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Communications • Computing • Multimedia & Consumer • Industrial & Semiconductor • Defense & Aerospace • Medical • Automotive
Mirko Stevanovic, M.A.Sc. Mech. Eng.
New Product Design
Sanmina-SCI Enclosure Systems
Toronto, Canada
IBM Power and Cooling Technology Symposium, September 2008

Preamble: Clear Market Trends
“We are currently in the biggest data center construction boom in history. At the same time, this boom is dramatically weakening the future flexibility and financial performance of
Information Technology. How can this be?
It's the old domino effect at work again.” The new “must know” topic for senior executives responsible for the energy consumption and costs of today’s increasingly high-density computing environments is the true economic and environmental costs of enterprise computing and what steps must be taken, beginning now , to control them”.
Source: Ken Brill, Director of “The Uptime Institute” Sept 2008
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Market Need
Current Requirement:
• Integrated enclosures with 30kW thermal management systems that provide optimum environment for high density “clustered computing”.
• Scalable systems deployable in large or small quantities in new or existing sites.
• Simple, efficient & highly reliable thermal management technology that enables cost savings in infrastructure, real estate and power.
• “Green” products with low acoustic output, built in ‘fail safe’ devices and appropriate redundancy of critical systems.
• Optional power distribution, environmental monitoring, smoke detection & fire suppression.
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What is The Problem?
High Density Blade Servers introduce new considerations:
Heat Loads continue to Rise
Heat Densities continue to Increase
Conventional Cooling can not cope (see next slide)
Efficiency and reliability of traditional Data Center declines and
“De-population” of room occurs when input power exceeds values >3.5kW per enclosure
Data Centers with raised floor (Plenum) cooling systems cannot support input power values of >7kW per enclosure without overheating problems
New generation processors in high density configurations can require as much as 25kW+ input power per enclosure
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What is The Problem?
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What is The Problem?
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Sanmina’s ECOBAY Solution
Our Solution:
An integrated enclosure using chilled water in a closed loop system to provide cooling & facilitate heat removal at a rate
3630 times greater than the same volume of air.
History
Sanmina was the first to develop & market a product of this type.
Update
In December 2007 the last of 5 ECOBAY Patents was granted by the USPTO providing Sanmina with greatly increased protection against Infringement of key elements of it’s design.
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ECOBAY Thermal Management System
What is ECOBAY?
High Performance, Closed Loop
Water Cooled Cabinet.
Heat generated inside the cabinet is removed by chilled water.
Minimal stress on room cooling system.
42RU of useable space.
Cooling Air
Constant air temperature in front of servers.
Uniform air distribution in front of servers.
Chilled Water ► from Chiller
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Heated Air
Thermal Core
◄ Warmed Water to Chiller

What Ecobay Offers
Solution for Customer Needs:
Improved Cooling
Sealed system
Noise Reduction
Dense packing/heat density per area
Lower energy cost
Smoke Detection/Fire suppression
Monitoring
Improved work area
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ECOBAY Solution
For Blade Servers
Low Density Solution
1 kW 7 kW
Current Generation
High Density Blades
NGR Blade’s & Multi
Processor Enterprise
24 kW 35 kW
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ECOBAY Thermal Management System
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ECOBAY Thermal Management System
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ECOBAY Thermal Management System
Five Blade Chassis operating at full power ~ 18 kW
0.76 l/s (12 gpm) Water at 14°C
(57°F)
Blades operated within manufacturers specs.
RH 40% - 60% inside cabinet
Acoustic performance – “very good”
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ECOBAY Thermal Management System
Performance Table (in US units)
Inputs Heat Load
Water Temp
Water Flow
24 kW
55 °F
12 USgpm
Results
Background
Cold Air Supply
Hot Air Disch
Air ∆ T
Water Rise
Water Disch
Water ∆ P
Server Fans
Fan Power
73.0
°F
115.5
°F
42.1
°F
12.8
°F
67.8
°F
7.0
psi
1680 CFM
700 W
SI units
24.0
kW
12.8
degC
0.76
l/sec
22.8
°C
49.8
°C
23.4
°C
7.1
°C
19.9
°C
48.3
kPa
Varies by manufacturer
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Typical Mechanical Layout
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ECOBAY For Smaller Projects
- 324 KW LOAD
Traditional Air-Cooled Cabinets
TOTAL ROOM FT
ELECTRICAL
2 2170 FT 2
324.0 kW
# of Cabinets @ 5kW each
4 Power Distribution Units
65
225 kVA/pdu
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ECOBAY 1-18 High Density Enclosures
TOTAL ROOM FT 2 910 FT 2
ELECTRICAL 324.0 kW
# of Cabinets @ 18kW each
4 Power Distribution Units
18
225 kVA/pdu

Cabinet Monitoring
Temperature in front and back of servers
Fans/Power Supply Status
Humidity
Actual water leakage
Door security
Incipient Smoke Detection
Fire Suppression Activation
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To Central Monitor or Building BMS

CABLE/POWER MANAGEMENT
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Rack Mounted Smoke/Fire Suppression with
Optional VESDA
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Fire Suppression
Fully monitored smoke detection and fire suppression
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Closed-Loop Water-Cooled System
RESILIENCY
How do we make the Cabinet Cooling System Reliable ?
Redundant Pumps, Heat Exchangers, and Chillers
Matrix piping system
Redundant Fans
Redundant power supplies
Preemptive Monitoring & Alarm System
Fall Back Strategy
If the cooling in a cabinet fails for any reason:
Automatic door release.
Room air temporarily removes heat.
Door release has dual power & dual thermostats
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Communications • Computing • Multimedia & Consumer • Industrial & Semiconductor • Defense & Aerospace • Medical • Automotive