Online maintainable isolation control system for data center refrigeration systems

Abstract

The utility model provides a kind of online maintainable isolation control system for data center refrigeration system, comprising: first power supply module and second power supply module;First switch, its input end is connected with the output end of the first power supply module and the second power supply module respectively, for selecting one way for load power supply;Wherein, the input, output and monitoring loop of the first power supply module and second power supply module, and the control and feedback loop of the first switch, all are provided with the electrical connector that can be inserted by hand pluggable. Greatly improve the authentication pass rate and consistency.

Description

Technical Field

[0001] This utility model relates to the field of data center management technology, and in particular to an online maintainable isolation control system for data center cooling systems. Background Technology

[0002] As the core infrastructure of the digital economy, the continuity and high availability of data centers are crucial for ensuring business operations. The Tier 1 certification system developed by the Uptime Institute is a globally recognized standard for assessing the reliability of data center infrastructure. Among them, Tier III (Simultaneously Maintainable) and Tier IV (Fault-Tolerant) levels impose stringent "online maintainability" requirements on critical subsystems such as cooling systems: that is, while ensuring the uninterrupted operation of critical IT loads, it is necessary to be able to perform planned maintenance or fault isolation demonstrations on any single point of failure without interrupting the overall system functionality.

[0003] To verify this capability, on-site certification testing by the TCCF (Tier Certification of Constructed Facility) is required. This test is typically conducted under extreme conditions simulating mains power failure and being powered by a diesel generator set. It requires maintenance personnel to demonstrate on-site the safe and rapid isolation of critical equipment in the refrigeration system (such as diesel generator sets, parallel cabinets, PLC control cabinets, precision air conditioners, and building automation system controllers) from the system. However, a significant bottleneck exists in existing technologies: all secondary circuits (including control, signal, communication, and protection circuits) between these critical devices and the control network generally use fixed soldered terminals or screw-fastened (such as grid-type or DIN rail-type) terminal blocks for connection. Utility Model Content

[0004] The purpose of this invention is to provide an online maintainable isolation control system for data center cooling systems, thereby alleviating the technical problems existing in the prior art.

[0005] In a first aspect, this utility model provides an online maintainable isolation control system for a data center cooling system, comprising: First power supply module and second power supply module; The first switching switch has its input terminal connected to the output terminals of the first power supply module and the second power supply module respectively, and is used to select one of them to supply power to the load. The input, output, and monitoring circuits of the first and second power supply modules, as well as the control and feedback circuit of the first switching switch, are all equipped with hand-pluggable electrical connectors.

[0006] This invention enables efficient, standardized, and risk-free demonstrations of various complex isolation scenarios in TCCF certification by pre-setting standardized and secure physical isolation points for the secondary circuits of each critical device. This perfectly meets the core requirements of Tier III / IV certification for online maintainability, significantly improving certification pass rates and consistency. It also drastically shortens the downtime window for planned maintenance, significantly improving the overall availability and operational efficiency of data center cooling systems. Attached Figure Description

[0007] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0008] Figure 1 A schematic diagram of an online maintainable isolation method for key equipment in a data center cooling system, provided in an embodiment of this application; Figure 2 This is a schematic diagram of the control system of a refrigeration system provided in this embodiment; Figure 3 This is a schematic diagram of the control system of another refrigeration system provided in this embodiment; Figure 4 This is a schematic diagram of the control system of another refrigeration system provided in this embodiment; Figure 5 This is a schematic diagram of the control system of another refrigeration system provided in this embodiment; Figure 6 This is a schematic diagram of the control system of a chiller unit provided in this embodiment; Figure 7 This is a schematic diagram of the control system of another refrigeration system provided in this embodiment; Figure 8 This is a schematic diagram of the control system of another refrigeration system provided in this embodiment. Detailed Implementation

[0009] The technical solutions in the embodiments of this application will now be described with reference to the accompanying drawings.

[0010] Figure 1 This is a schematic flowchart illustrating an online maintainable isolation method for key equipment in a data center cooling system, provided as an embodiment of this application. Figure 1 As shown, the method may include: S110 identifies all critical devices in the refrigeration system that require online, non-disruptive isolation, and identifies the secondary cable loops that connect each critical device to the system. These secondary cable loops include at least control command loops, status feedback loops, sensor signal loops, and data communication loops.

[0011] Key equipment may include any one or more of the following: diesel generator sets, generator parallel control cabinets, dual busbar distribution cabinets, programmable logic controller cabinets, fuel supply system control cabinets, chillers, chilled water pump sets, cooling water pump sets, cooling towers, precision air conditioning units, cold storage devices, building automation system field controllers, power monitoring system acquisition units, and fire protection system linkage control modules.

[0012] This step is the foundation of the isolation plan. It is necessary to clarify which devices need to be isolated and through which loops, so as to ensure that subsequent isolation operations accurately cover critical connections.

[0013] Critical equipment refers to devices that perform core functions in the refrigeration system, and whose offline operation may lead to system performance degradation or interruption. These devices need to be identified based on their functional irreplaceability, the scope of their impact from failure, and compliance certification requirements (such as TCCF testing). Specific equipment and functions:

[0014] Secondary cable circuits refer to non-main power circuits that transmit control signals, status information, and sensor data (as opposed to primary circuits that transmit high-power electricity), and serve as the "nerve channels" for interaction between equipment and systems.

