BUSWAY CONNECTION THROUGH EXTERIOR WALL

A modular data center includes an outer wall having an opening formed therein. The opening is configured to enable a busway to pass through the outer wall. The modular data center further includes an electrical box configured to be coupled to the busway. The electrical box is positioned inboard with respect to the outer wall. The modular data center further includes a shroud configured to extend through the opening of the outer wall. The shroud includes a plurality of outer edges coupled to an outer surface of the outer wall. The modular data center further includes a cover, including a cover opening, configured to enable the busway to pass through the cover opening, and to at least partially seal the opening of the outer wall having the busway passing therethrough.

BACKGROUND OF DISCLOSURE

1. Field of Disclosure

This disclosure is directed to busways used in data centers, and more particularly to a system and method of extending a busway through an outer or exterior wall of a facility, such as a data center or a modular data center.

2. Discussion of Related Art

Busway electrical distribution systems are well known in the art of electrical distribution. Busway systems are comprised of a number of factory-assembled sections, each including a number of individually insulated generally flat electrical conductors or busbars stacked one upon another and enclosed within a housing which provides protection and support for the busbars. For example, typical powerbus busway systems have ten-foot (or four-foot) sections of flat, stacked, electrical conductors for transporting electrical energy from a point A to a point B, while distributing the electrical energy to various electrical loads. Busway construction is modular, and, in many ways, is superior to cable and conduit systems from an installation standpoint.

Typically, a busway can be used internally within a facility or externally to supply power to a facility, such as a data center or a modular data center. Although the busway can pass through a closed wall section of the facility, the busway is not typically terminated at the interface. Further, the busway is typically not rated to go through a closed wall section of the facility.

SUMMARY OF DISCLOSURE

One aspect of the present disclosure is directed to a modular data center comprising an outer wall having an opening formed therein. The opening is configured to enable a busway to pass through the outer wall. The modular data center further comprises an electrical box configured to be coupled to the busway. The electrical box is positioned inboard with respect to the outer wall. The modular data center further comprises a shroud configured to extend through the opening of the outer wall. The shroud includes a plurality of outer edges coupled to an outer surface of the outer wall. The modular data center further comprises a cover, including a cover opening, configured to enable the busway to pass through the cover opening, and to at least partially seal the opening of the outer wall having the busway passing therethrough.

Embodiments of the modular data center further may include configuring the shroud with a plurality of walls that extend in a direction generally perpendicular to the plurality of outer edges. The plurality of outer edges may be configured to extend in an outboard direction with respect to the outer wall. A bottom wall of the plurality of walls of the shroud may be sloped downwardly toward the plurality of outer edges. Inner surfaces of the plurality of outer edges each may include a seal configured to engage the outer surface of the outer wall. The shroud further may include a plurality of inner edges configured to be coupled to the electrical box. The plurality of inner edges may be configured to extend in an inboard direction with respect to the outer wall. The cover may be configured to be secured to the plurality of outer edges of the shroud. The cover opening may be sized to receive the busway. The cover opening may include a gasket to create at least a partial seal between the busway and the cover. The cover further may include at least one slider plate mounted on the cover adjacent an edge of the opening. The at least one slider plate may be configured to improve the seal between the busway and the cover. The cover may include one or more small openings formed along a bottom edge of the cover. The modular data center further may include a shield secured to the outer wall and positioned over the busway. The shield may include a top wall and two side walls extending downwardly from the top wall. The modular data center further may include at least one heater secured to a wall of the shroud. The modular data center further may include a thermostat coupled to the at least one heater, the thermostat being configured to control the at least one heater. The at least one heater may include two heaters. The modular data center further may include a ceiling coupled to the outer wall, with the ceiling including at least one support member configured to support the electrical box. The modular data center further may include a clamp configured to secure the electrical box, with the clamp being coupled to the at least one support member to enable the electrical box slide with respect to the ceiling.

Another aspect of the present disclosure is directed to an assembly to protect a busway configured to be coupled to an electrical box, with the busway extending through an opening of an outer wall of a modular data center. In one embodiment, the assembly comprises a shroud configured to extend through the opening of the outer wall. The shroud includes a plurality of outer edges coupled to an outer surface of the outer wall. The assembly further comprises a cover, including a cover opening, configured to enable the busway to pass through the cover opening, and to at least partially seal the opening of the outer wall having the busway extending therethrough.

