Exhaust air removal system

• US 20040099747A1
• Filed: 11/25/2002
• Published: 05/27/2004
• Est. Priority Date: 11/25/2002
• Status: Active Grant

• Current Assignee: Schneider Electric IT Corporation (Schneider Electric SE)
• Original Assignee: American Power Conversion Corporation (Schneider Electric SE)
• Inventors: Rasmussen, Neil, Johnson, Rollie R.
• Granted Patent: US 7,752,858 B2
• Time in Patent Office: Days
• US Class Current: 236/49.3
• CPC Class Codes: H05K 7/20736 within cabinets for removing heat from server blades
• CPC Class Codes: H05K 7/20836 Thermal management, e.g. server temperature control

Abstract

An exhaust air removal system and method for use with a rack or enclosure containing equipment is provided. The system and method are configured for removal of exhaust air vented from equipment during operation to thereby remove heat from the equipment. In one aspect, the system includes a fan unit preferably configured to serve as a back door of an equipment rack or enclosure and configured to provide access to an interior of the rack or enclosure. The fan unit provides multiple fans coupled to internal exhaust ducts that are arranged to draw and to remove exhaust air vented from rack-mounted equipment. The fan unit is further configured to vent exhaust air to an area external to a rack or enclosure, such as an external exhaust duct or plenum. Removal of hot and warm exhaust air vented from rack-mounted equipment enables the equipment to operate effectively, drawing sufficient amounts of cooling air to meet its cooling requirements. The fan unit is constructed for portability and for easy attachment to and removal from a rack or enclosure, providing flexibility in handling equipment exhaust needs.

Claims

1. A system for exhausting air from an equipment enclosure and returning air to an air conditioner, the system comprising:

an exhaust unit that couples to a back section of the equipment enclosure, the exhaust unit having at least one duct to direct air to a top portion of the exhaust unit;

an exhaust duct that has a first end and a second end, the first end being constructed and arranged to couple to the top portion of the exhaust unit; and

at least one fan contained within one of the exhaust unit and the exhaust duct to draw air from within the equipment enclosure and out through the exhaust unit and through the exhaust duct.

2. The system of claim 1, wherein the at least one fan includes a plurality of fans contained within the exhaust unit.

3. The system of claim 2, wherein the exhaust unit forms a back door of the equipment enclosure, and is constructed and arranged to replace an existing back door of the equipment enclosure.

4. The system of claim 3, wherein the exhaust unit includes a corresponding duct for each fan of the plurality of fans, with a first corresponding duct having a minimum cross-sectional area approximately equal to a minimum cross-sectional area of a second corresponding duct.

5. The system of claim 4, further comprising the equipment enclosure, and wherein the equipment enclosure includes an internal frame to allow mounting of equipment in an equipment area formed by the internal frame, a top panel, a bottom panel, a first side panel, a second side panel, and a front door having formed therein a number of openings to allow air drawn by the plurality of fans to by drawn through the openings, wherein the internal frame is coupled to the top panel, the first side panel and the second side panel to provide a substantially air tight seal so that substantially all air drawn through the openings in the front door passes through the equipment area and into the exhaust unit.

6. The system of claim 5, wherein the at least one fan is configured to operate at a variable speed.

7. The system of claim 6, further comprising a controller coupled to the at least one fan and constructed and arranged to control the variable speed of the fan.

8. The system of claim 7, wherein the controller controls the variable speed based on power drawn by equipment contained in the equipment enclosure

9. The system of claim 7, wherein the controller controls the variable speed in response to a temperature of air in one of the equipment enclosure and the exhaust unit.

10. The system of claim 6, further comprising at least one user control to allow a user to control the variable speed of the at least one fan.

11. The system of claim 7, further comprising multiple power inputs and a circuitry module coupling the power inputs to the at least one fan.

12. The system of claim 11, wherein the circuitry module is configured to disconnect a first of the power inputs from the at least one fan and connect a second of the power inputs to the at least one fan in response to a loss of power at the first of the power inputs.

13. The system of claim 7, wherein the controller is constructed and arranged to sense opening of the back door of the equipment enclosure and to switch the at least one fan off when the back door is opened.

14. The system of claim 7, wherein the controller is constructed and arranged to sense opening of the back door of the equipment enclosure and to control the at least one fan to operate at maximum speed when the back door is opened.

