Abstract
A cooling distribution unit includes a primary closed loop, a secondary closed loop, and a heat exchanger configured to receive at least a portion of the primary closed loop, receive at least a portion of the secondary closed loop, and to draw heat away from the portion of the secondary closed loop and conduct the heat to the portion of the primary closed loop. A first pump is connected to the secondary closed loop. A second pump is connected to the secondary closed loop. The cooling distribution unit further includes a plurality of sensors, and a controller. The controller is configured to optimize the operational parameters of a given pump based on the correlation of the heat load of the given pump to the power consumption of the given pump.
Claims
1. A cooling distribution unit comprising: a primary closed loop configured to have a first fluid flow therethrough; a secondary closed loop configured to have a second fluid flow therethrough; a heat exchanger configured to receive at least a portion of the primary closed loop, receive at least a portion of the secondary closed loop, and draw heat away from the portion of the secondary closed loop and conduct heat to the portion of the primary closed loop; a first pump connected to the secondary closed loop; a second pump connected to the secondary closed loop; a plurality of sensors; and, a controller configured to: store and update operational parameters of the first pump and of the second pump in a memory; correlate a heat load of a given pump selected from the first pump or the second pump to a power consumption of the given pump; and optimize the operational parameters of the given pump based on the correlation of the heat load of the given pump to the power consumption of the given pump.
2. The cooling distribution unit of claim 1, wherein optimizing the operational parameters includes adjusting a setting of the first pump and a setting of the second pump to rebalance a fluid pumping workload between the first pump and second pump such that an energy efficiency of the first pump and second pump is maximized.
3. The cooling distribution unit of claim 1, wherein optimizing the operational parameters includes adjusting a setting of the first pump and a setting of the second pump to rebalance a fluid pumping workload between the first pump and second pump such that a heat load of the first pump and second pump is maximized.
4. The cooling distribution unit of claim 1, wherein the controller is configured to generate a heartbeat signal.
5. The cooling distribution unit of claim 4, wherein the heartbeat signal contains data collected by the plurality of sensors.
6. The cooling distribution unit of claim 5, wherein the plurality of sensors includes a temperature sensor, a pressure sensor, a dew point sensor, and a flow meter.
7. The cooling distribution unit of claim 4, wherein the controller is configured to communicate the heartbeat signal to another cooling distribution unit.
8. The cooling distribution unit of claim 1, wherein the plurality of sensors includes a temperature sensor, a pressure sensor, a dew point sensor, and a flow meter.
9. The cooling distribution unit of claim 1, further comprising a service screen configured to receive user input to change pump control settings and to reflect a user input.
10. The cooling distribution unit of claim 1, wherein the operational parameters include an amount of electrical power conducted to each of the first pump and the second pump.
11. The cooling distribution unit of claim 1, wherein optimizing the operational parameters includes operating the first pump to run at 50% power.
12. The cooling distribution unit of claim 1, wherein optimizing the operational parameters includes operating the first pump to run at 30% power and the second pump to operate at 70% power.
13. The cooling distribution unit of claim 1, wherein optimizing the operational parameters includes operating the first pump to run at 100% power and operating the second pump at 0% power.
14. The cooling distribution unit of claim 1, wherein the controller is configured to determine a ratio between an energy consumption of the first pump and the heat load of the first pump.
15. The cooling distribution unit of claim 1, wherein the plurality of sensors includes a temperature sensor, and wherein the heat load is configured to be calculated based on data from the temperature sensor.
16. A method comprising: determining, using a controller, an energy consumption of a pump in a cooling distribution unit; determining, using the controller, a heat load of the pump; determining, using the controller, an efficiency of the pump by correlating the energy consumption of the pump to the heat load of the pump; predicting, using the controller, optimized operating parameters for the pump based on stored system data and the determined efficiency of the pump; and, optimizing, using the controller, the operational parameters of the pump based on the predicted optimized operating parameters for the pump.
17. The method of claim 16, wherein the step of determining the heat load includes collecting data from a temperature sensor.
18. The method of claim 16, wherein the step of optimizing the operational parameters includes operating the pump at 0% power or at 100% power.
19. The method of claim 16, wherein the step of optimizing the operational parameters includes operating the pump at a power somewhere greater than 0% power and less than 100% power.
20. The method of claim 16, further comprising communicating control signals to a variable frequency drive connected to the pump to drive the pump to achieve the predicted optimized operating parameters.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic view of a cooling distribution unit in accordance with one example.
[0008] FIG. 2 is a perspective view of the cooling distribution unit of FIG. 1.
