calculate a caloric heat
transfer level (Q) based upon the Trat and the Tsat, wherein the
controller is also configured to determine whether the Q is within
a predetermined setpoint caloric heat transfer range and to
determine whether the Q is below a minimum setpoint caloric heat
transfer level in response to the Q being outside of the
predetermined setpoint caloric heat transfer range, wherein the
controller is configured to cause the CRAC unit to enter into a
reduced power mode in response to the Q being below the minimum
setpoint caloric heat transfer level; and wherein the first
temperature sensor is configured to detect the Trat and the second
temperature sensor is configured to detect the Tsat while the CRAC
unit is in the reduced power mode, wherein the controller is
configured to calculate the Q while the CRAC unit is in the reduced
power mode, and wherein the controller is configured to withdraw
the CRAC unit from the reduced power mode in response to the Q
exceeding a predefined caloric heat transfer level. .Iaddend.
.Iadd.38. The CRAC unit according to claim 37, wherein the
controller is configured to calculate costs associated with the
power consumptions of the cooling system and the blower and to base
the reduction of the at least one operation of the CRAC unit on the
costs associated with operating the cooling system and the blower.
.Iaddend.
.Iadd.39. The CRAC unit according to claim 37, wherein the cooling
system comprises at least one of a variable capacity compressor and
a constant capacity compressor with a variable frequency drive
(VFD), and wherein the controller is operable to reduce operations
of the at least one of the variable capacity compressor and the
constant capacity compressor with a VFD in response to the
temperature of the return air being within a predetermined setpoint
temperature range. .Iaddend.
.Iadd.40. The CRAC unit according to claim 37, wherein the cooling
system comprises a three-way valve located upstream of a cooling
coil, said cooling system further comprising a refrigeration
circuit configured to cool a coolant for delivery into the cooling
coil, said three-way valve being configured to control the
temperature of the coolant contained in the cooling coil by
controlling coolant delivery into the cooling coil, wherein the
controller is configured to operate the three-way valve to reduce
the coolant delivery into the cooling coil in response to the
return air being within a predetermined setpoint temperature range.
.Iaddend.
.Iadd.41. The CRAC unit according to claim 37, wherein the cooling
system comprises a two-way valve located upstream of a cooling coil
and a mass flow sensor located along a coolant line of the two-way
valve, said cooling system further comprising a refrigeration
circuit configured to cool a coolant for delivery into the cooling
coil, said two-way valve being configured to control the
temperature of the coolant contained in the cooling coil by
controlling coolant delivery into the cooling coil, wherein the
controller is configured to calculate the Q based upon the Trat,
the Tsat, and a measured mass flow through the coolant line, and
wherein the controller is configured to operate the two-way valve
to reduce the coolant delivery into the cooling coil in response to
the Q being within the predetermined setpoint caloric heat transfer
range. .Iaddend.
.Iadd.42. The CRAC unit according to claim 37, wherein the blower
comprises a variable frequency drive (VFD), and wherein the
controller is configured to operate the VFD to reduce the speed of
the blower in response to the Q being within the predetermined
setpoint caloric heat transfer range. .Iaddend.
.Iadd.43. A system for controlling a computer room air conditioning
(CRAC) unit, said system comprising: means for varying a
temperature of air supplied by the CRAC unit; means for varying a
volume flow rate of air supplied by the CRAC unit; means for
detecting a power consumption of the means for varying temperature
and the means for varying volume flow rate; means for detecting a
temperature of air returned (Trat) into the CRAC unit; means for
detecting a temperature of air supplied (Tsat) by the CRAC unit;
means for calculating a caloric heat transfer level (Q) based upon
the detected Trat and Tsat, wherein the means for calculating
comprises means for determining whether the Q is within a
predetermined setpoint caloric heat transfer range, the means for
calculating further comprising means for reducing at least one
operation of the CRAC unit in response to the Q being within the
predetermined setpoint caloric heat transfer range; wherein the
means for determining further comprises means for comparing the Q
to a minimum setpoint caloric heat transfer level, said means for
determining further comprising means for operating at least one of
the means for varying temperature and the means for varying volume
flow rate to operate at reduced energy consumption levels in
response to the Q being below the minimum setpoint caloric heat
transfer level; and wherein the means for determining further
comprises means for causing the CRAC unit to enter into a reduced
power mode in response to the Q being below the minimum setpoint
caloric heat transfer level, said means for detecting Trat being
configured to detect the Trat and the means for detecting Tsat
being configured to detect the Tsat while the CRAC unit is in the
reduced power mode, and wherein the means for determining is
further configured to cause the CRAC unit to exit from the reduced
power mode in response to the Q exceeding a predefined caloric heat
transfer level. .Iaddend.
.Iadd.44. The system according to claim 43, wherein the means for
determining further comprises means for calculating costs
associated with the power consumptions of the means for varying
temperature and the means for varying volume flow rate.
.Iaddend.
.Iadd.45. A computer readable storage medium on which is embedded
one or more computer programs, said one or more computer programs
implementing a method for controlling a computer room air
conditioning (CRAC) unit for energy efficient operation, said CRAC
unit being configured to receive return air, cool said received air
and supply the cooled air, said one or more computer programs
comprising a set of instructions for: detecting the temperature of
the air returned (Trat) into the CRAC unit; detecting the
temperature of the air supplied (Tsat) by the CRAC unit;
calculating a caloric heat transfer level (Q) based upon the Trat
and the Tsat; determining whether the Q is within a predetermined
setpoint caloric heat transfer range; determining whether the Q is
below a minimum setpoint caloric heat transfer level in response to
the Q being outside the predetermined setpoint caloric heat
transfer range; causing the CRAC unit to enter into a reduced power
mode in response to the Q being below the minimum setpoint caloric
heat transfer level; detecting the Trat and the Tsat while the CRAC
unit is in the reduced power mode; calculating the Q while the CRAC
unit is in the reduced power mode; and causing the CRAC unit to
exit from the reduced power mode in response to the Q exceeding a
predefined caloric heat transfer level. .Iaddend.
.Iadd.46. The computer readable storage medium according to claim
45, said one or more computer programs further comprising a set of
instructions for: operating the CRAC unit to at least one of
decrease a temperature of air delivered by the CRAC unit and
increase a volume flow rate of air delivered by the CRAC unit in
response to the Q being above the minimum setpoint caloric heat
transfer level. .Iaddend.
Description
BACKGROUND OF THE INVENTION
A data center may be defined as a location, for instance, a room,
that houses computer systems arranged in a number of racks. A
standard rack, for example, an electronics cabinet, is defined as
an Electronics Industry Association (EIA) enclosure, 78 in. (2
meters) high, 24 in. (0.61 meter) wide and 30 in. (0.76 meter)
deep. These racks are configured to house a number of computer
systems, about forty (40) systems, with future configurations of
racks being designed to accommodate 200 or more systems. The
computer systems typically include a number of printed circuit
boards (PCBs), mass storage devices, power supplies, processors,
micro-controllers, and semi-conductor devices, that dissipate
relatively significant amounts of heat during their operation. For
example, a typical computer system comprising multiple
microprocessors dissipates approximately 250 W of power. Thus, a
rack containing forty (40) computer systems of this type dissipates
approximately 10 KW of power.
The power required to transfer the heat dissipated by the
components in the racks to the cool air contained in the data
center is generally equal to about 10 percent of the power needed
to operate the components. However, the power required to remove
the heat dissipated by a plurality of racks in a data center is
generally equal to about 50 percent of the power needed to operate
the components in the racks. The disparity in the amount of power
required to dissipate the various heat loads between racks and data
centers stems from, for example, the additional thermodynamic work
needed in the data center to cool the air. In one respect, racks
are typically cooled with fans that operate to move cooling air
across the heat dissipating components; whereas, data centers often
implement reverse power cycles to cool heated return air. The
additional work required to achieve the temperature reduction, in
addition to the work associated with moving the cooling fluid in
the data center and the condenser, often add up to the 50 percent
power requirement. As such, the cooling of data centers presents
problems in addition to those faced with the cooling of the
racks.
Conventional data centers are typically cooled by operation of one
or more computer room air conditioning (CRAC) units. For example,
compressors of CRAC units typically consume a minimum of about
thirty (30) percent of the required operating energy to
sufficiently cool the data centers. The other components, for
example, condensers and air movers (fans), typically consume an
additional twenty (20) percent of the required total operating
energy. As an example, a high density data center with 100 racks,
each rack having a maximum power dissipation of 10 KW, generally
requires 1 MW of cooling capacity. CRAC units with a capacity of 1
MW of heat removal generally requires a minimum of 300 KW input
compressor power in addition to the power needed to drive the air
moving devices, for instance, fans and blowers. Conventional data
center CRAC units do not vary their cooling fluid output based on
the distributed needs of the data center. Instead, these CRAC units
generally operate at or near a maximum compressor power level even
when the heat load is reduced inside the data center.
The substantially continuous operation of the CRAC units is
generally designed to operate according to a worst-case scenario.
