WO2012142262A1 - Integrated data center containment system - Google Patents

Integrated data center containment system Download PDF

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Publication number
WO2012142262A1
WO2012142262A1 PCT/US2012/033287 US2012033287W WO2012142262A1 WO 2012142262 A1 WO2012142262 A1 WO 2012142262A1 US 2012033287 W US2012033287 W US 2012033287W WO 2012142262 A1 WO2012142262 A1 WO 2012142262A1
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WO
WIPO (PCT)
Prior art keywords
rack
cabinets
cabinet
data center
containment system
Prior art date
Application number
PCT/US2012/033287
Other languages
French (fr)
Inventor
Frank J. DESROCHERS
Douglas P. DUDLEY
Original Assignee
Fire And Ice Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fire And Ice Llc filed Critical Fire And Ice Llc
Publication of WO2012142262A1 publication Critical patent/WO2012142262A1/en

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Classifications

    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00Constructional details common to different types of electric apparatus
    • H05K7/20Modifications to facilitate cooling, ventilating, or heating
    • H05K7/20709Modifications to facilitate cooling, ventilating, or heating for server racks or cabinets; for data centers, e.g. 19-inch computer racks
    • H05K7/208Liquid cooling with phase change
    • H05K7/20818Liquid cooling with phase change within cabinets for removing heat from server blades

Definitions

  • the present invention relates to a data center containment system that provides a physical structure supporting a plurality of electronic network components, especially computer servers and interface devices like routers.
  • Data center containment systems typically comprise racks or cabinets in which electronic components are stacked in a compact space. Because the stacked electronic components operate at a high power, they generate a great amount of heat that is a hazard to the electronic components themselves and also increases a risk of fire. Therefore, data center containment systems are typically open to the free flow of air and accommodated in air-conditioned rooms specifically designed as server rooms. These server rooms have a powerful air-conditioning (A/C) system that keeps the entire room at a low temperature. Internal fans in the components blow low-temperature ambient air through the interior of the individual components. But not every business has sufficient space or financial resources available to create a special room with its own A/C system and fire protection just for the electronic networking components. Also, cooling an entire room in order to provide cool air to all the rack cabinets results in high operating costs. Furthermore, if the A/C system is defective, all components operating in the server room need to be shut down to prevent costly damage.
  • A/C air-conditioning
  • a row of rack cabinets has one of two A/C end cabinets placed at each end of the row.
  • a cooling duct system selectively connects each of the two A/C cabinets with each rack cabinet in the row.
  • Each A/C cabinet is dimensioned for generating a cooling power sufficient to continuously cool the entire row of rack cabinets.
  • a computer may receive individual information on the interior climate of each of the rack cabinets and may control the A/C cabinets according to the prevailing requirements. Different rack cabinets may require different cooling temperatures and are controllable independently of each other.
  • the data system may include a fire suppression system that is capable of isolating an individual rack cabinet from any air circulation if a fire has ignited or is imminent inside the rack cabinet.
  • each rack cabinet may include an air-sealed front door and an air-sealed rear door. Between the air-sealed doors of each rack cabinet, rack-mounted electronic components are arranged above each other.
  • each rack cabinet may have a horizontal cold air channel above the electronic components and a horizontal hot air channel below the electronic components.
  • the cold air channel may communicate with a front space between the electronic components and the front door of the rack cabinet.
  • the hot air channel in turn may communicate with a rear space between the electronic components and the rear door of the rack cabinet.
  • Each of the two A/C cabinets arranged at the ends of the row of rack cabinets may include a cold air duct connected to the cold air channel of the adjacent rack cabinet. All cold air channels are preferably connected with each other so that either A/C cabinet can cool the entire row of rack cabinets.
  • each of the two A/C cabinets may also have a return duct that is connected to the hot air channel of the adjacent rack cabinet. All hot air channels of the rack cabinets are connected with each other so that the hot air channels of all rack cabinets can communicate with either one of the return ducts.
  • the cold air ducts may include damper flaps that allow a stream of air from the cold air duct of the A/C cabinets into the cold air channels of the rack cabinets, but not in the opposite direction.
  • air entering the return duct of the associated A/C cabinet is preferably cooled down by the A/C unit accommodated inside the A/C cabinet.
  • the cooled air is expelled as cold air from the A/C cabinet through the cold air duct and fed into the cold air channels of the rack cabinets.
  • each of the A/C units is powerful enough to cool the entire row of rack cabinets, a true 2N redundancy is achieved.
  • the 2N configuration is preferred, but less stringent cooling requirements may allow for the use of only one A/C cabinet.
  • additional A/C cabinets can be placed between rack cabinets within the row of rack cabinets.
  • These intermediate A/C cabinets are configured to provide an adjustable cooling air flow to either side as needed. This configuration provides an N+1 redundancy because the data center containment system includes one more A/C cabinet than needed to cool all rack cabinets.
  • Any or all of the A/C cabinets may contain monitoring equipment monitoring the power distribution and current draw, depending on specific demands of the data center containment system. And all of the rack cabinets may contain individual canisters of fire retardant gas that can be triggered by either extreme heat or the presence of smoke particles.
  • FIG. 1 depicts a front view of a data center containment system according to the present invention
  • Fig. 2 depicts a cross-sectional view of the data center containment system of
  • FIG. 3 shows a detail of an air channel assembly for a rack cabinet
  • FIG. 4 is a schematic diagram of a data center containment system with an added intermediate A/C cabinet.
  • FIG. 5 is a schematic diagram of a control system controlling and operating a data center containment system according to the invention.
  • a data center containment system 10 is shown in a frontal view.
  • a first A/C cabinet 20 is positioned on the right side of the row rack cabinets 12-18 adjacent to the rack cabinet 18.
  • a second A/C cabinet 22 is located on the other side of the row of rack cabinets, adjacent to rack cabinet 12. While Fig. 1 shows a number of four rack cabinets 12- 18, the invention is not limited to this number and can include two or more rack cabinets.