[0015] Specific circuit and function:

[0016] Based on the electrical schematic diagram and cable list, clarify the number, routing, and connected devices at both ends of the secondary circuits for each piece of equipment. For example, the control command circuit of the chiller unit is connected to the DO module of the PLC cabinet. Form a circuit list, which may include the circuit number, function description, and cable model and specifications.

[0017] S120, at the power supply side or signal access point of each secondary cable circuit of each critical equipment, a set of pluggable electrical connection terminals is serially connected. The terminal set includes a male connector and a female socket that are separable and electrically connected to each other. The cable conductor end is fixedly connected to the male connector, and the female socket is fixedly installed on the control cabinet, distribution cabinet or dedicated centralized terminal board of the corresponding critical equipment.

[0018] The fixed connection method is to use one of the following: butterfly spring crimping technology, direct insertion spring cage crimping technology, or screw fastening technology to fix the end of the cable conductor into the wiring cavity of the male connector. The mating interface between the male connector and the female socket of the pluggable electrical connection terminal is provided with an asymmetrical mechanical keyway structure and / or a differentiated color coding structure.

[0019] This step enables rapid physical disconnection / restore of secondary connections by connecting pluggable terminals in the secondary circuit, replacing the tedious operation of disconnecting each wire individually from traditional terminal blocks. It is the core hardware for "online maintainability".

[0020] The terminal block consists of a male connector (Plug) and a female socket. The male connector connects to an external cable (from the control system / sensor), while the female connector is fixed to the equipment side (control cabinet, distribution cabinet, or centralized terminal block).

[0021] Terminal blocks can be installed on the "power supply side" (such as the PLC output terminal of the control command circuit) or the "signal access point" (such as the signal input terminal block on the equipment side) of the secondary circuit and connected in series to ensure that the electrical connection between the equipment and the system can be completely cut off when disconnected.

[0022] A fixed connection method can be used to ensure a reliable connection between the male connector and the cable conductor (low contact resistance, vibration resistance), and to avoid abnormal signal transmission or equipment malfunction.

[0023] Specific technologies:

[0024] It can also be equipped with a design to prevent mis-insertion. For example, an asymmetrical "key-slot" structure can be designed on the mating surfaces of the male and female terminals, such as a protrusion on the left side of the male terminal and a groove on the left side of the female terminal, so that only the matching male and female terminals can be inserted, avoiding mis-insertion of male terminals from different circuits.

[0025] Colors can also be assigned according to loop function (control commands - red, status feedback - blue, sensor signals - yellow, data communication - green) to visually distinguish loop types and help operators quickly identify them.

[0026] S130 When planned maintenance or compliance certification testing is required for designated critical equipment, provided that the system redundancy mechanism has taken effect and is operating stably, all male connectors connected to the equipment are simultaneously or sequentially disconnected from their corresponding female sockets, thereby physically severing all secondary circuit electrical connections between the equipment and the refrigeration system, and putting it into a completely isolated state with no voltage and no electrical connection.

[0027] The compliance certification test is the Uptime Institute Tier III or Tier IV TCCF certification test, and the system operates under simulated mains power failure conditions powered by a diesel generator set.

[0028] The isolation scenarios for certification testing include: simulating isolation of a single diesel generator set and its parallel control cabinet, simulating isolation of a single power distribution control unit in a dual power supply system, simulating isolation of a single controller in a redundant programmable logic controller, and simulating isolation of at least one of a single chiller unit or precision air conditioning controller in a cold source system.

[0029] This step is the execution phase of the isolation operation. Under the premise of ensuring system safety, the equipment and the system are "completely isolated" by physically disconnecting the secondary circuit, creating a safe environment for maintenance or testing.

[0030] Redundancy mechanisms are configured with backup equipment / circuits for critical functions. When the primary equipment is isolated, the backup equipment can seamlessly take over, ensuring uninterrupted functionality.

[0031] Effective confirmation is achieved by monitoring to confirm that the backup equipment has taken over the functions, thus preventing instability caused by isolation.

[0032] During Uptime Tier III / IV TCCF certification testing, especially when switching from mains power to diesel generator power, the process is prone to failure. Therefore, the power supply scenario during the switching process is an important simulation scenario for TCCF testing. At this time, it is necessary to additionally confirm whether the diesel generator output voltage and frequency fluctuations meet the requirements.

[0033] Operation methods for isolation and complete isolation: Simultaneous disconnection: Suitable for devices with a small number of circuits and no dependencies, disconnecting all public terminals at once and shortening the isolation time.

[0034] Disconnect in sequence: This applies to devices with a logical sequence of circuits. Non-emergency circuits should be disconnected first, followed by emergency circuits, to avoid accidental startup caused by disconnecting the emergency circuit first.

[0035] Definition of complete isolation state: The equipment and system secondary circuits are physically disconnected, satisfying the following conditions: no voltage in the equipment-side secondary circuit; no signal transmission; and the control system cannot affect the equipment through the secondary circuit.

[0036] Isolation scenarios for compliance certification testing

[0037] S140, in a fully isolated state, performs the necessary inspection, repair, replacement or functional test operations on the critical equipment; after the equipment operation is completed, accurately reinsert all previously unplugged male connectors into their respective corresponding female sockets and ensures they are locked to restore the electrical connection of all secondary circuits, so that the critical equipment can be reconnected to the refrigeration system and operated under control.

[0038] It is essential to ensure that the equipment can be accurately and reliably reconnected after maintenance, and to avoid equipment failure or instability caused by connection errors.

