An overhead-mounted cable tray and busway support system is provided for supporting communication cables and power busways that are connected to computer equipment housed within a data center. The system includes a plurality of brackets, and a roof mounting assembly. Each of the brackets is formed by a vertical member, a horizontal mounting member having a central portion affixed to a top end of the vertical member that is mountable directly or indirectly to a building roof, two cable tray supports connected to the vertical member at different points, and a busway support. The tray supports and the busway support are cantilevered from a same side of the vertical member so that all of the cables and busways may be conveniently installed from the front side of the cabinets housing the computer equipment. The horizontal mounting member is parallel to the tray supports to resist the torque applied to the brackets from the one-sided weight load of the cables and busways. The busway support mounts two or more horizontal busways at different heights and vertically-staggered with respect to each other to facilitate the installation of busplugs that provide power to the computer equipment.
1. An overhead-mounted cable tray and busway support system, comprising:
at least one roof-supported bracket including
a vertical member, a horizontal mounting member affixed to a top end of the vertical member that is mountable directly or indirectly to a building roof, at least one tray support connected to the vertical member, a busway support connected to the vertical member and having a busway retaining flange that mounts two or more horizontal busways at different heights, and a roof mounting assembly that includes a rail member suspended from an underside of a roof of a building that is parallel to and connected to the horizontal mounting member of the bracket, wherein both the rail member and horizontal mounting member are parallel to the at least one tray support. 2. The overhead-mounted cable tray and busway support system of 3. The overhead-mounted cable tray and busway support system of 4. The overhead-mounted cable tray and busway support system of 5. The overhead-mounted cable tray and busway support system of 6. The overhead-mounted cable tray and busway support system of 7. The overhead-mounted cable tray and busway support system of 8. The overhead-mounted cable tray and busway support system of 9. The overhead-mounted cable tray and busway support system of 10. An overhead-mounted cable tray and busway support system, comprising:
at least one roof-supported bracket including
a vertical member, a horizontal mounting member affixed to a top end of the vertical member that is mountable directly or indirectly to a building roof, at least one tray support connected to the vertical member, a busway support connected to the vertical member and having a busway retaining flange that mounts two or more horizontal busways at different heights, wherein the at least one tray support and the busway support are parallel and cantilevered from a same side of the vertical member, and the horizontal mounting member is parallel to the at least one tray support and the busway support, and a roof mounting assembly that is connected to the horizontal mounting member of the bracket and which bears all of a weight load of the bracket. 11. The overhead-mounted cable tray and busway support system of 12. The overhead-mounted cable tray and busway support system of 13. The overhead-mounted cable tray and busway support system of 14. The overhead-mounted cable tray and busway support system of 15. The overhead-mounted cable tray and busway support system of 16. The overhead-mounted cable tray and busway support system of 17. The overhead-mounted cable tray and busway support system of 18. An overhead-mounted cable tray and busway support system, comprising:
at least one roof-supported bracket including
a vertical member, a horizontal mounting member having a central portion affixed to a top end of the vertical member that is mountable directly or indirectly to a building roof, two tray supports connected to the vertical member at different points along a vertical axis, and a busway support connected to the vertical member and having a busway retaining flange that mounts two or more horizontal busways at different heights with respect to each other, wherein each tray support and busway support connected to the vertical member is cantilevered from a same side of the vertical member and the tray supports and busway support are parallel to one another, and wherein the horizontal mounting member is at least as long as the tray supports and is parallel to the tray supports and the busway support, and a roof mounting assembly that is connected to the horizontal mounting member of the bracket having an elongated member that is parallel to and connected to the horizontal mounting member and which bears all of a weight load of the bracket. 19. The overhead-mounted cable tray and busway support system of
This invention generally relates to a cable support system for a building, and is specifically concerned with a two-tiered, overhead-mounted cable tray and busway support system for separately supporting redundant power busways and data communication cables for digital processing equipment. Systems for supporting data communication cables in buildings housing large amounts of computer equipment are known in the prior art. Some of these prior art systems include rows of cable-supporting brackets suspended from rails attached to the underside of the roof of the building. The rows of brackets hang over rows of server racks and other data-processing equipment. Each of the brackets is shaped like an inverted “T”, where the stem corresponds to a vertical support member, and the two sides of the hat of the inverted “T” correspond to a pair of opposing support arms for supporting cable trays on either side of the vertical support member. In operation, the vertical support members of the brackets are mounted on the overhead-mounted rails. Next, cable tray