Embodiments of the assembly further may include configuring the shroud with a plurality of walls that extend in a direction generally perpendicular to the plurality of outer edges. The plurality of outer edges may be configured to extend in an outboard direction with respect to the plurality of walls. A bottom wall of the plurality of walls of the shroud may be sloped downwardly toward the plurality of outer edges. Inner surfaces of the plurality of outer edges each may include a seal configured to engage the outer surface of the outer wall. The shroud further may include a plurality of inner edges configured to be coupled to the electrical box. The plurality of inner edges may be configured to extend in an inboard direction with respect to the plurality of wall. The cover may be configured to be secured to the plurality of outer edges of the shroud. The cover opening may be sized to receive the busway. The cover opening may include a gasket to create at least a partial seal between the busway and the cover. The cover further may include at least one slider plate mounted on the cover adjacent an edge of the opening. The at least one slider plate may be configured to improve the seal between the busway and the cover. The cover may include one or more small openings formed along a bottom edge of the cover. The assembly further may include a shield secured to the outer wall and positioned over the busway. The shield may include a top wall and two side walls extending downwardly from the top wall. The assembly further may include at least one heater secured to a wall of the shroud. The assembly further may include a thermostat coupled to the at least one heater. The thermostat may be configured to control the at least one heater. The at least one heater may include two heaters.

DETAILED DESCRIPTION

Busways may be used to provide power to modules positioned within configurable racks located within the data center. A typical busway includes a sheet metal duct having resin insulated copper or aluminum busbars to conduct a substantial current of electricity.

Busways are used in many electrical power distribution devices, such as power modules, switching apparatus, distribution apparatus, and batteries. Oftentimes, busways are connected to busway cable tap boxes, which are used to draw power from the busways. In certain embodiments, the busway cable tap box is mounted on a ceiling and includes a busway splice joint which mates with the busway.

Modular data centers provide additional challenges. Previously, when installers of electronic equipment desired to run a busway to a modular data center, the installer was required to wait until the modular data center was delivered and then create an opening in an exterior wall of the modular data center. Also, the installer needed to create a watertight seal around the opening to ensure water was prohibited from entering the modular data center.

Next, the installer would be required to connect the busway to the equipment inside the modular data center, including a busway cable tap box, thereby requiring the installer to enter the modular data center. Sometimes, customers do not want to provide access to service personnel within the modular data center for a variety of reasons, including the prevention of damage caused by the installer when connecting cables to the equipment within the modular data center. In addition, switchgear can be tested and commissioned at the factory to save time at the customer site.

The present disclosure offers a solution that enables a continuation of a busway through an exterior wall while weatherproofing the opening through which the busway extends. Installers need not access inside the building thereby ensuring the protection of the facility and the cleanliness of the facility while allowing work to continue without the customer needing to be present.

Referring toFIG.1, a portion of a modular data center is generally indicated at10. In one embodiment, the modular data center10is a modular structure that is designed to house and support electrical equipment. As shown, the modular data center10includes a floor12, a wall14including several panels, and a ceiling16. In some embodiments, the modular data center10further includes a variety of electronic modules, e.g., switchgear18, supported by the floor12of the modular data center. Positioned outside the modular data center10are electrical equipment, such as a transformer20and a generator22. Although two units of electrical equipment20,22are shown and described herein, any number of units of equipment may be provided based on the size of the modular data center10. As shown, a busway24is connected to the transformer20to provide electrical connection between the transformer20and a cable tap box60(FIG.3). Similarly, another busway24is connected to the generator22to provide electrical connection between the generator and another cable tap box60provided within the modular data center10. There are openings in the wall14to enable the busways24to connect the transformer20and the generator22to their respective cable tap boxes.