[0039] In a state of complete isolation, the following operations can be performed: Inspection: Visually inspect the appearance of the equipment, check for loose or burnt wiring terminals, and calibrate the sensors.

[0040] Repair: Replace damaged parts and repair damaged wire insulation.

[0041] Replacement: Replace the aging equipment entirely.

[0042] Functional testing: Offline testing of device functions.

[0043] Reconnection restoration requires accurate insertion and locking: using mechanical keyways and color coding (inserting the male end into the corresponding female end to ensure reliable contact).

[0044] Sequential restoration: For circuits that are disconnected in sequence, restore them in reverse order to avoid equipment malfunctions caused by restoring non-emergency circuits first.

[0045] In some embodiments, for the same critical equipment, all the female sockets of its pluggable electrical connection terminals are arranged in a centralized and modular manner and integrated on an insulating base plate to form the online maintenance interface panel of the equipment.

[0046] The online maintenance interface panel can be labeled to indicate the circuit function, cable number, and remote device information corresponding to each female socket or male connector.

[0047] In some embodiments, the system further includes: through the human-machine interface of the monitoring system, the operator or the system automatically confirms that the control functions or monitoring tasks carried by the critical equipment to be isolated have been seamlessly taken over by the redundant backup equipment configured in the system, and that the operating parameters of the entire refrigeration system are within a stable and normal range.

[0048] All female sockets for the same equipment are centrally and modularly arranged on an insulating base plate to form an online maintenance interface panel, which is installed on the front / side of the equipment control cabinet for easy operation.

[0049] Each female / male terminal can be labeled on the panel with: loop function; cable number; remote device information.

[0050] Centralized layout reduces operating space requirements, clear labeling reduces the risk of misoperation, and modular design facilitates terminal maintenance.

[0051] Figure 2This diagram illustrates a power supply system for a refrigeration system controller based on a multi-bus redundancy architecture. It demonstrates a system that provides highly available power to the first controller 11 of a chiller unit 10. The system adopts a "multi-bus input, end-redundancy" architecture and mainly includes three power supply units: a first power supply unit 12, a second power supply unit 15, and a third power supply unit 16.

[0052] The first power supply unit 12 may include a first switching switch 121, a first power supply module 122, and a second power supply module 123.

[0053] The first switching switch 121 is a dual power input selection switch (automatic or manual) used to select whether the power supply is provided by the first power supply module 122 and / or the second power supply module 123. The first power supply module 122 and the second power supply module 123 can operate in parallel. Under normal conditions, they can share the load equally; when either module fails, the other module can take over the entire load, ensuring uninterrupted power supply to the first controller 11. The first power supply module 122 can be powered by 380V AC mains, and the second power supply module 123 can be powered by a 380V UPS.

[0054] Electrical connectors that can be plugged and unplugged by hand are provided on the control circuit and status feedback circuit of the first switching switch 121, as well as the input, output, and monitoring signal circuits of the first power supply module 122 and the second power supply module 123. This allows the entire first power supply unit 12 or any module within it to be safely isolated and maintained while the other power supply unit is supplying power normally.

[0055] The first power supply unit 12 is connected to the chiller unit 10 through the first controller 11.

[0056] The second power supply unit 15 includes a first power supply module 122, a third power supply module 153, a first switch 152, and a second switching switch 151, and its power input terminal is connected to the first switching cabinet 13.

[0057] The second switching switch 151 serves as the main input switch for this unit. The first power supply module 122 is connected to the second switching switch 151 via the first switch 152, and the third power supply module 153 is directly connected to the second switching switch 151. After the outputs are combined, they form the main output of this unit, which is sent to the chiller unit 10. The first power supply module 122 and the third power supply module 153 within the unit can be considered as parallel redundant power conversion links, improving the reliability of this channel itself.

[0058] Plug-in connectors are integrated into the control circuits of all switches (151, 152) and the monitoring circuits of each power supply module (122, 153) in this unit. When this unit requires overall maintenance or any of its internal components needs to be replaced, the first power supply module 122 can be switched to be powered by the third power supply module 153, and then the unit can be safely isolated.

[0059] The third power supply unit 16 includes a first power supply module 123, a third power supply module 153, a third switch 162, and a third switching switch 161, and its power input terminal is connected to the first switching cabinet 13.

[0060] The first switching cabinet 13 may include a switching cabinet body 131 and a switch 132 located inside the switching cabinet body 131, through which the second switching switch 151 and the third switching switch 161 are connected to the chiller unit 10.

[0061] The third switching switch 161 serves as the main input switch for this unit. Its internal structure is mirror-symmetrical to that of the second power supply unit 15, and its output is also sent to the chiller unit 10. Its principle is exactly the same as that of the second power supply unit 15, forming the second backup power supply link of the system.

[0062] The first switch 152, the third switch 162, the second switching switch 151 and the third switching switch 161 can be placed in the second switching cabinet 14.

[0063] This system incorporates multiple safeguards: the first controller 11 can automatically switch between the first power supply module 122 and the second power supply module 123 to address corresponding risks; the first switching cabinet 13 can switch between the second power supply unit 15 and the third power supply unit 16; and for the contents of the second power supply unit 15 and the third power supply unit 16, switching can also be achieved between the first power supply module 122 and the third power supply module 153. Standardized, manually operable pluggable electrical connectors are uniformly deployed on the secondary control, monitoring, and signal loops of every critical functional node in the entire power supply chain (whether it's a path selection switch or a power conversion module). This pluggable design allows maintenance personnel to safely, quickly, and systematically isolate any component in the system without interrupting power supply, thereby efficiently completing various online maintenance scenario demonstrations in TCCF certification and greatly simplifying daily maintenance operations.

