INTEGRATED INVERTER COMPRESSOR VARIABLE VOLUME REFRIGERANT LOOP DATA CENTER COOLING UNIT AND CONTROL SYSTEM

Abstract

A point to point, point to multipoint, or multipoint to multipoint integrated inverter compressor variable volume refrigerant loop data center cooling unit and control system used to regulate volume of refrigerant to air handling systems used to supply cold air ventilation to data center rooms and to the electronic equipment mounted therein which require constant cooling by using a control system controlling variable speed pumps, fans, compressors and condensers to operate a one or a plurality of closed loop, variable volume refrigerant loop systems in conjunction with one or a plurality of associated interior air handling systems located within a data center.

Description

CROSS-REFERENCE TO RELATED APPLICATION 35 USC §119(e)

Not Applicable

FIELD OF INVENTION

This invention relates to the assembly and integration of Variable Refrigerant Flow (VRF) inverter compressors, variable speed pumps, valves, control modules, sensors and closed loop variable volume refrigerant piping into a plurality configuration to be installed and operated within a data center to provide point to point, point to multipoint or multipoint to multipoint cooling capacity to various air handling systems located within a data center used to provide air conditioning throughout the data center and adjacent rooms. The invention also relates to the simultaneous supply of various temperature levels as temperature zones within the same environment utilizing the same system.

BACKGROUND OF INVENTION

For many decades now telecommunications, cable television and large scale information services companies have constructed and operated “data” centers as central nodes for housing equipment, interconnecting voice and data circuits and storing information in large databases. These data centers have evolved from telephone switching centers and large scale computer rooms to modern day “server farms”.

Equipment miniaturization has increased the density of data traffic served by a single chip, computer processor and server array. Increases in fiber optic cable capacity, wireless network expansion and over-all density in deployment of broadband facilities which interconnect buildings, networks and people has increased the number of data centers and the density of equipment housed within these data center facilities.

Several standards for building and operating data centers exist and one of the standards is the control of the ambient air temperature within the data center which is integral in cooling of the electronics. It may be desirable to control the temperature within the data center within zones to conserve energy. The present invention introduces a new configuration for using variable refrigerant flow technology integrated with traditional air handlers used to cool the data center environment.

Traditionally, cooling systems were designed to operate on/off and thus are not efficient at partial loads. Existing facilities may need more cooling but have limited space for additional system components. The piping and ducting for typical systems is large and requires use of flame/welding to install. Also, compressors are typically located inside the indoor cooling cabinet.

Existing heat loads can be located inside a facility, which often times may be too far from the outside location of condenser equipment to be economically served by conventional systems.

The system in the present embodiment integrates Variable Refrigerant Flow (VRF) components and optimal placement of these components into indoor and outdoor units interconnected with a closed loop refrigerant piping network to: 1) Provide efficient cooling at all load conditions; 2) provide point to point, point to multipoint, or multipoint to multipoint configuration; and 3) allow long runs of refrigerant piping to reach existing heat loads.

The present invention simplifies the deployment of multipoint distributed variable refrigerant flow cooling systems within the data center. In short, the present invention works equally well in either a primary system or auxiliary system within the data center.

Although there are several apparatuses which may have various functions related to the variable refrigerant flow multipoint distributed chilled water cooling and control system for data centers, none of these either separately or in combination with each other, teach or anticipate the current invention. Therefore, there remains an unmet need in the field of data center cooling. The current invention will fulfill this unmet need.

SUMMARY OF INVENTION

The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed invention. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

The present embodiment presents a multipoint capable cooling and control system consisting of integrated variable speed pumps, valves, coils, control modules, sensors and closed loop variable flow rate refrigerant piping network. The present embodiment consists of outdoor and indoor units within a data center which provides data center operators greater flexibility in deploying electronics requiring in-row temperature control and cold air flow circulation. The present invention provides for an integrated cooling and control package which remains compatible with traditional air handler systems and data center environments while expanding capacity of such systems.

The present embodiment as described provides for controllability of four aspects of the system which have not existed in combination prior to now. The first aspect is the variable refrigerant flow sub-system which allows for independent control of the refrigerant flow rate within the closed loop refrigerant piping and distribution system. The second aspect is the cascading assembly of coils and associated variable refrigerant flow closed loop piping which create zone cooling capacity. The third aspect is the integrated variable control manifold configuration to manage refrigerant distribution within the multipoint environment. The forth aspect is the multi-zone configuration assembly which provides secondary and tertiary stage temperature control within the data center.