For example, CRAC units are typically designed around the maximum
capacity and redundancies are utilized so that the data center may
remain on-line on a substantially continual basis. However, the
computer systems in the data center may only utilize around 30-50%
of the maximum cooling capacity. In this respect, conventional
cooling systems often attempt to cool components that may not be
operating at a level which may cause their temperatures to exceed a
predetermined temperature range. Consequently, many conventional
cooling systems often incur greater amounts of operating expenses
than may be necessary to sufficiently cool the heat generating
components contained in the racks of data centers.
Other types of conventional CRAC units are configured to vary the
temperature of the cooling fluid as well as the volume flow rate of
the cooling fluid supplied into the data center. These types of
CRAC units often include cooling systems configured to vary the
temperature of the received cooling fluid prior to delivery into
the data center. The cooling systems include variable capacity
compressors and chilled water systems. In addition, these CRAC
units also include blowers with variable frequency drives
configured to vary the volume flow rate of the cooling fluid
delivered into the data center.
The temperatures to which the cooling systems cool the cooling
fluid received from the data center are often based upon the
detected temperature of the cooling fluid returned into the CRAC
units. In addition, the speeds of the blowers are often correlated
to the operations of the cooling systems. In this respect, as the
cooling systems are operated to reduce the temperature of the
cooling fluid, the blowers are also operated to increase the volume
flow rate of the cooled cooling fluid. Operating the cooling
systems in this manner is inefficient as both the reduction in
cooling fluid temperature and increase in the cooling fluid volume
flow rate are typically unnecessary to maintain the components in
the data center within predetermined temperature ranges.
A method for controlling one or more computer room air conditioning
(CRAC) units for energy efficient operation is disclosed. In the
method, the temperature of the air returned (Trat) into the one or
more CRAC units and the temperature of the air supplied (Tsat) by
the one or more CRAC units is detected. The caloric heat transfer
level (Q) is calculated based upon the Trat and the Tsat and it is
determined whether the Q is within a predetermined setpoint caloric
heat transfer range. In addition, at least one operation of the one
or more CRAC units is reduced in response to the Q being within the
predetermined setpoint caloric heat transfer range to thereby
increase the efficiencies of the one or more CRAC units.
BRIEF DESCRIPTION OF THE DRAWINGS
Features of the present invention will become apparent to those
skilled in the art from the following description with reference to
the figures, in which:
FIG. 1A shows a simplified plan view of a data center, according to
an embodiment of the invention;
FIG. 1B shows a cross-sectional side view taken along lines
IIA--IIA of FIG. 1A, according to an embodiment;
FIG. 1C shows a cross-sectional side view taken along lines
IIB--IIB of FIG. 1A, according to another embodiment;
FIG. 1D shows a cross-sectional side view taken along lines
IIB--IIB of FIG. 1A, according to a further embodiment;
FIGS. 2A-2C are respective block diagrams of CRAC control systems
operable to control CRAC units according to various
embodiments;
FIG. 3 illustrates a graph of various cooling system operating
levels and the costs associated with their operations, according to
an embodiment;
FIGS. 4A and 4B illustrate flow diagrams of operational modes of
methods for CRAC unit control based upon setpoint temperatures and
setpoint caloric heat transfer determinations, respectively,
according to various embodiments; and
FIG. 5 illustrates a computer system which may be used as a
platform for various operations described in the present
disclosure, according to an embodiment.
DETAILED DESCRIPTION OF THE INVENTION
For simplicity and illustrative purposes, the present invention is
described by referring mainly to an exemplary embodiment thereof.
In the following description, numerous specific details are set
forth in order to provide a thorough understanding of the present
invention. It will be apparent however, to one of ordinary skill in
the art, that the present invention may be practiced without
limitation to these specific details. In other instances, well
known methods and structures have not been described in detail so
as not to unnecessarily obscure the present invention.
Throughout the present disclosure, reference is made to "cooling
fluid" and "heated cooling fluid". For purposes of simplicity,
"cooling fluid" may generally be defined as air that has been
cooled by a cooling device, e.g., an air conditioning unit. In
addition, "heated cooling fluid" may generally be defined as
cooling fluid that has been heated. It should be readily apparent,
however, that the terms "cooling fluid" are not intended to denote
air that only contains cooled fluid and that "heated cooling fluid"
only contains cooling fluid that has been heated. Instead,
embodiments of the invention may operate with air that contains a
mixture of heated cooling fluid and cooling fluid. In addition,
cooling fluid and heated cooling fluid may denote gases other than
air, e.g., refrigerant and other types of gases known to those of
ordinary skill in the art that may be used to cool electronic
components.
According to an example, computer room air conditioning (CRAC)
units include systems to enable energy efficient cooling and supply
of cooling fluid to a data center. In addition, the systems of the
CRAC units are operated in manners to generally optimize the costs
associated with cooling components contained in the data center.
The CRAC units may thus comprise variably controllable systems
designed and operated to cool the components under substantially
optimized cost structures.
In one example, the variably controllable systems include chilled
fluid systems having a two-way or a three-way valve for variably
controlling the flow of chilled fluid, for instance, water,
refrigerant, or other coolant, etc., through a cooling coil. In
another example, the variably controllable systems include variable
capacity compressors designed to variably control cooling of a
refrigerant configured to absorb heat from the cooling fluid
received from the data center. In either of the examples above, the
variably controllable systems include blowers with variable
frequency drives configured to control the outputs of the cooling
fluid cooled through heat transfer with the fluid contained in the
cooling coil.
The variably controllable systems may be operated in manners to
generally optimize their energy utilization while maintaining
thermal management requirements of the components in the data
centers. In one respect, the variably controllable systems may be
operated in substantially independent manners to enable the
substantial optimization of energy utilization. For instance, the
variably controllable systems may be operated to decrease output of
cooled cooling fluid in response to a decrease in the temperature
of the cooled cooling fluid. In addition, the variably controllable
systems may be operated to increase output of cooled cooling fluid
in response to an increase in the temperature of the cooled cooling
fluid. As the energy requirements of the variably controllable
systems may be minimized through these operations, the costs
associated with maintaining the components within the bounds of
thermal management concerns may also be substantially
minimized.
With reference first to FIG. 1A, there is shown a simplified plan
view of a data center 100, according to an embodiment of the
invention. The terms "data center" are generally meant to denote a
room or other space and are not meant to limit the invention to any
specific type of room where data is communicated or processed, nor
should it be construed that use of the terms "data center" limits
the invention in any respect other than its definition
hereinabove.
As shown in the FIG. 1A, the data center 100 includes a plurality
of racks 102, for instance, electronics cabinets, generally
positioned in substantially parallel rows. The racks 102 each house
one or more components (not shown). These components may include,
for instance, computers, servers, monitors, hard drives, disk
drives, etc., designed to perform various operations. Some
operations of the components may include, for instance, computing,
switching, routing, displaying, etc. These components may comprise
subsystems (not shown), for example, processors, micro-controllers,
high-speed video cards, memories, semi-conductor devices, and the
like to perform these functions. In the performance of these
electronic functions, the components, and therefore the subsystems,
generally dissipate relatively large amounts of heat. Because the
racks 102 have been known to include upwards of forty (40) or more
subsystems, they may dissipate substantially large amounts of heat.
Cooling fluid is therefore supplied to generally flow around and
through the components to absorb the dissipated heat through
convection, to maintain the subsystems and the components generally
within predetermined operating temperature ranges.
The cooling fluid is illustrated as being supplied through vent
tiles 104 in the floor 106 of the data center 100. As will be seen
in FIGS. 1B-1D, the floor 106 is a raised floor with a space
therebelow. The space generally enables power lines, communication
lines, and other wires (not shown), to be located below the floor
106 such that the wires and communication lines are substantially
positioned away from an upper surface of the floor 106. The space
may also function as a plenum for delivery of cooling fluid from
computer room air conditioner (CRAC) units 108 and 110 to the racks
102. The vent tiles 104 are illustrated as being positioned between
pairs of adjacent rows of racks 102.
Air or other cooling fluid is received by the CRAC units 108 and
110, cooled through heat transfer within the CRAC units 108 and 110
and supplied into the space below the floor 106. The cooled cooling
fluid is supplied from the space below the floor 106, through the
vent tiles 104 and through the racks 102 to cool the components
housed in the racks 102. The CRAC units 108 and 110 may control
various characteristics of the cooling fluid supplied to the racks
102. For instance, the CRAC units 108 and 110 may contain variably
controllable systems (not shown) configured to vary the temperature
of the cooling fluid supplied to the racks 102. In addition, the
CRAC units 108 and 110 may contain systems configured to vary the
volume flow rate of the cooling fluid supplied to the racks 102.
Various types of systems arranged in various configurations may be
employed to control the temperature and volume flow rate of the
cooling fluid. Examples of suitable components and configurations
are illustrated in FIGS. 1B-1D, which are described in greater
detail hereinbelow.