Referring additionally toFIGS.2and3, the modular data center10further includes an assembly, generally indicated at30, that is provided to enable and protect the busway24as it passes through an opening32provided in the wall14of the modular data center. As shown, the assembly30includes a shroud, generally indicated at34, and a cover, generally indicated at36. The shroud34functions as a guide to enable the busway24to pass through the opening32and to connect to the cable tap box60. The cover36functions to enclose an opening created by the shroud34and to seal the opening to prevent unwanted moisture from entering the modular data center10. The assembly30further includes a shield, generally indicated at38, which is secured to the wall14of the modular data center10above the opening32. As its name implies, the shield38is provided to divert moisture, e.g., rain, from the opening32and the opening created by the shroud34and protected by the cover36thereby providing additional protection to the busway34and its connection to the cable tap box60provided within the shroud.

Referring toFIGS.4A-4C, the shroud34is a generally rectangular structure that is configured to extend through the opening32of the wall14of the modular data center10. As shown, the shroud34includes four side walls40a,40b,40c,40d, each having a relatively substantial width. The width of the side walls40a-40dis sufficient to enable the connection of the busway24to the cable tap box60. In the shown embodiment, side walls40a,40bare longer than side walls40c,40dto create a rectangular structure. However, it should be understood that the size and shape of the shroud34can be configured to achieve a desired size and shape to accommodate the size and shape of the busway24that extends through the opening32of the wall14. The shorter side walls40c,40deach can include a relatively small opening42formed therein to enable wires, e.g., wires for heater elements, to pass through the shroud34.

The shroud34further includes four outer edges44a,44b,44c,44d, one for each side wall40a,40b,40c,40d, respectively, which extend in an outboard direction generally perpendicular to their respective side walls. The outer edges44a-44dare welded or bent to their respective side walls40a-40dand positioned to engage and secure the shroud34to the outer surface of the wall14, with the side walls extending into an interior of the modular data center10. As shown, the outer edges44a-44dof the shroud34have a plurality of openings, each indicated at46, which are spaced apart from one another to secure the shroud to the wall14of the modular data center10. In one embodiment, screw fasteners (not shown) can be provided to secure the shroud34to the wall14. Further, the outer edges44a-44dof the shroud34have inner surfaces having a seal48that is configured to engage the outer surface of the wall14to seal the shroud to the wall. In a certain embodiment, a sealing tape may be applied to the inner surfaces of the outer edges44a-44dto seal the shroud34to the wall14.

The shroud34further includes four inner edges50a,50b,50c,50d, one for each side wall40a,40b,40c,40d, respectively, that extend in an outboard direction generally perpendicular to their respective side walls. The inner edges50a-50dare welded or bent to their respective side walls40a-40dand provided to engage and secure the shroud34to the cable tap box60, which is sometimes referred to herein as an electrical box. As with the outer edges44a-44dof the shroud34, the inner edges50a-50dof the shroud34have a plurality of openings, each indicated at52, that are spaced apart from one another to secure the shroud to the cable tap box60. In one embodiment, screw fasteners can be provided to secure the shroud34to the cable tap box60. Further, the inner edges50a-50dof the shroud34have outer surfaces having a seal54that is configured to engage the outer surface of the cable tap box60to seal the shroud to the cable tap box.

In one embodiment, with particular reference toFIG.4C, a bottom longer side wall40bof the shroud34is sloped downwardly from the inner edges50a-50dto the outer edges44a-44d. When mounted on the wall14, the top longer side wall40aof the shroud extends generally perpendicularly from the wall14whereas the bottom longer side wall40bslopes downwardly with respect to a horizontal plane. The subtle slope of the bottom longer side wall40benables fluid, e.g., water, to drain from the shroud34should fluid enter the shroud.

Referring toFIG.5, an exemplary cable tap box60is shown and described herein. As shown, the cable tap box60includes a busway interface62that is configured to connect the busway24to the cable tap box. In one embodiment, the cable tap box60is an outdoor cable tap box that is rated for 4000 amps (A). Although oriented in a horizontal fashion, the busway interface62of the cable tap box60can be oriented vertically based on a desired use. The busway24is connected to the busway interface62of the cable tap box60in a manner shown inFIG.3.

Referring toFIGS.6and7, the cable tap box60is secured to the ceiling16of the modular data center10by clamp assemblies, each generally indicated at70, that are configured to slide within a metal framing system72provided on the ceiling. In another embodiment, the cable tap box60can be placed directly on the switchgear18. In the shown embodiment, the framing system includes two tracks74a,74b, which are spaced apart from one another a distance generally corresponding to a width of the cable tap box60. The manner in which the cable tap box60is secured to the ceiling16will be described in detail with reference toFIGS.24-27. The clamp assemblies70are configured to slide within the tracks74a,74bof the metal framing system72, which in one embodiment is sometimes referred to as Unistrut® channels or framing, to enable the cable tap box60to be moved from a remote location to an operational position, as shown inFIG.6.