sections are mounted on the opposing support arms to form two, parallel cable trays on either side of each row of brackets. In systems having a height-adjustable mechanism, the height of each row of brackets is made to be as uniform as possible so that the adjoining edges of the tray sections are mutually aligned. Finally, the communication cables are lifted up, laid into, and sometimes pulled along the cable trays to properly position them. Such cable support systems are often used in data centers housing rows of server racks or other data-processing equipment. While such overhead-mounted cable support systems are generally useful, the applicant has observed a number of shortcomings in such systems that limit their utility. For example, in many such data centers, the depth and density of the cabinets or racks containing the digital equipment only allows access to the cable support system from the front sides of the equipment cabinets. While such one-sided access poses no difficulty for the installers to lift and install the cables in the front-facing cable tray, installation of the cables in the back-facing cable tray is awkward and time-consuming, often requiring the cables to be “threaded” around the vertical support member of the support brackets and pulled into position over the back-facing tray. Another problem arises from the cooling chimneys present on the equipment cabinets. These chimneys extend upwardly from the back half of the cabinets in order to funnel air heated by the equipment into a plenum space defined between the underside of the building roof and a ceiling suspended beneath the roof. If the front-facing cable tray is positioned far enough back from the front side of the equipment so as not to interfere with the walkway aisles between adjacent rows of digital processing equipment, the back cable tray may interfere with the cooling chimneys. If one attempts to solve these problems by eliminating the back-facing tray and tray supports so that all of the weight of the cables is borne by a single front-facing cable tray, the resulting imbalance in the weight applies a substantial backwards-oriented torque to the brackets which can swing them into an interfering position with the chimneys extending from the back half of the equipment cabinets. If one attempts to counteract the torque by reinforcing the system with additional brackets, the weight and expense of the support system substantially increases. Another limitation of prior art cable support systems is their lack of ability to support, in any practical fashion, the cables or busways that provide electrical power to the digital processing equipment. To fully appreciate this limitation, some background is necessary. In the past, the power cables were installed between a raised floor which supported the digital processing equipment, and the actual floor of the building. However, such a configuration makes it difficult to re-route and re-connect power cables whenever the digital equipment is added, replaced or relocated on the floor of the building. Often when such changes are made the old cables are simply cut and left in place while new cables are snaked into place and connected. Over time, such a procedure leaves a “rat's nest” of cables that makes it difficult to distinguish between “live” and “dead” cables and further interferes with the efficient re-routing and re-connection of power cables. A possible solution to these problems would be to install busways on the cable support system. Such busways are similar in shape to a common two-by-four piece of lumber and include a series of plug-in ports along their lengths for receiving busplugs. The busplugs are in turn connected to a relatively short power cable or “whip” that ends in a female plug which receives the male plug of the equipment. In contrast to floor-mounted power cables, such an arrangement would make it easy to re-route and reconnect power cables whenever the digital equipment is added, replaced or relocated on the floor of the building. Such an arrangement would also obviate the need for a raised floor, thereby lowering construction costs. However, the installation of busways on prior art cable support systems generates additional problems that are yet unsolved. Modern “mission-critical” data centers require redundant sets of power sources to provide a reliable, uninterrupted flow of electrical power to the digital processing equipment. Since such redundant power requirements doubles the number of busways and busplugs that the brackets of the cable support system must bear, the resulting mechanical load on the support brackets becomes quite substantial as the combined weight of the data communication cables and copper-laden power cables can amount to 134 lbs. per linear foot or more. This in turn would exacerbate the backwards-oriented torque applied to overhead-mounted brackets having only a single, front facing tray. Additionally, code regulations prohibit merely laying the dual busways in the trays that support the communication cables, and no prior art cable system has any provision for separately supporting a pair of busways away from the cable trays. Consequently, there is a need for a overhead-mounted cable tray and busway support system that allows the data communication cables to be easily installed from the front side of the equipment cabinets by simply lifting them over the cabinets and laying them directly in the cable trays without the need for “threading” the cables through interfering portions of the support system. There is a further a need for such a system wherein any torque applied to the brackets as a result of weight load imbalances is sufficiently counteracted so that the brackets do not swing backwardly into an interfering position with the chimneys extending upwardly from the back half of the equipment cabinets. There is also a need for such a system that can support a pair of busways separately from the cable trays. It would also be desirable if the busways could be easily installed on the same side of the support system as the cables again by simply