AU2014101161A4 - Fitting of fan unit to existing fan assembly housing - Google Patents

Abstract

A method of fitting a fan unit (100) to an existing fan assembly housing (103) for conditioning air in a room, the method including the steps of measuring the air pressure of the existing fan assembly; removing the existing fan assembly; installing the fan unit (100) in the 5 existing housing (103) that housed the existing fan assembly; using a controller (40) to match the air pressure of the fan unit (100) to the air pressure measured in said measuring step. 25 KASPECIS\184100 .do 4o M8 NUTSERTS 10-PLACES & __ WELD LUGS 10-PLACES TO SUIT MOUNTING PLATE POSITION

Description

FITTING OF FAN UNIT TO EXISTING FAN ASSEMBLY HOUSING Field of the Invention This invention relates to a controller for controlling air conditioning, particularly in 5 existing rooms that house electronic equipment, including computer equipment. The invention also relates to a method of installing an air conditioning system in existing rooms that house electronic equipment such as computers. The present invention also relates to a housing for housing a fan and controller, adapted to fit to existing room air conditioning systems. 10 Background of the Invention Some existing fan units that are used for cooling electronic equipment, such as computer equipment, use a system of belts and/or pulleys in order to power or drive the fan units. Such systems require routine maintenance that can be costly, for example to replace the belts for pulleys, vibration mounts to absorb any shock or vibration from such belt-driven fan units. [5 Furthermore dust emanates from such systems which can float or be carried in the air into the rooms housing the electronic equipment which is a disadvantage if dust particles do pervade the electronic equipment. Such belt-driven systems also consume a great amount of power. The present invention seeks to overcome one or more of the above disadvantages by reducing the power consumption for air conditioning a computer room, providing a cleaner and 10 substantially maintenance free system using direct drive fan units in existing room air conditioning systems. Summary of the Invention According to a first aspect of the invention, there is provided a method of fitting a fan 25 unit to an existing fan assembly housing for conditioning air in a room, the method including the steps of: measuring the air pressure of the existing fan assembly; removing the existing fan assembly; 2 installing the fan unit in the existing housing that housed the existing fan assembly; using a controller to match the air pressure of the fan unit to the air pressure measured in said measuring step. 5 According to a second aspect of the invention, there is provided a controller unit for use in fitting a fan unit to an existing fan assembly housing for conditioning air in a room, said controller unit having: means for measuring air pressure of the fan unit; means for setting a desired air pressure of the fan unit that matches the air 10 pressure of the existing fan assembly; means for adjusting the measured air pressure of the fan unit to the set air pressure; display means to indicate the measured and set air pressures. According to a third aspect of the invention, there is provided a fan housing for 15 fitting to an existing fan assembly enclosure used to condition air in a room, said fan assembly including: a plurality of faces defining a space in which a fan is fitted, an aperture in one the faces against which a front portion of the fan abuts; wherein the aperture is positioned adjacent to an air duct of the existing fan assembly. 20 According to a fourth aspect of the invention, there is provided a computer readable medium comprising computer-executable instructions that, when executed on a processor, in a method of fitting a fan unit to an existing fan assembly housing for conditioning air in a room, directs a controller to: measure the air pressure of the fan unit; 25 enable setting of a desired air pressure of the fan unit that matches the air pressure of the existing fan assembly; and adjust the measured air pressure of the fan unit to the set air pressure. 3 Brief Description of the Drawings A preferred embodiment of the invention will hereinafter be described, by way of example only, with reference to the drawings in which: 5 Figure 1 is a schematic drawing of the steps involved in fitting a fan unit and housing in an existing fan assembly housing used to condition air in a room; Figure 2 is a flow diagram showing the process a user undertakes to match the air pressure of the fan unit to the previous air pressure of the existing fan assembly using a controller unit; 10 Figure 3 is a front view of the controller unit which is positioned inside the fan unit housing; Figure 4 is a partial view of the controller unit with cable connections to the fan and control buttons used by the user; Figure 5A is a perspective view from above of a fan unit housing according to a first 15 embodiment; Figure 5B is an exploded perspective view from below of the fan unit housing of Figure 5A; Figure 5C is an exploded perspective view from above of the fan unit housing of Figure 5A; 20 Figure 5D is a perspective view from above and behind a fully assembled fan unit housing of Figure 5A; Figure 5E is a perspective view from above and front the fully assembled fan unit housing of Figure 5D; Figure 5F is a sectional side view of the fully assembled fan unit housing of Figure 5D; 25 Figure SG is a front view of the fully assembled fan unit housing of Figure 5D (not showing the blades of the fan); Figure 5H is a rear view of the fully assembled fan unit housing of Figure 5D; 4 Figure 5J shows views of various types of CRAC units to which the fully assembled fan unit housing of Figure 5A is shown installed in varying positions; Figure 6A is a perspective view from above and behind of a fully assembled fan unit housing according to a second embodiment; 5 Figure 6B is a perspective view from above and front of the fully assembled fan unit housing of Figure 6A; Figure 6C shows two perspective views of the fan unit housing of Figure 6A (without the fan); Figure 6D is a front view of the fan unit housing of Figure 6C; and 10 Figure 6E is a side sectional view of a fully assembled fan unit housing of Figure 6A. Detailed Description of the Preferred Embodiments The present invention provides retro-fitting of a fan unit and cabinet to an existing fan assembly cabinet for the air conditioning of a room and in this case the air conditioning of a 15 room housing electronic equipment including computer systems, Prior to fitting the new fan unit and cabinet to the existing fan assembly, certain parameters associated with the existing system must be assessed and measured to ensure that steps are taken that are appropriate