GB2532257A

GB2532257A - Server cabinet coolers, server cabinets and system

Info

Publication number: GB2532257A
Application number: GB1420196.6A
Authority: GB
Inventors: Frank Garson James
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-11-13
Filing date: 2014-11-13
Publication date: 2016-05-18
Anticipated expiration: 2034-11-13
Also published as: GB2532257B; GB201420196D0

Abstract

A server cabinet cooler 1 comprises a housing and a refrigeration circuit with a compressor 19, a condenser 20, an expansion valve, and an evaporator 11. The refrigeration circuit is located within the housing which has a warm air intake for drawing warm air from a server cabinet 2 to the evaporator and a cooled air outlet for returning air into the server cabinet. The housing further comprises an external air intake for cooling the refrigerant in the condenser and a warm air outlet for returning warm air to the outside of the cooler. An additional valve, which may be a liquid solenoid valve, is located in the refrigerant circuit before the expansion valve, and a controller causes the additional valve to close the refrigeration circuit when the desired server cooling temperature is reached and to open the additional valve when cooling is required. A server cabinet comprising a server cabinet cooler has a sensor 18 located at or near the bottom of the cabinet, and the server cabinet cooler comprises a controller operating with the sensor to control the operation of the circuit.

Description

Server cabinet coolers, server cabinets and systems

Field of the Invention

The invention relates to server cabinet coolers, server cabinets and systems for operating these.

Background to the Invention

As is known, server cabinets generate lots of heat due to electrical activity of the contained appliances and need to be kept continuously cool to prevent overheating and remain functioning reliably. It can be a major challenge to keep the temperature of these cabinets stable and within a certain range. Current server cabinet coolers exist but these run into problems with overheating during the required rest periods of the refrigeration circuits. However, removing the rest period creates subsequent problems such as the compressor being put under high strain, shortening its life span.

This invention attempts to improve refrigeration circuits for cooling server cabinets.

Summary of the Invention

In a first, broad independent aspect, the invention provides a server cabinet cooler comprising a housing, a refrigeration circuit with a compressor, a condenser, an expansion valve, and an evaporator which are arranged to facilitate the circulation of a refrigerant around the circuit; the refrigeration circuit being located within the housing the housing having a warm air intake for drawing warm air from the server cabinet to the evaporator and a cooled air outlet for returning air into the server cabinet once it has interacted with the evaporator; the housing further comprising an external air intake drawing air from the outside of the cooler to the inside of the housing in order to cool the refrigerant in the condenser and a warm air outlet for returning warm air to the outside of the cooler; wherein the cooler further comprises an additional valve located in the refrigerant circuit before the expansion valve; and a controller which causes the additional valve to close the refrigeration circuit when the desired server cooling temperature is reached and to open the additional valve when cooling is required.

This configuration is particularly advantageous as it allows a server cabinet to be cooled reliably and efficiently without the need for a rest period during which cabinets have been known to overheat. In particular, the additional valve negates, in certain embodiments, the need for a rest period by preventing the suction and discharge pressures from equalising, allowing the compressor to re-start without the need for a high start up current which would damage and shorten the compressor's lifespan.

In a subsidiary aspect the cooler incorporates means for connecting to a temperature sensor located remotely from the cooler housing. This configuration is particularly advantageous because it means the temperature is monitored at the inlet to the server, so that the work required by the cooler can be adjusted appropriately based on this critical measurement.

In a further subsidiary aspect, the additional valve is a liquid solenoid valve. This configuration is particularly advantageous because a Liquid solenoid valve can stop the circuit pressures from equalising. These valves are also reliable and fast-acting which can efficiently prevent overheating without the need for manual opening and closing. A liquid solenoid valve is also particularly advantageous as it can prevent the 'migration' effect by preventing warm refrigerant liquid from passing through the expansion valve and warming the evaporator coils.

In a further subsidiary aspect, the housing incorporates side walls and a ceiling the housing's external air intake is Located to draw air in from a wall, preferably the front wall, of the housing and the housing expels warm air through the warm air outlet which is located in its ceiling.

This configuration is particularly advantageous as it allows the separation of hot and cold aisles. It also makes good use of available external air to cool necessary parts of the circuit and helps prevent re-circulation of hot waste air through the cooler.