The aisles 116 between the racks 102 having vent tiles 104 located
therebetween may be considered as cool aisles 116. These aisles 116
are considered "cool aisles" because they are configured to receive
cooling fluid from the vent tiles 104. In addition, the racks 102
are positioned to receive cooling fluid from the cool aisles 116.
The aisles 118 between the racks 102 which do not have vent tiles
104 may be considered as hot aisles 118. These aisles are
considered "hot aisles" because they are positioned to receive
cooling fluid heated by the components in the racks 102.
Also illustrated in FIG. 1A is a computing device 112. The
computing device 112 may comprise a computer system, a controller,
microprocessor, etc., configured to control operations of the CRAC
units 108 and 110. More particularly, the computing device 112 may
be configured to receive input from sensors (not shown) and to vary
operations of the various variable controllable systems contained
in the CRAC units 108 and 110. The computing device 112 may also be
configured to receive input from a user, for instance, data center
personnel, an administrator, a manager, etc. The input received
from a user may comprise various set points by which the computing
device 112 may determine how and when to manipulate the operations
of the variable controllable systems. The computing device 112 may,
in one instance, compare the conditions, for example, temperature,
humidity, pressure, etc., detected by the sensors with
predetermined set points for those conditions and control the
variably controllable systems in response to differences between
the set points and the detected conditions.
The computing device 112 is illustrated as communicating with the
CRAC units 108 and 110 via wired communication lines 114. However,
it should be understood that communications between the CRAC units
108 and 110 and the computing device 112 may be effectuated through
a wireless protocol, such as IEEE 802.11b, 802.11g, wireless serial
connection, Bluetooth, etc., or combinations thereof, without
departing from a scope of the invention. In addition, although a
single computing device 112 is illustrated as controlling both CRAC
units 108 and 110, each of the CRAC units 108 and 110 may include
their own computing device 112. Moreover, the computing device 112
may comprise controllers that are integrally formed or otherwise
form part of each of the CRAC units 108 and 110. Thus, although the
data center 100 has been illustrated as containing a certain
configuration, it should readily be understood that various other
configurations are possible for the data center 100 without
departing from a scope of the invention.
The data center 100 depicted in FIG. 1A represents a generalized
illustration and other components may be added or existing
components may be removed or modified without departing from the
scope of the invention. For example, the data center 100 may
include any number of racks and various other apparatuses known to
be housed in data centers. Thus, although the data center 100 is
illustrated as containing four rows of racks 102, it should be
understood that the data center 100 may include any number of
racks, e.g., 100 racks, without departing from the scope of the
invention. The depiction of four rows of racks 102 is thus for
illustrative and simplicity of description purposes only and is not
intended to limit the invention in any respect. In addition, the
data center 100 may include any number of CRAC units 108 and 110,
each having a number of different types cooling systems.
The data center 100 may also include a lowered ceiling (not shown)
configured with returns for receiving heated cooling fluid from
within the data center 100. The lowered ceiling may also include or
form a plenum for directing the heated cooling fluid to the CRAC
units 108 and 110. An example of a data center 100 having a lowered
ceiling may be found in co-pending and commonly assigned U.S.
patent application Ser. No. 10/262,879, filed on Apr. 17, 2002, the
disclosure of which is hereby incorporated by reference in its
entirety.
In FIGS. 1B-1D, there are shown simplified partial sections of the
data center 100 with three examples of the CRAC units 108, 110, and
110'. FIGS. 1B-1D represent generalized illustrations and other
components may be added or existing components may be removed or
modified without departing from the scope of the invention. In
addition, for instance, although the CRAC units 108 and 110 are
illustrated as having different configurations from each other, the
CRAC units 108 and 110 employed in the data center 100 illustrated
in FIG. 1A may have the same type of configuration without
departing from a scope of the invention.
With particular reference first to FIG. 1B, there is shown a
cross-sectional side view taken along lines IIA--IIA of FIG. 1A. As
shown, the CRAC unit 108 comprises a vapor-compression type air
conditioning unit. More particularly, the CRAC unit 108 includes a
blower 120 or a fan for delivering air or other cooling fluid into
a space 122. The space 122 may be created beneath the raised floor
106 and may include or otherwise function as a plenum. The blower
120 may also operate to draw heated cooling fluid from the data
center 100 by generally forcing airflow through the CRAC unit 108.
In this regard, the CRAC unit 108 may include one or more openings
to receive the heated cooling fluid from the data center 100. A
variable frequency drive (VFD) 124 is shown as being positioned
adjacent to the blower 120. The VFD 124 generally operates to
control the blower 120 to vary the volume flow rate of cooling
fluid flow into and out of the CRAC unit 108.
The VFD 124 may comprise any reasonably suitable VFD that is
commercially available from any number of manufacturers. The VFD
124 generally operates to variably control the speed of an
alternating current (AC) induction motor. More particularly, the
VFD 124 may operate to convert power from fixed voltages/fixed
frequencies to variable voltages/variable frequencies. By
controlling the voltage/frequency levels of the blower 120, the
volume flow rate of the cooling fluid supplied by the CRAC unit 108
may also be varied.
Although the VFD 124 is illustrated as being positioned adjacent to
the blower 120, the VFD 124 may be positioned at any reasonably
suitable location with respect to the blower 120 without departing
from a scope of the invention. The VFD 120 may be positioned, for
instance, outside of the CRAC unit 108 or various other locations
with respect to the CRAC unit 108.
In operation, the heated cooling fluid (shown as the arrow 126)
enters into the CRAC unit 108 and is cooled by operation of a
cooling coil 128a, .[.acompressor.]. .Iadd.a compressor
.Iaddend.130, .[.acondenser.]. .Iadd.a condenser .Iaddend.132, and
an expansion valve 134, which may operate under a vapor-compression
cycle. By way of example, a refrigerant, for instance, R-134a,
etc., may be contained in a refrigerant line 136, which generally
forms a loop between the various components of the cooling system
containing the CRAC unit 108. More particularly, the refrigerant is
supplied into the cooling coil 128a where it absorbs heat through
convection from the cooling fluid received from the data center
100. The cooled cooling fluid then flows out of the CRAC unit 108
and into the space 122 as indicated by the arrow 142.
The heated refrigerant flows into the compressor 130, which
compresses or pressurizes the refrigerant. The compressor 130 may
comprise a variable capacity compressor or it may comprise a
constant capacity compressor having a hot gas bypass (not shown).
In any regard, the pressurized refrigerant then flows into the
condenser 132 where some of the heat in the refrigerant is
dissipated into the air around the data center 100. Although not
shown, the condenser 132 may include a fan to generally enhance
heat dissipation of the refrigerant. The refrigerant then flows
through the expansion valve 134 and back through the cooling coil
128a. This process may be substantially continuously repeated as
needed to cool the cooling fluid drawn into the CRAC unit 108. In
terms of cooling system efficiency, it is generally desirable that
the heated cooling fluid supplied into the CRAC unit 108 is
composed of the relatively warmest portion of air in the room
100.
The cooling system illustrated in FIG. 1B has been described in a
relatively simplified manner. Therefore, it should be understood
that the cooling system incorporating the CRAC unit 108 may include
additional components without departing from a scope of the
invention. For instance, a three-way valve may be included to allow
some of the refrigerant to bypass the compressor 130 and return
into the cooling coil 128a. The three-way valve may be used, for
instance, to divert some of the refrigerant exiting the cooling
coil 128a back into the refrigerant line 136 for re-entry into the
cooling coil 128 to generally ensure that the refrigerant is almost
entirely in gaseous form prior to entering the compressor 130.
As described hereinabove, the computing device 112 may be
configured to control various operations of the CRAC unit 108. For
instance, the computing device 112 may be configured to control the
operations of the compressor 130 to thereby control the temperature
and flow of the refrigerant flowing through the cooling coil 128a.
The computing device 112 may also be configured to control the VFD
124. More particularly, the computing device 112 may control the
motor speed of a blower 122 to thereby control the volume flow rate
of the cooled cooling fluid supplied by the CRAC unit 108. By
controlling the temperature of the refrigerant and the airflow rate
through the CRAC unit 108, the computing device 112 is generally
capable of controlling the level of heat transfer between the
heated cooling fluid and the refrigerant to thereby control the
temperature of the cooling fluid supplied into the data center
100.
According to an example, the computing device 112 is configured to
substantially independently control the compressor 130 and the VFD
124. The computing device 112 may be configured to determine
manners in which to control the compressor 130 and the VFD 124
based upon, for instance, environmental condition measurements
obtained by sensors 138 and 140. As shown in FIG. 1B, the sensor
138 is positioned at an inlet of the CRAC unit 108 and is thus
configured to measure one or more conditions of the cooling fluid
returning to the CRAC unit 108.