[0064] Figure 3 Its in Figure 2Based on the system shown, key enhancements have been made. By introducing a bus tie circuit breaker 17, a controllable electrical connection is established between the second power supply unit 15 and the third power supply unit 16. This enables flexible allocation and mutual backup of power resources on the basis of a "multi-bus" architecture, further improving the system's power supply guarantee capability under extreme operating conditions and the convenience of online maintenance operations. The core of the system still consists of three power supply units, providing a highly available power supply for the first controller 11, and adds key interconnection devices.

[0065] The bus tie circuit breaker 17 is connected between the output bus of the first switch 152 of the second power supply unit 15 and the output bus of the third switch 162 of the third power supply unit 16.

[0066] When a power supply unit (such as the second power supply unit 15) is out of service due to a fault or maintenance, the bus tie circuit breaker 17 can be closed, and another power supply unit (such as the third power supply unit 16) can continue to supply power to the load through bus linkage, thus avoiding power outage caused by a single unit failure.

[0067] Under normal operating conditions, the bus tie circuit breaker 17 can be opened or closed according to the load conditions to realize dynamic load distribution or transfer between the two units, thereby improving the economy and flexibility of system operation.

[0068] The introduction of bus tie circuit breakers enables the system to maintain power supply continuity through electrical linkage even in the event of a single power source, a single power supply unit, or even a single switching path failure, forming a dual protection mechanism of "inter-unit redundancy + inter-unit mutual backup".

[0069] The bus tie circuit breaker provides an electrical interface and topology basis for future system expansion (such as adding a fourth power supply unit) or operation mode reconfiguration (such as segmented operation or parallel operation).

[0070] This system establishes multiple layers of protection through multi-level switching and bus-connected mutual backup: First layer: The first controller 11 can automatically switch between the first power supply module 122 and the second power supply module 123; Second layer: Switching between the second power supply unit 15 and the third power supply unit 16 is achieved through the first switching cabinet 13; The third layer: Within each power supply unit, the switching between the first power supply module and the third power supply module is realized; Fourth layer: Electrical backup and load transfer between power supply units are achieved through bus tie circuit breaker 17.

[0071] Standardized, pluggable electrical connectors that can be operated by hand are deployed on the secondary control, monitoring, and signal circuits of key functional nodes throughout the power supply chain (including switches, power supply modules, and bus tie circuit breakers). This design supports online logic isolation, enabling maintenance personnel to safely and quickly maintain or replace any component without interrupting power supply. It fully meets the online maintenance demonstration requirements of TCCF certification and greatly simplifies daily maintenance operations.

[0072] Figure 4 -exist Figure 3 Building upon the existing foundation, the system is further expanded. It not only retains the multi-bus redundant power supply architecture but also introduces a reactor starter cabinet 18 and a reactor 19 for the chiller unit 10 to support the smooth start-up and operational protection of high-power motors. The system continues to employ a "multi-bus input, end-redundancy" design to provide highly reliable power supply for the chiller unit and its controller, and adds a start-up control stage to adapt to the start-up characteristics and protection requirements of high-power loads.

[0073] This system introduces a reactor starter cabinet 18 and a reactor 19 into the power supply circuit of chiller unit 10. Their functions are as follows: Reactor starter cabinet 18: Provides soft-start control for the high-power motors of chiller unit 10, limiting starting current and reducing impact on the power grid and mechanical system. It can integrate frequency converters, protection relays, control logic units, etc., to achieve automation and monitoring of the startup process.

[0074] Reactor 19: Connected in series in the main circuit of the motor, it achieves smooth starting through inductive current limiting. After starting, it can be short-circuited by a bypass contactor to reduce operating losses. It can also be used for harmonic suppression or power factor compensation to improve power quality.

[0075] The normal power supply path is as follows: the first power supply unit 12 is the main power supply path, which provides control power to the reactor starter cabinet 18 through the first controller 11 and provides main power to the chiller unit 10.

[0076] Redundancy switching logic: The first power supply unit 12 can switch between the first power supply module 122 and the second power supply module 123; it can switch between the second power supply unit 15 and the third power supply unit 16 through the first switching cabinet 13; each unit also has the ability to switch between modules.

[0077] Start-up control process: First controller 11 sends start command → Reactor start cabinet 18 receives command → Reactor 19 is put into operation to limit start-up current → Motor gradually accelerates → After reaching rated speed, bypass reactor → Enter normal operation state.

[0078] By centrally installing standardized plug-in interfaces (integrated into the "maintenance interface panel" of each cabinet) on the power supply or signal source side of these circuits, maintenance personnel can safely and quickly isolate any single-point device in the chiller control subsystem or reactor starting subsystem from the control logic for testing or maintenance without interrupting the operation of another subsystem or other redundant paths. This provides a clear and feasible technical solution for refrigeration systems containing large reactor starting equipment to meet the "simultaneous maintainability" requirement in TCCF certification.

[0079] Figure 5 The power supply circuit of chiller unit 10 integrates a reactor starter cabinet 18, a reactor 19 for motor soft starting, and a comprehensive protector 20 for system-level electrical protection and monitoring. This system provides highly reliable energy security for the core refrigeration equipment throughout the entire process from power supply and startup to operational protection.