  • the number of rack cabinets 12-18 between the A/C cabinets 20 and 22 is limited based on cooling requirements of the rack cabinets 12-18 and the cooling output of each of the A/C cabinets 20 and 22. For cabinet rows with higher demands of cooling power, an exemplary arrangement is shown below in Fig. 4.
  • Each rack cabinet 12-18 comprises an air-sealed front door 24 and an air- sealed rear door 26, which is not visible in Fig. 1 .
  • each rack cabinet 12-18 a top space is free of any electronic components, forming a cold air channel 28 that is part of a cooling duct system.
  • the cold air channels 28 of all adjacent rack cabinets 12-18 share a free air flow with each other because the rack cabinets 12-18 do not have side walls extending into the area of the cold air channels.
  • each rack cabinet 12-18 serves as a hot air channel 30.
  • the rack cabinets 12-18 have no side walls, either, so that each hot air channel shares a free air flow with the hot air channels 30 of the neighboring rack cabinets 12-18. This is described in closer detail in connection with Fig. 3
  • the cold air channels 28 and hot air channels 30 are adapted to fit inside commercially available rack cabinets 12-18, which by industry standards can hold in excess of 2,000 lbs. of added weight.
  • the rack cabinets 12-18 thus retain their structural integrity.
  • a stacking space 32 with plurality of sliding rails 34 is arranged between the cold air channel 28 and the hot air channel 30 of each rack cabinet 12-18.
  • the stacking space 34 of each rack cabinet 12-18 has side walls extending from the front door 24 to the rear door 26 so that every stacking space 32 is separated from the stacking spaces 32 of the adjacent rack cabinets 12-18.
  • A/C cabinet 20 on the right side is currently operating, hence the display stating "ON".
  • A/C cabinet 22 on the left side is on stand-by to take over after a specified time off if A/C cabinet 20 encounters a malfunction.
  • Each of the A/C cabinets 20 and 22 contain an A/C unit 36 and 38, respectively, each dimensioned to be powerful enough to cool the entire row of rack cabinets 12-18 continuously.
  • a cold air duct 40 or 42 respectively, communicates with the cold air channel 28 of the adjacent rack cabinet 12 or 18, respectively.
  • a hinged damper flap 48 or 50 allows a stream of cold air from the associated cold air duct 40 or 42 into the cold air channel 28 of the neighboring rack cabinet 12 or 18, but not in the opposite direction.
  • the damper flaps 48 and 50 are lightweight, passive flaps that react to the air stream and do not need an external control.
  • the associated damper flap 48 is opened by the air stream to allow a stream of cold air from the cold air duct 40 of A/C cabinet 20 into the cold air channel 28 of rack cabinet 18.
  • the opposite damper flap 50 of the A/C cabinet 22 is pushed into a closed position by the air stream, thereby shutting off the connection from the cold air channel 28 of rack cabinet 12 to the cold air duct 42 of A/C cabinet 22.
  • the hot air channels 30 of the rack cabinets 12 and 18 communicate with a return duct 44 and 46, respectively, that leads heated air back to the respective A/C unit 36 or 38 of the neighboring A/C cabinet 20 or 22.
  • Each of the return ducts 44 and 46 also includes a respective passive damper flap 49 and 51 , respectively.
  • the currently operating A/C unit 20 sucks in the heated air through the associated damper flap 49 and simultaneously pulls the damper flap 51 of the other A/C cabinet 22 into a closed position.
  • the A/C unit 36 inside A/C cabinet 20 cools the air down again and feeds it through the cold air duct 40 back into the cold air channels 28 of the rack cabinets 12-18.
  • the exemplary embodiments show passive damper flaps 48-51 , that enhance the efficiency of the cooling operation because they force the cold air through the stacking spaces 32 while preventing the air from flowing through the inactive A/C cabinet.
  • the data center containment system 10 does not depend on these damper flaps because, even without the passive damper flaps 48-51 , the air flow through the inactive A/C cabinet is rather limited compared to the air flow through the stacking spaces 32.
  • Fig. 2 shows a schematic side view onto a cross-section of an exemplary rack cabinet 52.
  • the plane of the view shown in Fig. 2 corresponds to a vertical cross-section from the front to the back of the rack cabinet 52.
  • the rack cabinet 52 of Fig. 2 is shown with an equal spacing of the sliding rails 34.
  • the rack cabinet 52 has a front space 54 between the front of the stacking space 32 and the front door 24 extending across the entire width and height of the stacking space 32.
  • the cold air entering the cold air channel 28 of rack cabinet 52 can enter the front space 54 by passing an adjustable access slide gate 56 that controls the connection between the cold air channel 28 and the front space 54.
  • the rack cabinet also includes a rear space 58 extending between the stacking space 32 and the rear door 26.
  • the rear space 58 communicates with the hot air channel 30 through an adjustable exit slide gate 60. Access slide gate 56 and exit slide gate 60 will be discussed in greater detail in connection with Fig. 3.
  • a first barrier 62 at the top of rear space 58 permanently separates the rear space 58 from the cold air channel 28 so that the only way for the cold air in the cold air channel 28 to enter the stacking space 32 is past the access slide gate 56.
  • a second barrier 64 at the bottom of front space 54 separates the front space 54 from the hot air channel 30 so that the cold air in the front space 54 cannot directly exit the stacking space 32 through the hot air channel 30.
  • the cold air entering the front space 54 reaches the rear space through electronic components 66 arranged between the sliding rails 34.
  • the positive pressure of the cold air in the front space 54 in conjunction with internal fans 68 of the electronic components 66 propels the air through the electronic components 66 toward the rear space 58.
  • the initially cold air cools the electronic components 66 and heats up accordingly.
  • the heated air reaches the rear space 58, from where it passes the exit slide gate 60 into the hot air channel 30. As shown in Fig. 1 , the heated air then returns to the respective operating A/C unit 36 to repeat the cooling cycle.
  • Temperature sensor 70 is arranged in the cold air duct 28 to measure the temperature of the cold air fed into the rack cabinet 52.
  • Temperature sensor 72 is located near the bottom of the front space 54 and measures at which temperature the cold air reaches the stacking space 32.
