Blog

Nov 21 2023

Unlocking Operational Excellence: 5 Benefits of Lifecycle Services

By Stephen Mathew, Infinitum Product Manager

In the fast-paced world of industrial operations, the significance of comprehensive and proactive solutions cannot be overstated. As businesses strive for efficiency, reduced energy consumption, and optimized maintenance costs, Lifecycle Services have emerged as a crucial component in achieving these objectives. Let’s explore five key benefits that make these services an indispensable part of modern sustainable operations.

1. Comprehensive Solution
Services and expertise from a variety of vendors can vary and prolong resolutions and add to down time. Utilizing a skilled Lifecycle Services partner who understands the demands and maintenance management, particularly in the area of commission, start-up and retrofitting can minimize interruptions and help optimize your system.

Infinitum’s Lifecycle Services — includes spare parts and repairs to consulting and optimization — help to improve system productivity, minimize cost, and extend the useful life of products and systems. From start-up through factory warranty to end-of-life recycling, Infinitum’s service packages are tailored to meet the specific needs of partners, emphasizing professional technicians, product safety, and availability.

2. Scalability for Ever-Growing Demands
The industrial landscape is dynamic, and staying competitive requires a proactive approach to Lifecycle management. The complexity and the scale of these activities can often overwhelm a customer project team leading to cost and schedule overruns. Partners who provide field-proven, modular solutions with integrated engineering enable efficient project implementation with a significant reduction of both cost and risk.

Infinitum’s Lifecycle Support Services offer a scalable service approach that goes beyond traditional repair and replacement services to keep you running smoothly. Service packages include factory or onsite technicians and/or technical training delivered by field service engineers including hands-on instruction and guidance to facility personnel.

3. Expert Technicians for Optimal Performance
The quality of service is only as good as the expertise behind it. Retain a manufacturing partner with a team of certified technicians and service engineers on stand-by to carry out repairs on-site or in authorized workshops.

Infinitum’s factory-trained technicians with certified safety credentials not only detect and repair deficiencies but also anticipate and verify that operations meet the highest quality standards. The result is reduced downtime, increased revenue, and a Lifecycle management approach that ensures maximum system utilization and extended equipment life.

4. Sustainable Practices for Environmental Responsibility
In an era where environmental sustainability is a top priority, choosing Industrial Lifecycle Services with a focus on circular economy solutions becomes imperative. Begin with a comprehensive sustainability strategy that leverages the technologies available across your organization. Ensure a truly sustainable operation when you reduce your environmental footprint, buy renewable energy and keep your business compliant with all regulations. Employ an active energy management approach by breaking down silos to join your sustainability strategy with your energy efficiency projects and energy procurement.

Infinitum leads the way with modular designs that facilitate the replacement of individual components, promoting longevity and minimizing environmental impact. With the majority of components designed for reuse and a circular design strategy that involves recycling and remanufacturing, Infinitum’s Aircore EC motor sets an industry standard for sustainable practices.

5. Cost-Effective Asset Preservation
Financial stress often accompanies the need for frequent replacements and repairs. Lifecycle Services help reduce this burden by preserving assets and increasing their longevity. In reducing the need for new assets and extending the operational life of tools, motors, and equipment, these services prove to be a cost-effective solution. Lower repair costs and decreased operational expenses contribute to a more sustainable bottom line for businesses.

Infinitum Lifecycle Services can help you extend the life of your motors and increase production capacity, improve energy efficiency, and reduce maintenance costs to ensure that you meet your budget goals.

Lifecycle Services extend far beyond traditional repair and replacement services. As businesses seek continuous improvement and enhanced business performance, finding a comprehensive, holistic services team like Infinitum becomes essential. Understanding that every motor application is unique, and each motor undergoes different lifecycle stages ensures that Infinitum’s scalable service approach keeps operations running smoothly in the ever-evolving industrial landscape.

Learn more about Infinitum’s Lifecycle Services and tailored solutions.

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Aug 10 2023

Toss or Repair? The Impact of Serviceability on Motor Life and Costs

By Cam Witt, Infinitum Product Manager

In today’s throwaway culture, even electric motors aren’t immune. All too often, motors—especially those under 11 kW (15HP) — end up in a landfill rather than being repaired due to service costs and complexity. However, considering a motor’s serviceability – the ease of maintaining or repairing a motor – can play a pivotal role in a motor’s efficiency, longevity, sustainability, and greatly influence their total cost of ownership (TCO). Understanding this concept is crucial when choosing an electric motor. So, what should you consider about serviceability, and which questions should you ask when evaluating motors? Dive in to find out.

Minimize Downtime

High serviceability means less downtime. With the right design, key motor components can be accessed and replaced quickly and efficiently, drastically cutting downtime during maintenance or repair. Rapid availability of replacement parts and technical support can further minimize disruption to operations. 