In addition, the sensor 140 is positioned at an outlet of the CRAC
unit 108 and is thus configured to measure one or more conditions
of the cooling fluid supplied by the CRAC unit 108. Alternatively,
the sensor 140 may be positioned at an inlet of a rack 102 or near
a vent tile 104, provided that the rack 102 or the vent tile 104 is
located within a relatively close proximity to the exhaust of CRAC
unit 108. More particularly, the sensor 140 may be positioned at a
location substantially downstream of the CRAC unit 108 where the
temperature of the cooling fluid supplied by the CRAC unit 108 does
not vary beyond a certain level from the time the cooling fluid
exits the CRAC unit 108. In one respect, the computing device 112
may be configured to control the compressor 130 and the VFD 124 to
substantially minimize energy usage by the CRAC unit 110 as will
described in greater detail hereinbelow.
With reference now to FIG. 1C, there is shown a cross-sectional
side view taken along lines IIB--IIB of FIG. 1A. As shown, the CRAC
unit 110 comprises a chiller type air conditioning unit. More
particularly, the CRAC unit 110 includes a blower 120 or a fan for
delivering air or other cooling fluid into a space 122. As
described hereinabove with respect to FIG. 1B, the space 122 may be
created beneath the raised floor 106 and may include or otherwise
function as a plenum. The blower 120 may also operate to draw
heated cooling fluid from the data center 100 by generally forcing
airflow through the CRAC unit 110. In this regard, the CRAC unit
110 may include one or more openings to receive the heated cooling
fluid from the data center 100. A variable frequency drive (VFD)
124 is shown as being positioned adjacent to the blower 120. The
VFD 124 generally operates to control the blower 120 to vary the
volume flow rate of cooling fluid flow into and out of the CRAC
unit 110 as described hereinabove.
The arrow 126 indicates the heated cooling fluid received by the
CRAC unit 110. The heated cooling fluid flows past a cooling coil
128b and exchanges heat with a coolant contained in the cooling
coil 128b. The coolant may comprise water or other fluid capable of
being heated and cooled in a repeated manner. The speed at which
the heated cooling fluid flows past the cooling coil 128b and the
temperature of the coolant contained in the cooling coil 128b
generally affect the temperature of the cooling fluid. Thus, for
instance, as the temperature of the coolant decreases with the
blower 120 operating at a constant level, so too does the
temperature of the cooling fluid. The cooled cooling fluid then
flows out of the CRAC unit 110 and into the space 122 as indicated
by the arrow 142.
The temperature of the coolant contained in the cooling coil 128b
may be controlled through operation of a cooling system comprising
the CRAC unit 110. In operation, the coolant receives heat from the
cooling fluid received into the CRAC unit 110. The heat transfer
from the cooling fluid into the coolant in the cooling coil 128b
may be effectuated through convection. The heated coolant then
flows out of the cooling coil 128b and into a first coolant line
144a. The heated coolant flows through the first coolant line 144a
and into a heat exchanger 146 which may also include a coil 148.
The heated coolant is cooled through heat transfer with a
refrigeration circuit 150, which includes an evaporator 152, a
compressor 154, a condenser 156 and an expansion valve 158. The
refrigeration circuit 150 may operate under a vapor-compression
cycle generally known to those of ordinary skill in the art.
The cooled coolant returns toward the cooling coil 128b through a
second coolant line 144b. A three-way valve 160 is provided
generally upstream from the cooling coil 128b along the second
coolant line 144b. The three-way valve 160 generally operates to
control the amount of cooled coolant supplied into the cooling coil
128b. The three-way valve 160 may control the cooled coolant
delivery into the cooling coil 128b by diverting some or all of the
cooled coolant back into the first coolant line 144a through a
third coolant line 144c, thereby bypassing the cooling coil 128b.
The three-way valve 160 may thus substantially control the
temperature of the coolant delivered into the cooling coil 128b by
controlling the amount of cooled coolant delivered into the cooling
coil 128b. In one respect, therefore, the three-way valve 160 may
also control the temperature of the cooling fluid supplied into the
space 122.
A pump 162 is illustrated as being located along the first coolant
line 144a. The pump 162, however, may be positioned along the
second coolant line 144b without departing from a scope of the
invention. The pump 162 generally operates to pressurize the
coolant contained in the coolant lines 144a-144c, such that the
coolant may flow along the circuit created by the coolant lines
144a-144c. The pump 162 may be controlled in addition to or in
place of the three-way valve 160 to enable reduced energy usage. In
one regard, because the pump 162 may be operated to vary the flow
rate of the coolant in the coolant lines 144a-144c, the pump 162
operations may be reduced, for instance, commensurate with
increases in the cooling fluid temperature. In addition, a valve
configured to enable a substantially constant and predictable
coolant flow in the coolant lines 144a and 144b may be positioned
upstream of the pump 162. The valve may include a spring-loaded
valve configured to deliver constant flow for certain pressure
ranges. A suitable valve may be available from GRISWOLD CONTROLS of
Irvine, Calif.
In operation, the temperature of the coolant contained in the
coolant lines 144a-144c generally dictates the amount of energy
consumed in operating the CRAC unit 110. More particularly, the
refrigeration circuit 150 generally requires less energy when the
temperature of the coolant entering into the heat exchanger 146 is
lower. In contrast, the refrigeration circuit 150 generally
consumes greater amounts of energy when the temperature of the
coolant entering into the heat exchanger 146 is higher. In
addition, the desired temperature of the coolant supplied from the
heat exchanger 146 also generally dictates the amount of energy
consumed by the refrigeration circuit 150. That is, the more work
required by the refrigeration circuit 150 in reducing the
temperature of the coolant, the greater the energy consumption.
In one example, the refrigeration circuit 150 is operated to cool
the coolant to substantially the highest temperature where the
three-way valve 160 may remain in a generally fully open position
to thus cause substantially all of the coolant to flow into the
cooling coil 128b. In this regard, the energy consumed by the
refrigeration circuit 150 may be substantially minimized as
relatively no coolant is diverted away from the cooling coil 128b.
Moreover, energy consumption of the refrigeration circuit 150 may
be lower because the temperature of the refrigerant contained in
the refrigeration circuit 150 may be higher and because coolant at
higher temperatures generally gains less energy from its
surroundings. When multiple CRAC units 110 are employed to cool the
components in a data center 100, at least one of the CRAC units 110
may be operated in this manner to thereby reduce energy usage of
the at least one of the CRAC units 110.
The computing device 112 is configured to substantially
independently control the three-way valve 160 and the VFD 124 to
thereby control the temperature of the cooling fluid and the volume
flow rate of the supplied cooling fluid. The computing device 112
may be configured to determine manners in which to control the
three-way valve 160 and the VFD 124 based upon, for instance,
environmental condition measurements obtained by the sensors 138
and 140. In one respect, the computing device 112 may be configured
to control the three-way valve 160 and the VFD 124 to substantially
minimize energy usage by the CRAC unit 110 as will described in
greater detail hereinbelow.
Although reference is made in FIGS. 1B and 1C to the use of a
blower 120 to draw heated cooling fluid from the data center 100,
it should be understood that any other reasonably suitable manner
of cooling fluid removal from the data center 100 may be
implemented without departing from the scope of the invention. By
way of example, a separate fan or blower (not shown) may be
employed to draw heated cooling fluid from the data center 100. In
addition, the CRAC units 108 and 110 may include a humidifier
and/or a dehumidifier as is known to those of ordinary skill in the
art.
In addition, one or more isolation valves (not shown) may be placed
at various locations along the coolant lines 144a-144c to thereby
enable, for instance, preventative maintenance.
FIG. 1D depicts a cross-sectional side view taken along lines
IIB--IIB of FIG. 1A, according to another example. In FIG. 1D,
there is shown a CRAC unit 110'. The CRAC unit 110' includes all of
the components illustrated in FIG. 1C and thus specific reference
to those components are not reiterated. Instead, only those
elements depicted in FIG. 1D, which differ from the components
depicted in FIG. 1C are discussed hereinbelow.
The major difference between the CRAC unit 110 and the CRAC unit
110' is that the CRAC unit 110' includes a two-way valve 164 in
place of the three-way valve 160. In addition, the CRAC unit 110'
does not include the third coolant line 144c illustrated in FIG.
1C. The CRAC unit 110' also includes a mass flow sensor 166
positioned along the first coolant line 144a. The mass flow sensor
166 is configured to detect the mass flow rate of the fluid flowing
through the first coolant line 144a. The mass flow sensor 166 may
be required in the CRAC unit 110' since the two-way valve 164 does
not enable constant coolant flow through the coolant lines 144a and
144b, as is the case with the three-way valve 160 of the CRAC unit
110. In addition, with use of the two-way valve 164, the valve
orifice opening in the two-way valve 164 may require
calibration.
The pump 162 may be controlled in addition to or in place of the
two-way valve 164 to enable reduced energy usage. In one regard,
because the pump 162 may be operated to vary the flow rate of the
coolant in the coolant lines 144a-144c, the pump 162 operations may
be reduced, for instance, commensurate with increases in the
cooling fluid temperature.