15. The system of claim 7, wherein the controller is constructed and arranged to detect a failure of one fan of the plurality of fans and to control an indicator to indicate the failure.

16. The system of claim 7, wherein the controller is constructed and arranged to communicate the failure to a device external to the equipment enclosure

17. The system of claim 2, wherein the exhaust duct is flexible, and wherein the second end of the exhaust duct is constructed and arranged to mate with a ceiling tile to allow exhaust air to be directed to an air plenum located above a ceiling.

18. The system of claim 1, wherein the at least one fan is configured to operate at a variable speed.

19. The system of claim 18, further comprising a controller coupled to the at least one fan and constructed and arranged to control the variable speed of the fan.

20. The system of claim 19, wherein the controller controls the variable speed based on power drawn by equipment contained in the equipment enclosure

21. The system of claim 19, wherein the controller controls the variable speed in response to a temperature of air in one of the equipment enclosure and the exhaust unit.

22. The system of claim 18, further comprising at least one user control to allow a user to control the variable speed of the at least one fan.

23. The system of claim 1, further comprising multiple power inputs and a circuitry module coupling the power inputs to the at least one fan.

24. The system of claim 23, wherein the circuitry module is configured to disconnect a first of the power inputs from the at least one fan and connect a second of the power inputs to the at least one fan in response to a loss of power at the first of the power inputs.

25. The system of claim 1, further comprising multiple power inputs and a circuitry module coupling the power inputs to the at least one fan.

26. The system of claim 25, wherein the circuitry module is configured to disconnect a first of the power inputs from the at least one fan and connect a second of the power inputs to the at least one fan in response to a loss of power at the first of the power inputs.

80. The system of claim 1, wherein the second end of the exhaust duct is constructed and arranged to allow exhaust air to be directed above the exhaust duct, and wherein the second end of the exhaust duct is substantially aligned with one or more openings defined in one of a ceiling or a ceiling tile to allow exhaust air to be directed to an air plenum above the ceiling.

27. A method for exhausting air from an equipment enclosure and returning air to an air conditioner, the equipment enclosure having a front door and a back door, the method comprising:

receiving air through openings in the front door of the enclosure;

drawing the air across equipment in the enclosure toward the back door of the enclosure;

drawing the air toward an opening in the top of the back door and through an exhaust duct to a ceiling plenum; and

returning the air to the air conditioner through the ceiling plenum;

wherein drawing the air across the equipment and toward an opening in the top of the back door is accomplished using at least one fan mounted in one of the back door of the enclosure and the exhaust duct.

28. The method of claim 27, wherein the air is directed through a plurality of door ducts formed in the back door of the equipment enclosure using a plurality of fans such that one fan is contained within one of the plurality of door ducts.

29. The method of claim 27, further comprising replacing the back door of the enclosure with a replacement door having a plurality of door ducts formed in the replacement door and having a fan mounted in each of the plurality of ducts, and coupling a first end of the exhaust duct to a top part of the replacement door, wherein each of the plurality of ducts are configured to direct air towards the exhaust duct.

30. The method of claim 28, wherein each of the plurality of fans is configured to operate at a variable speed, and wherein the method further includes controlling the variable speed of each of the plurality of fans based on power drawn by equipment contained in the equipment enclosure.

31. The method of claim 28, wherein each of the plurality of fans is configured to operate at a variable speed, and wherein the method further includes controlling the variable speed of each of the plurality of fans based on a temperature of air in one of the equipment enclosure and the exhaust duct.

32. The method of claim 30, wherein each of the plurality of fans is configured to operate from one of two power sources, and wherein the method further includes disconnecting each of the plurality of fans from a first power source and connecting each of the plurality of fans to a second power source upon detection of a failure of the first power source.

33. The method of claim 32, further comprising switching each of the plurality of fans off when the back door is opened.

34. The method of claim 32, further comprising controlling each of the fans to operate at maximum speed when the back door is opened.

35. The method of claim 32, further comprising providing an indication, detectable by a user from outside the electronic enclosure, of the failure of the first power source.

36. The method of claim 32, further comprising coupling a second end of the exhaust duct to a ceiling tile.

37. The method of claim 27, wherein the at least one fan is configured to operate at a variable speed, and wherein the method further includes controlling the variable speed based on power drawn by equipment contained in the equipment enclosure.

