Equipment enclosure with multi-mode temperature control system

• US 10,451,295 B2
• Filed: 02/23/2015
• Issued: 10/22/2019
• Est. Priority Date: 12/22/2014
• Status: Active Grant

• Current Assignee: Diversified Control, Inc.
• Original Assignee: Diversified Control, Inc.
• Inventors: James, Brent A., James, Lewis G., King, Aron J.
• Primary Examiner(s): Malik, Raheena R
• Application Number:
  US14/628,934
• Publication Number:
  US 20160178223A1
• Time in Patent Office: 1,702 Days
• Field of Search: 165250, 165 47
• CPC Class Codes: F24F 1/022 comprising a compressor cycle
• CPC Class Codes: F24F 11/0001 for ventilation F24F11/30 takes precedence
• CPC Class Codes: F24F 11/30 for purposes related to the operation of the system, e.g. for safety or monitoring
• CPC Class Codes: F24F 11/74 for controlling air flow rate or air velocity
• CPC Class Codes: F24F 11/77 by controlling the speed of ventilators
• CPC Class Codes: F24F 13/14 built up of tilting members, e.g. louvre
• CPC Class Codes: F24F 2011/0002 for admittance of outside air
• CPC Class Codes: F24F 2011/0006 using low temperature external supply air to assist cooling
• CPC Class Codes: F24F 2110/00 Control inputs relating to air properties
• CPC Class Codes: F24F 2110/10 Temperature
• CPC Class Codes: F24F 2110/12 of the outside air
• CPC Class Codes: F24F 2140/60 Energy consumption
• CPC Class Codes: H05K 7/20209 Thermal management, e.g. fan control
• CPC Class Codes: H05K 7/206 Air circulating in closed loop within cabinets wherein heat is removed through air-to-air heat-exchanger
• CPC Class Codes: H05K 7/20618 Air circulating in different modes under control of air guidance flaps
• CPC Class Codes: Y02B 30/70 Efficient control or regulation technologies, e.g. for control of refrigerant flow, motor or heating

Abstract

An equipment enclosure with temperature control components, an equipment enclosure temperature control unit, an equipment enclosure temperature control method, and various modular temperature control subassemblies are respectively disclosed for controlling the temperature of equipment in an equipment chamber. The temperature control components and unit may be implemented with a modular design wherein an air-conditioning unit is selectively mountable on an air handler assembly. The temperature control components and unit may support air-conditioning, free-air-cooling, free-air-cooling-with-return, and heating modes of operation. An emergency-free-air-cooling mode of operation may also be supported.

Claims

1. An equipment enclosure, comprising:

a temperature-controlled equipment chamber for housing equipment in said equipment enclosure; and

temperature control components that comprise;

an inside air inlet arranged to receive air from said equipment chamber;

an inside air outlet arranged to deliver air to said equipment chamber;

said inside air inlet and said inside air outlet each being on an inside cover;

a first outside air outlet arranged to deliver air to outside said equipment enclosure;

a second outside air outlet arranged to deliver air to outside said equipment enclosure;

a first outside air inlet arranged to receive air from outside said equipment enclosure;

a second outside air inlet arranged to receive air from outside said equipment enclosure;

said first outside air outlet, said second outside air outlet, said first outside air inlet and said second outside air inlet each being on an outside cover;

an interior air exhaust pathway extending between said inside air inlet and said first outside air outlet for venting interior air in said interior equipment chamber to outside said enclosure;

an interior air return pathway extending between said inside air inlet and said inside air outlet for recirculating interior air in said interior equipment chamber;

a first controllable damper operable to selectively communicate air from said inside air inlet to said air exhaust pathway and said interior air return pathway;

a fresh air inlet pathway extending between said first outside air inlet and said inside air outlet;

a second controllable damper operable to selectively communicate air from said interior air return pathway and said fresh air inlet pathway to said inside air outlet;

a primary air mover disposed to move air through said interior air return pathway and said fresh air inlet pathway;

an air heater in said interior air return pathway;

an air conditioning evaporator in said interior air return pathway;

an air conditioning warm air vent pathway extending between said second outside air inlet and said second outside air outlet;

an air conditioning condenser in said air conditioning warm air vent pathway;

a variable speed air conditioning compressor operably connected to pump a coolant through a coolant loop that includes said air conditioning condenser and air conditioning evaporator;

an air conditioning air mover disposed to move air through said air conditioning warm air vent pathway;

upper and low temperature sensors for sensing temperature in upper and lower portions of said equipment chamber;

an outside air temperature sensor for sensing outside air temperature; and

a temperature controller operable to control said dampers, said air movers and said air conditioning compressor based on temperature readings provided by said temperature sensors.