[0009] FIG. 3 is another perspective view of the cooling distribution unit of FIG. 1.
[0010] FIG. 4 is another perspective view of the cooling distribution unit of FIG. 1.
[0011] FIG. 5 illustrates a block diagram of the controller of FIGS. 2-4 in accordance with some aspects.
[0012] FIG. 6 illustrates a flow chart for an auto-restart operation of the cooling distribution unit of FIG. 1.
[0013] FIG. 7 illustrates a transformer configured to provide power to a pressure independent control valve of the cooling distribution unit of FIG. 1.
[0014] FIG. 8 illustrates a service screen displayed on a display screen of the cooling distribution unit of FIG. 1.
[0015] FIG. 9 illustrates a main menu screen displayed on a display screen of the cooling distribution unit of FIG. 1.
[0016] FIG. 10 illustrates a service screen displayed on a display screen of the cooling distribution unit of FIG. 1.
[0017] FIG. 11 illustrates a configuration screen displayed on a display screen of the cooling distribution unit of FIG. 1.
[0018] FIG. 12 illustrates a configuration screen displayed on a display screen of the cooling distribution unit of FIG. 1.
[0019] FIG. 13 illustrates a diagnostics screen displayed on a display screen of the cooling distribution unit of FIG. 1.
[0020] FIG. 14 illustrates a flowchart for a method of optimizing the operation of a pump in the cooling distribution unit to achieve a maximum energy efficiency of the cooling distribution unit of FIG. 1.
DETAILED DESCRIPTION
[0021] FIGS. 1-4 illustrate an example of a cooling distribution unit 110. The cooling distribution unit 110 may be used in any of a variety of settings, including for example in a server, data center, medical, semiconductor, and/or industrial application. The illustrated cooling distribution unit 110 is an in-row unit, although any of the concepts described herein related to the cooling distribution unit 110 may alternatively be used with an in-rack unit, or with any other type of cooling distribution unit.
[0022] With reference to FIG. 1, the cooling distribution unit 110 generally includes a primary closed loop 114 and a secondary closed loop 118. The primary closed loop 114 circulates a first fluid (e.g., facility water located and/or otherwise supplied at a data server center). The secondary closed loop 118 circulates a second fluid (e.g., a process water solution that includes 25% propylene glycol and 75% water). Other examples include different first and second fluids within either of the primary closed loop 114 or the secondary closed loop 118. As illustrated in FIGS. 2-4, the primary closed loop 114 includes piping (e.g., stainless steel piping) through which the first fluid circulates. The secondary closed loop 118 similarly includes piping (e.g., stainless steel piping) through which the second fluid circulates. In some examples, at least a portion of the piping for the primary closed loop 114 and/or the secondary closed loop 118 is cylindrical in shape and/or has a circular cross-section. In some examples, at least a portion of the piping for the primary closed loop 114 and/or the secondary closed loop 118 has a linear section and/or a curved section. Other examples include other types of piping, including piping made of other materials (e.g., metal or non-metal), or having other shapes and configurations than that illustrated.
[0023] In some examples, the first fluid may be composed of or include water or propylene glycol-water solutions having a 50% maximum concentration. In other words, the concentration of the glycol-water solution may have a maximum concentration of 10 mg/L. The second fluid may be composed of or include water or a premixed solution of uninhibited ethylene-glycol or propylene-glycol and water. The first fluid and the second fluid may have a largest particle size of less than 200 microns. Other examples may include other materials and/or compositions of materials and/or particle sizes for the first fluid and/or the second fluid.
[0024] With continued reference to FIG. 1, the secondary closed loop 118 circulates the second fluid through and/or across one or more electrical components 122, to pick up heat from the electrical components 122. The electrical components 122 may include, for example, computer chips or other heated electrical components in one or more servers or server racks. In some examples, cold plates or other thermal devices may be positioned over the computer chips, and the piping of the secondary closed loop may pass through the cold plates or other thermal devices to pick up the heat from the electrical components 122. Once the second fluid in the secondary closed loop 118 has been heated by the electrical components 122, the heated second fluid is directed to a heat exchanger 126.
[0025] With continued reference to FIG. 1, each of the primary closed loop 114 and the secondary closed loop 118 extends through the heat exchanger 126. In the illustrated example, the heat exchanger 126 is a liquid-to-liquid heat exchanger. The primary closed loop 114 directs the first fluid in a first direction (e.g., to the left as viewed in FIG. 1) through the heat exchanger 126, and the secondary closed loop 118 directs the second fluid in a second direction (e.g., to the right as viewed in FIG. 1) through the heat exchanger 126. In the illustrated example, the first direction is parallel to, and opposite, the first direction. In other examples the first fluid and the second fluid may be directed in the same direction, or in a transverse direction, or the first and second fluids may be moved in more than one direction in the heat exchanger 126.