to the existing system (where the new fan unit and cabinet or housing is being installed). Referring to Figure 1 there is shown a flow diagram 10 of the various steps taken to 20 install a new direct drive fan unit and housing to an existing fan assembly cabinet. At step 12 the air pressure (Pa) emanating from the existing fan unit is measured prior to its removal. At step 14 the power to the existing computer and air conditioning system is switched off and isolated. At step 16 the existing fan unit and its associated mountings are removed and at step 18 the internal components within the original fan assembly are assessed so that they do not obstruct the 25 installation of the new fan unit. Such items as heaters and humidifiers can obstruct the installation of the new unit. At step 20 these obstructions that have been identified are relocated or removed. At step 22 the existing fan unit is cleaned internally and made certain that it is free of any loose materials. At step 24 the new fan unit and housing is installed into the existing cabinet and 5 positioned to the rear of the existing cabinet in order to completely cover the existing air duct opening that then leads to the room to be air conditioned. Thus the complete fan unit in its specially designed cabinet is secured to the rear of the existing cabinet and secured so that the air duct opening through which hot air is removed is covered. There will be an opening in the rear 5 of the new cabinet/housing where air is extracted from the room and flows through that opening. At step 26 the new fan unit and its housing is secured to a base plate of the existing cabinet using heavy duty supplied self-drilling screws or are secured using another appropriate fixing. At step 28 connection of all the relevant electrical cables (including mains cables) is made to the fan unit in the same position of the existing fan within the existing cabinet. At step 10 30 all connections are checked and the fixing of the fan is also checked to ensure that all fixtures and connections have been completed and that no hazards exist. At step 32 the electrical mains supply (240V) is reinstated to the new unit and the system started. Finally at step 34 a user will use an interface screen of a controller unit in order to have the new fan unit meet the existing measurements that were taken in step 12 of the old fan system. This is described in relation to 15 the flow diagram of Figure 2. The object of going through each of the steps in Figure 2 is to adjust the new fan so that it meets the air flow of the existing fan in the existing housing, which airflow characteristics are measured inside the air intake to the existing fan. The measurement can be done with a Testo 510 pressure meter for differential pressure of the inlet site to the room or space pressure. The 20 steps in Figure 2 are programmed on controller unit 40 shown in Figure 3 which measures the air intake of the new fan. It is able to be adjusted by an operator cycling through the program which is controlled using buttons TI (42) and T2 (44) shown in Figure 4 at the front of the device 40. A flap lifts up on the device 40 which gives access to the buttons Tl and T2 and display unit 46, Sockets 1, 2 and 3 are used for power input and power output while sockets 4 and 5 can be used 25 to obtain a second setpoint after bridging the circuit between these two points. This will be described later in relation to Figure 2. The controller device 40 has a memory, which stores inter alia information associated with the process steps shown in Figure 2 such as the required setpoints or required pressure that the new fan unit must produce in the existing enclosure. The controller device also has a 30 computer program stored in the memory, which is on or forms part of a computer-readable medium, the program when executed by the processor enables the controller device 40 to carry out the required tasks as directed by a user going through the process steps of Figure 2. 6 The flow diagram 60 in Figure 2 first starts at step 62 where the controlling mode function is selected which signifies altering the pressure. The air intake or pressure to the fan is measured using a pressure sensor or meter that is linked to a processor in the controller device 40, and needs to be adjusted to a defined setpoint, for example a measured value of 150kPa 5 which is the measured air pressure of the existing fan assembly. Thus at step 62 the measured value of the air pressure is what that new fan unit is currently emitting. The air flow and current draw of the unit can also be measured. A Figure of 150kPa as the first setpoint (the air pressure needed is entered) and then a AP is calculated, for example, showing the difference in the measured air pressure and the desired air pressure at 150kpa. At step 64 a user presses and holds 10 down button TI, which is identified by numeral 42 in Figure 4, for two seconds. A menu appears on the display screen 46 and the user presses button T2, identified by numeral 44 in Figure 4. This takes the user to step 66 where the device displays the units that the pressure is measured in, Pascals or millimetres of mercury (mmig) for example. Once the desired units are selected the process moves to step 68 where the operating mode or measuring mode is selected 15 by pressing button T2. On pressing button 42 (TI) the user is directed to step 70 which is the operating mode or controlling mode. On pressing button 44 (12) again, the user is directed to step 72 which is a measurement of the differential pressure, processed by a processor in the device 40. This is the difference between what is currently measured and the set air pressure. On depressing button T2 the user is directed to step 74 where the first setpoint is made at for W example 150kPa. Button TI (42) can be used to reset the value or confirm the set pressure. The display flashes once to confirm this. At step 72 as an alternative for fitting other fans, button 42 (TI) can be depressed to insert the measured volume flow at step 73 and account for the fan K factor at step 75 (after pressing button 44) which then determines the setpoint at step 74. As mentioned previously a further second setpoint can be made at step 76 by bridging the 25 circuit between inputs 4 and 5, identified by numerals 46 and 47 in Figure 4. The second setpoint is set, for example at 125kPa by depressing button 44 (T2). Further depression of button 44 (T2) leads to step 78 wherein an output voltage reading is given from 0-10 volts. The 0-10 Volt signal is the driving signal of the fan unit to increase or decrease the fan speed. The controller device 40 modulates this to meet the required pressure. The further setpoint can be 30 used to provide a different air pressure or speed of the fan to suit a particular purpose for a user. Continually