38. The method of claim 27, wherein the at least one fan is configured to operate at a variable speed, and wherein the method further includes controlling the variable speed based on a temperature of air in one of the equipment enclosure and the exhaust duct.

39. The method of claim 27, wherein the at least one fan is configured to operate from one of two power sources, and wherein the method further includes disconnecting the at least one fan from a first power source and connecting the at least one fan to a second power source upon detection of a failure of the first power source.

40. The method of claim 39, further comprising providing an indication, detectable by a user from outside the electronic enclosure, of the failure of the first power source.

41. The method of claim 29, further comprising coupling a second end of the exhaust duct to a ceiling tile.

42. A system for exhausting air from an equipment enclosure and returning air to an air conditioner, the equipment enclosure having a front door and a back door, the system comprising:

an exhaust duct that has a first end and a second end, the first end being constructed and arranged to couple to a top portion of the equipment enclosure; and

means, contained within one of the exhaust duct and the equipment enclosure, to draw air out of the equipment enclosure and through the exhaust duct.

43. The system of claim 42, wherein the means to draw air includes a plurality of variable speed fans mounted in the back door, and wherein the system further includes means for controlling the variable speed of each of the plurality of fans based on power drawn by equipment contained in the equipment enclosure.

44. The system of claim 42, wherein the means to draw air includes a plurality of variable speed fans mounted in the back door, and wherein the system further includes means for controlling the variable speed of each of the plurality of fans based on a temperature of air in one of the equipment enclosure and the exhaust duct.

45. The system of claim 43, wherein each of the plurality of fans is configured to operate from one of two power sources, and wherein the system further includes means for disconnecting each of the plurality of fans from a first power source and connecting each of the plurality of fans to a second power source upon detection of a failure of the first power source.

46. The system of claim 45, further comprising means for switching each of the plurality of fans off when the back door is opened.

47. The system of claim 45, further comprising means for controlling each of the fans to operate at maximum speed when the back door is opened.

48. The system of claim 45, further comprising means for providing an indication, detectable by a user from outside the electronic enclosure, of the failure of the first power source.

49. The system of claim 48, further comprising means for coupling a second end of the exhaust duct to a ceiling tile to allow exhaust air to return to the air conditioner through a ceiling plenum.

50. The system of claim 42, wherein the means to draw air includes a plurality of fans, and wherein each of the plurality of fans is configured to operate from one of two power sources, and wherein the system further includes means for disconnecting each of the plurality of fans from a first power source and connecting each of the plurality of fans to a second power source upon detection of a failure of the first power source.

51. The system of claim 42, wherein the means to draw air includes a plurality of fans, and wherein the system further includes means for switching each of the plurality of fans off when the back door is opened.

52. The system of claim 42, wherein the means to draw air includes a plurality of fans, and wherein the system further includes means for controlling each of the fans to operate at maximum speed when the back door is opened.

53. The system of claim 50, further comprising means for providing an indication, detectable by a user from outside the electronic enclosure, of the failure of the first power source.

54. The system of claim 42, further comprising means for coupling a second end of the exhaust duct to a ceiling tile to allow exhaust air to return to the air conditioner through a ceiling plenum.

55. A air exhaust system for use with an enclosure containing equipment, the system comprising:

a housing defining a chamber, an exhaust port in a top of the housing, and at least one intake port, the at least one intake port being configured to provide fluid communication between the chamber and a volume of air external to the housing, the housing being configured to couple to the enclosure such that the housing is adjacent to a first portion of the enclosure on a first side of the equipment from which the equipment vents air; and

at least one fan disposed within the chamber and coupled to the at least one intake port such that the fan is in fluid communication with the chamber and with the equipment, the fan being configured to draw air through the at least one intake port from the first side of the equipment,

the at least one fan being further configured to force the drawn-in air into an exhaust duct provided by the housing, the exhaust duct being configured to channel fan-exhausted air from the fan to the exhaust port in a substantially parallel orientation to the first side of the equipment.

56. The system of claim 55 wherein the exhaust duct corresponding to a first fan of the at least one fan and an exhaust duct corresponding to a second fan of the least one fan are configured and arranged in the chamber such that the exhaust duct of the first fan and the exhaust duct of the second fan about equally impede the fan-exhausted air.