[0026] Within the heat exchanger 126, heat is exchanged between the second fluid and the first fluid. Accordingly, at least a portion of the heat picked up from the electrical components 122 is transferred from the second fluid to the first fluid within the heat exchanger 126. In some examples, the piping of the primary closed loop 114 does not contact the piping of the secondary closed loop 118 within the heat exchanger 126, and the heat is exchanged through an intermediary material (e.g., through a thermally conductive material). Other examples may include various other types or number or arrangements of heat exchangers 126 than that illustrated.
[0027] With continued reference to FIG. 1, the primary closed loop 114 directs the first fluid (after having been heated in the heat exchanger 126) away from the heat exchanger 126, and to a cooling structure 130. The cooling structure 130 may be located for example within a data server center. The cooling structure 130 may be any of a variety of different structures, including a cooling tower or other thermal device that sheds or otherwise removes heat from the first fluid. In some examples, the cooling structure 130 may include a cold plate, fins, and/or other structures that remove heat, and/or may use a fan or fans to facilitate removal of heat from the first fluid.
[0028] As illustrated in FIG. 1, once the heat has been removed from the first fluid at the cooling structure 130, the first fluid is then circulated back toward the heat exchanger 126. Similarly, once the heat has been removed from the second fluid at the heat exchanger 126, the second fluid is circulated back toward the electrical components 122. This circulation through each of the primary closed loop 114 and the secondary closed loop 118 may continue (e.g., for as long as the electrical components 122 are generating heat), such that heat is continuously picked up from the electrical components and delivered to the heat exchanger 126, where the heat is then transferred to the first fluid and the primary closed loop 114, and eventually discarded at the cooling structure 130.
[0029] With continued reference to FIG. 1, each of the primary closed loop 114 and the secondary closed loop 118 may include one or more pumps to pump the first fluid and the second fluid through the piping. In the illustrated example, the primary closed loop 114 includes one or more pumps (not illustrated) located within the data server center (e.g., at the location of the cooling structure 130, or elsewhere within the data server center, to pump the first fluid (e.g., facility water) through the primary closed loop 114. The secondary closed loop 118 includes both a first pump 134 and a second pump 138. The first and second pumps 134, 138 are redundant pumps, positioned along parallel lines within the closed loop, such that if one of the pumps fails, the other may continue to operate the overall flow of the second fluid within the secondary closed loop 118. The first pump 134 and the second pump 138 may be any type of pump that is capable of pumping the second fluid. In some examples, the first pump 134 and the second pump 138 are identical pumps, having a same size and/or rating. In some examples, one or more of the first pump 134 or the second pump 138 is a centrifugal pump. Other examples include other types of pumps, and also numbers of pumps. For example, secondary closed loop 118 may in some examples include only a single pump, or may include more than two pumps. Overall, the first pump 134 and/or the second pump 138 may generate a flow rate of for example between 25 gallons per minute (GPM) and 200 GPM (e.g., 25 GPM, 50 GPM, 100 GPM, 125 GPM, 140 GPM, 160 GPM, or other values and ranges of values).
[0030] With continued reference to FIG. 1, in some examples the secondary closed loop 118 includes a refill tank 142 and a replenishing pump 146, for adding additional second fluid into the secondary closed loop 118. Additionally, in some examples the secondary closed loop 118 includes at least one expansion tank, for controlling an overall pressure and flow of the second fluid in the secondary closed loop 118. In the illustrated example, the secondary closed loop 118 includes a first expansion tank 150 and a second (e.g., redundant) expansion tank 154. Other examples may include just a single expansion tank, or more than two expansion tanks.
[0031] Additionally, both the primary closed loop 114 and the secondary closed loop 118 may include one or more valves (e.g., pressure control valves, check valves, pressure independent control valves, etc.) that operate to control the overall pressure and/or flow of fluid through the cooling distribution unit 110. In the illustrated example, the primary closed loop 114 includes a pressure independent control valve 158.