In a further subsidiary aspect, the housing incorporates a base which is of insulating material. This configuration is particularly advantageous as an insulating base helps to keep the temperature of the cooler stable by preventing hot air and cool air escaping other than from where it is supposed to travel.

In a further subsidiary aspect, the housing incorporates a compartment for containing the evaporator; said compartment having walls of insulating material. This configuration is particularly advantageous as it helps keep the evaporator cool despite the warm surroundings, by preventing air escaping out of and entering the compartment in which the evaporator is Located.

In a further subsidiary aspect, the server cabinet cooler further comprises a duct which directs cooled air from one side of the server towards its opposite side. This configuration is particularly advantageous because it forces the air to travel in the required direction to efficiently circulate around the server inlet.

In a further subsidiary aspect, the server cabinet cooler further comprises a deflector plate which is located in an upper corner of the server to direct the flow of cooled air downwards. This configuration is particularly advantageous because it improves the circulation of the air around the server by helping it to reach all the corners of the server cabinet.

In a further subsidiary aspect, the server cabinet cooler further comprises detachable lifting handles. This configuration is particularly advantageous because provides a means to easily lift and transport the cooler to the desired Location, yet the detachability means the handles do not to interfere with the usage of the cabinet cooler or get in the way after installation.

In a further subsidiary aspect, the base seals the server cabinet when placed on the upper portion of a server cabinet with sealed walls. This configuration is particularly advantageous as a sealed unit means there is no escape of air which maximises the cooling efficiency.

In a further, broad independent aspect, the invention provides a system for cooling a server cabinet comprising a server cabinet cooler and a controller operating with a sensor located at or near the bottom of the cabinet; whereby the cooler refrigerates the air until the sensor detects a desired temperature.

This configuration is particularly advantageous because the cooler will run automatically according to the desired temperature which is detected at cool air side of the cabinet and therefore the system is controlled according to the critical measurement, allowing control of the inlet temperature precisely and quickly to maintain the temperature of the air within its narrow recommended limits.

In a further broad independent aspect, the invention provides a server cabinet comprising a server cabinet cooler incorporating a housing, a refrigeration circuit with a compressor, a condenser, an expansion valve, and an evaporator which are arranged to facilitate the circulation of a refrigerant around the circuit; the refrigeration circuit being located within the housing the housing having a warm air intake for drawing warm air from the server cabinet to the evaporator and a cooled air outlet for returning air into the server cabinet once it has interacted with the evaporator; the housing further comprising an external air intake drawing air from the outside of the cooler to the inside of the housing in order to cool the refrigerant in the condenser and a warm air outlet for returning warm air to the outside of the cooler; wherein the cabinet has a sensor located at or near the bottom of the cabinet; and the server cabinet cooler comprises a controller operating with said sensor to control the operation of said circuit This configuration is particularly advantageous because it provides a server cabinet that can be efficiently cooled without the cooler requiring a rest period between switching off and re-energising which could be problematic in that during a rest period, enough heat can be generated within the cabinet raising the temperature outside safe operating Limits of the servers. This server cabinet prevents this occurrence and extends the life of both the servers unit and the server cabinet cooler.

In a further subsidiary aspect, the cooler has an additional valve which is located before the expansion valve.

In a further subsidiary aspect, the additional valve is a liquid solenoid valve.

In a further subsidiary aspect, the housing incorporates side walk and a ceiling the housing's external air intake is located to draw air in from a wall, preferably the front wall, of the housing and the housing expels warm air through the warm air outlet which is located in its ceiling.

In a further subsidiary aspect, the housing incorporates a base which is of insulating material.

In a further subsidiary aspect, the housing incorporates a compartment for containing the evaporator; said compartment having walk of insulating material.

In a further subsidiary aspect, the server cabinet further comprises a duct which directs cooled air from one side of the server towards its opposite side.

In a further subsidiary aspect, the server cabinet further comprises a deflector plate which is Located in an upper corner of the server to direct the flow of cooled air downwards.

In a further subsidiary aspect, the server cabinet further comprises detachable Lifting handles.

In a further subsidiary aspect, the server cabinet has sealed walls, and the base of the cooler seals the upper portion of the server cabinet.