  • the other two temperature sensors 74 and 76 are both placed in the hot air duct and provide redundant information on the air temperature after the air stream has passed the stacking space 32 with the electronic components 66.
  • the individually measured temperatures on both the cold air feed and hot air return side can be automatically analyzed by a control system and result in automatic and individual motorized slide gate adjustments.
  • This individualized control not only saves money by tightly controlling the cooling energy expended in each rack cabinet 52, but allows the control system to automatically isolate a single rack cabinet by shutting the respective access slide gate 56 and exit slide gate 60 in the event of a fire.
  • a smoke sensor mounted inside the rack cabinet 52 to give a fire alarm based on smoke particles in the rack cabinet 52. Extinguishing gas can be released inside the individual isolated rack cabinet 52, while all other rack cabinets are cooled on a continuous basis.
  • FIG. 3 shows a detail of an air channel assembly 78 for a rack cabinet for the type shown in Fig. 1 or Fig. 2.
  • the air channel assembly 78 of Fig. 3 is shown in an orientation that is suitable for the hot air channel 30 underneath the stacking space 32. Turning the air channel assembly 78 upside down puts the air channel assembly in an orientation suitable for the cold air channel 28.
  • the air channel assembly 78 includes the exit slide gate 60 and the second barrier 64, which is integrally formed on a body 80.
  • the body 80 is made of sheet metal and has a substantially tubular structure with a rectangular cross-section having a width greater than its height.
  • the tubular body 80 has a top surface 84 with a rectangular opening 86 that can be closed by the slide gate 60.
  • the slide gate 60 is guided between two guide rails 85 formed on both sides of the opening 86 on the top surface 84 of the body 80.
  • the top surface 84 also includes the air barrier 64 in an area remote from the opening 86.
  • the air channel assembly 78 features a spindle drive 82 that operates the slide gate 60 and is mounted on a vertical wall 89 of the body proximate to the opening 86.
  • the spindle drive 82 includes an electric motor 88 and a spindle 90 that penetrates the wall 89 and cooperates with a nut 92 fastened on the slide gate 60.
  • the electric motor rotates the spindle 90, which depending on the direction of rotation, moves the slide gate 60 in a closing or opening direction of the opening 86.
  • the electric motor is connected to a computer (not shown) that is part of a control system and also receives information from all temperature sensors 70-76 of the respective rack cabinet. Based on this temperature information and the individual rack cabinet's cooling requirements, the computer calculates an individualized slide gate position for the access slide gate 56 and the exit slide gate 60 for each individual rack cabinet.
  • Additional intermediate A/C cabinets 94 can be arranged between rack cabinets 12-18 as shown in Fig. 4. Such an arrangement allows for less costly but still highly reliable A/C units 36, 38, and 94 in larger or higher density heat producing installations by establishing a so-called N+1 redundancy.
  • the intermediate A/C cabinet 94 is interposed between rack cabinets 14 and 16.
  • the intermediate A/C cabinet 94 has a bidirectional cold air duct 96 and also a bidirectional return duct 98.
  • the A/C cabinet 94 is equipped with motorized louvers 100 that are remotely adjustable to provide an air flow from and to either one or both of the two adjacent rack cabinets 14 and 16.
  • the louvers are centrally controlled by the central control system that also controls the A/C units 36, 38 and 94 as well as the slide gates 56 and 60 and that receives information from all temperature sensors 70- 76.
  • the arrangement of Fig 4 can be expanded by adding more rack cabinets and additional intermediate A/C cabinets to satisfy stringent cooling requirements with low-cost commercially available A/C units 36, 38 and 94.
  • FIG. 5 is a diagram of communication paths within a data containment system
  • FIG. 5 provides a symbolic, schematic view only and does not show the physical arrangement or actual perspectives of depicted devices and connections. Where applicable, the devices of Fig. 5 bear reference numerals raised by 100 with respect to comparable devices of Figs. 1 and 2.
  • the data center containment system 110 of Fig. 5 comprises a computer 102 acquiring data and controlling the operation of the data center containment system.
  • the computer 102 is configured to perform an automatic climate control for two rack cabinets 1 12 and 1 18.
  • Each of the rack cabinets 1 12 and 1 18 features four temperature sensors 170 sending individual input temperature readings T ⁇ T 2 , T 3 and T 4 to the computer 102.
  • the computer 102 further has a user input device 104 for a manual input of maximum operating values of temperature for each individual rack cabinet 1 12 and 1 18.
  • a display 106 gives information about admissible maximum values.
  • the exemplary display of Fig. 3 shows information about the admissible maximum temperature in each rack cabinet 1 12 and 1 18. Information about the measured temperature values T can be displayed in a similar manner.
  • A/C cabinets 120 and 122 are placed on opposite ends of the row of rack cabinets 1 12 and 1 18.
  • the computer 102 communicates with A/C units 136 and 138 in the A/C cabinets 120 and 122, respectively.
  • the computer 102 initiates and terminates operation of the A/C units 136 and 138 and dictates an operating power output sufficient to maintain all rack cabinets 1 12 and 1 18 concurrently within allowable climate ranges for given climate conditions.
  • the computer 102 also controls the access slide gates 156 and exit slide gates 160 of the rack cabinets 1 12 and 1 18.
  • Each individual rack cabinet, for instance rack cabinet 1 12 has a climate requirement that depends on the respective electronic components 166 stacked in the specific stacking space 132 of the rack cabinet 1 12.
  • Rack cabinet 118 may accommodate electronic components 166 that are more tolerant to heat than those stored in rack cabinet 1 12.
  • the maximum temperature at which the electronic components 166 of rack cabinet 1 12 can operate on a continuous basis is 80 °F.
  • the electronic components 166 of rack cabinet 1 18 tolerate an operating temperature of 100°F.
  • the data center containment system 1 10 of the present invention can take these different requirements into account by individually controlling the access slide gate 156 and optionally the exit slide gate 160 of each rack cabinet 1 12 and 1 18.
  • the more stringent requirements of rack cabinet 1 12 can be met by widely opening the access slide gate 156 (and exit slide gate 160).