[0032] With continued reference to FIG. 1, in the illustrated example, the cooling distribution unit 110 includes a housing 162 (e.g., an outer housing). The housing 162 may include a steel frame (e.g., with interconnected vertical and/or horizontal frame members), or may be another type of frame, or be formed from different materials. In some examples, the housing 162 includes one or more doors (e.g., pivotally coupled or otherwise coupled to the frame). Other examples may include various other types, sizes, and/or shapes of housing 162 than that illustrated. In the illustrated example the housing 162 includes a first outlet 166 where the primary closed loop 114 exits, and the first fluid is sent to the cooling structure 130. The housing 162 also includes a first inlet 170, wherein the primary closed loop 114 enters, and wherein the first fluid is then directed to the heat exchanger 126 (e.g., located within the housing 162). The housing 162 also includes a second outlet 174, where the secondary closed loop 118 exits and the second fluid is sent to the electrical components 122, and a second inlet 178, where the second fluid enters and is then directed to the heat exchanger 126.
[0033] With continued reference to FIG. 1, in some examples, the cooling distribution unit 110 additionally includes one or more sensors that measure pressure, temperature, or other aspects of the cooling distribution unit 110. In the illustrated example, the cooling distribution unit 110 includes a plurality of pressure and temperature sensors (labeled as PT and RTD in FIG. 1) that are positioned generally at the first outlet 166, the first inlet 170, the second outlet 174, and the second inlet 178. As illustrated in FIG. 1, the cooling distribution unit 110 may include redundant pressure and temperature sensors (e.g., in the event one or more of the sensors fails or provide inaccurate readings). In the example shown, two redundant pressure transducers PT3A and PT3B are installed near the first inlet 170 of the primary closed loop 114 and are configured to sense an inlet pressure at the first inlet 170 of the primary closed loop 114. Two redundant pressure transducers PT2A and PT2B are also installed near the second inlet 178 of the secondary closed loop 118 and are configured to sense an inlet pressure at the second inlet 178 of the secondary closed loop 118. Additionally, two redundant pressure transducers PT4A and PT4B are installed near the first outlet 166 of the primary closed loop 114 and are configured to sense an outlet pressure at the first outlet 166 of the primary closed loop 114. Two redundant pressure transducers PT2A and PT2B are installed near the second outlet 174 of the secondary closed loop 118 and are configured to sense an outlet pressure at the second outlet 174 of the secondary closed loop 118. A pressure transducer PT3F is installed near the first input F3 to the heat exchanger 126, and a pressure transducer PT2F is installed near the second input F2 of the heat exchanger 126. Each of the pressure transducers may be used to measure fluid pressure at specific points in the system. In the example shown, the pressure transducers are rated for 0 to 100 pounds per square inch gauge (PSIG) but may be rated for other PSIG ranges in other examples.
[0034] In the example shown, two redundant temperature sensors (e.g., resistive temperature detectors [RTD]) T3A and T3B are installed near the inlet location of the primary closed loop 114 and two temperature sensors (e.g., RTDs) T4A and T4B are installed near the outlet location of the primary closed loop 114. Additionally, two redundant temperature sensors T2A and T2B are installed near the inlet location of the secondary closed loop 118 and two temperature sensors RTDs T1A and T1B are installed near the outlet location of the secondary closed loop 118. These are used to measure the fluid temperature at certain locations in the system. In the example shown, all temperature sensors are rated for 0 C. to 150 C. but may be rated for other temperature ranges in other examples.
[0035] In some examples, these sensors are coupled (e.g., wired or wirelessly) to a controller 182 (FIGS. 1-4) or other device that receives signals regarding the pressure and temperature of the first fluid and the second fluid. In the illustrated example, the controller 182 is located on and/or within the housing 162, and may include a user interface (e.g., graphical user interface, such as a color touchscreen). In some examples, the controller 182 is located remotely from the housing 162. In some examples, the controller 182 may be used to monitor pressure, monitor temperature, and/or control a flow and pressure differential of the second fluid.
[0036] FIG. 5 illustrates a block diagram of the controller 182 of FIGS. 2-4 in accordance with some aspects. The controller 182 includes, among other things, an electronic processor 500, a memory 502, and an input/output (I/O) interface 504. The electronic processor 500, the memory 502, and the I/O interface 504 communicate over one or more control and/or data buses. FIG. 5 illustrates only one example of the controller 182. The controller 182 may include more or fewer components and may perform functions other than those explicitly described herein.
[0037] In some examples, the electronic processor 500 is implemented as a microcontroller with a separate memory, such as the memory 502. In other examples, the electronic processor 500 may be implemented as a microcontroller with memory 502 on the same chip. In other examples, the electronic processor 500 may be implemented partially or entirely as, for example, a field-programmable gate array (FPGA), an applications specific integrated circuit (ASIC), and the like and the memory 502 may not be needed or may be modified accordingly.
