EXECUTIVE SUMMARY:
- Energy costs can account for more than half of the total operating expenses of a data centre – so managing critical infrastructure is key to ensuring energy efficiency and reliability
- ‘Plug and play’ connectors and pre-assembled cable assemblies are one solution, instead of hardwired connections; as well as improving current carrying capacity
- Optimised connector design is key to improving overall current carrying capacity – and companies like HARTING ensure materials can be selected and adapted accordingly during the design process
The International Data Corporation reports that energy consumption per server is growing by around 9% per year globally. Despite servers becoming more compact to save installation space, their improved performance increases their energy requirement over volumetric space. As energy costs can account for more than 50% of the total operating expenses of a data centre, it’s essential to focus on managing critical data centre infrastructure to ensure energy efficiency and reliability.
One solution is using ‘plug and play’ connectors and pre-assembled cable assemblies instead of hardwired connections. These connectorised assemblies can reduce installation and commissioning times, maintenance downtimes and the overall cost of ownership when compared to hardwiring. They can also contribute to improving energy efficiency.
HARTING has calculated the effect of power usage from connectors in data centres, by comparing the power consumption of three different connector solutions in its independently accredited test laboratory. One of the connectors tested was the HARTING Han-Eco®. The other two were CEE (IEC 60309) plugs from different manufacturers.
Compared to the two brands of IEC connectors, the Han-Eco® connector reduced power wastage through leakage by up to 50% by using low-impedance contacts. These contacts reduce the power wasted through connections and significantly improve the Power Usage Efficiency (PUE) of data centres.
Depending on the electricity price, which differs regionally and worldwide, one hyperscale data centre with 15,000 racks can achieve annual power consumption savings of around £100,000.
As we have seen, data centre servers require more energy despite becoming more compact. That’s why it’s crucial to improve the efficiency and performance of electrical connections through design optimisations and leading-edge technologies. Connectors must be able to offer higher current-carrying capacity while remaining the same size.
One method for boosting efficiency is current carrying capacity, the maximum current that a connector can transmit for a specific cable diameter. The capacity results from the balance between the heat generated by electrical resistance and the heat dissipated. While higher current-carrying capacities can be realised with larger connectors and cables, this is not an option in many applications due to limited space.
To improve current carrying capacity, there are three key areas to examine: the cable connection, the contact material and the contact point itself.
For the cable connection, crimping provides both efficient electrical contact and mechanical strength. A well-executed crimp considerably reduces resistance due to high contact density. It’s the ideal solution for pre-assembling connectors in large quantities and delivers a consistently high-quality result when using the appropriate crimp tools. This method also maximises the current capacity of a cable’s connector whilst minimizing the footprint of the connection itself.
In terms of the contact material, the alloy selected is also important as it can significantly increase conductivity. Copper alloy is generally used as the base material and the resistance in the mating area is influenced by various factors, such as the number and size of the contact points: the larger the contact surface, the lower the resistance. The strength of the connection between the mating parts also plays a significant role because it increases the effective contact surface, meaning that more current can flow per contact point.
Ultimately, optimised connector design is essential to improving the overall current carrying capacity. HARTING employ state of the art simulation tools during the design phase, so materials can be selected and adapted accordingly.
Alongside current capacity, new smart connectivity solutions are being developed to improve safety, identify faults, and ensure systems within data centres are working efficiently.
One of the most important additional functions powered by smart connectivity is the signalling of the mating state. The mating state can indicate a range of different parameters, including if the connector is electrically connected and whether it is mechanically locked. It can also indicate if the connector is overloaded and monitor whether environmental parameters such as temperature and humidity are within the permitted range.
Energy efficiency is not just a hot topic in data centres, which is why HARTING are fully focused on the ‘All Electric Society’, a vision of the future, which is highly electrified, and meets the criteria of climate neutrality. By combining renewable energies, smart grids and the electrification of industrial processes, HARTIING aim to connect data and power efficiently and sustainably. To efficiently utilise and optimise electrical energy, it’s important to integrate electricity generation, storage and consumption to ensure a stable and needs-based energy supply.
In view of the fluctuating supply from renewable sources, new energy storage technologies are key. Companies are investing in innovative storage systems to bridge the time gaps between generation and consumption as well as compensating for so-called dark periods. Technology such as modularised plug-in battery storage systems makes it possible to store electricity when it is produced. When demand increases, it can then be sold or utilised, which enables more flexible pricing and contributes to a more stable energy market.
To learn more about HARTING, the All Electric Society and their range of connectors and cabling solutions for data centres, please visit https://www.harting.com/en-GB/data-centres.