In addition, the temperature of the coolant supplied from the heat
exchanger 146 also generally dictates the amount of energy consumed
by the refrigeration circuit 150. That is, the more work required
by the refrigeration circuit 150 in reducing the temperature of the
coolant, the greater the energy consumption. In one example, the
refrigeration circuit 150 is operated to cool the coolant to
substantially the highest temperature where the two-way valve 164
may remain in a generally fully open position to thus cause
substantially all of the coolant to flow into the cooling coil
128b. The energy consumed by the refrigeration circuit 150 may be
lower because the temperature of the refrigerant contained in the
refrigeration circuit 150 may be higher and because coolant at
higher temperatures generally gains less energy from its
surroundings. When multiple CRAC units 110 are employed to cool the
components in a data center 100, at least one of the CRAC units 110
may be operated in this manner to thereby reduce energy usage of
the at least one of the CRAC units 110.
FIGS. 2A-2C are respective block diagrams 200, 250, and 250' of
CRAC control systems 202, 252, and 252' operable to control the
CRAC units 108, 110 and 110'. The following descriptions of the
block diagrams 200, 250, 250' are some manners of a variety of
different manners in which such CRAC control systems 202, 252, 252'
may be configured. In addition, it should be understood that the
block diagrams 200, 250, 250' may include additional components and
that some of the components described herein may be removed and/or
modified without departing from the scope the invention.
With reference first to FIG 2A, the CRAC control system 202
includes a controller 204 for controlling operations of the CRAC
control system 202. The controller 204 may comprise the computing
device 112 and thus may also comprise a microprocessor, a
micro-controller, an application specific integrated circuit
(ASIC), and the like. The controller 204 is generally configured to
receive temperature measurements from an inlet temperature sensor
138, an outlet temperature sensor 140 and an optional power meter
206.
As described hereinabove, the inlet temperature sensor 138
generally operates to detect the temperature of the heated cooling
fluid received by the CRAC unit 108. In addition, the outlet
temperature sensor 140 is configured to detect the temperature of
the cooled cooling fluid supplied by the CRAC unit 108. In a
general sense, the controller 204 may determine manners in which to
control the CRAC unit 108 based substantially upon the temperatures
detected by the temperature sensors 138 and 140.
Communications between the sensors 138 and 140 and the controller
204 may be effectuated through, for instance, an Ethernet-type
connection or through a wired protocol, such as IEEE 802.3, etc.,
or wireless protocols, such as IEEE 802.11b, 802.11g, wireless
serial connection, Bluetooth, etc., or combinations thereof.
The temperature information received from the temperature sensors
138 and 140 may be stored in a memory 208. In addition, various
control schemes for operating the CRAC unit 108 may be stored in
the memory 208. In this regard, the memory 208 may comprise a
traditional memory device, such as, volatile or non-volatile
memory, such as DRAM, EEPROM, flash memory, combinations thereof,
and the like. The controller 204 may thus access information stored
in the memory 208 to determine the manners in which the CRAC unit
108 may be operated.
The optional power meter 206 may detect the power consumption of
the CRAC unit 108 and thus may be positioned or otherwise
configured to measure the power consumption of the CRAC unit 108.
The power member 206 may comprise any reasonably suitable, and
commercially available power meter capable of measuring the CRAC
unit 108 power consumption. The controller 204 may receive the
detected power consumption and may also store this information in
the memory 208. The power meter 206 is considered as being optional
because the controller 204 may be configured to calculate the CRAC
unit 108 power consumption based upon operations of the various
components, for instance, compressor 130, blower 120, etc. As an
example, the controller 204 may be configured to determine the
power consumption of the compressor 130 based upon its current
operating load. A correlation between the power consumption levels
and the operating loads of the compressor 130 may be employed to
make this determination.
With reference now to FIG. 2B, the CRAC control system 252 includes
similar components to those described hereinabove with respect to
the CRAC control system 202. Therefore, only those components that
differ from the elements described hereinabove with respect to the
CRAC control system 202 will be described. More particularly, the
CRAC control system 252 includes the CRAC unit 110 instead of the
CRAC unit 108. In this regard, the CRAC control system 252 is
configured to control the three-way valve 160 to vary the
temperature of the cooling fluid supplied to the data center
100.
As an example, the controller 204 may operate to control the
three-way valve 160 and the blower 120 in manners to substantially
minimize the power consumption of the CRAC unit 110 while
maintaining the temperature of the cooling fluid supplied by the
CRAC unit 110 within the threshold setpoint temperature range. The
controller 204 may thus determine various operating conditions for
the three-way valve 160 and the blower 120 to substantially
minimize the power consumptions associated with their operations.
Although reference is made throughout the present disclosure to the
control of the blower 120, the controller 204 may control the VFD
124 to thereby control the blower 120 speed.
As depicted in FIG. 2C, the CRAC control system 252' include
similar components to those described hereinabove with respect to
the CRAC control system 202 and 252. Therefore, only those
components that differ from the elements described hereinabove with
respect to those CRAC control systems 202 and 252 will be
described. As shown, the CRAC control system 252' includes the CRAC
unit 110' instead of the CRAC units 108 and 110. In this regard,
the CRAC control system 252' is configured to control the two-way
valve 164 to vary the temperature of a coolant and therefore vary
the temperature of the cooling fluid supplied by the CRAC unit
110'.
In addition, the controller 204 may control the blower 120 to
control the volume flow rate of the cooling fluid supplied by the
CRAC unit 110'. In this regard, the controller 204 may control the
temperature and the volume flow rate of the cooling fluid supplied
by the CRAC unit 110' in manners to substantially minimize the
power consumption of the CRAC unit 110' while maintaining the
temperature of the cooling fluid supplied by the CRAC unit 110
within the threshold setpoint temperature range. The controller 204
may thus determine various operating conditions for the two-way
valve 164 and the blower 120 to substantially minimize the power
consumptions associated with their operations.
In each of the CRAC control systems 202, 252, 252', the controller
204 may be configured to receive input from a user, for instance, a
technician, an administrator, etc. As described in greater detail
hereinbelow, the controller 204 may include one or more input
devices, for instance, keyboard, mouse, disk drives, etc., for
receiving input from the user. The input may, for instance, be in
the form of predetermined operating set points for the CRAC units
108, 110, 110'. By way of example, a user may input a setpoint
temperature (Tset) range into the controller 204. The setpoint
temperature (Tset) range may be based upon desired heat removal
characteristics in the data center 100. In one respect, the
setpoint temperature (Tset) range may comprise temperatures that
ensure safe operating conditions for the components housed in the
data center 100. The safe operating conditions for the components
may be based upon the specifications provided by the component
manufacturers. Alternatively, the safe operating conditions may be
determined through testing of the components or through historical
data. For instance, the components may be operated at various
temperatures to determine at which temperatures the performance
characteristics of the components being to decline or when the
components begin to fail.
A maximum setpoint temperature (Tset,max) of the setpoint
temperature (Tset) range may constitute an upper limit of safe
operating conditions for the components. In other words, if the
heated cooling fluid returning to the CRAC units 108, 110, 110' is
above the maximum setpoint temperature (Tset,max), it may be
determined that the temperature of the components may be beyond the
safe operating conditions. As another example, a minimum setpoint
temperature (Tmin,set) of the setpoint temperature (Tset) range may
constitute a lower limit indicating a temperature at which
operations of the CRAC units 108, 110, 110' may be ceased. In
addition, the controller 204 may store the inputted threshold
setpoint temperature (Tset) range in the memory 208.
In addition, the controller 204 may utilize the information
received from one or both of the sensors 138, 140, the power meter
206, and the user received input, to determine manners in which to
operate the compressor 130, the three-way valve 160, or the two-way
valve 164, and the blower 120 of the CRAC unit 108. In one example,
the controller 204 may operate the compressor 130, three-way valve
160, or the two-way valve 164, and the blower 120 to substantially
minimize power consumption of the respective CRAC units 108, 110,
110' while maintaining the temperature of heated cooling fluid
returned to the CRAC units 108, 110, 110' within the setpoint
temperature (Tset) range. Thus, for instance, the controller 204
may manipulate the compressor 130, the three-way valve 160, or the
two-way valve 164, and the blower 120 operations to various levels
so long as the temperature of the heated cooling fluid returned to
the CRAC units 108, 110, 110' remains within the setpoint
temperature (Tset) range.
As another example, the controller 204 may determine manners in
which to operate the compressor 130, the three-way valve 160, or
the two-way valve 164, and the blower 120 based upon the loading of
the CRAC unit 108. In this instance, the controller 204 may be
configured to calculate the caloric heat transfer from the heated
cooling fluid to the refrigerant of the CRAC units 108, 110, 110'.
The caloric heat transfer (Q) may be calculated from the following
equation: Q=mC.sub.p(T.sub.out-T.sub.in) Equation (1) where m is
the mass flow rate of the cooling fluid, C.sub.p is the heat
capacity of the cooling fluid, T.sub.out is the temperature of the
cooled cooling fluid supplied and T.sub.in is the temperature of
the heated cooling fluid received by the CRAC units 108, 110,
110'.