The present embodiment is a system which integrates Variable Refrigerant Flow (VRF) components with an in-row cabinet configuration loop to: 1) provide variable cooling capacity under all load conditions; 2) eliminate the need for indoor compressor installation; 3) allow for long runs of refrigerant piping to reach existing heat loads; and 4) provide multiple temperature control zones utilizing the same cooling system.

This system shown in the present embodiment varies its energy use with the heat load and is more efficient at partial loads. It requires no indoor compressor nor does it require large piping or ducting. It is also capable of supplying cooling to locations within a facility that cannot be reached by typical systems. Additionally, the system is configurable as a point to point, point to multipoint or a multipoint to multipoint system.

The VRF Inverter Compressor Condenser(s) utilized in the present embodiment are required to enable the system to vary its capacity to the heat load. Refrigerant to coils contained within the indoor cabinet are critical to the operation and integration of the system. The variable speed pump allows refrigerant to be pumped at flow rates that match the flow required by the facility cooling equipment (Heat Load). Multiple temperature zones are accomplished by routing variable refrigerant flows to separate coils which are configured in serial or parallel and which are regulated by controllable valves.

The present embodiment consisting of components in the system to cool a facility in a unique way by integrating a VRF refrigerant system with a regulated variable flow rate refrigerant loop. The process begins when refrigerant is cooled and routed to a coil located in the indoor cabinet. Variable speed fans force air across the coil in a traditional fashion. Circulating chilled air within the data center effectively envelops the data center equipment to maintain a constant operating temperature within the data center or within zones within the data center.

The present embodiment improves upon the traditional system by incorporating VFR technology with a control system used to regulate both the flow rate of the refrigerant and the destination of the refrigerant to coils installed within the indoor cabinets. Using combinations of controllable pumps, fans, compressors and routing valves, the control system within the present embodiment functions to operate a network of components to maintain air temperature within the data center.

The present embodiment consists of outdoor units (ODUs) equipped with a VRF inverter compressor and corresponding condenser(s) which are installed outside the facility. The indoor unit (IDUs) consists of coils, fans and valves and the associated control system which is located inside the facility. The copper piping loops for refrigerant run from connection points located at the ODUs VFR to the connections points at the IDUs. A network of refrigerant piping is formed using additional controllable vales to create multipoint distribution networks of cooling capacity.

Sensors are installed which air temperature temp and refrigerant temp, flow and pressure. This measurement data is processed by the control system which controls the automatic valves, the pump and the ODUs to signal necessary changes in capacity (compressor speed).

The facility equipment (heat load) to be cooled by the system shown in the present embodiment should be identified and the required cooling capacity calculated. Then the system is sized and configured to deliver the required flow rate and fan speed.

The logic required to make the system presented in the present embodiment work efficiently and seamlessly is programmed into the controls. Data from various sensors is used as follows:

• • Outdoor air temp increasing=Compressor/Condenser speed increasing
  • Outdoor air temp decreasing=Compressor/Condenser speed decreasing
  • Return refrigerant temp increasing=Compressor/Condenser speed increasing
  • Return refrigerant temp decreasing=Compressor/Condenser speed decreasing
  • Rack air temp increasing=Fan Speed Increasing
  • Rack air temp decreasing=Fan Speed Decreasing

Still other objects of the present invention will become readily apparent to those skilled in this art from the following description wherein there is shown and described the embodiments of this invention, simply by way of illustration of the best modes suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modifications in various obvious aspects all without departing from the scope of the invention. Accordingly, the drawing and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

Various exemplary embodiments of this invention will be described in detail, wherein like reference numerals refer to identical or similar components, with reference to the following figures, wherein:

FIG. 1 is a detailed view of the preferred embodiment illustrating the essential components of the indoor unit.

FIG. 2 is a detailed view of the preferred embodiment illustrating the essential components of the outdoor unit.

FIG. 3 is a detailed view of the preferred embodiment illustrating a multiple coil the indoor manifold assembly.

FIG. 3a is a detailed view of the preferred embodiment illustrating a single coil configuration.

FIG. 4 is a detail view of the preferred embodiment illustrating the essential components of the outdoor unit, indoor unit and piping configured as a point to point application within a data center.

FIG. 5 is a perspective view of the preferred embodiment illustrating point to multipoint data center application.

FIG. 6 is a perspective view of the preferred embodiment illustrating multipoint to multipoint data center application.

DETAILED DESCRIPTION

The claimed subject matter is now described with reference to the drawings. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the claimed subject matter. It may be evident; however, that the claimed subject matter may be practiced with or without any combination of these specific details, without departing from the spirit and scope of this invention and the claims.

The present embodiment shown in FIG. 4 can be understood by looking at the integrated inverter compressor variable volume refrigerant loop data center cooling unit and control system 100 as four sub-systems: 1) outdoor system 200; 2) indoor system 300; 3) closed loop refrigerant piping 400; and 4) control system 500.