[0080] The integrated protector 20 has been newly added. Located between the output of the first switching cabinet 13 and the chiller unit 10, the integrated protector 20's main functions are: System-level electrical protection: providing comprehensive electrical protection against overcurrent, short circuit, overvoltage, undervoltage, and grounding faults. Operational status monitoring: real-time monitoring of power supply voltage, current, power, power quality, and other parameters, and uploading the data to the first controller 11 or the higher-level monitoring system. Fault recording and analysis: recording historical fault events and electrical parameters, supporting fault tracing and preventative maintenance. Interlocking control: able to interlock with the first controller 11 and the reactor starter cabinet 18 to perform orderly shutdown or switching operations in case of electrical abnormalities.

[0081] By providing pluggable interfaces on the control power supply or signal source side of these circuits and integrating them into the maintenance interface panels of each cabinet, maintenance personnel can safely and quickly isolate and repair any component (such as the integrated protector 20) in the high-power motor drive subsystem without stopping motor operation (in redundant configuration) or affecting the operation of the chiller unit control subsystem. This greatly enhances the flexibility and safety of refrigeration systems containing large reactor starting equipment in TCCF certification and daily operation and maintenance.

[0082] Figure 6 for Figure 5 This is a typical engineering implementation plan. The figure shows the complete power supply path from high-voltage mains power to low-voltage load power supply. By combining high-voltage side automatic switching with low-voltage side ATS switching, a power supply system with multiple redundancies, automatic switching and comprehensive protection functions is constructed.

[0083] The system adopts a dual power input architecture of "10kV high voltage main supply + 380V low voltage backup". It achieves automatic switching between high voltage and low voltage through two-stage ATS (automatic transfer switch) to ensure the reliability of power supply throughout the entire path from the power grid to the load.

[0084] High-voltage power supply section: 10kV mains power: the main power source, from the high-voltage lines of the power grid. 10kV mains switches (multiple): used for connecting, disconnecting, and protecting high-voltage circuits, usually vacuum circuit breakers equipped with relay protection devices.

[0085] 10kV Automatic Switchgear: Its core function is to automatically switch between two 10kV power sources. When the primary 10kV power source fails or malfunctions, the automatic switchgear will switch the load to the backup 10kV power source.

[0086] Step-down and low-voltage power supply section (380V side): Transformer: Reduces the 10kV high voltage to 380V low voltage to supply power to the chiller unit and control system.

[0087] ATS Dual Power Switch (Low Voltage Side): Serves as the core switching device for low voltage power supply.

[0088] The two input power sources are typically: one is a 380V power source obtained by stepping down 10kV AC mains power, and the other is an independent 380V AC mains power source or a 380V UPS.

[0089] The system monitors the status of both power supplies in real time and automatically switches to the backup power supply when the main power supply is abnormal, ensuring uninterrupted operation of the load.

[0090] 380V AC power: One of the low-voltage backup power supplies, which can be used as a second AC power source or come from a diesel generator.

[0091] 380V UPS: Uninterruptible power supply, providing millisecond-level switching time and short-term backup power to cope with momentary interruptions or voltage dips.

[0092] Chiller unit: The core refrigeration equipment, which is the main power load.

[0093] Control center corresponds to Figure 5 The first controller 11 is responsible for the operation control, status monitoring and linkage with the power supply system of the chiller unit.

[0094] Integrated protector corresponds to Figure 5 The integrated protector 20 provides electrical protection such as overcurrent, short circuit, and grounding, as well as system monitoring on the low-voltage side.

[0095] The first power supply unit 12 consists of a low-voltage main and backup redundant power supply channel composed of 380V mains power, 380V UPS and ATS.

[0096] The second / third power supply unit forms a high-voltage side redundancy and automatic switching channel through 10kV mains power and automatic switching cabinet.

[0097] The first switching cabinet 13 achieves automatic selection of two low-voltage power supplies through the ATS dual power switch and control logic.

[0098] The integrated protector 20 enables system-level electrical protection and monitoring.

[0099] The reactor starter cabinet 18 / reactor 19 is a soft starter for the motor of the chiller unit.

[0100] The first controller 11 is used for coordinated control of the unit and power supply.

[0101] The high-voltage side (10kV automatic switching), the low-voltage side (ATS switching), and the UPS backup form a triple protection system.

[0102] High-voltage main power supply side: First 10kV mains line and second 10kV mains line: These represent two independent 10kV high-voltage mains power supplies from different substations or different busbars of the same substation, constituting redundancy on the power input side. First 10kV mains switch and second 10kV mains switch: These correspond to the main isolating and protection switches for the two 10kV incoming lines, typically high-voltage circuit breakers.

[0103] High-voltage automatic switching and protection layer: ATS (Automatic Transfer Switch) dual power switch: An automatic transfer switch used for automatic or manual switching between two high-voltage power sources, ensuring rapid switching to the other power source in case of a failure in one power source. Automatic transfer switch cabinet: A cabinet for automatically transferring backup power. In a high-voltage system, when the main high-voltage power supply fails, this device automatically controls the relevant switches to switch the load to the backup high-voltage power source. 10kV automatic transfer switch cabinet: As the core execution part of the automatic transfer switch cabinet, it contains control logic and drive mechanisms to perform the opening and closing operations of the high-voltage circuit breaker to achieve power switching. Integrated protector: A microcomputer-based integrated protection device for high-voltage lines or transformers, providing overcurrent, instantaneous overcurrent, and grounding protection functions, and can upload fault signals.

