SYSTEMS AND METHODS FOR PROVIDING COOLING TO A HEAT LOAD

• US 20180073753A1
• Filed: 11/15/2017
• Published: 03/15/2018
• Est. Priority Date: 05/15/2015
• Status: Active Grant

• Current Assignee: Nortek Air Solutions Canada, Inc. (Melrose Industries Plc)
• Original Assignee: Nortek Air Solutions Canada, Inc. (Melrose Industries Plc)
• Inventors: LePoudre, Philip Paul, Gerber, Manfred, Ghadiri Moghaddam, Davood
• Granted Patent: US 11,092,349 B2
• Time in Patent Office: Days
• CPC Class Codes: F24F 1/0007 Indoor units, e.g. fan coil units self-contained units F24F1/02
• CPC Class Codes: F24F 1/0059 characterised by heat exchangers
• CPC Class Codes: F24F 12/002 using an intermediate heat-transfer fluid
• CPC Class Codes: F24F 5/0035 using evaporation
• CPC Class Codes: H05K 7/20827 within rooms for removing heat from cabinets, e.g. air conditioning devices
• CPC Class Codes: Y02B 30/54 Free-cooling systems
• CPC Class Codes: Y02B 30/56 Heat recovery units

Abstract

Conditioning systems and methods for providing cooling to a heat load can include an evaporative cooler arranged in a scavenger plenum with a pre-cooler upstream and a recovery coil downstream of the evaporative cooler. Outdoor or scavenger air can be conditioned in the evaporative cooler such that the conditioned scavenger air can provide cooling to a cooling fluid circulating through the recovery coil. The reduced-temperature cooling fluid can provide liquid cooling or air cooling for an enclosed space (for example, a data center) or for one or more devices that are enclosed or open to the atmosphere. Given the design and arrangement of the pre-cooler, evaporative cooler and recovery coil in the plenum, the system can operate in multiple modes. The pre-cooler can be configured to circulate a cooling fluid to condition the scavenger air. The pre-cooler fluid circuit can be coupled or decoupled from a process cooling fluid circuit.

Claims

1. A conditioning system for providing cooling to a heat load, the conditioning system comprising:

a scavenger plenum having an air inlet and outlet, the scavenger plenum configured to direct scavenger air in an air flow path from the air inlet to the air outlet;

an evaporative cooler arranged inside the scavenger plenum in the air flow path and having a first cooling fluid circuit configured to circulate a first cooling fluid through the evaporative cooler, the evaporative cooler configured to selectively evaporate a portion of the first cooling fluid;

a first cooling component arranged inside the scavenger plenum between the air inlet and the evaporative cooler, the first cooling component configured to selectively condition the scavenger air flowing through the first cooling component;

a second cooling component arranged inside the scavenger plenum between the evaporative cooler and the air outlet and having a second cooling fluid circuit configured to circulate a second cooling fluid through the second cooling component, the second cooling component configured to reduce a temperature of the second cooling fluid using scavenger air; and

a process cooling fluid circuit connected to at least one of the first cooling fluid circuit and the second cooling fluid circuit, the process cooling fluid circuit configured to provide a process cooling fluid to cool the heat load.

2. The conditioning system of claim 1 wherein the first cooling fluid circuit and the second cooling fluid circuit are fluidly connected, and the first and second cooling fluids are the same.

3. The conditioning system of claim 2 wherein the first cooling fluid and the second cooling fluid provide at least one of liquid cooling or air cooling to the heat load.

4. The conditioning system of claim 2 wherein the second cooling fluid exiting the second cooling component selectively flows through the evaporative cooler.

5. The conditioning system of claim 2 wherein the evaporative cooler is a liquid-to-air membrane energy exchanger (LAMEE), and the first cooling fluid is separated from the air flow path by a membrane, the LAMEE configured to condition the scavenger air and evaporatively cool the first cooling fluid.

6. The conditioning system of claim 1 further comprising one or more bypass dampers configured to permit scavenger air to enter or exit the air flow path at one or more locations between the air inlet and outlet.

7. The conditioning system of claim 6 wherein the one or more bypass dampers include a first set of bypass dampers configured to direct scavenger air into the air flow path at a location between the first cooling component and the evaporative cooler.

8. The conditioning system of claim 6 wherein the one or more bypass dampers include a second set of bypass dampers configured to direct scavenger air into the air flow path at a location between the evaporative cooler and the second cooling component.

9. The conditioning system of claim 1 wherein the evaporative cooler operates in an adiabatic mode, and the first cooling fluid circuit is a closed circuit within the evaporative cooler.

10. The conditioning system of claim 1 wherein the heat load is from an enclosed space with one or more heat-generating components.

11. The conditioning system of claim 10 further comprising:

a process plenum configured to direct process air from the enclosed space in an air flow path from a process air inlet to a process air outlet; and

a liquid-to-air heat exchanger (LAHX) arranged inside the process plenum, wherein the LAHX is part of the process cooling fluid circuit and configured to direct the process cooling fluid through the LAHX to provide air cooling to the process air flow path,

wherein the process air exiting the process plenum at the process air outlet is returned to the enclosed space as cool supply air.