In one embodiment, the shield38is designed to extend from the wall14to divert fluid, e.g., rain, from the busway24and busway interface connection62to the cable tap box60. In one embodiment, the shield38is secured to the wall14and positioned over the busway24and the busway interface62, and includes a top wall76and two side walls78,80extending downwardly from the top wall (FIG.2). A front edge of the top wall76of the shield38is bent downwardly to further prevent unwanted moisture, e.g., rain, from entering the space below the shield. The top wall76of the shield38is sized to span beyond a width of the shroud34and the cover38to protect the busway24and the busway interface62. This is best shown inFIGS.1and2.

Referring particularly toFIG.7, two cable tap boxes60are secured to the ceiling16of the modular data center10by clamp assemblies70configured to slide within tracks74a,74bof two metal framing systems72provided on the ceiling. The cable tap boxes60are shown to be in their operational positions. Electronic equipment, typically switchgear18, are shown to be positioned below the cable tap boxes60. It should be understood that any number of cable tap boxes60and busways24may be provided depending on the size of the modular data center10and the number of transformers20and generators22provided.

Referring toFIG.8, two assemblies30are shown to be provided on the exterior wall14. The lefthand assembly30shows the shroud34connected to the outer surface of the exterior wall14of the modular data center10and to the cable tap box60. The cable tap box interface62is presented to be coupled to the busway24. The righthand assembly30shows the busway24connected to the cable tap box60and the cover36and the shield38secured to the shroud34and to the exterior wall14, respectively. As shown, the cover36is configured to be secured to the plurality of outer edges of the shroud34. The cover36has a cover opening94configured to enable the busway24to pass through the cover opening and to at least partially seal the interface of the cover opening and the busway. The cover opening94provided in the cover36is smaller than the opening32of the wall14and sized to accommodate the busway.FIG.9illustrates the cover36providing a seal to the busway24.

Referring toFIG.10, the assembly further includes a heating system that is provided to heat the space within the shroud34that surrounds the interface62between the busway24and the cable tap box60. In one embodiment, the heating system includes two dedicated heaters, each indicated at100, secured to inner surfaces of the shorter side walls40c,40dof the shroud34.FIG.10shows one heater100mounted on the inner surface of the shorter side wall40cof the shroud below the busway interface62. The other heater100is mounted on the inner surface of the opposite shorter side wall40dof the shroud34. The heaters100are connected to a thermostat102that is also mounted on the inner surface of one of the shorter side walls40c,40dof the shroud34, e.g., side wall40c. The thermostat102is provided to control the heaters100to achieve a desired temperature within the shroud34. In one embodiment, the thermostat102can be wirelessly controlled so that the assembly30, when fully assembled, can remain intact. In another embodiment, the thermostat102can be controlled by a controller associated with the modular data center10. The heaters100are provided to address moisture within the shroud that surrounds the cable tap box interface connection62. A humidity sensor can also be provided within the space defined by the shroud34as well.

Referring toFIG.11, each assembly30is shown with its respective cover36removed. Each assembly30is provided with its own heating system that includes the two heaters100and two thermostats102per assembly. The heating system can be provided for each cable tap box60and busway interface62. Referring toFIG.12, in one embodiment the heater system includes two ClimaSys 55W heaters and a single ClimaSys CC-simple thermostat, each being provided by Schneider Electric. The heater100is a resistance heater and configured to provide localized heat to the space defined by the shroud34. As shown, the thermostat102is suitably connected to the heater100(wired or wirelessly) to provide control to the heater.