2. The equipment enclosure of claim 1, wherein said first outside air inlet and said second outside air outlet comprise an outside bidirectional air opening arranged to deliver air to and receive air from outside said equipment enclosure.

3. The equipment enclosure of claim 1, further including:

an emergency fresh air pathway extending between said second outside air inlet and said inside air outlet, said emergency pathway including said air conditioning air mover; and

a controllable emergency damper operable to selectively communicate air from said second outside air inlet to said air conditioning warm air vent pathway and said emergency fresh air pathway.

4. The equipment enclosure of claim 1, wherein said interior air return pathway and said fresh air inlet pathway are merged to form a common air pathway between said second controllable damper and said inside air outlet.

5. The equipment enclosure of claim 1, wherein said temperature control components are embodied in a temperature control unit mounted on a wall of said equipment enclosure.

6. The equipment enclosure of claim 5, wherein said temperature control unit comprises a modular air conditioning unit that is selectively attachable to a modular temperature control unit air handler assembly.

7. The equipment enclosure of claim 6, wherein:

said modular air conditioning unit comprises said air conditioning evaporator, said air conditioning condenser, said variable speed air conditioning compressor, said air conditioning air mover, a portion of said air conditioning warm air vent pathway, and a portion of said interior air return pathway;

said modular air handler assembly comprises a portion of said interior air return pathway, said first controllable damper, said fresh air inlet pathway, said second controllable damper, said primary air mover, said air heater, and a portion of said air conditioning warm air vent pathway;

and further wherein;

said inside air inlet and said inside air outlet comprise an inside cover on said air handler assembly; and

said first and second outside air outlets and said first and second outside air inlets comprise an outside cover on said air handler assembly.

8. The equipment enclosure of claim 1, wherein said temperature controller is programmed to operate said temperature control unit in a first mode, representing an air-conditioning mode, wherein:

said primary air mover is in a power-on state;

said air conditioning air mover is in a power-on state;

said air conditioning compressor is in a power-on state and operating at a selected speed;

said air heater is in a power-off state;

said first controllable damper is positioned to communicate air from said inside air inlet to said interior air return pathway;

said second controllable damper is positioned to communicate air from said interior air return pathway to said inside air outlet, while blocking air flow from said first outside air inlet; and

air flows from said second outside air inlet through said air conditioning warm air vent pathway to said second outside air outlet.

9. The equipment enclosure of claim 1, wherein said temperature controller is programmed to operate said temperature control unit in a second mode, representing a free-air-cooling mode, wherein:

said primary air mover is in a power-on state;

said air conditioning air mover is in a power-off state;

said air conditioning compressor is in a power-off state;

said air heater is in a power-off state;

said first controllable damper is positioned to communicate air from said inside air inlet through said interior air exhaust pathway to said first outside air outlet, while blocking air flow from said inside air inlet into said interior air return pathway; and

said second controllable damper is positioned to communicate air from said first outside air inlet through said fresh air inlet pathway to said inside air outlet, while blocking air flow from said inside air inlet.

10. The equipment enclosure of claim 1, wherein said temperature controller is programmed to operate said temperature control unit in a third mode, representing a free-air-cooling-with-return mode, wherein:

said primary air mover is in a power-on state;

said air conditioning air mover is in a power-off state;

said air conditioning compressor is in a power-off state;

said air heater is in a power-off state;

said first controllable damper is positioned to communicate air from said inside air inlet through said interior air exhaust pathway to said first outside air outlet, while also allowing air flow from said inside air inlet into said interior air return pathway; and

said second controllable damper is positioned to communicate air from said first outside air inlet through said fresh air inlet pathway to said inside air outlet, while also allowing air flow from said inside air inlet through said interior air return pathway to said inside air outlet.