depressing button 44 provides options to the user to set various parameters in a PID controller or proportional-integral-derivative controller. This is a control loop feedback mechanism that is used by the system for controlling the fan. A PID controller calculates an error value as the difference between a measured variable and a desired setpoint as described 7 above. The controller attempts to minimise the error by adjusting the process through a use of a manipulated variable. The proportional value, denoted by P, depends on the present error, the integral or I value depends on the accumulation of past errors and the derivative value or D is a prediction of future errors, based on a current rate of change. The weighted sum of these three 5 values being P, I and D is used to adjust the process by a control element and in this case to adjust the air pressure. The P parameter can be determined at step 80 and the I parameter at step 82. At step 84 the controlling mode is accessed by pressing button 44 and is in a normal state. If, for example, the fan pressure drops and it is desired to increase the speed of the fan then pressing button 42 can activate step 86 which is the inverse controlling mode. By pressing 10 button T2 the process returns to step 88 where the user goes back to the original menu at step 64 and confirms the controlling mode pressure is set to the first setpoint at 150kPa. Referring to Figures 5A, 5B and 5C there is shown various views of a first embodiment of a housing 100 for a fan unit. The housing 100 has a front angled face 102, top face 104, side face 106 which is stepped so that a ledge/step 108 separates a top portion 109 from a lower 15 portion 107 of face 106. It also has an opposite side face 110, a rear face 112 and an underneath face 114. The front face 102 is angled, such that the area of top face 104 is less than the area of underneath face 114, to provide the optimum amount of pressurised air from the fan to blow into a room or open area that requires air conditioning of electronic equipment and removal of excess heated air. Thus, the housing 100 is so shaped to fit a number of different styles of CRAC 20 (Computer Room Air Conditioning) units and to conform to the various internal constraints with each of the units, to provide the optimum air flow at the required pressure. The front face has an aperture 116 to which is fastened a cone element I 18 which is so shaped to provide better air flow from the fan unit. Referring to Figure 5J, there is shown a number of different types of CRAC units or 25 existing fan assembly housings 101, 103 and 105 having evaporator coils 111 positioned therein. The housing 100 is affixed through tabs or flanges 120 to a rear or bottom wall/plate 119 through suitably strengthened securing means. Opening 160 is aligned with respective ducts 113, 115, 117 associated with the different types of existing housings to remove excessively warm or hot air from the room to be conditioned to an underfloor cavity or space 121, with the air flow of the 30 warm or hot air indicated by red arrows. Fan 122 has a front side 123 which sits flush against the interior side of the cone 118 and a rear side 125 which sits flush against panel 124. The fan has a rear portion 126 which protrudes through an opening 150 in panel 124 and enables connection of cables to the fan unit 8 122. The panel 124 has top flange 128, bottom flange 130 and side flanges 132 and 134 which are bent at right angles inwardly to enable connection of the panel 124 to the interior of the housing 100 through suitable securing means, such as screws. The fully assembled fan unit shown in the housing 100 is illustrated in Figures 5D and 5E. Figure 5D shows a perspective 5 view from above and behind while Figure 5E is a perspective view from above and forward or in front of the fan unit 100. Figure SD shows the installation of the panel 124 which is angled to match the angle of the front face 102 of the housing 100. The fan 122 has a safety fallback hard setpoint to ensure that the system still continues to operate in the event that the controller 40 or its communications to the fan fail, to ensure that the 10 system continues to provide the minimum air required for cooling. Thus the fan runs at a certain duty point that the air flow speed will not fall below. Referring to Figure 5F there is shown a side view of the fan unit housing 100 with the fan 122 installed therein. The controller 40 would be located in a bottom corner of the housing where there is space (through a bottom panel) for control by a user and for connection of cables 15 140 to the rear 126 of the fan 122. The sockets 1 to 5 on the controller 40, as seen in Figure 4, provide for these connections. Figure 5G shows a front view of the unit 100 and in particular shows the opening 150 through which the rear portion 126 of the fan 122 is inserted to fit snugly. Figure 5H more clearly shows the opening 150 in panel 124. An opening 160 (see Figure SD) exists between the 20 top face 104 of the housing 100 and the top flange 128 of panel 124. This enables air flow to be extracted from the fan and dispersed outside of the housing 100. Shown in Figures 6A, B and C is a second embodiment of the fan and its housing 200. The housing 200 has a top face 202, a bottom face 204, front face 206 and optional side panels 208 and 210. The panels 202, 208 and 210 can either be present or not in order to leave an open 25 area for air to flow through. Those panels can also be adjustable to create however large an opening is required. An interior panel 211 is connected through connection points 212 and supports the rear portion 214 of the fan 218. As with the previous embodiment, a cone 216 is secured to a front portion of fan 218. The cone 216 sits against the opening 220 and the interior side of the opening 220 has the front portion of the fan 218 sitting flush against that interior side. 30 Aperture 222 exists in panel 211 in order to receive and support the rear portion 214 of the fan 218. 9 Referring to Figure 6E, as with the embodiment shown in Figure 5F a rear portion of the housing 200 enables the installation of the controller 40 (that can be accessed through a bottom panel of housing 200) which has various cables 230 connected to the rear portion 214 of the fan 218. 5 The housing 100 can have dimensions of for example 700 x 500 x 500mm. The fan unit and housings 100, 200 can reduce power consumption by up to 40 to 50% and in some cases 60%. The fan units of the present invention retro-fitted to existing fan assembly enclosures have been shown to provide 4500 cubic metres of air flow at 380 Pa (900rpm) with a power draw of 1,095W and current draw of 1.66A. This compares favourably against a belt-driven fan unit 10 having a total power draw of 2,645W and current draw of 4.6A. 10