Referring toFIGS.13A and13B, in one embodiment, the cover36includes a top part110shown inFIG.13Aand a bottom part112shown inFIG.13B. The top part110and the bottom part112, when assembled on the shroud34, together define the cover opening94that is centrally provided within the cover36. The top part110of the cover36includes two slider plates, each indicated at114, which are provided to enclose the sides of the cover opening around the busway24once the cover is secured to the shroud34. When assembled, the cover opening94of the cover36is sized to seal against the busway24. The slider plates114can be adjusted in a lateral or horizontal direction to adjust a size of the cover opening94to engage the busway24as it passes through the cover opening. In one embodiment, the top part110and the bottom part112of the cover36each includes a foam gasket116surrounding the cover opening94to provide a seal or at a minimum at least a partial seal between the cover and the busway24. The backside of the cover36is covered with insulation material118to prevent or minimize heat loss within the shroud34once the cover is installed.

The top part110and the bottom part112of the cover36further includes several openings, each indicated at120, provided around the peripheries of the top part and the bottom part of the cover to secure the cover to the shroud34. In one embodiment, the top part110and the bottom part112of the cover36can be secured by fasteners, such as machine screw or sheet metal screw fasteners. Several drain slots, each indicated at122, are provided along the periphery of the bottom part112of the cover36to serve as drain holes to enable fluid to flow from the cover once the cover is installed on the shroud34.

Referring toFIG.14, the slider plates114of the cover36are shown to be mounted on the body of the cover on each side of the cover opening94adjacent the cover opening. The slider plates114are provided to improve the seal between the busway24and the cover36. Each slider plate114is laterally adjustable to engage the side edge of the busway24or busway interface62to prevent moisture from entering the shroud34. Each slider plate114, once adjusted in place, can be locked in place by a lock nut or some other locking device to secure the slider plate against the busway24or the busway interface62. The drain slots122are located below the busway24adjacent to a bottom edge of the bottom part112of the cover36. The openings120along the periphery of the top part110and the bottom part112of the cover36can be shared with the shroud34to secure the shroud and the cover in place with the fasteners.

Referring toFIG.15, the covers36are mounted on the shroud34to illustrate the completed assembly. In one embodiment the lefthand assembly protects the busway24that is provided to connect the transformer20to the cable tap box60and the righthand assembly protects the busway that is provided to connect the generator22to the cable tap box. The rain shields38are provided to protect the busways24and the interfaces62of the busways. It should be understood that the busways24can be used to connect any type of electrical equipment, and the provision of the transformer20and the generator22are exemplary only.

Referring toFIGS.16-19, the manner in which the cable tap boxes60are installed is shown and described below. As shown inFIG.16, the modular data center10includes several switchgear modules18aligned in a row along the wall14of the modular data center. One cable tap box60is shown to be fully installed above the switchgear modules18in a position in which the cable tap box is adjacent to the wall14. As shown inFIGS.16and17, the other cable tap box60is shown in a pre-installation position in which the cable tap box is supported by an equipment jack130that is provided on a roller base132. The equipment jack130is configured to lift the cable tap box60toward the ceiling16for installation, while the roller base132is provided to laterally move or roll the equipment jack and the cable tap box to its desired, operational position. The cable tap box60is positioned within an aisle of the modular data center10behind the row of switchgear modules18and secured by suitable hardware, e.g., clamp assemblies70, to the tracks74a,74bof the framing system72provided on the ceiling16. As shown inFIGS.18and19, the cable tap box60is moved into the fully installed position within the framing system72and suitable clamped in place against the opening32in the wall14that receives the shroud34. Each cable tap box60includes cables136that are provided to connect the cable tap boxes to the switchgear18.

Referring toFIG.20, a modified cable tap box is indicated at140, the modified cable tap box having a side panel142provided on both sides of the cable tap box. Each side panel142is configured to be removed by removing fasteners used to secure the side panel to a frame of the cable tap box. A back panel144is configured to be removed as well. The removable side panels142and the back panel144are provided to easily access the interior of the cable tap box140after the cable tap box is installed in its operable position.

Referring toFIG.21, when installing the cable tap boxes60, a gap indicated at150can be provided adjacent to a wall152of the modular data center10and an outer edge of the cable tap box. This gap150can enable accessories, hardware and cabling to be installed adjacent to the cable tap box60. In one embodiment, the gap150is 30-inches wide, but any size gap can be provided. As shown, the switchgear18similarly are positioned in the modular data center10a distance from the wall152that is the same distance as the gap150between the wall and the cable tap box.