According to this example, a setpoint caloric heat transfer (Qset)
range may be used in place of the setpoint temperature (Tset)
range. Thus, for instance, the controller 204 may be configured to
substantially minimize the power consumptions of the CRAC units
108, 110, 110' by varying operations of the compressor 130, the
three-way valve 160, or the two-way valve 164, and the blower 120
so long as the caloric heat transfer (Q) is within the setpoint
caloric heat transfer (Qset) range. In one respect, the caloric
heat transfer (Qset) range may comprise heat transfer rates that
ensure safe operating conditions for the components housed in the
data center 100. The safe operating conditions for the components
may be based upon the specifications provided by the component
manufacturers. Alternatively, the safe operating conditions may be
determined through testing of the components or through historical
data. For instance, the components may be operated at various
temperatures to determine at which temperatures the performance
characteristics of the components being to decline or when the
components begin to fail.
In similar fashion to those manners described hereinabove, if the
calculated caloric heat transfer (Q) is above a maximum setpoint
caloric heat transfer level (Qset,max), the components in the data
center 100 may be insufficiently cooled. In addition, if the
calculated caloric heat transfer (Q) is below a minimum setpoint
caloric heat transfer level (Qset,min), operations of the CRAC
units 108, 110, 110' may be ceased as the CRAC unit 108 may be
drawing power unnecessarily.
In operation, the controllers 204 of the CRAC control systems 202,
252, 252' may determine the compressor 130, three-way valve 160, or
the two-way valve 164, and the blower 120 operations to
substantially minimize CRAC unit 108, 110, 110' power consumptions
when the temperatures of the heated cooling fluid returned to the
CRAC units 108, 110, 110' are within the setpoint temperature
(Tset) range. In addition, operations of these systems may be
varied when the caloric heat transfer is within the setpoint
caloric heat transfer (Qset) range. More particularly, the
controllers 204 may determine which combinations of compressor 130,
three-way valve 160, or two-way valve 164, and blower 120
operations substantially minimize CRAC unit 108, 110, 110' power
consumption levels when the temperatures of the cooling fluid
received from the components are within an acceptable range.
Thus, for instance, if the temperatures of the cooling fluid
supplied from the components are acceptable, the controllers 204
may select operating levels of the compressor 130, the three-way
valve 160, or the two-way valve 164, and the blower 120 that
substantially minimize the costs associated with their operations.
These operating levels and costs may be considered in terms of the
graph 300 illustrated in FIG. 3. In the graph 300, there is
illustrated two x-axes 302 and 304 and a y-axis 306. The first
x-axis 302 denotes the speed of the blower 120 and the second
x-axis 304 denotes the temperature of the cooling fluid (Tcf,out)
supplied by the respective CRAC units 108, 110, 110'. The y-axis
306 denotes the energy consumptions and thus the costs associated
with various cooling fluid temperatures (i.e., compressor 130,
three-way valve 160, or two-way valve 164, operations) and blower
120 speeds.
The power consumption levels or costs associated with operating the
compressor 130, the three-way valve 160, or the two-way valve 164,
and the blower 120 at various levels may be based upon manufacturer
provided specifications. In addition, or alternatively, the power
consumption levels or costs may be determined through testing. In
terms of testing, for instance, the power meter 206 may be used to
measure the power draws of the compressor 130, the refrigeration
circuit 150 (under various three-way valve 160 and the two-way
valve 164 settings), and the blower 120 at different levels of
operation. The correlations between the power consumption levels or
costs and the operating levels of the compressor 130, the
refrigeration circuit 150, and the blower 120 may be stored in the
memory 208. This information may be stored in the form of, for
instance, a look-up table, or through other searchable means.
As shown in the graph 300, the energy consumption level of the
compressor 130 (or a refrigeration circuit 150 in the case of the
CRAC units 110, 110', decreases as the temperature of the cooling
fluid (Tcf,out) supplied by the CRAC unit 108 decreases at constant
CRAC unit loading. In addition, the energy consumption level of the
blower 120 increases as the speed of the blower 120 increases.
Thus, the controllers 204 of the CRAC units 108, 110, 110' may be
configured to vary the operations of the compressor 130, the
three-way valve 160, or the two-way valve 164, and the blower 120
such that they consume the least amount of power while maintaining
the temperatures of the cooling fluid returned into the CRAC units
108, 110, 110' within the setpoint temperature ranges.
FIGS. 4A and 4B illustrate flow diagrams of operational modes 400
and 450 of methods for CRAC unit control based upon setpoint
temperatures and setpoint caloric heat transfer determinations,
respectively. It is to be understood that the following
descriptions of the operational modes 400 and 450 are two manners
of a variety of different manners in which CRAC unit control may be
effectuated. It should also be apparent to those of ordinary skill
in the art that the operational modes 400 and 450 represent
generalized illustrations and that other steps may be added or
existing steps may be removed, modified or rearranged without
departing from a scope of the invention.
The descriptions of the operational modes 400 and 450 are made with
reference to the block diagrams 200, 250, 250' illustrated in FIGS.
2A-2C, respectively, and thus makes reference to the elements cited
therein. It should, however, be understood that the operational
modes 400 and 450 are not limited to the elements set forth in the
block diagrams 200, 250, 250'. Instead, it should be understood
that the operational modes 400 and 450 may be practiced by CRAC
unit control systems having a different configuration than those
set forth in the block diagrams 200, 250, 250'.
The operational modes 400 and 450 may be initiated or started at
steps 402 and 452, respectively, for instance, by activating one or
more CRAC units 108, 110, 110', activating one or more components
in the data center 100, etc. In addition, or alternatively, the
operational mode 400 may be manually initiated, after a
predetermined period of time, etc. It is to be understood that
either or both of the operational modes 400 and 450 may be
performed depending upon the configuration of the CRAC units 108,
110, 110'. For instance, those CRAC units 108, 110, 110' configured
to operate based upon setpoint temperatures, may perform the
operational mode 400, whereas those CRAC units 108, 110, 110'
configured to operate based upon setpoint caloric heats may perform
the operation mode 450. Additionally, performance of either
operational mode 400 and 450 may be user-specified.
With reference first to the operational mode 400 of FIG. 4A, the
controllers 204 of one or more of the CRAC control systems 200,
250, 250.Iadd.' .Iaddend.may receive a setpoint temperature (Tset)
range as indicated at step 404. The setpoint temperature (Tset)
range may be supplied by the CRAC manufacturers or they may
user-specified and inputted into the computing device 112 through
any known input means. Step 404, however, may be omitted for
situations in which the controllers 204, for instance, have
previously received the setpoint temperature (Tset) range.
At step 406, one or more of the sensors 138 may detect the
temperatures of the return air (Trat). A comparison of the detected
return air temperatures (Trat) and the setpoint temperature (Tset)
range may be made at step 408. More particularly, at step 408, it
may be determined whether the temperatures of the heated cooling
fluid returning into the CRAC units 108, 110, 110' are within the
setpoint temperature (Tset) range. For those CRAC units 108, 110,
110' having detected return air temperatures (Trat) outside of the
setpoint temperature (Tset) range, the controllers 204 of those
CRAC units 108, 110, 110' may determine whether the detected return
air temperatures (Trat) are below minimum setpoint temperature
levels (Tset,min), at step 410. The minimum setpoint temperature
levels (Tset,min) for the CRAC units 108, 110, 110' may be the same
for each of the CRAC units 108, 110, 110' or they may vary for each
of the CRAC units 108, 110, 110'. In this regard, for instance,
each of the CRAC units 108, 110, 110' may be operated in
substantially independent manners.
At step 410, for those CRAC units 108, 110, 110' having detected
return air temperatures (Trat) are not below the minimum set point
temperature levels (Tset,min), the detected return air temperatures
(Trat) are considered as being above maximum setpoint temperature
levels (Tset, max), since they are outside of the setpoint
temperature (Tset) ranges. The controllers 204 of those CRAC units
108, 110, 110' may therefore decrease the temperature and/or
increase the volume flow rate of cooling fluid supplied to the data
center 100, as indicated at step 412. The decreased temperature
and/or the increased cooling fluid volume flow rate may be required
to bring the detected return air temperatures (Trat) within the
maximum setpoint temperature levels (Tset,max).
Additionally, at step 412, the controllers 204 of those CRAC units
108, 110, 110' may decrease the temperature of the
refrigerant/coolant and/or increase the volume flow rate of cooling
fluid supplied based upon the costs associated with each action.
For instance, if the costs associated with decreasing the
temperature of the refrigerant/coolant is relatively less than
increasing the volume flow rate, the controllers 204 may cause the
refrigerant/coolant temperature to be decreased while maintaining
the volume flow rate level. As another example, if the controllers
204 determine that a combination of actions are associated with the
lowest costs, the controllers 204 may find substantially optimum
combinations of actions to achieve the desired results at the
lowest costs.
As another example, at step 412, the controllers 204 of those CRAC
units 108, 110, 110' may decrease the temperature of the
refrigerant/coolant and/or increase the volume flow rate of cooling
fluid supplied based upon the known effectiveness of each action.