Brief Description of the Drawings

Figure 1 shows a diagram of the server cabinet cooler Figure 2 shows a perspective view of the server cabinet cooler.

Figure 3 shows a perspective view of an embodiment of the cooler.

Figure 4 shows a view of the server cabinet cooler from above Figure 5 shows a side view of the server cabinet cooler Figure 6 front a side view of the server cabinet cooler.

Figure 7 shows a diagram of the refrigeration circuit.

Detailed Description of the Embodiments

Figure 1 shows a diagrammatic overview of an embodiment. The cooler 1 is shown on top of a server cabinet 2. Arrows 3-8 show the direction of the warm air, generated by electrical devices within the sever cabinet, being drawn up by a fan 10 into the evaporator 11 within the cooler. In an alternative embodiment, two fans may exist to draw the hot air up.

In the evaporator, the warm air is cooled as the heat is absorbed by the refrigerant liquid and the cool air flows back down into the cabinet shown by arrows 12 and 13. In a preferred embodiment, this air travels through a duct 9 which is in place to direct the air to the opposite side of the cabinet.

In a preferred embodiment, a deflector 14 is in place to improve the air circulation around the server air inlets.

Fans 15, in place within each server 16 of the cabinet 2, push the air in the direction of the arrows 16a shown, where the air repeats the cycle of being pushed upwards by fan 10 through to the evaporator where it is cooled. In use, this provides a constant cooling to the cabinet.

In a preferred embodiment, the cooler sits above the cabinet on top of an insulated base 17 which is between the cabinet and the cooler. This is required due to the differences in temperature between the cabinet and the cooler. In a preferred embodiment the insulated base is made from foam, however in an alternative embodiment, the base could be made from any suitable insulating material.

In a preferred embodiment, a temperature sensor 18 is located at or near the base of the server cabinet on the air inlet side of the servers, rather than at the entrance to the cooler. This unique location specifically allows for a temperature measurement at the critical part of the server to cool and therefore quickly provides a more effective and accurate recording of the temperature of the cabinet, in order for the control mechanism to recognise when the cabinet has reached the desired temperature.

In a preferred embodiment of the invention, the temperature sensor is connected to a control mechanism which controls the refrigeration circuit. When the desired temperature is reached, the system can cause the compressor 19 to switch off and stop cycling, during which time, the fan 22 continues to rotate but in an idle state. The inclusion of the solenoid valve 30 (Figure 2) prevents the pressures equalising whilst the compressor is not active and allows the compressor to re-start without a high starting current, even without a rest period.

In a preferred embodiment, the cooler 1 sits on top of the server cabinet and comprises a standard closed refrigeration circuit, in which a refrigerant is circulated around the circuit, pumped by the compressor 19 through to the condenser 20. At the condenser, the refrigerant gas (not shown) is cooled to a liquid by the air from the room shown by arrow 21, which is drawn into the cooler by fan 22 and expelled upwards and backwards, shown by arrows 23 and 24 and out through the ceiling of the server cabinet cooler 25.

The cooled refrigerant, having liquefied, flows to the receiver tank (not shown) and then through an expansion valve to the insulated evaporator 11 where it absorbs the heat generated from the server cabinet and becomes a gas again. Here it is pumped back to the compressor to begin the cycle again.

In a preferred embodiment the cabinet and cooler is sealed on all sides and is made from steel. In a preferred embodiment the front and rear doors to the cabinet are solid and made of glass. The use of glass doors allows the server to be seen from the outside to allow for checking of the server conditions.

In a preferred embodiment, the cooler comprises detachable lifting handles to ease the lifting process.

In a further preferred embodiment, the cooler comprises a fail -safe mechanism to prevent the incorrect or back to front installation.

Figure 2 shows the components of the cooler. The compressor 19 is the pump which circulates the refrigerant around the circuit. The evaporator is located within the insulated box 26 which has an insulated pod cover 27 to maximise the cooling efficiency.

An electrical control box 28 sits above condenser 20. This controls certain parts of the circuit in response to the temperature detection. This control unit may cause the fans to alter their speed depending on the amount of cooling that is required as detected by the controller.

In an alternative embodiment, the electrical box may be placed elsewhere in any appropriate part of the unit such as shown in Figure 3.