  • the access slide gate 156 (and exit slide gate 160) of rack cabinet 1 18 can be set to leave a narrower opening so that cooling energy is efficiently dosed to meet the requirements of all components 166.
  • the computer 102 moves the associated access slide gate 156 to improve the air flow from the cold air channel 128 to the front space 154. Likewise, the computer 102 may operate the associated exit slide gate 160 to increase the air flow from the rear space 158 to the hot air channel 130. At the same time, the computer 102 commands the operating A/C unit 136 to increase the cooling power output if necessary to match the increased demand.
  • the computer 102 detects this emergency based on the input from the respective temperature sensor 170 of from a smoke detector (not shown) and issues a fire alarm.
  • a smoke detector not shown
  • current-sensing equipment not shown in the drawing will detect rises in current draw and communicate this information to the computer 102, which issues respective warnings.
  • Computer 102 alerted by the various sensing equipment, immediately shuts the access slide gate 156 of the specific rack cabinet 1 18, thereby cutting off a further oxygen supply to the stacking space 132 of rack cabinet 1 18.
  • the computer 102 also commands a closing of the exit slide gate 160 of rack cabinet 1 18 to contain the fire within the individual rack cabinet 1 18 and to protect the electronic components accommodated in the other rack cabinets 1 14 and 1 12. Extinguishing gas is then released within the isolated space of the affected rack cabinet 1 18 without affecting the other rack cabinet 1 12.
  • each of the A/C units 136 and 138 is dimensioned to produce sufficient cooling power to continuously cool all rack cabinets 1 12 and 1 18 lined up in the row between the A/C cabinets 120 and 122.
  • the computer 102 periodically alternates the operation between the A/C units 136 and 138 to achieve an approximately equal wear on each A/C unit 136 and 138. If the currently operating A/C unit 136 encounters a malfunction, the computer 102 issues a defect warning, turns off A C unit 136 and switches A/C unit 138 on to take over the cooling operation. Therefore, a complete redundancy is achieved by using two A/C units, each of which producing sufficient cooling power for all rack cabinets 1 12 and 118.
  • the data center containment system 1 10 establishes a 2N redundancy, where N is the number of A/C units 136 and 138 required for cooling the rack cabinets 1 12 and 1 18.
  • one or more intermediate A/C cabinets 94 are provided as shown in Fig. 4, an N+1 redundancy is established. Only at least one A/C cabinet less than provided is necessary to cool all rack cabinets. Thus, if one of the A/C cabinets 20, 22 or 94 fails, the central computer 102 directs the air flow from the remaining A/C cabinets provide the cooling power.
  • any number of A/C cabinets 20, 22 and 94 can include power distribution and monitoring hardware. Constant monitoring of the current being fed the multiple circuits in the rack cabinets 12-18 provides for sensing of electronic equipment failures or spikes in current draw which may result in a fire. When the monitoring hardware senses conditions which may result in a fire, the computer can send out local and remote notices to other equipment, to building administrators and to fire authorities for intervention.

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  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Cooling Or The Like Of Electrical Apparatus (AREA)

Abstract

A data center containment system includes a row of rack cabinets between two A/C cabinets. Electronic components are arranged in a stacking space of the rack cabinets. Each rack cabinet has a horizontal cold air channel above the stacking space (32) and a horizontal hot air channel below the stacking space. All cold air channels of adjacent rack cabinets are connected with each other so that either A/C cabinet can cool all rack cabinets between the A/C cabinets. Each A/C cabinet contains an NC unit that is dimensioned to provide a cooling power sufficient to cool all rack cabinets between the A/C cabinets on a continuous basis. Each rack cabinet has individually controllable slide gates that adjust the air flow to and from the individual rack cabinet.

Description

INTEGRATED DATA CENTER CONTAINMENT SYSTEM
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional Patent Application Number 61/474,801 filed April 13, 201 1 , the content of which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to a data center containment system that provides a physical structure supporting a plurality of electronic network components, especially computer servers and interface devices like routers.
BACKGROUND OF THE INVENTION
[0003] Data center containment systems typically comprise racks or cabinets in which electronic components are stacked in a compact space. Because the stacked electronic components operate at a high power, they generate a great amount of heat that is a hazard to the electronic components themselves and also increases a risk of fire. Therefore, data center containment systems are typically open to the free flow of air and accommodated in air-conditioned rooms specifically designed as server rooms. These server rooms have a powerful air-conditioning (A/C) system that keeps the entire room at a low temperature. Internal fans in the components blow low-temperature ambient air through the interior of the individual components. But not every business has sufficient space or financial resources available to create a special room with its own A/C system and fire protection just for the electronic networking components. Also, cooling an entire room in order to provide cool air to all the rack cabinets results in high operating costs. Furthermore, if the A/C system is defective, all components operating in the server room need to be shut down to prevent costly damage.
SUMMARY OF THE INVENTION
[0004] It is therefore an object of the present invention to provide a data center containment system that does not require a dedicated server room and can be set up in a workshop or in office space.
[0005] It is further an object of the present invention to provide a data center containment system with a cooling system that meets high redundancy standards for cooling the electronic components at an affordable cost. [0006] It is also an object of the present invention to provide a data center containment system that closes off rack cabinets from the free flow of room air to cool just the racks not the entire room and save energy.
[0007] It is another object of the present invention to provide a data center containment system with an integrated and monitored power distribution system to aid in maximizing power usage efficiency and to predict potential fire conditions.
[0008] It is yet another an object of the present invention to provide a data center containment system with integrated and rack specific fire suppression that is less environmentally damaging.
[0009] According to the invention, a row of rack cabinets has one of two A/C end cabinets placed at each end of the row. A cooling duct system selectively connects each of the two A/C cabinets with each rack cabinet in the row. Each A/C cabinet is dimensioned for generating a cooling power sufficient to continuously cool the entire row of rack cabinets.
[0010] A computer may receive individual information on the interior climate of each of the rack cabinets and may control the A/C cabinets according to the prevailing requirements. Different rack cabinets may require different cooling temperatures and are controllable independently of each other.
[0011] Additionally, the data system may include a fire suppression system that is capable of isolating an individual rack cabinet from any air circulation if a fire has ignited or is imminent inside the rack cabinet.