Thus, for instance, the controllers 204 may have access to
historical data indicating the effects of the various actions taken
by the CRAC units 108, 110, 110'. By way of example, if it is
determined that reducing the refrigerant/coolant temperature to a
certain level requires X amount of energy and increasing the volume
flow rate to another certain level requires the same amount of
energy, and increasing the volume flow rate is more effective, the
controllers 204 may decide to increase the volume flow rate as this
action is more efficient.
At step 410, for those CRAC units 108, 110, 110' having detected
return air temperatures (Trat) that are below the minimum set point
temperature level (Tset,min), those CRAC units 108, 110, 110' may
enter a sleep mode as indicated at step 414. The sleep mode may
include a powered down mode in which the CRAC units 108, 110, 110'
draw reduced amounts of power as compared to when the CRAC units
108, 110, 110' are fully operational. The reduced amounts of power
may comprise power states that are somewhere between the fully
operational mode and a completely shut down mode. In addition, the
sleep mode may constitute a power saving mode in which the CRAC
units 108, 110, 110' may be reactivated or otherwise brought back
to fully operational status in a relatively short period of time.
The reduced power state of the CRAC units 108, 110, 110' may vary
for differing types of CRAC units.
In any regard, the sleep mode may include a mode in which the power
supply to the temperature sensor 138 positioned to detect the
temperature of the cooling fluid around the inlet of the CRAC unit
108, 110, 110', remains active. In addition, the sleep mode may
also include the supply of a small amount of power to enable the
blower to substantially continuously cause a relatively small
amount of cooling fluid flow through the CRAC units 108, 110, 110'.
In this regard, the temperatures of the cooling fluid supplied into
the CRAC units 108, 110, 110' may be substantially continuously
monitored when the CRAC units 108, 110, 110' are in the sleep
mode.
The CRAC units 108, 110, 110' may exit from the sleep mode, for
instance, when the detected return air temperature (Trat) exceeds
the maximum setpoint temperature (Tset, max), as indicated at step
412. Alternatively, the CRAC units 108, 110, 110' may be configured
to exit from the sleep mode when the return air temperature (Trat)
exceeds another predefined temperature, which may be defined
according to, for instance, operating requirements of the
components to which the CRAC units 108, 110, 110' delivers cooling
fluid. As another alternative, the CRAC units 108, 110, 110' may
exit the sleep mode after a predetermined period of time, manually
revived, in response to receipt of a setpoint temperature range,
etc.
In another example, a plurality of CRAC units 108, 110, 110' may be
networked or otherwise configured to communicate with one another.
For instance, the same controller 204 may control the plurality of
CRAC units 108, 110, 110'. In any regard, the controllers 204 of
the CRAC units 108, 110, 110' may be configured to communicate
their statuses to the other CRAC units 108, 110, 110'. The statuses
of the CRAC units 108, 110, 110' may be used by the controllers 204
to determine the provisioning levels of the CRAC units 108, 110,
110'. By way of example, if one of the CRAC units 108, 110, 110' is
in the sleep mode and the provisioning level of a neighboring CRAC
unit 108, 110, 110' is too high, for instance, the return air
temperature (Trat) into the neighboring CRAC unit 108, 110, 110' is
above a predefined level, the CRAC unit 108, 110, 110' may be
brought out of the sleep mode. In this instance, the return air
temperature (Trat) may not need to be measured during the sleep
mode thereby enabling that CRAC unit 108, 110, 110' to draw less
power when in the sleep mode.
With reference back to step 408, for those CRAC units 108, 110,
110' having return air temperatures (Trat) within the setpoint
temperature (Tset) range, the controllers 204 of those CRAC units
108, 110, 110' may determine the power consumption of the
respective cooling systems at step 416. The cooling systems may
comprise, for instance, the compressor 130 in FIG. 1B or the
refrigeration circuits 150 in FIGS. 1C and 1D. The controllers 204
may also determine the power consumptions of the blowers 120 at
step 418.
The power meter 206 may be employed to determine the power
consumptions of the cooling system components. Alternatively, the
power consumption may be calculated based upon operations of the
various components, for instance, the compressor 130, the blower
120, etc. As an example, the controllers 204 may be configured to
determine the power consumption of the compressor 130 based upon
its current operating load. A correlation between the power
consumption levels and the operating loads of the compressor 130
may be employed to make this determination.
At step 420, the power consumptions of the cooling systems and the
blower 120 may be correlated to a cost function. For instance, the
costs associated with the power consumed by the cooling systems and
the blower 120 may be determined. In addition, the power consumed
by the cooling systems and the blower 120 may be utilized in
determining the operations of the cooling systems and the blower
120. The power consumptions of the cooling systems may include a
determination of the conditions external to the condenser 132 or
refrigeration circuit 150. That is, for instance, the costs
incurred by the cooling systems may vary according to the external
conditions. For instance, if ambient conditions are relatively hot
and/or humid, greater amounts of energy may be expended by the
cooling systems to enable sufficient heat transfer between the
refrigerant and/or coolant to thereby maintain the refrigerant
and/or coolant at desired temperatures.
At step 422, the controllers 204 may determine whether the costs
may be reduced. The controllers 204 may ascertain whether costs may
be reduced through, for instance, a determination of the output
requirements of the CRAC units 108, 110, 110' to substantially
maintain the cooling fluid temperature and delivery to the
components in the data center within the setpoint temperature
ranges.
If the costs cannot be reduced, that is, the controllers 204
determine that the CRAC units 108, 110, 110' are operating at or
near optimum energy levels, the controllers 204 may not vary the
cooling system operations and the operational mode 400 may be
continued, for instance, at step 406. However, if the controllers
204 determine that costs may be reduced, the controllers 204 may
determine a scheme to enable the costs associated with operating
the cooling systems to be reduced at step 424. The controllers 204
may determine how costs may be reduced based upon the costs
associated with increasing refrigerant/coolant temperature and/or
decreasing the volume flow rate of the cooling fluid supplied. For
instance, if the cost savings associated with increasing the
temperature of the refrigerant/coolant is relatively higher than
the cost savings associated with decreasing the volume flow rate,
the controllers 204 may cause the refrigerant/coolant temperature
to be increased while maintaining the volume flow rate level. In
the alternative, if the cost savings associated with decreasing the
volume flow rate is relatively higher than the cost savings
associated with increasing the refrigerant/coolant temperature, the
controllers 204 may cause the volume flow rate to be decreased
while maintaining the refrigerant/coolant temperature level. As
another example, if the controllers 204 determine that a
combination of actions produces the greatest cost savings, the
controllers 204 may find substantially optimum combinations of
actions to achieve the desired results at the greatest cost
savings.
At step 426, the controllers 204 may implement the reduced cost
scheme determined at step 424. The reduced cost scheme may be
implemented according to an iterative process or it may implemented
according to historical data. If an iterative process is
implemented, the controllers 204 may cause either or both of the
cooling fluid temperature to the increased and the volume flow rate
to the decreased incrementally until the CRAC units 108, 110, 110'
are operating at or near optimal levels. If historical data is
relied upon, the controllers 204 may know how to manipulate the
CRAC units 108, 110, 110' based upon previously performed
manipulations to reach the substantially optimal performance
levels.
In addition, the operational mode 400 may be continued to thereby
enable substantially continuous monitoring and control over the
CRAC units 108, 110, 110'. In one respect, operations of the CRAC
units 108, 110, 110' may be substantially continuously altered to
enable energy and cost savings.
With reference now to the operational mode 450 of FIG. 4B, the
controllers 204 of one or more of the CRAC control systems 200,
250, 250' may receive a setpoint caloric heat transfer (Qset) range
at step 454. The caloric heat transfer (Q) of a CRAC unit 108, 110,
110' may be used to determine the workload on the CRAC unit 108,
110, 110' and may be determined through Equation (1) recited
hereinabove. In this regard, and as described in greater detail
hereinbelow, if the caloric heat transfer (Q) of a CRAC unit 108,
110, 110' is within a predefined range, operations of the
compressor 130, the three-way valve 160, or the two-way valve 164
may be varied to substantially minimize their energy consumptions.
It should be appreciated that step 454 may be omitted for
situations in which the controllers 204, for instance, have
previously received the setpoint caloric heat transfer (Qset)
range.
At step 456, one or more of the sensors 138 may detect the
temperatures of the return air (Trat) and one or more of the
sensors 140 may detect the temperatures of the supply air (Tsat) at
step 458. At step 460, the controllers 204 may calculate the
caloric heat transfer rates (Q). In addition, the controllers 204
may determine whether the calculated caloric heat transfer rates
(Q) are within the setpoint caloric heat transfer (Qset) range at
step 462.
For those CRAC units 108, 110, 110' having calculated caloric heat
transfer rates (Q) that are within the Qset range, steps 416-426
set forth in the box A of FIG. 4A may be performed at step 464.