The refrigerant is stored in a receiver storage tank 29 located next to the condenser. This tank acts as a buffer for liquid refrigerant to be stored for use by the system. The liquid refrigerant is taken from the receiver to the evaporators as it is needed to satisfy the heat load. A receiver is particularly necessary for when the system refrigeration load varies greatly.

In a preferred embodiment, a removable filter (not shown) may be located past the condenser to capture large particles such as carpet, dust and other large particles to stop these from accumulating and dogging the condensor. In a preferred embodiment, the filter is removable and can be shaken out if required. In a preferred embodiment, the filter does not require any additional maintenance.

In a preferred embodiment, a filter / dryer 37 is included in the refrigeration circuit to capture any debris from the assembly of the pipework.

The liquid solenoid valve 30 is located next to the box containing the evaporator. In a preferred embodiment, in use, the Liquid solenoid valve shuts and blocks the circuit when the compressor switches off having reached the desired target temperature, as sensed by the temperature sensor. This consequently blocks the circuit and the valve prevents the pressures in the circuit from equalising, which allows the compressor to re-start when required without drawing a high starting current, which would occur due to the lack of rest period and cause potential damage due to high mechanical strain on the compressor.

In addition, the solenoid valve stops the warm refrigerant going through the expansion valve without turning to a gas and consequently warming up the evaporator coils. This would warm the air entering the evaporator rather than cooling it. The overall, general effect of this valve is that the system is able to run without a rest period.

In a preferred embodiment, the cooler further comprises a tray 31 (Figure 3) which captures any condensation arising on the evaporator as the warm air passing through it is cooler. In a preferred embodiment, the tray may have an automatic heater to ensure any water collected is evaporated off. This ensures the tray never overflows.

Pipe work 32 can be seen connecting all the components of the circuit. In a preferred embodiment all the pipe work is insulated.

Figure 4, shows more clearly the location of the different components in the refrigeration circuit in relation to one another and the piping connecting the components of the circuit can also be seen.

Figure 6 shows a front view of the cooler in which the condenser 20 is clearly shown head on. The external air is drawn in here.

Figure 7 shows the refrigeration circuit. For clarity, the same numbering has been used for components, as in previous figures. The arrows 40 depict the direction of the refrigerant.

Beginning at the compressor 19, the refrigerant gas is pumped through to the condenser 20 where it is cooled to a liquid. This liquid flows to the storage tank / receiver 29. From here, it passes through a filter dryer 37 and the liquid solenoid valve 30. From here it passes through the expansion valve 38 and to the evaporator 11 where it absorbs the heat from the server to become a gas before being pumped through the compressor again. In a preferred embodiment, the solenoid valve is located between the condenser and the evaporator. Preferably the valve is located between the receiver and the expansion valve.

In a preferred embodiment, the circuit is completely closed and operates as a conventional refrigeration circuit, with the addition of the liquid solenoid valve and is controlled by a control unit.

Claims

Claims 1. A server cabinet cooler comprising a housing, a refrigeration circuit with a compressor, a condenser, an expansion valve, and an evaporator which are arranged to facilitate the circulation of a refrigerant around the circuit; the refrigeration circuit being Located within the housing the housing having a warm air intake for drawing warm air from the server cabinet to the evaporator and a cooled air outlet for returning air into the server cabinet once it has interacted with the evaporator; the housing further comprising an external air intake drawing air from the outside of the cooler to the inside of the housing in order to cool the refrigerant in the condenser and a warm air outlet for returning warm air to the outside of the cooler; wherein the cooler further comprises an additional valve located in the refrigerant circuit before the expansion valve; and a controller which causes the additional valve to close the refrigeration circuit when the desired server cooling temperature is reached and to open the additional valve when cooling is required.
2.
3.
4.
5.

A server cabinet cooler according to claim 1, wherein the cooler incorporates means for connecting to a temperature sensor located remotely from the cooler housing.

A server cabinet cooler according to claim 1 or claim 2, wherein the additional valve is a liquid solenoid valve.

A server cabinet cooler according to any of the preceding claims, wherein the housing incorporates side walls and a ceiling; the housing's external air intake is located to draw air in from a wall, preferably the front wall, of the housing and the housing expels warm air through the warm air outlet which is located in its ceiling.