57. The system of claim 56 wherein the exhaust duct corresponding to the first fan includes a minimum cross-section about equal to a minimum cross-section of the exhaust duct, corresponding to the second fan.

58. The system of claim 56 wherein the first fan draws air and forces the drawn-in air into its corresponding exhaust duct at a rate about equal to a rate at which the second fan draws air and forces the drawn-in air into its corresponding exhaust duct.

59. The system of claim 55 wherein the at least one fan is further configured to draw cool air from outside of the enclosure into the enclosure and across the equipment.

60. The system of claim 55 wherein the housing forms a part of a door of the enclosure.

61. The system of claim 55 further comprising multiple power inputs and a circuitry module electrically coupling the power inputs to the at least one fan.

62. The system of claim 61 wherein the circuitry module is configured to disconnect a first of the power inputs from a first fan and connect a second of the power inputs to the first fan in response to a loss of power on the first power input.

63. The system of claim 55 wherein the at least one fan is configured to operate at a variable speed.

64. The system of claim 63 wherein the at least one fan is electrically coupled to a controller, the controller being configured to adjust the variable speed of the fan in response to at least one of a temperature of the drawn-in air and a temperature of the fan-exhausted air.

65. The system of claim 64, wherein the at least one fan is electrically coupled to a controller, the controller being configured to adjust the variable speed of the fan based on a quantity of power drawn by equipment in the enclosure.

66. An enclosure for containing equipment comprising:

a frame configured to support the equipment in the enclosure;

a door coupled to the frame, the door having at least one internal duct with an exhaust port; and

means for drawing air across the equipment into the at least one internal duct and out the exhaust port.

67. The enclosure of claim 66 wherein the exhaust port is configured in a top of the door.

68. The enclosure of claim 66 wherein the means for drawing air includes at least one fan disposed in and coupled to the at least one internal duct such that the at least one internal duct and the equipment are in fluid communication.

69. The enclosure of claim 68 wherein the fan is configured to operate at a variable speed.

70. The enclosure of claim 68 further comprising multiple power inputs and a circuitry module electrically coupling the power inputs to the at least one fan wherein the circuitry module is configured to disconnect a first of the power inputs to the at least one fan and connect a second of the power inputs to the at least one fan in response to a loss of power on the first power unit.

71. The enclosure of claim 68 wherein the at least one fan is operatively coupled to a controller, the controller being configured to adjust a speed of the at least one fan in response to at least one of a temperature of air in the at least one fan and a temperature of air in the at least one internal duct.

72. The enclosure of claim 68, wherein the at least one fan is operatively coupled to a controller, the controller being configured to adjust a speed of the at least on fan based on a quantity of power drawn by equipment contained in the enclosure.

73. The enclosure of claim 68 wherein the internal duct corresponding to a first fan of the at least one fan and an internal duct corresponding to a second fan of the at least one fan are configured and arranged in the door such that the internal duct of the first fan and the internal duct of the second fan about equally impede fan-exhausted air.

74. The enclosure of claim 68 wherein the internal duct corresponding to a first fan of the at least one fan includes a minimum cross-section about equal to a minimum cross-section of an internal duct corresponding to a second fan of the at least one fan.

75. The enclosure of claim 68 wherein a first fan of the at least one fan draws air and forces the drawn-in air into a first of the at least one internal duct at a rate about equal to a rate at which a second fan of the at least one fan draws air and forces the drawn-in air into a second of the at least one internal duct.

76. The enclosure of claim 68 further comprising a means for detecting at least one of a temperature of air in the at least one fan and a temperature of air in the at least one internal duct.

77. A method for cooling equipment contained in an enclosure, the equipment being configured and arranged in the enclosure to vent air to a first portion of the enclosure on a first side of the equipment, the method comprising:

drawing air from a second portion of the enclosure on a second side of the equipment;

drawing air from the first portion of the enclosure on the first side of the equipment;

forcing the air into a duct provided by a housing;

the housing coupled with the enclosure such that the duct and the first side of the equipment are in fluid communication;

guiding the air through the duct to a top of the housing; and

venting the air from the top of the housing to an area external to the enclosure.

78. The method of claim 77 wherein the drawing air includes pulling cool air from outside of the enclosure into the enclosure and across the equipment.

79. The method of claim 77 wherein venting the air from the top of the housing includes venting air from an exhaust port configured in the top of the housing.