[0012] According to one embodiment of the invention, each rack cabinet may include an air-sealed front door and an air-sealed rear door. Between the air-sealed doors of each rack cabinet, rack-mounted electronic components are arranged above each other.
[0013] Furthermore, each rack cabinet may have a horizontal cold air channel above the electronic components and a horizontal hot air channel below the electronic components. The cold air channel may communicate with a front space between the electronic components and the front door of the rack cabinet. The hot air channel in turn may communicate with a rear space between the electronic components and the rear door of the rack cabinet.
[0014] Each of the two A/C cabinets arranged at the ends of the row of rack cabinets may include a cold air duct connected to the cold air channel of the adjacent rack cabinet. All cold air channels are preferably connected with each other so that either A/C cabinet can cool the entire row of rack cabinets.
[0015] Additionally, each of the two A/C cabinets may also have a return duct that is connected to the hot air channel of the adjacent rack cabinet. All hot air channels of the rack cabinets are connected with each other so that the hot air channels of all rack cabinets can communicate with either one of the return ducts.
[0016] To prevent the cold air from one A/C cabinet with a currently operating A/C unit to enter the cold air duct of the other A/C cabinet whose A/C unit is currently on standby, the cold air ducts may include damper flaps that allow a stream of air from the cold air duct of the A/C cabinets into the cold air channels of the rack cabinets, but not in the opposite direction.
[0017] When one of the A/C units is operating, air entering the return duct of the associated A/C cabinet is preferably cooled down by the A/C unit accommodated inside the A/C cabinet. The cooled air is expelled as cold air from the A/C cabinet through the cold air duct and fed into the cold air channels of the rack cabinets.
[0018] From the cold air channel of each rack cabinet, air flows through the front space, through the electronic components, and reaches the rear space. From the rear space, the air moves downward through the hot air channel to the return duct.
[0019] Because each of the A/C units is powerful enough to cool the entire row of rack cabinets, a true 2N redundancy is achieved. The 2N configuration is preferred, but less stringent cooling requirements may allow for the use of only one A/C cabinet.
[0020] To meet highly demanding cooling requirements with commercially available
- and dramatically less costly - A/C units, additional A/C cabinets can be placed between rack cabinets within the row of rack cabinets. These intermediate A/C cabinets are configured to provide an adjustable cooling air flow to either side as needed. This configuration provides an N+1 redundancy because the data center containment system includes one more A/C cabinet than needed to cool all rack cabinets.
[0021] Any or all of the A/C cabinets may contain monitoring equipment monitoring the power distribution and current draw, depending on specific demands of the data center containment system. And all of the rack cabinets may contain individual canisters of fire retardant gas that can be triggered by either extreme heat or the presence of smoke particles.
[0022] Further details and advantages become apparent from the subsequent description of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In the drawings,
[0024] Fig. 1 depicts a front view of a data center containment system according to the present invention; [0025] Fig. 2 depicts a cross-sectional view of the data center containment system of
Fig. 1 ;
[0026] Fig. 3 shows a detail of an air channel assembly for a rack cabinet;
[0027] Fig. 4 is a schematic diagram of a data center containment system with an added intermediate A/C cabinet; and
[0028] Fig. 5 is a schematic diagram of a control system controlling and operating a data center containment system according to the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0029] In Fig. 1 , a data center containment system 10 is shown in a frontal view.
Four rack cabinets 12, 14, 16 and 18 are arranged side-by-side adjacent to each other. A first A/C cabinet 20 is positioned on the right side of the row rack cabinets 12-18 adjacent to the rack cabinet 18. A second A/C cabinet 22 is located on the other side of the row of rack cabinets, adjacent to rack cabinet 12. While Fig. 1 shows a number of four rack cabinets 12- 18, the invention is not limited to this number and can include two or more rack cabinets. The number of rack cabinets 12-18 between the A/C cabinets 20 and 22 is limited based on cooling requirements of the rack cabinets 12-18 and the cooling output of each of the A/C cabinets 20 and 22. For cabinet rows with higher demands of cooling power, an exemplary arrangement is shown below in Fig. 4.
[0030] Each rack cabinet 12-18 comprises an air-sealed front door 24 and an air- sealed rear door 26, which is not visible in Fig. 1 .
[0031] Within each rack cabinet 12-18, a top space is free of any electronic components, forming a cold air channel 28 that is part of a cooling duct system. The cold air channels 28 of all adjacent rack cabinets 12-18 share a free air flow with each other because the rack cabinets 12-18 do not have side walls extending into the area of the cold air channels.
[0032] Likewise, a bottom space of each rack cabinet 12-18 serves as a hot air channel 30. In the area of the hot air channels 30, the rack cabinets 12-18 have no side walls, either, so that each hot air channel shares a free air flow with the hot air channels 30 of the neighboring rack cabinets 12-18. This is described in closer detail in connection with Fig. 3
[0033] The cold air channels 28 and hot air channels 30 are adapted to fit inside commercially available rack cabinets 12-18, which by industry standards can hold in excess of 2,000 lbs. of added weight. The rack cabinets 12-18 thus retain their structural integrity.
[0034] A stacking space 32 with plurality of sliding rails 34 is arranged between the cold air channel 28 and the hot air channel 30 of each rack cabinet 12-18. The stacking space 34 of each rack cabinet 12-18 has side walls extending from the front door 24 to the rear door 26 so that every stacking space 32 is separated from the stacking spaces 32 of the adjacent rack cabinets 12-18.
