Systems and methods for cooling data centers and other electronic equipment

Abstract

Temperature, humidity, and pressure control systems and methods for enclosed spaces, including data centers. In some embodiments, the rotational frequency of the air supply fans is controlled based on a pressure associated with the enclosed space. In some embodiments, the rotational frequency of the air supply fans is controlled based on a pressure differential between an inlet region and an exhaust region within the enclosed space. In some embodiments, air within the inlet region is segregated from air within the exhaust region. In some embodiments, the cooling capacity of the cooling equipment is controlled responsive to a temperature associated with the enclosed space. In some embodiments, the cooling capacity is controlled based on a temperature associated with the inlet region of the enclosed space. In some embodiments, the humidity within the enclosed space is controlled.

1 . An environmental control assembly configured to provide a supply air stream to an enclosed space, which includes a hot aisle and a cold aisle, to control at least one characteristic of the supply air stream, and to receive a return air stream from the enclosed space, the environmental control assembly comprising:
 a fluid drive assembly including a supply fan configured to provide a motive force to the supply air stream, wherein the supply fan is configured to selectively vary a flow rate of the supply air stream;   a primary cooling assembly;   a supplemental cooling assembly;   a differential pressure sensor configured to detect a pressure differential between the hot aisle and the cold aisle;   a temperature sensor configured to detect a temperature associated with the enclosed space; and   a controller, wherein the controller includes a pressure control portion and a temperature control portion, and further wherein:   (i) the pressure control portion is programmed to control a flow rate of the supply air stream, with the supply fan, to maintain a pressure in the hot aisle less than a pressure in the cold aisle, wherein the control of the flow rate is based, at least in part, on the pressure differential;   (ii) the temperature control portion is programmed to control operation of at least one of the primary cooling assembly and the supplemental cooling assembly to control a temperature of the supply air stream based, at least in part, on the temperature associated with the enclosed space; and   (iii) the pressure control portion is independent of the temperature control portion.   
     
     
         2 . The environmental control assembly of  claim 1 , wherein the supply fan includes a wheel fan, a motor, and a solid shaft operatively coupling the wheel fan to the motor. 
     
     
         3 . The environmental control assembly of  claim 2 , wherein the supply fan includes a rigid shaft coupler operatively coupling the solid shaft to the motor. 
     
     
         4 . The environmental control assembly of  claim 3 , wherein the solid shaft extends through a plug assembly that fluidly isolates the motor from the supply fan. 
     
     
         5 . The environmental control assembly of  claim 4 , wherein the supply fan includes an intake, which is configured to receive the supply air stream into fluid contact with the wheel fan, and an exhaust, which is configured to produce the supply air stream from the wheel fan, and further wherein the motor is fluidly separated from the intake and from the exhaust by the plug assembly. 
     
     
         6 . The environmental control assembly of  claim 2 , wherein the supply fan further includes a front bearing spider mount, wherein the solid shaft extends between the motor and the front bearing spider mount, wherein the fan includes a bearing that rotationally couples the solid shaft to the front bearing spider mount, and further wherein the fan wheel extends between the bearing and the motor. 
     
     
         7 . The environmental control assembly of  claim 6 , wherein the supply fan further includes an aerodynamic front bearing protection cone that extends from the front bearing spider mount and away from the fan wheel. 
     
     
         8 . The environmental control assembly of  claim 6 , wherein the supply fan further includes an aerodynamic front bearing rear cone that extends, along the solid shaft, away from the front bearing spider mount, and toward the fan wheel. 
     
     
         9 . The environmental control assembly of  claim 2 , wherein the supply fan further includes a motor mount assembly, wherein the motor mount assembly includes:
 (i) a motor mounting plate;   (ii) a horizontal pivot that pivotally couples the motor to the motor mounting plate and permits rotation of the motor relative to the motor mounting plate about a horizontal pivot axis; and   (iii) a vertical pivot that pivotally couples the motor mounting plate to a plug assembly that fluidly isolates the motor from the supply fan.   
     