[0104] The transformer connects between the high-voltage and low-voltage sides, stepping down the 10kV voltage to 380V / 220V for downstream equipment. 380V AC Busbar: The low-voltage mains busbar obtained after the transformer step-down. 380V UPS Input: The AC input interface of the uninterruptible power supply system, connected to the 380V AC busbar. When the AC power is normal, it provides energy to the UPS system and stores energy.

[0105] Emergency Backup Power Side: Diesel Generator: The core emergency power supply for the data center, activated when the mains power is completely interrupted to power critical loads. Diesel Generator Switch: The control and protection switch at the generator output. ATS Dual Power Switch: A critical automatic transfer switch located on the low-voltage side. It has two inputs: one from the 380V UPS output or purified power from the mains power after passing through the UPS (extended from the 380V UPS input in the diagram), and the other directly from the diesel generator output. This switch is responsible for switching between normal mains / mains-UPS power and emergency generator power.

[0106] Final power receiving load: Cooling unit control center: Represents the core control load of the refrigeration system, for example... Figure 2 and Figure 3 The first controller 11, the first power supply unit 12, and their switching cabinet shown are integrated control cabinets or systems that provide final power and signal interfaces. Internally, they contain all the logic controllers, PLCs, human-machine interfaces, and auxiliary power supplies required to control equipment such as chillers, water pumps, and cooling towers.

[0107] Figure 6 This describes a power supply guarantee chain with multiple redundancies, from high voltage to low voltage and from primary to backup. Its core logic is as follows: two high-voltage mains power supplies achieve high-voltage side redundancy through an automatic transfer switch (ATS); after voltage reduction, the low-voltage mains power and diesel generator achieve low-voltage side redundancy through an ATS, and supply power to the UPS system, ultimately ensuring the power supply continuity of the cooling unit control center.

[0108] In order to achieve Figure 6 The online maintainable isolation of all critical electrical nodes (such as switches, control cabinets, and protection devices) is achieved, and the pluggable electrical connection device described in this application is deployed on the following critical secondary circuits: High-voltage side control circuits: such as the control power supply, status feedback, and remote start / stop signal circuits of the 10kV automatic switching cabinet inside the automatic transfer switch; and the communication and alarm signal circuits of the integrated protector.

[0109] Low-voltage side control and signal circuits: such as ATS dual power switch status indication, fault signals, and automatic / manual switching control circuits.

[0110] Diesel generator control circuit: such as diesel generator start command, speed / voltage / oil pressure status monitoring, and parallel control signal circuit.

[0111] Core load monitoring loop: All communication, telemetry, and remote control signal loops between the cooling unit control center and the upper-level monitoring system.

[0112] By centrally configuring pluggable interfaces on the control power supply side or signal source end of these circuits, maintenance personnel can safely and quickly isolate equipment from the control and monitoring network for testing or maintenance without affecting the overall power supply continuity of the system. This is especially crucial for demonstrating complex scenarios such as mains power failure, diesel generator operation under load, and isolation of a high-voltage switch or ATS device during TCCF certification demonstrations.

[0113] Figure 7 Inheriting the core design of multi-level redundant power supply and soft-start control, it adds power distribution device 22, cooling tower system and automatic water replenishment device, forming a closed-loop, high-availability engineering system from power receiving from the grid to the final heat dissipation.

[0114] The power distribution unit 22 is not a single cabinet, but a comprehensive power distribution unit that includes high-voltage power receiving, transformer protection and low-voltage power distribution functions. It is the interface between this system and the external power grid and the dispatch center of internal energy.

[0115] Transformer 222 serves as the voltage transformation and system power source, used to reduce the 10kV medium-voltage power from the grid to the 380V / 220V low-voltage required by the entire refrigeration system and auxiliary equipment. Dry-type transformers are typically equipped with core functional components such as temperature control devices, fans, and intelligent monitoring systems to achieve temperature monitoring, automatic cooling, and operational protection.

[0116] As a low-voltage main distribution cabinet, the distribution cabinet 221 receives 380V power from the transformer 222, performs total metering and protection, and then distributes power radially to the following key circuits to the first power supply unit 12 and the dual power supply cabinet 21, which can supply power to equipment such as cooling tower fans, water pumps and water replenishment devices.

[0117] Cooling tower 210 removes heat from the chiller unit's condenser through water evaporation.

[0118] The dual power supply cabinet 21 provides two independent 380V power inputs for the cooling water pump and cooling tower fan.

[0119] Both power supply cabinets integrate automatic transfer switches (ATS), which automatically and seamlessly switch to the backup power supply when the main power supply fails, ensuring that the cooling system is never interrupted. This is a key design feature to prevent the chiller unit from tripping due to heat dissipation failure.

[0120] The water replenishment device 23 automatically replenishes the water lost due to evaporation, dispersion, and sewage discharge to the cooling water circulation system and cooling tower water collection basin, maintaining the normal operating water level of the system.

[0121] The water supply device 23 may include a water supply pump 231 and a frequency converter control cabinet 232. The water supply pump 231 delivers water from the water storage tank into the system.

[0122] To achieve online maintainable isolation of each critical node in the diagram, the pluggable electrical connection device of this application is systematically and comprehensively deployed on all the following secondary circuits: Existing equipment circuits include the first controller 11, the first power supply unit 12, each switching cabinet (13, 14) and switch (121, 151, 152), and all control, monitoring and communication circuits in the reactor start cabinet 18.