In FIG. 4, application of the integrated inverter compressor variable volume refrigerant loop data center cooling unit and control system 100 is illustrated by showing the data center envelop 110 which is the volume of space defined as the data center to be cooled.

FIG. 4 presents illustration of the outdoor sub-system 200 with additional detail shown in outdoor units 210 FIG. 2 which contain the inverter compressor 220, condenser 230 and variable speed fans 240. These sub-system components can be operated with or without redundancy and are controlled by the control system 500.

FIG. 4 also presents illustration of the closed loop refrigerant piping system 400 which consists of small diameter pipe 410 forming long runs 430. The supply side of the closed loop refrigerant piping small diameter pipe 410 is connected to the indoor supply manifold 305 FIG. 1, at connection point 470. In FIG. 4, the supply side of the closed loop refrigerant piping small diameter pipe 410 is connected to the inverter compressor 220 at connection point 260. The long runs 430 consist of small diameter pipe 410 and connect the indoor coil 320 to the compressor 220 and condenser 230 to effectuate the cooling effect of the system

As shown in FIG. 4, the return side of the closed loop refrigerant piping small diameter pipe 410 is connected to the indoor return valve 348 FIG. 3 at connection point 475 FIG. 1. In FIG. 4, the return side of the closed loop refrigerant piping small diameter pipe 410 is connected to the inverter compressor 220 at connection point 265.

In FIG. 4, the data center envelope 110 is shown which contains the indoor system 300 and control system 500. FIG. 4 also shows the heat recovery box 440 connected to the auxiliary water heater air heater 460 using auxiliary refrigerant distribution lines 450 which is used to divert refrigerant to auxiliary units to recover heat which can be used to heat water or heat adjacent rooms to the data center where desirable.

FIG. 4 illustrates of the indoor sub-system 300 which contains the indoor air handler unit 310 which is a cabinet 505 containing an indoor coil 320, control valves 340 detailed as in FIG. 3 as valves 341, 342, 343, 344, 345, 346, 347 and 348; fans 330; and, the control system 500 which has a plurality of temperature sensors 510 within the data center envelop 110. Routing piping 420 is shown in FIG. 1. A plurality of indoor coils 321, 322 and 323 FIG. 3 can be connected to control valves 340 FIG. 4, detailed in FIG. 3 as 341, 342, 343, 344, 345, 346, 347 and 348 to supply a plurality of zones each maintained at a different temperature within the data center envelop 110. As shown in FIG. 3a, a single control valve 343, an expansion value controlling refrigerant flow to a single coil 323 is suitable for operations requiring a single temperature zone.

The preferred embodiment as illustrated in FIG. 3a and FIG. 3 provides for single coil 320 configuration or multiple coil 321, 322 and 323 configurations, respectively, or any combination thereof. This configuration flexibility provides for redundancy of components to prevent down time due to individual coil 321, 322 or 323 failure and which also provides for in-service maintenance and service capabilities of the system 100 without having to take the system 100 out of service completely to perform maintenance or repairs.

The preferred embodiment as illustrated in FIG. 3 can be configured to distribute refrigerant to each coil 321, 322 and 323 individually by adjusting control valves 341 through 348 respectively. To isolate coil 323, control valves 343 and 346 would be activated to create a closed loop. To cascade coil 322 and 323, control valves 342, 343, 344 and 346 would be activated to create a closed loop. To cascade coils 321, 322, 323, all control valves will be activated to create a continuous closed loop circulating refrigerant through all three coils 321, 322 and 323.

The capacity of cooling provided by the system 100 FIG. 4 is a function of control provided by the control system 500. The control system 500 can adjust the flow rate of refrigerant within the close loop refrigerant piping 400 to the coil 320, or coils 321, 322 and 323 when a plurality of coils is configured.

Additionally, as illustrated in FIG. 5, a point to multipoint network of indoor systems 301 and 302 is created by connecting mid-span control valve 349 to control the distribution of refrigerant flow, through refrigerant piping branches in the closed loop refrigerant piping 400 described below, to multiple indoor systems 301 and 302.

As shown in FIG. 6, a multipoint to multipoint network of outdoor systems 200 to indoor systems 300 is illustrated using a mid-span control valve 349 to serve a plurality of data center envelops 110, 120 and 130. A plurality of temperature sensors 510 are positioned within the data center envelops 110, 120 and 130 as shown in FIG. 5 and FIG. 6.