[0035] In the example of Fig. 1 , A/C cabinet 20 on the right side is currently operating, hence the display stating "ON". A/C cabinet 22 on the left side is on stand-by to take over after a specified time off if A/C cabinet 20 encounters a malfunction. Each of the A/C cabinets 20 and 22 contain an A/C unit 36 and 38, respectively, each dimensioned to be powerful enough to cool the entire row of rack cabinets 12-18 continuously. Near the top of each A/C cabinet 20, 22, a cold air duct 40 or 42, respectively, communicates with the cold air channel 28 of the adjacent rack cabinet 12 or 18, respectively. A hinged damper flap 48 or 50 allows a stream of cold air from the associated cold air duct 40 or 42 into the cold air channel 28 of the neighboring rack cabinet 12 or 18, but not in the opposite direction. The damper flaps 48 and 50 are lightweight, passive flaps that react to the air stream and do not need an external control. When the A/C unit 36 of A/C cabinet 20 is operating, the associated damper flap 48 is opened by the air stream to allow a stream of cold air from the cold air duct 40 of A/C cabinet 20 into the cold air channel 28 of rack cabinet 18. The opposite damper flap 50 of the A/C cabinet 22, however, is pushed into a closed position by the air stream, thereby shutting off the connection from the cold air channel 28 of rack cabinet 12 to the cold air duct 42 of A/C cabinet 22.
[0036] The hot air channels 30 of the rack cabinets 12 and 18 communicate with a return duct 44 and 46, respectively, that leads heated air back to the respective A/C unit 36 or 38 of the neighboring A/C cabinet 20 or 22. Each of the return ducts 44 and 46 also includes a respective passive damper flap 49 and 51 , respectively. The currently operating A/C unit 20 sucks in the heated air through the associated damper flap 49 and simultaneously pulls the damper flap 51 of the other A/C cabinet 22 into a closed position. The A/C unit 36 inside A/C cabinet 20 cools the air down again and feeds it through the cold air duct 40 back into the cold air channels 28 of the rack cabinets 12-18.
[0037] The exemplary embodiments show passive damper flaps 48-51 , that enhance the efficiency of the cooling operation because they force the cold air through the stacking spaces 32 while preventing the air from flowing through the inactive A/C cabinet. The data center containment system 10, however, does not depend on these damper flaps because, even without the passive damper flaps 48-51 , the air flow through the inactive A/C cabinet is rather limited compared to the air flow through the stacking spaces 32.
[0038] Fig. 2 shows a schematic side view onto a cross-section of an exemplary rack cabinet 52. The plane of the view shown in Fig. 2 corresponds to a vertical cross-section from the front to the back of the rack cabinet 52. The rack cabinet 52 of Fig. 2 is shown with an equal spacing of the sliding rails 34. The rack cabinet 52 has a front space 54 between the front of the stacking space 32 and the front door 24 extending across the entire width and height of the stacking space 32. The cold air entering the cold air channel 28 of rack cabinet 52 can enter the front space 54 by passing an adjustable access slide gate 56 that controls the connection between the cold air channel 28 and the front space 54.
[0039] The rack cabinet also includes a rear space 58 extending between the stacking space 32 and the rear door 26. The rear space 58 communicates with the hot air channel 30 through an adjustable exit slide gate 60. Access slide gate 56 and exit slide gate 60 will be discussed in greater detail in connection with Fig. 3.
[0040] A first barrier 62 at the top of rear space 58 permanently separates the rear space 58 from the cold air channel 28 so that the only way for the cold air in the cold air channel 28 to enter the stacking space 32 is past the access slide gate 56. Likewise, a second barrier 64 at the bottom of front space 54 separates the front space 54 from the hot air channel 30 so that the cold air in the front space 54 cannot directly exit the stacking space 32 through the hot air channel 30.
[0041] The cold air entering the front space 54 reaches the rear space through electronic components 66 arranged between the sliding rails 34. The positive pressure of the cold air in the front space 54 in conjunction with internal fans 68 of the electronic components 66 propels the air through the electronic components 66 toward the rear space 58. On its path through the electronic components 66, the initially cold air cools the electronic components 66 and heats up accordingly. The heated air reaches the rear space 58, from where it passes the exit slide gate 60 into the hot air channel 30. As shown in Fig. 1 , the heated air then returns to the respective operating A/C unit 36 to repeat the cooling cycle.
[0042] Four temperature sensors 70, 72, 74, and 76 are arranged in specific locations within the rack cabinet 52. The temperature sensors 70-76 measure the air temperature and optionally humidity. Temperature sensor 70 is arranged in the cold air duct 28 to measure the temperature of the cold air fed into the rack cabinet 52. Temperature sensor 72 is located near the bottom of the front space 54 and measures at which temperature the cold air reaches the stacking space 32. The other two temperature sensors 74 and 76 are both placed in the hot air duct and provide redundant information on the air temperature after the air stream has passed the stacking space 32 with the electronic components 66. The individually measured temperatures on both the cold air feed and hot air return side can be automatically analyzed by a control system and result in automatic and individual motorized slide gate adjustments. This individualized control not only saves money by tightly controlling the cooling energy expended in each rack cabinet 52, but allows the control system to automatically isolate a single rack cabinet by shutting the respective access slide gate 56 and exit slide gate 60 in the event of a fire. Not shown is a smoke sensor mounted inside the rack cabinet 52 to give a fire alarm based on smoke particles in the rack cabinet 52. Extinguishing gas can be released inside the individual isolated rack cabinet 52, while all other rack cabinets are cooled on a continuous basis.
[0043] Fig. 3 shows a detail of an air channel assembly 78 for a rack cabinet for the type shown in Fig. 1 or Fig. 2. The air channel assembly 78 of Fig. 3 is shown in an orientation that is suitable for the hot air channel 30 underneath the stacking space 32. Turning the air channel assembly 78 upside down puts the air channel assembly in an orientation suitable for the cold air channel 28.
[0044] The air channel assembly 78 includes the exit slide gate 60 and the second barrier 64, which is integrally formed on a body 80. The body 80 is made of sheet metal and has a substantially tubular structure with a rectangular cross-section having a width greater than its height. The tubular body 80 has a top surface 84 with a rectangular opening 86 that can be closed by the slide gate 60. The slide gate 60 is guided between two guide rails 85 formed on both sides of the opening 86 on the top surface 84 of the body 80. The top surface 84 also includes the air barrier 64 in an area remote from the opening 86. The air channel assembly 78 features a spindle drive 82 that operates the slide gate 60 and is mounted on a vertical wall 89 of the body proximate to the opening 86. The spindle drive 82 includes an electric motor 88 and a spindle 90 that penetrates the wall 89 and cooperates with a nut 92 fastened on the slide gate 60. The electric motor rotates the spindle 90, which depending on the direction of rotation, moves the slide gate 60 in a closing or opening direction of the opening 86. After the air channel assembly 78 is installed in a rack cabinet, the electric motor is connected to a computer (not shown) that is part of a control system and also receives information from all temperature sensors 70-76 of the respective rack cabinet. Based on this temperature information and the individual rack cabinet's cooling requirements, the computer calculates an individualized slide gate position for the access slide gate 56 and the exit slide gate 60 for each individual rack cabinet.