12. The conditioning system of claim 10 wherein the process cooling fluid is delivered to the enclosed space to provide liquid cooling to at least one of process air in the enclosed space or one or more components in the enclosed space.

13. The conditioning system of claim 10 wherein the enclosed space is a data center.

14. The conditioning system of claim 1 wherein the first cooling component is a liquid-to-air heat exchanger (LAHX) having a third cooling fluid circuit and configured to selectively circulate a third cooling fluid to condition the scavenger air.

15. A method of providing cooling to a heat load, the method comprising:

selectively directing scavenger air through a pre-cooling unit arranged in a scavenger air plenum, the scavenger air entering the plenum at an air inlet and exiting the plenum at an air outlet, and the pre-cooling unit configured to condition the scavenger air entering the plenum;

selectively directing the scavenger air exiting the pre-cooling unit through an evaporative cooler arranged in the plenum, the evaporative cooler having a first cooling fluid circuit and configured to selectively evaporate a first cooling fluid in the first cooling fluid circuit;

directing the scavenger air exiting the evaporative cooler through a recovery coil arranged in the plenum, the recovery coil having a second cooling fluid circuit and configured to reduce a temperature of a second cooling fluid in the second cooling fluid circuit using the scavenger air; and

providing cooling to the heat load using a process cooling fluid in a process cooling fluid circuit, the process cooling fluid circuit connected to at least one of the first cooling fluid circuit and the second cooling fluid circuit.

16. The method of claim 15 wherein selectively delivering scavenger air through a pre-cooling unit includes using a bypass damper between the pre-cooling unit and the evaporative cooler to bypass the pre-cooling unit depending on outdoor air conditions.

17. The method of claim 15 wherein selectively delivering scavenger air through an evaporative cooler includes using a bypass damper between the evaporative cooler and the recovery coil to bypass the pre-cooling unit and the evaporative cooler depending on outdoor air conditions.

18. The method of claim 15 wherein selectively directing the scavenger air exiting the pre-cooling unit through an evaporative cooler comprises:

operating the evaporative cooler adiabatically to condition the scavenger air stream in the evaporative cooler; and

recirculating the first cooling fluid through the evaporative cooler such that the first cooling fluid circuit is a closed circuit in the evaporative cooler.

19. The method of claim 15 wherein selectively directing scavenger air through a pre-cooling unit arranged in a scavenger air plenum includes circulating a third cooling fluid through the pre-cooling unit to condition the scavenger air.

20. The method of claim 19 wherein the third cooling fluid is in a third cooling fluid circuit connected to the process cooling fluid circuit.

21. The method of claim 19 wherein the third cooling fluid is in a third cooling fluid circuit connected to the first and second cooling fluid circuits.

22. The method of claim 19 wherein the third cooling fluid is in a third cooling fluid circuit separate from the process cooling circuit and the first and second cooling fluid circuits, and the method further comprises:

directing the third cooling fluid exiting the pre-cooling unit through an auxiliary cooling unit configured to reduce a temperature of the third cooling fluid; and

recirculating the reduced-temperature third cooling fluid through the pre-cooling unit during operation of the pre-cooling unit.

23. A conditioning system for providing cooling to a heat load, the conditioning system comprising:

a process cooling unit comprising;

a scavenger air plenum having an air inlet and outlet, the plenum configured to direct scavenger air in an air flow path from the air inlet to the air outlet;

an evaporative cooler arranged inside the plenum in the air flow path and having a first cooling fluid circuit configured to selectively circulate a first cooling fluid through the evaporative cooler, the evaporative cooler configured to selectively evaporate a portion of the first cooling fluid;

a pre-cooler arranged inside the plenum upstream of the evaporative cooler, the pre-cooler having a second cooling fluid circuit configured to selectively circulate a second cooling fluid through the pre-cooler to selectively condition the scavenger air, prior to selectively passing the scavenger air through the evaporative cooler; and

a recovery coil arranged inside the plenum downstream of the evaporative cooler, the recovery coil having a third cooling fluid circuit configured to circulate a third cooling fluid through the recovery coil, the recovery coil configured to reduce a temperature of the third cooling fluid;

a process cooling fluid circuit connected to at least one of the first cooling fluid circuit and the third cooling fluid circuit, the process cooling fluid circuit configured to supply at least one of the first cooling fluid and the third cooling fluid to the heat load to cause heat rejected by the heat load to be received by the at least one of the first and third cooling fluids; and

an auxiliary cooling unit configured to cool the second cooling fluid exiting the pre-cooler, wherein the auxiliary cooling unit is part of the second cooling fluid circuit and separate from the first and third cooling fluid circuits.

24. The conditioning system of claim 23 wherein the auxiliary cooling unit comprises a LAMEE arranged inside an auxiliary scavenger air plenum and a recovery coil arranged downstream of the LAMEE in the auxiliary scavenger air plenum, and wherein the second cooling fluid flows through at least one of the LAMEE and the recovery coil to reduce a temperature of the second cooling fluid.