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Data Center Cooling EC Systems for HVAC architecture and Direct air Cabinet Cooling
Presented by David J. SpoffordProduct Manager IT/Telecomm
IBM Symposium 2008
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Agenda – Data Center trends for IT and Cooling
•What is EC?• EC Systems Basics•Why is EC better? •Applications for EC product?•Examples of EC in a data center
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It is a brushless, permanent magnet, synchronous motor with electronic commutation…
EC
LECTRONICALLY
OMMUTATED motor or EC motor…but we just name it
What is an EC motor?
EC BasicsEC Motor With Integrated Electronic
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bearingsystem
laminationstack
windingcommutationelectronics
rotor
permanentmagnet
Hall-effectsensor
EC Systems with External Rotor MotorThe heart of ebmpapst designs for Data Center application
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What are EC Systems
• E.C = Electronically Commutated motors• E.C Systems include:• Brushless motors incorporated. • Permanent magnets• Integrated commutation electronics • Integrated P.I.D functionality
> P.I.D.- Proportional Integrative Derivative- Ability to have open or closed loop control functionality.
• Factory balanced air moving device • Factory assembled motor mount brackets and housings
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What are EC Systems
• Will always operate in the correct direction of rotation• Operate on 50-60Hz – with the same performance• Operate on a wide voltage range with the same
performance:• 200-277 volt – Single phase• 200-240 volt – Three phase• 380-480 volt – Three phase• Power Factor Correction • Operate much cooler – longer life
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EC SystemsProtective Features
• Alarm relay• Locked-rotor protection• Phase failure protection• Soft start • Low voltage protection• Over-temperature protection of
electronics and motor• Short-circuit protection• EMI & RFI Filtering
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Data Center EC Cooling Opportunities todayEC applications today for use in the Data Center
EC Axial fans for:•Air Cooled Chillers•Air Cooled Condensers•Dry Coolers•Fluid Coolers•Evaporative Condensers/Cooling Towers
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Data Center EC Cooling Opportunities todayEC applications today for use in the Data Center
EC Radial Backward Curved and Forward Curved fans for:
•CRAC (Direct Expansion A/C) Units•CRAH Unit (Water Cooled Air Handling A/C) Units•Supplementary Cooling Systems•Free Air Cooling Systems•In-Row Cooling•UPS Cooling•Full Rack Cooling
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Why EC Motors?Highest Motor Efficiency
10
20
30
40
50
Moto
r effi
cienc
y [%
]
60
70
80
90
0 50 100 150 200 250 300 350Output power P2 [W]
400 450 500
1~AC
3~ACEC-Motor
Shaded pole motor
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Electrical input
Mechanical output
shaft power
stator
air gap
rotor
loss
lamination loss 200 W 80 W
copper loss 200 W 120 Wadditional losses
slip loss 60 W 0 Wfrictional loss
Variable speed 160 W 80 Wdrive
losses AC EC
Why is an EC motor so efficient?Let’s identify with system losses
total losses 620 W 280 W
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0%
25%
50%
75%
100%
13% 25% 38% 50% 63% 75% 88% 100%
airflow capacity
pow
er in
put
On/Off operation
EC modulation
P1 ~ n3
EC Systems: Power Consumption Electricity savings in multi-fan applications
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-24
-21
-18
-15
-12
-9
-6
-3
0
13% 25% 38% 50% 63% 75% 88% 100%
airflow capacity
nois
e di
ffere
nce
[dBA
]
On/Off operation
EC modulation
delta Lp [dB] = 50 x log10 (n1/n2)
EC Systems: Acoustics Noise reduction in multi-fan applications
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Examples of CRAC with EC SystemsComparison of Operating Costs for EC vs. AC for 12 Months
• Example A> Company A runs a medium-sized computer center with a thermal
load of 300 kW. Instead of using air conditioning units with traditional belt-driven centrifugal fans, the company decided on a precision air conditioning solution with EC fans.
Unit Type Unit of Measure Traditional Technology EC TechnologyNumber of Units 4 4Air Flow m3/h 96,000 96,000Cooling Capacity (Total) kW 375 375Cooling Capacity (Sensible) kW 296 296Compressor Power Consumption kW 94.5 79.0Fan Power Consumption kW 40.0 23.5Total Power Consumption kW 134.5 102.5Noise Level, 2 m, free field dB(A) 69 66Purchase Price $ 63,070.00 74,284.00Annual Operating Costs $ 88,366.50 67,342.50Savings in Energy Costs $ 21,024.00Payback Months 6.4Energy Costs at $.10
Cost Saving$21,024 AnnuallyPayback Period
6.4 Months
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Examples of CRAC with EC SystemsComparison of Operating Costs for EC vs. AC with/without StandbyUnit for 12 Months
• Example B> This example shows running 3 units full vs. 4 at reduced speed.
Unit Type Unit of Measure
Conventional Energy Saving Mode
Number of Units 4 4Number of Units in Standby 1 0Operating Point, Air Flow % 100 73Total Air Flow m3/h 85,000 85,000Cooling Capacity (Sensible) kW 335 335Total Power Consumption kW 24.0 12.4Noise Level 2 m, free field dB(A) 65 59Annual Operating Costs $ 15,768.00 8,147.00Savings in Energy Costs $ 7,621.00
Cost Saving$7,621 Annually
Conventional Operation3 units run at full load to cover the thermal load. One unit is in standby mode.
Energy Saving Mode with EC4 units run at partial load.
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EC Systems: Power saving designs and Examples at the cabinet level
Replacing standard AC fans with EC
• 10 inch AC fan> 230VDC> 550CFM> 61Watts
• 10 inch EC fan> 230 VAC> 600 CFM> 34 Watts
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EC Systems: Power saving designs and Examples at the cabinet level
Today• Current Design- 80 fans per system (120mm), 50 Watts
each, 4000 CFM requirement• Power consumption- 4000 Watts
Next Generation• Diagonal design- 8 fans per system, 4000 CFM, • Estimated-130 Watts per fan• Power Consumption- 1040 Watts
2960 Watts per Rack Power Savings
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EC Systems: Cooling for the next generationConclusion
• EC Systems• 30% less power consumption • Longer life • Communication link• Lower noise• Global voltage/frequency• Good for the environment.
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Thank you for your attention!