[0038] In the example illustrated, the memory 502 includes non-transitory, computer-readable memory (or medium) that stores instructions that are received and executed by the electronic processor 500 to carry out the functionality of the cooling distribution unit 110 described herein. The memory 502 may include, for example, a program storage area and a data storage area. The program storage area and the data storage area may include combinations of different types of memory, such as non-volatile read-only memory, non-volatile flash memory and volatile random-access memory. The data storage area includes system data 505, which includes data collected from sensors 510, 512, 514, 516 of the cooling distribution unit 110 (e.g., temperature sensors 510, pressure sensors 512, dew point sensors 514, and flow meters 516), and also includes data such as the settings and configurations of the components (e.g., the pumps 134, 138, the sensors 510, 512, 514, 516, the expansion tanks 150, 154, the various strainers, the various valves, the various switches, etc.) of the cooling distribution unit 110. In some implementations, the memory 502 stores differential pressure mode instructions 506 and flow rate mode instructions 508. The electronic processor 500, when implementing the differential pressure mode instructions 506, may operate the controller 182 according to a differential pressure mode, as described below in more detail. The electronic processor 500, when implementing the flow rate mode instructions 506, may operate the controller 182 according to a flow rate mode, as described below in more detail.
[0039] The controller 182 receives feedback regarding the state of the cooling distribution unit 110 from the temperature sensors 510, the pressure sensors 512, the dew point sensors 514, and the flow meters 516. For example, the temperature sensors 510 are installed near the inlet and outlet locations of the primary closed loop 114 and the secondary closed loop 118 (e.g., the first outlet 166, the first inlet 170, the second outlet 174, and the second inlet 178). The temperature sensors 510 are configured to sense a fluid temperature at their respective locations. The temperature sensors 510 are configured to provide temperature signals to the controller 182 indicative of the fluid temperature.
[0040] The pressure sensors 512 are also installed near the inlet and outlet locations of the primary closed loop 114 and the secondary closed loop 118 (e.g., the first outlet 166, the first inlet 170, the second outlet 174, and the second inlet 178). The pressure sensors 512 are configured to measure fluid pressure at their respective locations. The pressure sensors 512 are configured to provide pressure signals to the controller 182 indicative of the fluid pressure.
[0041] The dew point sensor 514 is configured to provide a dew signal to the controller 182 indicative of the current dew point temperature and the ambient air temperature. The flow meters 516 (e.g., flow meters FM1, FM2) are installed on the first outlet 166 and the second outlet 174 lines and are configured to provide a flow signal to the controller 182 indicative of the flow rate of fluid exiting the housing 162 via the first outlet 166 and the second outlet 174.
[0042] The controller 182 may be configured to control modulating valves 518 to control the flow of fluid within the cooling distribution unit 110. For example, a modulating ball valve 518 may be situated at the first outlet 166, the first inlet 170, the second outlet 174 and/or the second inlet 178 to control the flow of fluid into and out of the primary closed loop 114 and/or the secondary closed loop 118.
[0043] The controller 182 may include and/or be electrically connected to a capacitor 519 for storing energy to provide power to the controller 182.
[0044] A human machine interface 520 connected to the controller 182 and configured to communicate user input to the controller 182. The human machine interface 520 may include a display (e.g., a touchscreen) and may include buttons, dials, sliders, toggles, and other types of input devices. As will be described in greater detail below, the human machine interface 520 is configured to display a graphical user interface that may provide feedback to a user as the user interacts with the input devices of the human machine interface 520.
[0045] FIG. 6 illustrates a flow diagram for a method 600 of operating the cooling distribution unit 110. The method may be implemented by the controller 182 using, by way of example, the electronic processor 500.
[0046] In the event of a power interruption, at step 610 an auto-restart algorithm may be executed. The auto-restart algorithm begins when a drop in and/or loss of power is detected for a given amount of time. During operation, the method 600 includes at step 612 storing current operating settings in, for example, the memory 502. In one example operating settings (e.g., operational parameters) are continuously stored in the memory 502. At step 614, in an event where the drop in and/or loss of power is detected the most recent operating settings are re-sent to the cooling distribution unit 110 upon power restoration.
[0047] The capacitor 519 (FIG. 5) is configured to store enough energy to provide power to run the cooling distribution unit 110 for the given amount of time. In one example, the cooling distribution unit 110 can undergo a full second of power loss with no intervention required.
[0048] Turning to FIG. 7, in one example the cooling distribution unit 110 contains a transformer 700 which provides 24 VAC power to the pressure independent control valve 158. For 380V or 400V of incoming power a 400V tap terminal 710 of the transformer 700 is connected to the pressure independent control valve 158. For 460V or 480V incoming power a 460V tap terminal 712 of the transformer 700 is connected to the pressure independent control valve 158.