11. The equipment enclosure of claim 1, wherein said temperature controller is programmed to operate said temperature control unit in a fourth mode, representing a heating mode, wherein:

said primary air mover is in a power-on state;

said air conditioning air mover is in a power-off state;

said air conditioning compressor is in a power-off state;

said air heater is in a power-on state;

said first controllable damper is positioned to communicate air from said inside air inlet to said interior air return pathway, while blocking air flow from said inside air inlet to said interior air exhaust pathway; and

said second controllable damper is positioned to communicate air from said interior air return pathway to said inside air outlet, while blocking air flow from said first outside air inlet.

12. The equipment enclosure of claim 3, wherein said control electronics is programmed to operate said temperature control unit in a fifth mode, representing an emergency-free-air-cooling mode, wherein:

said primary air mover is in a power-off state;

said air conditioning air mover is in a power-on state;

said air conditioning compressor is in a power-off state;

said air heater is in a power-off state;

said first controllable damper is positioned to communicate air from said inside air inlet through said interior air exhaust pathway to said first outside air outlet, while blocking air flow from said inside air inlet into said interior air return pathway;

said second controllable damper is positioned to block air flow from said first outside air inlet; and

said emergency damper is positioned to allow air flow through said emergency air pathway, while blocking said air conditioning warm air vent pathway.

13. A temperature control unit adapted for use with an equipment enclosure requiring a temperature-controlled equipment chamber for housing equipment in said enclosure, said temperature control unit comprising:

an inside air inlet arranged to receive air from said equipment chamber;

an inside air outlet arranged to deliver air to said equipment chamber;

said inside air inlet and said inside air outlet each being on an inside cover;

a first outside air outlet arranged to deliver air to outside said equipment enclosure;

a second outside air outlet arranged to deliver air to outside said equipment enclosure;

a first outside air inlet arranged to receive air from outside said equipment enclosure;

a second outside air inlet arranged to receive air from outside said equipment enclosure;

said first outside air outlet, said second outside air outlet, said first outside air inlet and said second outside air inlet each being on an outside cover;

an interior air exhaust pathway extending between said inside air inlet and said first outside air outlet for venting interior air in said interior equipment chamber to outside said enclosure;

an interior air return pathway extending between said inside air inlet and said inside air outlet for recirculating interior air in said interior equipment chamber;

a first controllable damper operable to selectively communicate air from said inside air inlet to said air exhaust pathway and said interior air return pathway;

a fresh air inlet pathway extending between said first outside air inlet and said inside air outlet;

a second controllable damper operable to selectively communicate air from said interior air return pathway and said fresh air inlet pathway to said inside air outlet;

a primary air mover disposed to move air through said interior air return pathway and said fresh air inlet pathway;

an air heater in said interior air return pathway;

an air conditioning evaporator in said interior air return pathway;

an air conditioning warm air vent pathway extending between said second outside air inlet and said second outside air outlet;

an air conditioning condenser in said air conditioning warm air vent pathway;

a variable speed air conditioning compressor operably connected to pump a coolant through a coolant loop that includes said air conditioning condenser and air conditioning evaporator;

an air conditioning air mover disposed to move air through said air conditioning warm air vent pathway;

upper and low temperature sensors for sensing temperature in upper and lower portions of said equipment chamber;

an outside air temperature sensor for sensing outside air temperature; and

a temperature controller operable to control said dampers, said air movers and said air conditioning compressor based on temperature readings provided by said temperature sensors.

14. The temperature control unit of claim 13, wherein said first outside air inlet and said second outside air outlet comprise an outside bidirectional air opening arranged to deliver air to and receive air from outside said equipment enclosure.

15. The temperature control unit of claim 13, further including:

an emergency fresh air pathway extending between said second outside air inlet and said inside air outlet, said emergency pathway including said air conditioning air mover; and

a controllable emergency damper operable to selectively communicate air from said second outside air inlet to said air conditioning warm air vent pathway and said emergency fresh air pathway.

16. The temperature control unit of claim 13, wherein said interior air return pathway and said fresh air inlet pathway are merged to form a common air pathway between said second controllable damper and said inside air outlet.

17. The temperature control unit of claim 13, wherein said temperature control unit configured for mounting on a wall or door of said equipment enclosure.