A server cabinet cooler according to any of the preceding claims, wherein the housing incorporates a base which is of insulating material.
6. A server cabinet cooler according to any of the preceding claims, wherein the housing incorporates a compartment for containing the evaporator; said compartment having walls of insulating material.
7. A server cabinet cooler according to any of the preceding claims, further comprising a duct which directs cooled air from one side of the server towards its opposite side.
8. A server cabinet cooler according to any of the preceding claims, further comprising a deflector plate which is located in an upper corner of the server to direct the flow of cooled air downwards.
9. A server cabinet cooler according to any of the preceding claims, further comprising detachable lifting handles.
10. A server cabinet cooler according to claim 5 and claim 5 in combination with any of claims 6 to 9, wherein the base seals the server cabinet when placed on the upper portion of a server cabinet with sealed walls.
11. A server cabinet cooler substantially as hereinbefore described and/or illustrated in any appropriate combination of the accompanying text and/or figures.
12. A system for cooling a server cabinet comprising a server cabinet cooler and a controller operating with a sensor located at or near the bottom of the cabinet; whereby the cooler refrigerates the air until the sensor detects a desired temperature.
13. A system for cooling a server cabinet substantially as hereinbefore described and / or illustrated in any appropriate combination of the accompanying text and/or figures.
14. A server cabinet comprising a server cabinet cooler incorporating a housing, a refrigeration circuit with a compressor, a condenser, an expansion valve, and an evaporator which are arranged to facilitate the circulation of a refrigerant around the circuit; the refrigeration circuit being located within the housing; the housing having a warm air intake for drawing warm air from the server cabinet to the evaporator and a cooled air outlet for returning air into the server cabinet once it has interacted with the evaporator; the housing further comprising an external air intake drawing air from the outside of the cooler to the inside of the housing in order to cool the refrigerant in the condenser and a warm air outlet for returning warm air to the outside of the cooler; wherein the cabinet has a sensor located at or near the bottom of the cabinet; and the server cabinet cooler comprises a controller operating with said sensor to control the operation of said circuit.
15. A server cabinet according to claim 14, wherein the cooler has an additional valve which is Located before the expansion valve.
16. A server cabinet according to either claim 14 or claim 15, wherein the additional valve is a liquid solenoid valve.
17. A server cabinet according to any of claims 14 to 16, wherein the housing incorporates side walls and a ceiling; the housing's external air intake is located to draw air in from a wall, preferably the front wall, of the housing and the housing expels warm air through the warm air outlet which is located in its ceiling.
18. A server cabinet according to any of claims 14 to 17, wherein the housing incorporates a base which is of insulating material.
19. A server cabinet according to any of claims 14 to 18, wherein the housing incorporates a compartment for containing the evaporator; said compartment having walls of insulating material.
20. A server cabinet according to any of claims 14 to 19, further comprising a duct which directs cooled air from one side of the server towards its opposite side.
21. A server cabinet according to any of claims 14 to 20, further comprising a deflector plate which is located in an upper corner of the server to direct the flow of cooled air downwards.
22. A server cabinet according to any of claims 14 to 21, further comprising detachable lifting handles.
23. A server cabinet according to any of the claims 14 to 22, wherein the server cabinet has sealed walk, and the base of the cooler seals the upper portion of the server cabinet.
24. A server cabinet substantially as hereinbefore described and/or illustrated in any appropriate combination of the accompanying text and/or figures.AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS1. A server cabinet cooler comprising, a housing, a eration circuit with a compressor, a condenser, an expansion valve, and an evaporator which are arranged to facilitate the circulation of a refrigerant around the circuit; the refrigeration circuit being located within the housing; the housing having a warm air intake for drawing warm air from a server cabinet to the evaporator and a cooled air outlet for returning air into the server cabinet once it has interacted with the evaporator; the housing further comprising an external air intake drawing air from the outside of the cooler to the inside of the housing in order to coo; the refrigerant in the condenser and a warm air outlet for returning warm air to the outside of the cooler; wherein the