[0049] In One example the auto-restart algorithm is implemented when the cooling distribution unit 110 is in a remote mode. FIG. 8 illustrates a service screen 800 for the cooling distribution unit 110 displayed on, by way of example, a display screen of the human machine interface 520. A user may select a local/remote control button 810 to toggle between a local control mode and a remote-control mode. In one example when the local/remote control button is selected, a local control is active. An option for setting a local control time-out may be made available. If the local control time-out is activated, after the time-out has passed, the cooling distribution unit 110 may switch to the remote-control mode. If the local control time-out is not activated, the cooling distribution unit 110 will remain in the local control mode unless manually set to remote control mode.
[0050] FIG. 9 shows a main menu screen 900 displayed on a display screen 901 of the human machine interface 520. In the example shown, the main menu screen 900 includes a Logout button 905, a Data Access button 910, a Diagnostics button 915, a Configuration button 920, a Service button 925, and a Process Start/Stop button 930. Each of the Data Access button 910, the Diagnostics button 915, the Configuration button 920, the Service button 925, and the Process Start/Stop button 930 are configured to be selected by a user via the human machine interface 520. The Logout button 905 may be configured to cause the display screen 901 to display a login screen that acts as a gateway to the main menu screen 900. For example, the login screen may require a user to enter a personal identification number (PIN) or password. In response to the PIN or password being entered, the display screen 901 may display the main menu screen 900. The Data Access button 910, when selected, may cause the display screen 901 to display a screen presenting data collected from various sensors 510, 512, 514, 516 in the cooling distribution unit 110 or stored in the system data 505 regarding the states of the various components of the cooling distribution unit 110 (e.g., the pumps 134, 138, the expansion tanks 150, 154, the various valves, the strainers, the heat exchanger, etc.) The Diagnostics button 915, when selected, may cause the display screen 901 to display one or more shortcuts (e.g., buttons) leading to various diagnostic screens (e.g., diagnostic screen 1300, see FIG. 13) that provide to the user, via the display screen 901, diagnostic information related to the cooling distribution unit 110. The Configuration button 920, when selected, may cause the display screen 901 to display to display one or more shortcuts (e.g., buttons) leading to various configuration screens (e.g., configuration screens 1100, 1200, see FIGS. 11, 12) that provide to the user, via the display screen 901, options for configuring various components of the cooling distribution unit 110. The Service button 925, when selected, may cause the display screen 901 to display to display one or more shortcuts (e.g., buttons) leading to various service screens (e.g., service screen 1000, see FIG. 10) that provide to the user, via the display screen 901, options for servicing (e.g., manually controlling or preparing for replacement) various components of the cooling distribution unit 110. In the example shown, the main menu screen 900 also includes an Optimize button 935 configured to cause the controller 182 to automatically optimize settings and configurations (e.g., the settings and configurations of pumps 134, 138) for maximum energy efficiency or maximum cooling capability. The optimization process will be described in greater detail below.
[0051] FIG. 10 shows the display screen 901 displaying a service screen 1000 configured to receive user input to change pump control settings and to reflect the user input via the display screen 901. The service screen 1000 includes a pump identification and statistics pane 1002, and a plurality of pump settings inputs (e.g., buttons, dropdown widows, text boxes, etc.) configured to display settings and setpoints of the pumps of the secondary closed loop 118 (e.g., pumps 134, 138, and the fill pump) in the cooling distribution unit, such as a flow control type input 1004, flow rate indicators and setpoints input 1006, pressure indicators and setpoints input 1008, a temperature control type input 1010, and temperature indicators and setpoints input 1012. The service screen 1000 also includes a pump selection override input 1014 configured to permit a user to select a pump for direct manual control via the pump select input 1016. In the example shown, the service screen allows a user to choose a method of directly controlling a selected pump via the variable frequency drive proportional-integral-derivative override input 1018, or the motor voltage proportional-integral-derivative override input 1020. In response to selecting the variable frequency drive proportional-integral-derivative override input 1018, the service screen 1000 allows the user to set a duty cycle ratio percentage 1021 for a variable frequency drive providing power to a motor of the pump (e.g., pump 134, 138). In response to selecting the motor voltage proportional-integral-derivative override input 1020, the service screen 1000 allows the user to set a percentage of max motor voltage 1024 provided by a power source to a motor of the pump. A process start/stop input 1022 is configured to cause the cooling distribution unit to start or stop the pump or pumps using the settings displayed in the service screen 1000.
