Airedale, a UK-based critical systems cooling specialist, has launched its Cooling System Optimizer (trademarked) in the US.
Airedale is part of Modine, a US-based thermal management company.
The launch in the US was in response to the demand in the data centre industry for sustainable, stable, and secure cooling systems.
The Cooling System Optimizer was first launched in Europe in 2022 and able to manage chilled water loops of up to 20MW and beyond.
Airedale told Cleanroom Technology that the new optimiser can offer up to 45% energy savings.
Demand for the Optimizer has grown as data centre providers adopt larger, more complex cooling systems.
Airedale has launched its Cooling System Optimizer in the US
The Optimizer is an intelligent controls layer that sits between product controls in chillers and CRAHs and below the site building management system (BMS).
It is programmed to unify indoor and outdoor cooling equipment to proactively manage the three most important things in any data centre cooling system: resilience, redundancy and energy use.
The spokesperson also explained that the system's design has been futureproofed to be fully compatible with loT (Internet of Things) and machine learning for in-depth analysis.
Leveraging the benefits of primary ring chilled water cooling systems as well as remaining compatible with primary/secondary systems, the Optimizer is designed to manage dynamic variable flow systems to consistently deliver on critical SLAs, at the lowest possible energy input.
Further, equipment outages as a result of power issues, network storms, and communication losses, are the scourge of many data centres.
The client was challenged to ‘break’ the system in the ways that are experienced on live sites
The Cooling System Optimizer has been developed with this in mind, with the built-in ability to effectively manage equipment drop-outs in a much quicker and efficient way than a standard BMS.
Residing in standard and proven PLC-based controllers, it is highly redundant and compatible with external ICT security networks.
In a recent factory acceptance test for a global data centre provider, the Optimizer was simulated on a 10MW loop comprising 7 chillers and twenty-four fan walls, with the client’s own security network.
The client was challenged to ‘break’ the system in the ways that are experienced on live sites. Despite their determined efforts, they were unable to disrupt the robust functionality of the system.
Airedale controls systems manage over 200MW of data centers across Europe and that is only set to grow, with the Optimizer proving extremely popular in larger data centers with variable flow cooling systems
Delivery of Optimizer systems in the US will be managed by a new, dedicated controls team based out of the North America Data Center headquarters in Rockbridge in Virginia.
Backed by the global controls team in the UK, the US team will work with product teams to deliver software solutions for data centre providers.
These solutions will eventually encompass all aspects of building management, remote monitoring and predictive maintenance.
Leveraging the benefits of primary ring chilled water cooling systems as well as remaining compatible with primary/secondary systems, the Optimizer is designed to manage dynamic variable flow systems to consistently deliver on critical SLAs, at the lowest possible energy input
Challenges with a standard BMS
Data centre cooling systems are larger and more complex than ever. Managing all the components and variables using a standard Building Management System (BMS) is no longer viable in an industry that demands resilience and redundancy at the lowest possible energy input.
One core issue is that a BMS, whilst still needed for overall monitoring and reporting, is not designed for precise control of complex systems.
Data center cooling systems are larger and more complex than ever
A BMS mostly pushes data, and isn’t capable of addressing the anomalies that it identifies. It can’t make the necessary changes to optimise the system. With a BMS, redundancy is not built in.
As cooling plants get larger and more numerous, this is key to ensuring that cooling requirements are met, and the load is evenly balanced across the system.
Key factors for data center cooling systems
In reality, with data centre cooling only three things matter, and individual computer room air handlers (CRAHs), chillers, pumps, and valves should all be modulated in harmony to deliver the above.:
- Small positive pressure at the front of server rack, so air is drawn through server.
- Correct temperature at the server, according to the Service Level Agreement (SLA).
- Ensuring points 1 and 2 while maintaining resilience and redundancy, at the lowest possible energy input
Redundancy
Data centres are considered critical infrastructure and have to be designed to withstand multiple failures. The Cooling System Optimizer has a built-in failover strategy. it does not reside on one controller alone. Each controller can smoothly migrate control to the next one in case of failure or maintenance.
This guarantees that cooling is always available and minimises disruption in case of failure. Where communication is lost with a chiller Optimizer controller, the chiller will revert to stand-alone control via the local product controller.
Data centers are considered critical infrastructure and have to be designed to withstand multiple failures
The chiller fixes pump speed at this point to achieve the required design flow-rate and cooling demand is managed locally to ensure the design chilled water flow temperature is achieved.
The remaining active Optimizer controllers control the system low-flow bypass valves to the required pre-defined differential pressure setpoint, to ensure design flow-rate is achieved by the chiller.
At a glance
At a glance, the Cooling System Optimizer has many practical features, including:
- Up to 45% energy savings: Lower cost of ownership can be achieved, both in running and maintenance costs thanks to the use of latest technologies and full redundancy. Free cooling is maximised
- Lower Maintenance Costs: Demand is balanced across all chillers and CRAHs with no fixed leading unit, distributing the load evenly and avoiding excessive wear and tear. Full redundancy and the option of remote support leads to fewer call-outs.
- Maximum Operating Efficiency: Leveraging the benefits of variable flow chilled water systems, the Optimizer increases cooling efficiency by running components at their most effective and efficient operating points. Chilled water flow through the chillers and CRAHs are constantly modulated.
- Full Redundancy: Failover strategy is built into the Optimizer, so each controller can smoothly migrate control to the next one, providing redundancy and eliminating the risk of downtime.
- Standardised solution: Cooling System Optimizer is essentially an off-the[1]shelf solution, with minimal requirement for tailor-made programming to individual sites. It uses standard PLC-based controllers and works with existing unit controllers in the cooling units.
- Futureproof: Fully compatible with loT (Internet of Things) and machine learning for in-depth analysis.
- Free cooling: A fully integrated control strategy enables the chillers to operate on a reduced water flow rate during free cooling operation, sensibly increasing the efficiency of water coils and pumps.
Reece Thomas, Controls Director at Airedale said, “The US is an incredibly important market for us and we are seeing increasing demand for more intelligent software. Airedale controls systems manage over 200MW of data centres across Europe and that is only set to grow, with the Optimizer proving extremely popular in larger data centres with variable flow cooling systems.”
“With a dedicated US controls team, we can support our local and global customers with the high levels of service we are renowned for. The Optimizer has been incredibly well received in the industry, as many operators struggle to manage increasingly complex cooling systems with out-of-the-box BMS solutions,” Thomas added.
“They are relieved to find a proven robust solution that is compatible with end-user ICT security systems, that takes on the responsibility of keeping cooling systems up and running while keeping energy bills down,” Thomas concluded.
Top image: Airedale's Cooling System Optimizer (trademarked)