18. The temperature control unit of claim 13, wherein said temperature control unit comprises a modular air conditioning unit that is selectively attachable to a modular temperature control unit air handler assembly.

19. The temperature control unit of claim 18, wherein:

said modular air conditioning unit comprises said air conditioning evaporator, said air conditioning condenser, said variable speed air conditioning compressor, said air conditioning air mover, a portion of said air conditioning warm air vent pathway, and a portion of said interior air return pathway;

said modular air-handler assembly comprises a portion of said interior air return pathway, said first controllable damper, said fresh air inlet pathway, said second controllable damper, said primary air mover, said air heater, and a portion of said air conditioning warm air vent pathway;

and further wherein;

said inside air inlet and said inside air outlet comprise an inside cover on said air handler assembly; and

said first and second outside air outlets and said first and second outside air inlets comprise an outside cover on said air handler assembly.

20. The temperature control unit of claim 13, wherein said temperature controller is programmed to operate said temperature control unit in a first mode, representing an air-conditioning mode, wherein:

said primary air mover is in a power-on state;

said air conditioning air mover is in a power-on state;

said air conditioning compressor is in a power-on state and operating at a selected speed;

said air heater is in a power-off state;

said first controllable damper is positioned to communicate air from said inside air inlet to said interior air return pathway;

said second controllable damper is positioned to communicate air from said interior air return pathway to said inside air outlet, while blocking air flow from said first outside air inlet; and

air flows from said second outside air inlet through said air conditioning warm air vent pathway to said second outside air outlet.

21. The temperature control unit of claim 13, wherein said temperature controller is programmed to operate said temperature control unit in a second mode, representing a free-air-cooling mode, wherein:

said primary air mover is in a power-on state;

said air conditioning air mover is in a power-off state;

said air conditioning compressor is in a power-off state;

said air heater is in a power-off state;

said first controllable damper is positioned to communicate air from said inside air inlet through said interior air exhaust pathway to said first outside air outlet, while blocking air flow from said inside air inlet into said interior air return pathway; and

said second controllable damper is positioned to communicate air from said first outside air inlet through said fresh air inlet pathway to said inside air outlet, while blocking air flow from said inside air inlet.

22. The temperature control unit of claim 13, wherein said temperature controller is programmed to operate said temperature control unit in a third mode, representing a free-air-cooling-with-return mode, wherein:

said primary air mover is in a power-on state;

said air conditioning air mover is in a power-off state;

said air conditioning compressor is in a power-off state;

said air heater is in a power-off state;

said first controllable damper is positioned to communicate air from said inside air inlet through said interior air exhaust pathway to said first outside air outlet, while also allowing air flow from said inside air inlet into said interior air return pathway; and

said second controllable damper is positioned to communicate air from said first outside air inlet through said fresh air inlet pathway to said inside air outlet, while also allowing air flow from said inside air inlet through said interior air return pathway to said inside air outlet.

23. The temperature control unit of claim 13, wherein said temperature controller is programmed to operate said temperature control unit in a fourth mode, representing a heating mode, wherein:

said primary air mover is in a power-on state;

said air conditioning air mover is in a power-off state;

said air conditioning compressor is in a power-off state;

said air heater is in a power-on state;

said first controllable damper is positioned to communicate air from said inside air inlet to said interior air return pathway, while blocking air flow from said inside air inlet to said interior air exhaust pathway;

said second controllable damper is positioned to communicate air from said interior air return pathway to said inside air outlet, while blocking air flow from said first outside air inlet.

24. The temperature control unit of claim 15, wherein said temperature controller is programmed to operate said temperature control unit in a fifth mode, representing an emergency-free-air-cooling mode, wherein:

said primary air mover is in a power-off state;

said air conditioning air mover is in a power-on state;

said air conditioning compressor is in a power-off state;

said air heater is in a power-off state;

said first controllable damper is positioned to communicate air from said inside air inlet through said interior air exhaust pathway to said first outside air outlet, while blocking air flow from said inside air inlet into said interior air return pathway;

said second controllable damper is positioned to block air flow from said first outside air inlet; and

said emergency damper is positioned to allow air flow through said emergency fresh air pathway, while blocking said air conditioning warm air vent pathway.