[0052] FIG. 11 shows the display screen 901 displaying a configuration screen 1100 configured to receive user input to change pump control settings and to reflect the user input via the display screen 901. The configuration screen 1100 includes a plurality of pump configuration inputs (e.g., buttons, dropdown widows, text boxes, etc.), such as a control mode input 1102, a flow rate setpoint input 1104, a differential pressure setpoint input 1106, a first low flow threshold alarm input 1108, a second low flow threshold alarm input 1110, a low differential pressure threshold alarm input 1112, a low flow alarm delay input 1114, a low differential pressure alarm delay input 1116, and an over-pressure setpoint input 1118.
[0053] In the example shown, the control mode input 1102 is configured to toggle between a differential pressure control mode and a flow rate control mode when manipulated by a user. The flow rate setpoint input 1104 is configured to toggle between a differential pressure control mode and a flow rate control mode when manipulated by a user. In the differential control mode, the cooling distribution unit 110 controls the operation of pumps 134, 138 based on a difference in pressure readings between one of pressure sensors PT1A, PT1B and pressure sensors PT2A, PT2B. For example, the differential pressure mode may be configured to control the pumps 134, 138 to maintain a particular differential pressure (e.g., 5 PSI, 10 PSI, 15 PSI, etc.), defined in the differential pressure setpoint input 1106 or to maintain a differential pressure within a defined range (e.g., a range defined in the differential pressure setpoint input: 5-10 PSI, 10-15 PSI, etc.). In the flow rate control mode, the cooling distribution unit 110 controls the operation of pumps 134, 138 based on readings (e.g., gallons per minute [GPM] readings) from the flow meters 516 (e.g., flow meter FM1) indicating the flow rate of fluid through the secondary closed loop 118. For example, the flow rate mode may be configured to control the pumps 134, 138 to maintain a flow rate (e.g., 20 GPM, 30 GPM, 40 GPM, etc.) defined in the flow rate setpoint input 1104 or to maintain a flow rate within a defined range (e.g., defined in the flow setpoint input: 10-20 GPM, 20-30 GPM, 30-40 GPM, etc.). The first low flow threshold alarm input 1108, the second low flow threshold alarm input 1110, and the low differential pressure threshold alarm input 1112 each allow the user to establish thresholds (as a percentage of a setpoint) at which the cooling distribution unit 110 communicates an alarm (e.g., produces a noise, sends a text message, produces a visual alert on the display screen 901, etc.). The low flow alarm delay input 1114 and the low differential pressure alarm delay input 1116 allow the user to set delays for associated alarms. The over-pressure setpoint input 1118 allows the user to establish a pressure value at which overpressure in the cooling distribution unit 110 is vented from the system (e.g., via a vent or valve).
[0054] FIG. 12 shows the display screen 901 displaying a configuration screen 1200 configured to receive user input to change a pump duty rotation and to reflect the user input via the display screen 901. A first pump assignment input 1202 and a second pump assignment 1204 allow the user to set which pump (e.g., pump 134) is the primary pump, and which pump (e.g., pump 138) is the backup pump for the secondary closed loop 118. A first pump run cycle time input 1206 and a second pump run cycle time input 1208 allow the user to select the respective runtime of each pump before cycling between pumps.
[0055] FIG. 13 Shows the Display Screen 901 displaying a diagnostics screen 1300 configured to show diagnostics for various sensors of the cooling distribution unit 110 via the display screen 901. In the example shown, component identification (ID) numbers 1302 for various sensors (e.g., pressure sensors 512) in the cooling distribution unit 110 are shown. Descriptions 1304 for each of the sensors, an amount of electrical power drawn 1306 by each of the sensors, and an amount of pressure experienced 1308 by each of the sensors are also shown. Although the diagnostics screen 1300 shown only shows diagnostic values for the sensors of the cooling distribution unit 110, in some examples of the diagnostics screen 1300 also includes data provided by the controller 182 (e.g., pulled from memory 502) relating the operation of certain components of the cooling distribution unit 110.
[0056] In some examples of the diagnostics screen 1300, the electrical power consumption and amount of fluid processed by the pumps (e.g., pumps 134, 138) may be displayed, in addition to other items like pump motor voltage or current, etc.