Claims (7)

1. A method of fitting a fan unit to an existing fan assembly housing for conditioning air in a room, the method including the steps of: measuring the air pressure of the existing fan assembly; 5 removing the existing fan assembly; installing the fan unit in the existing housing that housed the existing fan assembly; using a controller to match the air pressure of the fan unit to the air pressure measured in said measuring step. 10

2. A method according to claim I including setting on the controller an air pressure value equivalent to the measured air pressure of the existing fan assembly.

3. A method according to claim 2 including the steps of the controller measuring the [5 air pressure of the fan unit and adjusting parameters of the fan unit so that fan unit air pressure becomes the same as the set air pressure value.

4. A method according to claim 3 further including setting on the controller a second air pressure value that is different to the first set air pressure value. 20

5. A controller unit for use in fitting a fan unit to an existing fan assembly housing for conditioning air in a room, said controller unit having: means for measuring air pressure of the fan unit; means for setting a desired air pressure of the fan unit that matches the air 25 pressure of the existing fan assembly; 11 means for adjusting the measured air pressure of the fan unit to the set air pressure; display means to indicate the measured and set air pressures. 5

6. A fan housing for fitting to an existing fan assembly enclosure used to condition air in a room, said fan assembly including: a plurality of faces defining a space in which a fan is fitted, an aperture in one the faces against which a front portion of the fan abuts; wherein the aperture is positioned adjacent to an air duct of the existing fan assembly. 10

7. A computer-readable medium comprising computer-executable instructions that, when executed on a processor, in a method of fitting a fan unit to an existing fan assembly housing for conditioning air in a room, directs a controller to: measure the air pressure of the fan unit; [5 enable setting of a desired air pressure of the fan unit that matches the air pressure of the existing fan assembly; and adjust the measured air pressure of the fan unit to the set air pressure. K:\SPECiS~I841OINN doc docx 12