     
         10 . The environmental control assembly of  claim 1 , wherein the supply fan includes a variable rotational frequency fluid drive fan, wherein the pressure control portion is configured increase a rotational frequency of the variable rotational frequency fluid drive fan responsive at least in part to the pressure differential being less than a threshold pressure differential, and further wherein the pressure control portion is configured to decrease the rotational frequency of the variable rotational frequency fluid drive fan responsive at least in part to the pressure differential being greater than the threshold pressure differential. 
     
     
         11 . The environmental control assembly of  claim 10 , wherein the fluid drive assembly includes a plurality of variable rotational frequency fluid drive fans, and further wherein the controller is programmed to take one or more of the plurality of variable rotational frequency fluid drive fans offline responsive to airflow needs of the environmental control assembly. 
     
     
         12 . The environmental control assembly of  claim 11 , wherein the plurality of variable rotational frequency fluid drive fans are sized to provide enough excess capacity to permit the environmental control assembly to operate at a rated air flow rate thereof despite failure of an individual fluid drive fan of the plurality of variable rotational frequency fluid drive fans. 
     
     
         13 . The environmental control assembly of  claim 1 , wherein the enclosed space includes a data center, wherein the data center includes electronic equipment, and further wherein the hot aisle and the cold aisle are configured such that at least a substantial portion of the supply air stream passes through the electronic equipment only once before returning to the environmental control assembly as the return air stream. 
     
     
         14 . An environmental control assembly configured to provide a supply air stream to an enclosed space and to receive a return air stream from the enclosed space, the environmental control assembly including:
 a primary cooling assembly configured to provide primary cooling of the return air stream;   a supplemental cooling assembly configured to provide secondary cooling of the return air stream; and   a supply fan configured to provide a motive force for flow of the return air stream from the enclosed space, through the environmental control assembly, and back to the enclosed space as the supply air stream, the supply fan including:   (i) a wheel fan;   (ii) a motor;   (iii) a solid shaft that operatively couples the wheel fan to the motor; and   (iv) a plug assembly, wherein the solid shaft extends through the plug assembly such that the plug assembly fluidly isolates the motor from the supply fan, wherein the supply fan includes an intake, which is configured to receive the supply air stream into fluid contact with the wheel fan, and an exhaust, which is configured to produce the supply air stream from the wheel fan, and further wherein the motor is fluidly separated from the intake and from the exhaust by the plug assembly.   
     
     
         15 . The environmental control assembly of  claim 14 , wherein the supply fan includes a rigid shaft coupler operatively coupling the solid shaft to the motor. 
     
     
         16 . The environmental control assembly of  claim 14 , wherein the supply fan further includes a front bearing spider mount, wherein the solid shaft extends between the motor and the front bearing spider mount, wherein the fan assembly includes a bearing that rotationally couples the solid shaft to the front bearing spider mount, and further wherein the fan wheel extends between the bearing and the motor. 
     
     
         17 . The environmental control assembly of  claim 16 , wherein the supply fan further includes an aerodynamic front bearing protection cone that extends from the front bearing spider mount. 
     
     
         18 . The environmental control assembly of  claim 16 , wherein the supply fan further includes an aerodynamic front bearing rear cone that extends, along the solid shaft, away from the front bearing spider mount, and toward the fan wheel. 
     
     
         19 . The environmental control assembly of  claim 16 , wherein the supply fan further includes a motor mount assembly, wherein the motor mount assembly includes:
 (i) a motor mounting plate;   (ii) a horizontal pivot that pivotally couples the motor to the motor mounting plate and permits rotation of the motor relative to the motor mounting plate about a horizontal pivot axis; and   (iii) a vertical pivot that pivotally couples the motor mounting plate to a plug assembly that fluidly isolates the motor from the supply fan.   
     
     
         20 . A data center defining an enclosed space, the data center comprising:
 electronic equipment contained within the enclosed space; and   the environmental control assembly of  claim 14 .