The multipoint to multipoint system is created as shown in FIG. 6, where a plurality of outdoor units 211 and 212 are connected to a plurality of indoor units 301 shown as an inrow system, 302 shown as a CRAC system and 303 shown as a perimeter system using a mid-span control valve 349 to supply multiple branches 401, 402 and 403 within the closed loop refrigerant piping 400 shown as branch 401, 402 and 403 supplying indoor unit 301, 302 and 303 respectively.

In FIG. 4, the volume of refrigerant circulating in the closed loop refrigerant piping system 400 is control directly by adjusting the speed of the inverter compressor 220 by the control system 500. The volume of refrigerant circulating within the close loop refrigerant piping 400 is directly proportional to the cooling capacity available to the heat load with the data center envelop 110, FIG. 4. Increasing the flow rate of refrigerant circulating provides higher capacity to maintain the temperature of the data center envelop 110 constant when higher heat load is present.

In FIG. 4, the control system 500 also provides control to the outdoor system 200 controlling the inverter compressor 220, condenser 230 and variable speed fans 240. This combined control of outdoor system 200 and indoor system 300 provides operating efficiencies which are not found in other systems. The control system 350 operates to ensure the outdoor system 200 is operating at the most efficient speed to yield the optimum level of heat transfer from the refrigerant contained with the closed loop refrigerant line which was absorbed through the coil 320.

The control system 500 FIG. 4 accepts inputs signals from a plurality of temperature sensors 510 distributed throughout the data center envelop 110. According with logic within the control system 500, control signals are transmitted to the sub-systems to adjust the speed of the variable speed components and which controls the refrigerant flow rate within the closed loop refrigerant piping branches 401, 402 and 403 as shown in FIG. 6, by controlling mid-span valve 349, which supply a plurality of coils 321, 322, and 323 contained within the indoor system 300 shown in FIG. 3. The flow rate to individual coils 321, 322 and 323, FIG. 3, is controlled to create temperature zones within the data center envelop 110 which is accomplished by the control system 500 controlling indoor supply manifold 305 FIG. 1 to control the flow rate of refrigerant to each respective control valve 341, 342, 343, 344, 345, 346, 347 and 348 FIG. 3 respectively. Controlling the flow rate of refrigerant and distributing the refrigerant to various coils yields the maximum capacity for heat transfer with minimum demand for consumable services such as power consumption and wear on friction bearings contained within the compressors and fans.

It may be advantageous to set forth definitions of certain words and phrases used in this patent document. The term “couple” and its derivatives refer to any direct or indirect communication between two or more elements, whether or not those elements are in physical contact with one another. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like.

What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art can recognize that many further combinations and permutations of such matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.

While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.

Claims

1. An integrated inverter compressor variable volume refrigerant loop data center cooling unit and control system used to maintain air temperature control and distribute cold air within data centers consisting of:

outdoor inverter compressor; and,

outdoor variable speed fan; and,

outdoor variable volume condenser coil; and,

a variable volume refrigerant loop; and,

indoor electronic valves; and,

Indoor and outdoor headers;

Indoor coil; and,

Indoor variable speed fan; and,

a control system.

2. The integrated inverter compressor variable volume refrigerant loop data center cooling unit and control system in claim 1 which can be configured as a point to point, point to multipoint and multipoint to multipoint system.

3. The integrated inverter compressor variable volume refrigerant loop data center cooling unit and control system in claim 1 which can be configured as an in-row, computer room air conditioner “CRAC”, rear door air handler, overhead air handler, or underfloor cooling units.

4. The integrated inverter compressor variable volume refrigerant loop and data center cooling unit and control system in claim 1 which can be configured as modules to form multipoint networks of indoor and/or outdoor nodes to scale the capacity of the integrated system to cool variable load demands.

5. The integrated inverter compressor variable volume refrigerant loop and data center cooling unit and control system in claim 1 which consists of a multitude of separately configured indoor coils to produce different air temperature air flow outputs within the same data center resulting in separately controlled zoned air temperature control within the data center.

6. The integrated inverter compressor variable volume refrigerant loop and data center cooling unit and control system in claim 1 with an electronic system for controlling cooling with a data center or auxiliary space comprising:

A memory storing instructions; and,

at least one processor configured to execute the instructions; and,

at least one sensor(s) to detect air temperature within the cabinet; and,

at least one sensor(s) to detect proper operation of the variable flow refrigerant loop distribution system; and,

A management system to detect and generate a response to activate air cooling system; distribution system, generate a response to activate and control fan, pump, compressor and condenser speed; generate a response to control valves through which the refrigerant flows; generate a response to control variable controls of operation of the variable cooling system; generate a response to control header valves to mix point to point, point to multipoint, and multipoint to multipoint refrigerant flow paths; and, generate a response to maintain operation of the integrated systems to achieve cost efficiencies of the operational system.