IBM Symposium 2008 Data Center Cooling EC Systems for HVAC architecture and Direct air Cabinet Cooling Presented by David J. Spofford Product Manager IT/Telecomm 1
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
EC Basics EC Motor With Integrated Electronic What is an EC motor? It is a brushless, permanent magnet, synchronous motor with electronic commutation but we just name it E C LECTRONICALLY OMMUTATED motor or EC motor
EC Systems with External Rotor Motor The heart of ebmpapst designs for Data Center application rotor permanent magnet lamination stack Hall-effect sensor bearing system commutation electronics winding
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
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
EC Systems Protective 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
Data Center EC Cooling Opportunities today EC 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
Data Center EC Cooling Opportunities today EC 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
Why EC Motors? Highest Motor Efficiency Motor efficiency [%] 90 80 70 60 50 40 30 20 EC-Motor 3~AC 1~AC Shaded pole motor 10 0 50 100 150 200 250 300 350 Output power P2 [W] 400 450 500
Why is an EC motor so efficient? Let s identify with system losses Electrical input losses AC EC shaft power loss stator air gap lamination loss 200 W 80 W copper loss 200 W 120 W additional losses rotor slip loss 60 W 0 W frictional loss Mechanical output Variable speed 160 W 80 W drive total losses 620 W 280 W
EC Systems: Power Consumption Electricity savings in multi-fan applications 100% 75% On/Off operation EC modulation power input 50% 25% 0% 13% 25% 38% 50% 63% 75% 88% 100% airflow capacity P 1 ~ n 3
EC Systems: Acoustics Noise reduction in multi-fan applications noise difference [dba] 0-3 -6-9 -12-15 -18-21 -24 On/Off operation EC modulation 13% 25% 38% 50% 63% 75% 88% 100% airflow capacity delta Lp [db] = 50 x log10 (n 1 /n 2 )
Examples of CRAC with EC Systems Comparison 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. Cost Saving $21,024 Annually Payback Period 6.4 Months Unit Type Unit of Measure Traditional Technology EC Technology Number of Units 4 4 Air Flow m3/h 96,000 96,000 Cooling Capacity (Total) kw 375 375 Cooling Capacity (Sensible) kw 296 296 Compressor Power Consumption kw 94.5 79.0 Fan Power Consumption kw 40.0 23.5 Total Power Consumption kw 134.5 102.5 Noise Level, 2 m, free field db(a) 69 66 Purchase Price $ 63,070.00 74,284.00 Annual Operating Costs $ 88,366.50 67,342.50 Savings in Energy Costs $ 21,024.00 Payback Months 6.4 Energy Costs at $.10
Examples of CRAC with EC Systems Comparison of Operating Costs for EC vs. AC with/without Standby Unit for 12 Months Example B > This example shows running 3 units full vs. 4 at reduced speed. Cost Saving $7,621 Annually Unit Type Unit of Measure Conventional Energy Saving Mode Number of Units 4 4 Number of Units in Standby 1 0 Operating Point, Air Flow % 100 73 Total Air Flow m3/h 85,000 85,000 Cooling Capacity (Sensible) kw 335 335 Total Power Consumption kw 24.0 12.4 Noise Level 2 m, free field db(a) 65 59 Annual Operating Costs $ 15,768.00 8,147.00 Savings in Energy Costs $ 7,621.00 Conventional Operation 3 units run at full load to cover the thermal load. One unit is in standby mode. Energy Saving Mode with EC 4 units run at partial load.
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
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
EC Systems: Cooling for the next generation Conclusion EC Systems 30% less power consumption Longer life Communication link Lower noise Global voltage/frequency Good for the environment.
Thank you for your attention! 19