lifting them over the cabinets of the digital equipment and fastening them onto the support system without mechanical interference between the busways or their respective terminal boxes. Ideally, such a support system would allow the busplugs to be easily and quickly attached to the busways and would secure the busways against any movement from the forces applied during the installation or removal of busplugs. Finally, the support system should have a roof mounting assembly that allows the height of the brackets to be adjusted so that all of the trays may be aligned at a same height. Such a feature would provide uniform-height cable pathways through the building space, avoid localized stress concentrations from the weight of the cables, and facilitate the installation of a plenum-forming tile ceiling below the underside of the roof. To these ends, the overhead-mounted cable tray and busway support system of the invention comprises a plurality of roof-supported brackets, each of which includes a vertical member, a horizontal mounting member affixed to a top end of the vertical member that is mountable directly or indirectly to the underside of a building roof, two or more tray supports connected to the vertical member, and a busway support also connected to the vertical member above the tray supports. The tray supports and the busway support are cantilevered from a front side of the vertical member so that the cables and busways may be lifted upwardly from the access aisle in front of the cabinets and easily installed in the cable trays or on the busway support without the need for “threading” these components around interfering brackets components. The vertical support member is preferably formed from tubular steel having a rectangular cross-section for resisting the torque applied thereto as a result of having the entire weight load applied to the front side of the bracket. The busway support mounts two horizontal busways at different heights and vertically-staggered with respect to each other to provide screwdriver access to the top and bottom surface of both busways that facilitates the installation of busplugs on the busways. Preferably, the busway support is shaped like a sideways “T”, having a stem cantilevered from the vertical support member of the bracket, and a hat defining upper and lower flanges that provide mounting surfaces for busway brackets that surround and secure the busways against front and back movement during the installation or removal of the busplugs. The horizontal support member is parallel to the tray supports and hence is orthogonal to the direction of the cables and busways supported by the bracket. It is rigidly connected at its midpoint to the top end of the vertical support member. The horizontal support member is at least as long as, and preferably twice as long as, as the tray supports of the brackets. Hence the torque applied to the vertical member as a result of the weight load of the cables and busways is distributed over the relatively long length of the horizontal support member, which prevents localized buckling stresses from acting on the support rail that the horizontal support member is connected to. Preferably, this member includes integrally-formed horizontal and vertically-oriented flanges, wherein the vertically-oriented flange stiffens the horizontal member against bending in response to the aforementioned torque. The top end of the vertical support member is welded to or otherwise securely connected to both the horizontal and vertical flanges to provide a strong and rigid connection. The cable tray and busway support system further comprises a roof mounting assembly that includes the previously-mentioned rail members suspended from an underside of the roof of a building. Like the horizontal support member of each of the brackets, the rail members are parallel to the tray supports of the brackets and are orthogonally oriented to the direction of the cables and busways supported by the brackets. The roof mounting assembly preferably includes a pair of threaded rods that are threadedly engaged at one end at different points along an axis of the rail member, and threadedly engaged at an opposite end either directly or indirectly to the roof of a building such that the height and horizontal angle of the rail members (and hence the tray supports) may be adjusted to a same height and angle. With reference now to Each of the brackets 3 further includes a busway support 16 that is shaped like a sideways “T”. The stem 18 of the support 16 is cantilevered at one end to the vertical support member 12 in the same direction as the tray supports 14 Finally, each of the brackets 3 further includes a horizontal mounting member 30. This mounting member 30 is parallel to the tray supports 14 With reference now to With reference now to Turning now to the remaining components of the roof mounting system 4, a series of rectangular plates 44 are secured over the top surfaces of the rails 40 via mounting bolts 46. Bolts 46 extend through bolt holes in the plates 44 and through the upper slot 44 The installation steps associated with the cable and busway support system 1 may best be appreciated with reference to After the roof mounting assembly 4 has been installed, the brackets 3 (which have been conveniently manufactured off-site) are mounted on the rails 40. This is accomplished by pushing together the nut and spring forming the spring nuts 42 After the brackets 3 have been mounted on the rails 40, the busways 8 To complete the installation of the system 1, a pair of busplugs 63 The one-sided load exerted by the 134 lb./ft weight of the cables 6 and busways 8 Although the invention has been described in detail with particular reference to a preferred embodiment, it will be understood that variations and modifications can be effected within the spirit and scope of the invention, which is limited only by the recitations of the appended claims and equivalents thereof.FIELD
BACKGROUND
SUMMARY
BRIEF DESCRIPTION OF THE DRAWINGS
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT