IBM Symposium 2008 - IBM WWW Page rights reserved by ebm-papst Mulfingen GmbH & Co. KG bearing...

All rights reserved by ebm-papst Mulfingen GmbH & Co. KG1

Data Center Cooling EC Systems for HVAC architecture and Direct air Cabinet Cooling

Presented by David J. SpoffordProduct Manager IT/Telecomm

IBM Symposium 2008

All rights reserved by ebm-papst Mulfingen GmbH & Co. KG

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


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


bearingsystem

laminationstack

windingcommutationelectronics

rotor

permanentmagnet

Hall-effectsensor

EC Systems with External Rotor MotorThe heart of ebmpapst designs for Data Center application


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 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


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


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


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


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


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


-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


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


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.


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 generationConclusion

• EC Systems• 30% less power consumption • Longer life • Communication link• Lower noise• Global voltage/frequency• Good for the environment.

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