[0057] Referring back to FIG. 5, the controller 182 may be configured to calculate an efficiency of various pumps (e.g., pump 134, 138) by comparing the power consumption of a pump (e.g., pump 134) to the heat load carried to or away from the heat exchanger 126 via the fluid of the secondary closed loop 118 determined as a difference between a temperature reading at temperature sensor T1A or T1B and temperature sensor T2A, T2B. Referring back to FIG. 9, the Optimize button 935 may cause the controller to adjust the settings and configurations (as shown in FIGS. 11-13) of one or more of the pumps of the secondary closed loop 118 (e.g., pump 134, 138) to balance or rebalance the fluid pumping workload between the pumps to maximize energy efficiency or cooling capability. For example, in response to the Optimize button 935 being selected by the user, the controller 182 may cause pump 134 to operate at a particular power level (e.g., 50% of maximum) based upon a determination that at 50% power pump 134 carries heat to the heat exchanger with the greatest energy efficiency (e.g., relatively high cooling capability resulting from relatively low power consumption by the pump). In some examples, in response to a selection of the Optimize button 935, the controller 182 may optimize numerous pumps for a collective goal (e.g., maximum power efficiency or cooling capability) and, for example, cause pump 134 to run at 30% power (e.g., via the variable frequency drive) and pump 138 to operate at 70% power. As another example, in response to the Optimize button 935 being selected by the user, the controller 182 may cause pump 134 to run at 100% power (e.g., via the variable frequency drive) and pump 138 to operate at 0% power. The controller 182 may achieve these optimizations by automatically adjusting the settings and configurations shown in FIGS. 11-13.
[0058] In some examples, the controller 182 may be configured to regularly produce a heartbeat signal containing any data collected by the sensors 510, 512, 514, 516, or contained in the memory 502 (e.g., the settings and configurations shown in FIGS. 11-13). The controller 182 may communicate the heartbeat signal to other cooling distribution units (e.g., other cooling distribution units installed in a row with the cooling distribution unit 110) and the other cooling distribution units may adjust their settings or configurations in response to the heartbeat signal.
[0059] FIG. 14 shows a flowchart 1400 for a method of optimizing the operation of a pump (e.g., pump 134) in the cooling distribution unit 110 to achieve a maximum energy efficiency.
[0060] At block 1410 the method includes determining, using the controller 182, an energy consumption of the pump (e.g., pump 134). Similar to what is shown on the diagnostics screen 1300 with respect to the sensors of the cooling distribution unit 110, the controller 182 may track the amount of electrical energy consumed by each of the pumps of the cooling distribution unit 110 (e.g., pumps 134, 138). For example, the controller 182 may store and update data (e.g., operational parameters in memory 502) indicating an amount of electrical power conducted to each pump in response to control signals (e.g., motor control signals) produced by the controller 182.
[0061] At block 1420 the method includes determining, using the controller 182, a heat load of the pump. Similar to what is shown on the diagnostics screen 1300 with respect to the sensors of the cooling distribution unit 110, the controller 182 may track the amount of heat being pumped to the heat exchanger 126 by each of the pumps of the cooling distribution unit 110 (e.g., pumps 134, 138). For example, the controller may determine, using temperature sensors 510 that a single pump directing (e.g., via pumped fluid) a particular amount of heat (e.g., 130 British thermal units [BMU] or joules) to the heat exchanger 126 per predefined unit of time (e.g., 1 second).
[0062] At block 1430 the method includes determining, using the controller 182, an efficiency of the pump by correlating the energy consumption of the pump to the heat load of the pump. For example, the controller 182 may determine a ratio between the energy consumption of the pump and the heat load of the pump.
[0063] At block 1440 the method includes predicting, using the controller 182, optimized operating parameters for the pump based on stored system data (e.g., system data 505 in memory 502) and the determined efficiency of the pump. For example, the controller 182 may extrapolate stored system data (e.g., previously correlated pump energy consumptions and heat loads) to predict a pump power level (e.g., 50%) that will result in a maximized energy efficiency for the pump.
[0064] At block 1450 the method includes optimizing, using the controller 182, the pump based on the predicted optimized operating parameters for the pump. For example, based upon the predicted optimized operating parameters for the pump, the controller 182 may communicate control signals to a variable frequency drive connected to the pump to drive the pump to achieve the predicted optimized operating parameters.
[0065] In the illustrated example, the cooling distribution unit 110 has an overall dimension of 31.5 by 47.4 by 84.5, and an overall weight of approximately 1400 pounds. Other examples may include various different sizes and weights, including sizes smaller and larger than that illustrated, and weights smaller or greater than that illustrated. Additionally, in the illustrated example, the cooling distribution unit 110 may provide a cooling capacity of 550 kW (at 4 C. approach temperature difference) and 1100kW (at 8 C. approach temperature difference). Other examples may include other values and ranges of values of cooling capacity, including a cooling capacity smaller or greater than that illustrated.
[0066] Although various aspects and examples have been described in detail with reference to certain examples illustrated in the drawings, variations and modifications exist within the scope and spirit of one or more independent aspects described and illustrated.