[0123] Heat dissipation system circuit: all control and signal lines of cooling tower 210, including fan start / stop control, frequency conversion speed regulation signal, water temperature monitoring, vibration alarm, etc.

[0124] Power distribution system circuits: status signals of each outgoing circuit of distribution cabinet 221, power metering signals, and communication interface with the upper-level power monitoring system.

[0125] Water system loop: pressure sensor signal of water supply device 23, start / stop control, frequency setting, operation feedback, fault alarm and other signal lines of frequency converter control cabinet 232, as well as its communication link with building automation system (BAS).

[0126] By uniformly deploying standardized pluggable interfaces (integrated into the "maintenance interface panel" of each equipment cabinet) on the control side or signal source end of all the above circuits, Figure 7 Any component within the entire data center cooling system represented by this application can be safely, quickly, and systematically isolated and maintained without affecting the normal operation of other subsystems. The online maintainable isolation solution provided in this application can systematically meet the stringent requirements for "simultaneous maintainability" in TCCF certification and full lifecycle operation and maintenance of a complex, integrated data center cooling system.

[0127] Figure 8 exist Figure 7 Based on this, the first dual power supply cabinet 211, the second dual power supply cabinet 212, and the corresponding first frequency converter control cabinet 832 and second frequency converter control cabinet 842 drive the first water supply pump 831 in the first water supply system 83 and the second water supply pump 841 in the second water supply system 84, respectively, thereby realizing independent, efficient and highly reliable control of the two cooling circuits (cooling tower 210 and the corresponding cooling tower system).

[0128] To achieve online maintainable isolation of every component in such a complex system, the pluggable connection device of this application must be deployed systematically and without blind spots: All power supply and control units include: the first power supply unit 12, the second power supply unit 15, the first / second switching cabinet (13, 14), the third power supply module 153, and the internal status monitoring, inter-module communication, and external communication loops of the second power supply module 122.

[0129] All intelligent switches and cabinets: ATS control logic, position signals, and fault alarm circuits of the first switching switch 121, the second switching switch 151, the first switch 152, the first dual power supply cabinet 211, and the second dual power supply cabinet 212.

[0130] All equipment controllers: the control core of the first controller 11, the reactor starter cabinet 18, and all control and signal interfaces of the first frequency converter control cabinet 832 and the second frequency converter control cabinet 842.

[0131] All protection and actuators: the communication port of the integrated protector 20, the start / stop and feedback signal lines of the first water pump 831 and the second water pump 841.

[0132] Inter-system communication bus: a key node connecting all communication links (such as Ethernet, RS485) between each subsystem and the central monitoring system (such as BAS, SCADA).

[0133] By setting standardized pluggable interfaces at the source (power supply side, signal transmission side) of each of the above secondary circuits, Figure 8 Any numbered component in the ultra-complex cooling system represented can be safely, quickly, and systematically "logically removed" and maintained without interrupting the operation of any other parts. This diagram ultimately and concretely demonstrates that the online maintainable isolation solution proposed in this application is an essential key technology supporting the rigorous TCCF certification and efficient operation and maintenance of complex infrastructure in modern Tier III / IV data centers.

[0134] Based on the same inventive concept, this application also provides an online maintainable isolation control system for a data center cooling system, the structure of which can be referred to... Figure 2-8 As shown, it can specifically include: First power supply module 122 and second power supply module 123; The first switching switch 121 has its input terminal connected to the output terminals of the first power supply module 122 and the second power supply module 123 respectively, and is used to select one of them to supply power to the load. The input, output, and monitoring circuits of the first power supply module 122 and the second power supply module 123, as well as the control and feedback circuit of the first switching switch 121, are all equipped with hand-pluggable electrical connectors.

[0135] In some embodiments, the device further includes an electrician 9 and a reactor starter cabinet 18; The input terminal of the reactor starter cabinet 18 is connected to the output terminal of the first switching cabinet 13 and / or the second switching cabinet 14, and the output terminal of the reactor starter cabinet 18 is connected to the electric motor 9; The control signal circuit of the reactor starter cabinet 18 is connected in series with the hand-pluggable electrical connector.

[0136] In some embodiments, the first power supply module 122, the second power supply module 123 and the first switching switch 121 constitute a first power supply unit 12 for supplying power to the load; It also includes at least one second power supply unit 15, whose input is connected to an external power source and whose output is connected to the load through a first switching cabinet 13; The first switching cabinet 13 is equipped with a switch 132 for switching between the power supply paths of the first power supply unit 12 and the second power supply unit 15.

[0137] In some embodiments, a third power supply unit 16 with the same structure as the second power supply unit 15 is also included; The switch 132 in the first switching cabinet 13 is also used to switch between the second power supply unit 15 and the third power supply unit 16.

[0138] In some embodiments, a bus tie circuit breaker 17 is provided between the output buses of the second power supply unit 15 and the third power supply unit 16.

[0139] The integrated protector 20 has its input terminal connected to the total output terminal of the multi-redundant power supply system, and is used to monitor and protect the output power. The input terminal of the reactor starter cabinet 18 is connected to the output terminal of the integrated protector 20, and is used to drive the motor of the chiller unit 10; The first controller 11 is communicatively connected to the first switching switch 121, the first switching cabinet 13 and the integrated protector 20, and is used to coordinate and control power supply switching, system protection and unit operation.