Referring toFIG.22, in one embodiment, a modified framing system160can be provided. As shown, the modified framing system generally indicated at160is angled to account for a small gap provided between the cable tap box60and the outer edge of the equipment rack18and the wall152of the modular data center10. As shown, a first portion160aof the framing system160is relatively perpendicular to the wall adjacent to the wall14to position the cable tap box60in place once fully installed. However, a second portion160bof the framing system160is angled with respect to the first portion160ato enable better access to the cable tap box60when the cable tap box is in the pre-installation position. Specifically, in one embodiment, angled framing system160can be provided to achieve a small gap, e.g., six inches, from the wall152to enable the manipulation and access to the cable tap box60.

Referring toFIGS.23and24, in one embodiment, the cable tap box60is secured to the ceiling16by the aforementioned clamp assemblies and framing system72. The clamp assemblies70are configured to clamp onto the cable tap box60to support the weight of the cable tap box. As shown inFIG.23, four clamp assemblies70can be used to secure the cable tap box60, with a clamp assembly being provided at each corner of the cable tap box. The weight of the cable tap box60can be somewhat substantial, e.g., 400+ pounds (lbs). Thus, the ceiling16and each clamp assembly70must be sufficiently robust to carry its portion of the weight of the cable tap box60. Moreover, the tracks74a,74bof the framing system72must be robust enough to support the weight of the clamp assemblies70and the cable tap box72. The clamp assemblies70further are configured to be coupled to the tracks74a,74bof the framing system72to enable the cable tap box60to ride along a length of the framing system between the aforementioned pre-installation and installed positions.

Referring additionally toFIGS.25and26, each clamp assembly70includes a clamp180(FIG.25) that is secured to the track or rail of the framing system72(which is greased) or is secured to a roller assembly182(FIG.26). In one embodiment, the clamp180is a C-clamp in which a throat of the clamp can be widened to enable a flange184of the cable tap box60to be inserted within the clamp. The clamp180is tightened to firmly secure the clamp to the flange184of the cable tap box60. The manner in which the clamp180is secured to the cable tap box60is shown inFIG.24. Each clamp180can be locked in place by a nut186provided on the clamp. Alternatively, the roller assembly182, which includes four rollers or wheels, each indicated at188, can be configured to ride within a channel of the track74aor74bof the framing system72. The roller assembly182further includes a bracket190that can be secured to the clamp180. Another nut192is provided on the clamp180to firmly secure the clamp to the cable tap box60. Once assembled, the clamp hardware or the roller assembly182is configured to slide or roll along a length of the track74aor74bof the framing system72while the clamp180is secured to the cable tap box60to move the cable tap box to a desired location.

A method of assembling a busway cable assembly to protect a busway configured to be coupled to an electrical box is further disclosed. As discussed above, the busway transition of the cable tap box extends through an opening of an outer wall of a modular data center, and is provided to connect equipment within the modular data center, e.g., switchgear, to a transformer or a generator. In one embodiment, the method includes installing a shroud on the wall with the shroud extending through the opening of the wall. The shroud includes a plurality of outer edges that are secured to an outer surface of the outer wall and a plurality of inner edges that are secured to the cable tap box. Inner surfaces of the plurality of outer edges each include a seal configured to engage the outer surface of the outer wall.

The method further includes installing a cover to the shroud. The cover includes a cover opening that is sized to enable the busway to pass through the cover opening. The cover is provided to at least partially seal the opening of the outer wall having the busway extending through. Specifically, the cover is secured to the plurality of outer edges of the shroud and can include a gasket to create at least a partial seal between the busway and the cover. Further, the cover can include slider plates at each end of the cover opening to improve the seal between the busway and the cover.

The method further includes installing a shield to the outer wall, with the shield being positioned over the busway. The shield protects the connection of the busway to the cable tap box interface. The method further includes installing at least one heater to a wall of the shroud and a thermostat, coupled to the heater, to the wall or another wall of the shroud. The thermostat controls the heater.

Thus, it should be understood that the assembly described herein enables a busway to pass through an exterior wall of a modular data center to allow contractors to continue the busway connections outside the facility, for example, to a generator or a transformer, without the need to enter a locked facility. The system allows a busway connection through a wall, behind access panels, to permit system checkout in advance and keep contractors from requiring access inside a locked facility.