[0045] Additional intermediate A/C cabinets 94 can be arranged between rack cabinets 12-18 as shown in Fig. 4. Such an arrangement allows for less costly but still highly reliable A/C units 36, 38, and 94 in larger or higher density heat producing installations by establishing a so-called N+1 redundancy. In addition to the two end A/C cabinets 20 and 22, the intermediate A/C cabinet 94 is interposed between rack cabinets 14 and 16. The intermediate A/C cabinet 94 has a bidirectional cold air duct 96 and also a bidirectional return duct 98. Where the cold air duct 96 and the return duct 98 connect to the adjoining cold air channels 28 of the adjacent rack cabinets 14 and 16, the A/C cabinet 94 is equipped with motorized louvers 100 that are remotely adjustable to provide an air flow from and to either one or both of the two adjacent rack cabinets 14 and 16. The louvers are centrally controlled by the central control system that also controls the A/C units 36, 38 and 94 as well as the slide gates 56 and 60 and that receives information from all temperature sensors 70- 76. The arrangement of Fig 4 can be expanded by adding more rack cabinets and additional intermediate A/C cabinets to satisfy stringent cooling requirements with low-cost commercially available A/C units 36, 38 and 94.
[0046] Fig. 5 is a diagram of communication paths within a data containment system
1 10 of the present invention. Fig. 5 provides a symbolic, schematic view only and does not show the physical arrangement or actual perspectives of depicted devices and connections. Where applicable, the devices of Fig. 5 bear reference numerals raised by 100 with respect to comparable devices of Figs. 1 and 2.
[0047] The data center containment system 110 of Fig. 5 comprises a computer 102 acquiring data and controlling the operation of the data center containment system. The computer 102 is configured to perform an automatic climate control for two rack cabinets 1 12 and 1 18. Each of the rack cabinets 1 12 and 1 18 features four temperature sensors 170 sending individual input temperature readings T^ T2, T3 and T4 to the computer 102. The computer 102 further has a user input device 104 for a manual input of maximum operating values of temperature for each individual rack cabinet 1 12 and 1 18. A display 106 gives information about admissible maximum values. The exemplary display of Fig. 3 shows information about the admissible maximum temperature in each rack cabinet 1 12 and 1 18. Information about the measured temperature values T can be displayed in a similar manner.
[0048] Two A/C cabinets 120 and 122 are placed on opposite ends of the row of rack cabinets 1 12 and 1 18. The computer 102 communicates with A/C units 136 and 138 in the A/C cabinets 120 and 122, respectively. The computer 102 initiates and terminates operation of the A/C units 136 and 138 and dictates an operating power output sufficient to maintain all rack cabinets 1 12 and 1 18 concurrently within allowable climate ranges for given climate conditions. The computer 102 also controls the access slide gates 156 and exit slide gates 160 of the rack cabinets 1 12 and 1 18. Each individual rack cabinet, for instance rack cabinet 1 12, has a climate requirement that depends on the respective electronic components 166 stacked in the specific stacking space 132 of the rack cabinet 1 12. These different climate requirements may be due to different electronic components 166 generating different amounts of heat. It may also be due to different tolerance thresholds of the various components 166. Rack cabinet 118 may accommodate electronic components 166 that are more tolerant to heat than those stored in rack cabinet 1 12. In the example shown, the maximum temperature at which the electronic components 166 of rack cabinet 1 12 can operate on a continuous basis is 80 °F. The electronic components 166 of rack cabinet 1 18 tolerate an operating temperature of 100°F. The data center containment system 1 10 of the present invention can take these different requirements into account by individually controlling the access slide gate 156 and optionally the exit slide gate 160 of each rack cabinet 1 12 and 1 18. On the one hand, the more stringent requirements of rack cabinet 1 12 can be met by widely opening the access slide gate 156 (and exit slide gate 160). On the other hand, the access slide gate 156 (and exit slide gate 160) of rack cabinet 1 18 can be set to leave a narrower opening so that cooling energy is efficiently dosed to meet the requirements of all components 166.
[0049] If one of the rack cabinets 1 12 and 1 18, for example rack cabinet 1 18, reaches an interior temperature that is close or equal to the maximum operating temperature of the accommodated electronic components 166, the computer 102 moves the associated access slide gate 156 to improve the air flow from the cold air channel 128 to the front space 154. Likewise, the computer 102 may operate the associated exit slide gate 160 to increase the air flow from the rear space 158 to the hot air channel 130. At the same time, the computer 102 commands the operating A/C unit 136 to increase the cooling power output if necessary to match the increased demand.
[0050] Similar control procedures may be applied for humidity control if the rack cabinets include humidity sensors.
[0051] Should the inside of one of the rack cabinets 1 12 and 1 18, for instance rack cabinet 1 18, encounter overheating or smoke particles due to a fire, the computer 102 detects this emergency based on the input from the respective temperature sensor 170 of from a smoke detector (not shown) and issues a fire alarm. In order to minimize the threat of damage to the electronic components 166 in rack cabinets 1 14 and 1 12, current-sensing equipment not shown in the drawing will detect rises in current draw and communicate this information to the computer 102, which issues respective warnings. Computer 102, alerted by the various sensing equipment, immediately shuts the access slide gate 156 of the specific rack cabinet 1 18, thereby cutting off a further oxygen supply to the stacking space 132 of rack cabinet 1 18. The computer 102 also commands a closing of the exit slide gate 160 of rack cabinet 1 18 to contain the fire within the individual rack cabinet 1 18 and to protect the electronic components accommodated in the other rack cabinets 1 14 and 1 12. Extinguishing gas is then released within the isolated space of the affected rack cabinet 1 18 without affecting the other rack cabinet 1 12.