However, for those CRAC units 108, 110, 110' having calculated
caloric heat transfer rates (Q) that are outside of the Qset range,
the controllers 204 of those CRAC units 108, 110, 110' may
determine whether the calculated caloric heat transfer rates (Q)
are below minimum setpoint caloric heat transfer levels (Qset,min)
at step 466. The Qset,min for the CRAC units 108, 110, 110' may be
the same for each of the CRAC units 108, 110, 110' or they may vary
for each of the CRAC units 108, 110, 110'. In this regard, for
instance, each of the CRAC units 108, 110, 110' may be operated in
substantially independent manners.
At step 466, for those CRAC units 108, 110, 110' having calculated
caloric heat transfer rates (Q) are not below the minimum set point
caloric heat transfer levels (Qset,min), the calculated caloric
heat transfer rates (Q) are considered as being above maximum
setpoint caloric heat transfer levels (Qset,max), since they are
outside of the setpoint caloric heat transfer (Qset) ranges. The
controllers 204 of those CRAC units 108, 110, 110' may determine
whether the flow rates (FR) of the cooling fluid supplied by those
CRAC units 108, 110, 110' are below a flow rate set point (FRset).
The flow rate (FR) of the cooling fluid supplied by the CRAC units
108, 110, 110' may be detected through use of, for instance, an
anemometer. In addition, or alternatively, the flow rate (FR) may
be determined based upon the speed of the VFD. In any regard, the
flow rate set point (FRset) may be based upon, for instance,
historical data that indicates, for instance, a flow rate of
cooling fluid supplied by the CRAC units 108, 110, 110' are optimal
for a given CRAC unit 108, 110, 110'. The optimum flow rates may be
based, for instance, on the configuration and airflow patterns of
the areas in which the CRAC units 108, 110, 110' are configured to
deliver the cooling fluid. In this regard, the flow rate setpoints
may vary for each of the CRAC units 108, 110, 110' and may also
vary as airflow patterns change.
If it is determined at step 468 that the flow rate (FR) exceeds the
flow rate setpoint (FRset), the flow rate may not be varied. If,
however, it is determined that the flow rate (FR) does not exceed
the flow rate setpoint (FRset), the volume flow rate of the CRAC
unit 108, 110, 110' may be increased as indicated at step 470. The
level of increase in the volume flow rate may be based upon various
factors. For instance, the level of increase may be based upon a
set percentage of increase and may be based upon an iterative
process where the level of increase is performed during each cycle
until the flow rate (FR) equals or exceeds the flow rate setpoint
(FRset). As another example, the level of increase may be based
upon historical data that indicates the level of temperature change
in the areas affected by the CRAC units 108, 110, 110' in response
to various VFD speeds.
Also, at step 466, for those CRAC units 108, 110, 110' having
caloric heat transfer rates (Q) that are below the minimum set
point caloric heat transfer level (Qset,min), those CRAC units 108,
110, 110' may enter a sleep mode as indicated at step 414. The
sleep mode may include a powered down mode in which the CRAC units
108, 110, 110' draw reduced amounts of power as compared to when
the CRAC units 108, 110, 110' are fully operational. The reduced
amount of power may comprise a power state that is somewhere
between the fully operational mode and a completely shut down mode.
In addition, the sleep mode may constitute a power saving mode in
which the CRAC units 108, 110, 110' may be reactivated or otherwise
brought back to fully operational status in a relatively short
period of time. The reduced power state of the CRAC unit 108, 110,
110' may vary for differing types of CRAC units.
In any regard, the sleep mode may include a mode in which the power
supply to the temperature sensor 138 positioned to detect the
temperature of the cooling fluid around the inlet of the CRAC unit
108, 110, 110', remains active. In addition, the sleep mode may
also include the supply of a small amount of power to enable the
blower to substantially continuously cause a relatively small
amount of cooling fluid flow through the CRAC unit 108, 110, 110'.
In this regard, the temperature of the cooling fluid supplied into
the CRAC unit 108, 110, 110' may be substantially continuously
monitored when the CRAC unit 108, 110, 110' is in the sleep
mode.
The CRAC units 108, 110, 110' may exit from the sleep mode, for
instance, when the calculated caloric heat transfer rates (Q)
exceed the maximum setpoint caloric heat transfer level (Qset,max),
as indicated at step 412. Alternatively, the CRAC units 108, 110,
110' may be configured to exit from the sleep mode when the return
air temperature (Trat) exceeds another predefined temperature,
which may be defined according to, for instance, operating
requirements of the components to which the CRAC units 108, 110,
110' delivers cooling fluid. As another alternative, the CRAC units
108, 110, 110' may exit the sleep mode after a predetermined period
of time, manually revived, in response to receipt of a setpoint
temperature range, etc.
In another example, a plurality of CRAC units 108, 110, 110' may be
networked or otherwise configured to communicate with one another.
For instance, the same controller 204 may control the plurality of
CRAC units 108, 110, 110'. In any regard, the controllers 204 of
the CRAC units 108, 110, 110' may be configured to communicate
their statuses to the other CRAC units 108, 110, 110'. The statuses
of the CRAC units 108, 110, 110' may be used by the controllers 204
to determine the provisioning levels of the CRAC units 108, 110,
110'. By way of example, if one of the CRAC units 108, 110, 110' is
in the sleep mode and the provisioning level of a neighboring CRAC
unit 108, 110, 110' is too high, for instance, the return air
temperature (Trat) into the neighboring CRAC unit 108, 110, 110' is
above a predefined level, the CRAC unit 108, 110, 110' may be
brought out of the sleep mode. In this instance, the return air
temperature (Trat) may not need to be measured during the sleep
mode thereby enabling that CRAC unit 108, 110, 110' to draw less
power when in the sleep mode.
Through operation of the operational modes 400 and 450, the energy
consumption levels of the CRAC units 108, 110, 110' and therefore
the costs associated with their operations may substantially be
minimized. In one regard, the CRAC units 108, 110, 110' may be
operated substantially independently from one another in manners to
generally enable their energy efficient operations.
The operations set forth in the operational modes 400 and 450 may
be contained as utilities, programs, or subprograms, in any desired
computer accessible medium. In addition, the operational modes 400
and 450 may be embodied by computer programs, which can exist in a
variety of forms both active and inactive. For example, it can
exist as software program(s) comprised of program instructions in
source code, object code, executable code or other formats. Any of
the above can be embodied on a computer readable medium, which
include storage devices and signals, in compressed or uncompressed
form.
Exemplary computer readable storage devices include conventional
computer system RAM, ROM, EPROM, EEPROM, and magnetic or optical
disks or tapes. Exemplary computer readable signals, whether
modulated using a carrier or not, are signals that a computer
system hosting or running the computer program can be configured to
access, including signals downloaded through the Internet or other
networks. Concrete examples of the foregoing include distribution
of the programs on a CD ROM or via Internet download. In a sense,
the Internet itself, as an abstract entity, is a computer readable
medium. The same is true of computer networks in general. It is
therefore to be understood that any electronic device capable of
executing the above-described functions may perform those functions
enumerated above.
FIG. 5 illustrates an exemplary computer system 500, according to
an embodiment of the invention. The computer system 500 may
include, for example, the controllers 204 and/or the computing
device 112. In this respect, the computer system 500 may be used as
a platform for executing one or more of the functions described
hereinabove with respect to the various components of the CRAC
control systems 202, 252, 252'.
The computer system 500 includes one or more controllers, such as a
processor 502. The processor 502 may be used to execute some or all
of the steps described in the operational modes 400 and 450.
Commands and data from the processor 502 are communicated over a
communication bus 504. The computer system 500 also includes a main
memory 506, such as a random access memory (RAM), where the program
code for, for instance, the controllers 204 and/or the controller
of the computing device 112, may be executed during runtime, and a
secondary memory 508. The secondary memory 508 includes, for
example, one or more hard disk drives 510 and/or a removable
storage drive 512, representing a floppy diskette drive, a magnetic
tape drive, a compact disk drive, etc., where a copy of the program
code for the provisioning system may be stored.
The removable storage drive 510 reads from and/or writes to a
removable storage unit 514 in a well-known manner. User input and
output devices may include a keyboard 516, a mouse 518, and a
display 520. A display adaptor 522 may interface with the
communication bus 504 and the display 520 and may receive display
data from the processor 502 and convert the display data into
display commands for the display 520. In addition, the processor
502 may communicate over a network, e.g., the Internet, LAN, etc.,
through a network adaptor 524.
It will be apparent to one of ordinary skill in the art that other
known electronic components may be added or substituted in the
computer system 500. In addition, the computer system 500 may
include a system board or blade used in a rack in a data center, a
conventional "white box" server or computing device, etc. Also, one
or more of the components in FIG. 5 may be optional (e.g., user
input devices, secondary memory, etc.).
What has been described and illustrated herein is a preferred
embodiment of the invention along with some of its variations. The
terms, descriptions and figures used herein are set forth by way of
illustration only and are not meant as limitations. Those skilled
in the art will recognize that many variations are possible within
the spirit and scope of the invention, which is intended to be
defined by the following claims--and their equivalents--in which
all terms are meant in their broadest reasonable sense unless
otherwise indicated.
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