[0140] In some embodiments, it also includes: The power distribution device 22 includes a transformer 222 and a power distribution cabinet 221, which is used to convert the external high-voltage power supply into a low-voltage power supply and to supply power to the multi-redundant power supply system and cooling auxiliary equipment. Cooling tower 210; The dual power supply cabinet 21 has its input end connected to the power distribution cabinet 221 and its output end supplying power to the fan and water pump of the cooling tower 210. An automatic transfer switch is provided inside the cabinet. The water replenishment device 23 is connected to the circulating water system of the cooling tower 210 and is used to automatically replenish cooling water; the input end of the frequency converter control cabinet 232 is connected to the power supply, and the output end is connected to the water replenishment pump 231 to control its speed; the water replenishment pump 231 is connected to the water replenishment device 23; the hand-pluggable electrical connector is connected in series in the control signal circuit of the frequency converter control cabinet 232 and / or the liquid level or pressure signal circuit of the water replenishment device 23.

[0141] In some embodiments, the pluggable electrical connector is a pluggable terminal block, comprising a mating male connector and a female socket.

[0142] The male connector includes an insulating shell, conductive pins disposed therein, and elastic clips disposed on both sides of the shell. The female socket includes an insulating base, a conductive sleeve disposed therein and matched with the conductive pin, and a snap-lock groove for locking by the elastic snap. The male connector and the female socket have mating surfaces with mutually cooperating anti-misinsertion guide structures.

[0143] In the embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. The apparatus embodiments described above are merely illustrative. For example, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. Furthermore, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Additionally, the displayed or discussed mutual couplings, direct couplings, or communication connections may be through some communication interfaces; indirect couplings or communication connections between devices or units may be electrical, mechanical, or other forms.

[0144] Furthermore, the units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0145] Furthermore, the functional modules in the various embodiments of this application can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0146] It should be noted that if the function is implemented as a software functional module and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0147] In this document, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, without necessarily requiring or implying any such actual relationship or order between these entities or operations.

[0148] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. An online maintainable isolation control system for data center cooling systems, characterized in that, include: First power supply module (122) and second power supply module (123); The first switching switch (121) has its input terminal connected to the output terminals of the first power supply module (122) and the second power supply module (123) respectively, and is used to select one of them to supply power to the load; Among them, the input, output and monitoring circuits of the first power supply module (122) and the second power supply module (123), as well as the control and feedback circuit of the first switching switch (121), are all equipped with electrical connectors that can be plugged in and unplugged by hand.

2. The control system according to claim 1, characterized in that, The first power supply module (122), the second power supply module (123) and the first switching switch (121) constitute the first power supply unit (12) for supplying power to the load; it also includes at least one second power supply unit (15), whose input end is connected to an external power source and whose output end is connected to the load through the first switching cabinet (13); The first switching cabinet (13) is equipped with a switch (132) for switching between the power supply paths of the first power supply unit (12) and the second power supply unit (15).

3. The control system according to claim 2, characterized in that, It also includes electric motors (9) and reactor starter cabinets (18); The input terminal of the reactor starter cabinet (18) is connected to the output terminal of the first switching cabinet (13), and the output terminal of the reactor starter cabinet (18) is connected to the electric motor (9); The control signal circuit of the reactor starter cabinet (18) is connected in series with the hand-pluggable electrical connector.

4. The control system according to claim 2, characterized in that, It also includes a third power supply unit (16) with the same structure as the second power supply unit (15); The switch (132) in the first switching cabinet (13) is also used to switch between the second power supply unit (15) and the third power supply unit (16).

5. The control system according to claim 4, characterized in that, A bus tie circuit breaker (17) is provided between the output bus of the second power supply unit (15) and the third power supply unit (16). Also includes: The integrated protector (20) has its input terminal connected to the total output terminal of the second power supply unit (15) and the third power supply unit (16) for monitoring and protecting the output power; The input terminal of the reactor starter cabinet (18) is connected to the output terminal of the integrated protector (20) for driving the motor of the chiller unit (10); The first controller (11) is communicatively connected to the first switching switch (121), the first switching cabinet (13) and the integrated protector (20), and is used to coordinate and control power supply switching, system protection and unit operation.

6. The control system according to claim 5, characterized in that, Also includes: The power distribution device (22) includes a transformer (222) and a distribution cabinet (221) for converting external high-voltage power to low-voltage power and supplying power to the control system; Cooling tower (210); A dual power supply cabinet (21) has its input end connected to the power distribution cabinet (221) and its output end supplying power to the fan and water pump of the cooling tower (210). An automatic transfer switch is provided inside the cabinet. The water replenishment device (23) is connected to the circulating water system of the cooling tower (210) for automatically replenishing cooling water; the input end of the frequency converter control cabinet (232) is connected to the power supply, and the output end is connected to the water replenishment pump (231) for controlling its speed; the control signal circuit of the frequency converter control cabinet (232) and / or the liquid level or pressure signal circuit of the water replenishment device (23) are connected in series with the hand-pluggable electrical connector.

7. The control system according to claim 1, characterized in that, The pluggable electrical connector is a pluggable terminal block, comprising a mating male connector and a female socket.

8. The control system according to claim 7, characterized in that, The male connector includes an insulating shell, conductive pins disposed therein, and elastic clips disposed on both sides of the shell.

9. The control system according to claim 8, characterized in that, The female socket includes an insulating base, a conductive sleeve disposed therein and mating with the conductive pin, and a snap-lock groove for locking by the elastic snap.

10. The control system according to claim 7, characterized in that, The male connector and the female socket have mating surfaces with mutually cooperating anti-misinsertion guide structures.

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