[0052] As mentioned previously, each of the A/C units 136 and 138 is dimensioned to produce sufficient cooling power to continuously cool all rack cabinets 1 12 and 1 18 lined up in the row between the A/C cabinets 120 and 122. The computer 102 periodically alternates the operation between the A/C units 136 and 138 to achieve an approximately equal wear on each A/C unit 136 and 138. If the currently operating A/C unit 136 encounters a malfunction, the computer 102 issues a defect warning, turns off A C unit 136 and switches A/C unit 138 on to take over the cooling operation. Therefore, a complete redundancy is achieved by using two A/C units, each of which producing sufficient cooling power for all rack cabinets 1 12 and 118. Because only one A/C unit 136 or 138 is required for cooling all electronic components 166 and two A/C units 136 and 138 are provided, the data center containment system 1 10 establishes a 2N redundancy, where N is the number of A/C units 136 and 138 required for cooling the rack cabinets 1 12 and 1 18.
[0053] If one or more intermediate A/C cabinets 94 are provided as shown in Fig. 4, an N+1 redundancy is established. Only at least one A/C cabinet less than provided is necessary to cool all rack cabinets. Thus, if one of the A/C cabinets 20, 22 or 94 fails, the central computer 102 directs the air flow from the remaining A/C cabinets provide the cooling power.
[0054] Based on the power requirements of each individual installation, any number of A/C cabinets 20, 22 and 94 can include power distribution and monitoring hardware. Constant monitoring of the current being fed the multiple circuits in the rack cabinets 12-18 provides for sensing of electronic equipment failures or spikes in current draw which may result in a fire. When the monitoring hardware senses conditions which may result in a fire, the computer can send out local and remote notices to other equipment, to building administrators and to fire authorities for intervention.
[0055] The foregoing description of various embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Numerous modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

Claims

PATENT CLAIMS
1 . A data center containment system comprising:
at least a first and a second A/C cabinet;
a first set of at least two rack cabinets arranged adjacent to one another in a row between the first and the second A/C cabinets;
a cooling duct system forming selectively closable connections connecting each of the first and the second A/C cabinets with the at least two rack cabinets, each of the first and the second A/C cabinets being dimensioned for generating a cooling power sufficient to continuously cool the entire first set of rack cabinets.
2. The data center containment system of claim 1 , where each of the at least two rack cabinets has a specific cooling power requirement, the first A/C unit and the second A/C unit each individually being dimensioned to generate enough cooling power to meet a total cooling power requirement representing the sum of all specific cooling power requirements.
3. The data center containment system of claim 2, further comprising a computer receiving climate information from each of the at least two rack cabinets and controlling each of first and second A/C units to alternate in providing the cooling power meeting the total cooling power requirement.
4. The data center containment system of claim 3, further comprising power distribution circuit monitoring devices communicating with the computer.
5. The data center containment system of claim 2, further comprising a fire suppression system configured to isolate an individual rack cabinet containing a fire or at risk of an imminent fire.
6. The data center containment system of claim 2, where each of the at least two rack cabinets has a stacking space configured to accommodate electronic components, a cold air channel above the stacking space horizontally open to both sides of the rack cabinet, the cold air channel forming a part of the cooling duct system.
7. The data center containment system of claim 6, where each of the first and second A/C cabinets has a cold air duct forming a part of the cooling duct system, each cold air duct sharing a free air flow with the cold air channel of the respective adjacent rack cabinet through a unidirectional passive damper flap opening from the cold air duct into the cold air channel of the respective adjacent rack cabinet.
8. The data center containment system of claim 6, where each of the at least two rack cabinets has a temperature sensor measuring at least one of temperature and humidity in a space proximate to the stacking space.
9. The data center containment system of claim 6, where each of the at least two rack cabinets further comprises a hot air channel below the stacking space horizontally open to both sides of the rack cabinet, a vertical front space in front of the stacking space, a vertical rear space behind the stacking space.
10. The data center containment system of claim 9, where each of the at least two rack cabinets further comprises an adjustable access slide gate controlling a connection between the cold air channel and the front space, an exit slide gate controlling a connection between the rear space and the hot air channel, a first barrier separating the cold air channel from the rear space, and a second barrier separating the front space from the hot air channel.
1 1 . The data center containment system of claim 10, further comprising a computer receiving climate information from each of the at least two rack cabinets and controlling each of first and second A/C units to alternate in providing the cooling power meeting the total cooling power requirement, the computer further adjusting the access slide gate of each of the at least two rack cabinets to a setting meeting the respective specific cooling power requirement based on the total cooling power and other environmental factors.
12. The data center containment system of claim 1 1 , where the computer further adjusts the exit slide gate of each of the at least two rack cabinets.
13. The data center containment system of claim 1 1 , further comprising power distribution circuit monitoring devices communicating with the computer.
14. The data center containment system of claim 1 1 , further comprising a fire suppression system configured to isolate an individual rack cabinet by closing the access slide gate and the exit slide gate of the individual rack cabinet when sensors inside the individual rack cabinet indicate a fire or an imminent fire.
15. The data center containment system of claim 1 , further comprising a second set of rack cabinets arranged on a side of the second A/C cabinet opposite of the first set of rack cabinets and a third A/C cabinet arranged adjacent to the second set of rack cabinets opposite the second A/C cabinet, the second A/C cabinet having externally controllable closing mechanisms selectably directing cold air flow from the second A/C cabinet to one of the first set of rack cabinets and the second set of rack cabinets.
16. The data center containment system of claim 15, the second A C cabinet further comprising externally controllable closing mechanisms selectably directing warm air flow to the second A/C cabinet from one of the first set of rack cabinets and the second set of rack cabinets.
PCT/US2012/033287 2011-04-13 2012-04-12 Integrated data center containment system WO2012142262A1 (en)

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US10082857B1 (en) * 2012-08-07 2018-09-25 Amazon Technologies, Inc. Cooling electrical systems based on power measurements
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