cooler further comprises an additional valve located in the refrigerant circuit; and a controller which causes the additional valve to Close the refrigeration circuit when the desired server cooling temperature is reached and to open the additional va re when cooling is required: wherein the cooler further comprises means for connecting to a temperature sensor; and wherein the temperature sensor is located remotely from toe cooler housing and towards a bottom end of the server cabinet, er cabinet cooler according to claim 1 wherein the additional valve Is a liquid solenoid valve.LC) l5N C\JA server cabinet cooler according to,claimi1Hor claim 2, wherein the housing incorporates side walls and a ceiling, the housing's external a if intake is located to draw air in from a wall, preferably the front wall, of the housing and the housing expels warm air through the warm air outlet which is located in its ceiling, A server cabinet cooler according to any of the preceding claims,. wherein the= housing incorporates a base which IS of insulatingmaterial, A server cabinet Looter according to any, of the preceding claims, wherein th housing incorporates a compartment for containing the evaporator; said compartment having walls of insulating material, A server cabinet cooler according to any of the preceding claims, further comprising a duct which extends into a sen'er et and directs cooed it from tine side of the server cabinet towards its opposite A server cabinet cooler according to any of the preceding chaims, further comprising a deflector plate which extends into an Lipper comer of the server cabinet to direct the fiow of cooled air downwards.A server cabinet cooler accordi ndz of the g claims furth detachable lifting handles.A server cabinet cooler a.cording in combination with any of claims 5 to B. wherein the base seals the server when placed on the upper portion of a server cabinet with sealed waits.10, A server cabinet cooler substantialiyiesibereinbeforeidiescribeidwithrieferencesto and as illustrated by the accompanying figures.System for cooling a server cabinet comprising a server cabinet cooler and a controller operating with a sensor; wherein said controller and sensor are located at or near the bottom of the cabinet and remotely from the server cabinet cooler; whereby the cooler refrigerates the air until the sensor detects a desired temperature.system for cooling a SeriVerciabihet substantially as hereinbefore described with reference to:and as illustrated by the accompanyingfiguresh A server cabinet comprising a server cabinet cooler incorporating a housing, a sso refrigeration circuit with a compressor, a condenser, an expansion valve, and an evaporator which are arranged to facilitate the circulation of a refrigerant around the circuit; the retrigeration circuit being located within the housing; the housing having a warm air intake for drawing warm air from the server cabinet to the evaporator and a cooled aft outlet for returning air into the server cabinet on it has interacted with the evaporator; the housing further comprising an external air intake drawi. Eg air from the outside of the cooler to the 'de of the housing order to cool the refrigerant in the condenser and a warm air outlet for returning warm air to the outside of the cooler; wherein the cabinet has a sensor located at or neat t.e bottom of the cabinet and remotely fro rl said housing and the server cabinet cooler comprises a controller operating with said sensor to control the operation of said circuit.14, A se according to claim 13, wherein die cooler has an additional vase which is located before the expansion valve.15. A server cabinet according to ei wherein kadditional valve is a liquid solenoid valve.lilikservercabinet accordingEtaEanyclEclairrslato 15, wherein the housing incorporates side walls and a ceiling; the housing's external air intake is located to draw air in from a wall, preferably the front wall, of the housing and the housing C\I expels warm air tto4gh the warm air outlet which:IsHEwate41nHE.Cei1Tg. 4()r cabinet according to any of claims 13 to 1 herein the housing corporates a base which is of insulating material, 18. A server cabinet according to any of claims 13 to 17, beret the effusing zr incorporates a compartment for contain ing the evaporaton,said compartment haVing waits of insulating material, lq A server cabinet accordingto any of do/ s 13 to 18, furthe c g e duct which directs cooled sir from one side of server cabinet towards its opoo5ite, side.ac, A server cabinet according to any of claims 13 to 19, further co( pri sing a def ector plate which is Located in an upper corner of the se. cabinet direct the flow of cooled air downwards.21. A server cablm.t according to any of c a rm 13 to 20, further comprisi detachable lifting handles.server cabinet according to any of the claim's 17 to _1 wherein SPrifl" cabinet has seated wails, and the base of the cooler seals the u t' on of the server cabinet.A server cabinet substantially hereint,gore ecLwith referenc to and a, ill:uisitrated by the accompanying figures..N