Modularity is also a key factor in motor serviceability. In modular designs, a motor is divided into separate components or modules that can be independently replaced or repaired. This design principle enhances serviceability by making it possible to replace or repair individual components, such as the Variable Frequency Drive (VFD), without removing the entire motor from its application. 

When selecting a motor, the following questions can help users evaluate serviceability:  

Is this motor built in a way that lets me swap out parts easily? 
Can I get spare parts quickly and cost-effectively?
Can parts, like the controller, be replaced without taking the whole motor apart?

Extend Lifespan

Serviceability extends the lifespan of a motor since routine maintenance and repairs are easier to execute. A motor with high serviceability allows individual components to be replaced, eliminating the need for full motor replacement and substantially reducing costs. 

Preventive maintenance also plays a crucial role in the lifespan of a motor. Motors equipped with monitoring systems can provide early warnings of potential issues, allowing for proactive maintenance and issue prevention. Such features greatly increase serviceability, prevent more significant issues down the line, and prolong the motor’s life. 

The following questions can help users evaluate the lifespan of a motor:  

How long is this motor expected to last? 
Can this motor tell me when something’s about to go wrong? 
Are there guides or resources to help me take care of this motor?

Total Cost of Ownership

Total Cost of Ownership (TCO) is a crucial aspect to consider when selecting an electric motor. TCO includes not only the initial purchase price but also the costs associated with maintenance, repairs, operation, and downtime throughout the motor’s lifecycle. A highly serviceable motor with modular components and easily accessible parts can significantly reduce these ongoing costs. In addition, a motor that can be repaired rather than replaced contributes to lower TCO by reducing the need for potentially costly new motor purchases.

The following questions can help users evaluate the TCO of a motor:

What can I expect to save on operational costs due to this motor’s efficiency?
Does the manufacturer provide support or resources to help minimize repair and maintenance costs?
How does the TCO of this motor compare against a motor that has limited to no serviceability?

Increase Sustainability

Serviceability is also closely tied to sustainability. By facilitating repairs over replacements, serviceable designs reduce waste and support eco-friendly practices. Unlike the more common discard-and-replace approach, repairing or replacing individual components as needed results in less material waste and lower energy consumption during production. 

The following questions can help users evaluate the sustainability of a motor: 

Can this motor be repaired or reused instead of throwing it away – to help reduce waste?
Does this motor have a remanufacturing process in place?
Can this motor be reprogrammed to fit different configuration needs in the future?

Conclusion

In the world of electric motors, serviceability is a crucial factor affecting efficiency, lifespan, sustainability, and total cost of ownership. By incorporating a modular design and providing comprehensive support and resources, Infinitum motors ensure minimal downtime and extend the lifespan of the motor. Our commitment to sustainability means we favor repair over replacement, thereby reducing waste and supporting eco-friendly practices. 

When consumers and industries prioritize serviceability, they can make better choices. This means choosing motors that not only perform well, but also have a longer lifespan and are more sustainable. Infinitum motors are a great example of this, as they are redefining what’s possible in the electric motor industry.

Interested in learning more about Infinitum Aircore EC motor serviceability? Visit our Document Library for articles, guides, videos, and more.  

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Jun 21 2023

The 3 Motor Considerations that Optimize Sustainable Data Center Cooling Designs

With rapid advancements in AI technology and the availability of more powerful servers, the demand for data center infrastructure and more efficient cooling technologies only continues to rise. According to the International Energy Agency, data centers consume about 200 terawatt-hours (TWh) of electricity—amounting to nearly 2 percent of global electricity demand. Based on that usage, data centers contribute 0.3 percent of all global CO₂emissions.

In data centers, racks of servers require the most amount of energy to operate, and server cooling equipment is close behind. Cooling solutions use motors to move air and fluid, so motor efficiency and lower power usage effectiveness (PUE) ratings are top of mind.

Today, data center designers are tasked with keeping power consumption, resource consumption and energy costs as low as possible while maintaining the right environment for reliable operations at scale. Data centers are also subject to a growing number of regulations that seek to minimize their infrastructure and, by extension, their impact on the planet.

Each of these challenges presents an opportunity to help data center designers get closer to achieving their sustainability and efficiency goals. Many of the companies developing the components that make up data center cooling systems are already working towards the same objectives. Understanding how each component in your system supports facility-wide design goals is one way to support progress in this industry. Here, we’ll review three motor considerations to maximize the sustainability of your data center cooling design.

Motor Rightsizing

For fan systems and pump systems alike, finding a motor that has a high level of efficiency across a wide range of speeds and loads will have a significant impact on overall system efficiency. At data centers, loads can vary widely depending on the time of day. Identifying a motor with a flat efficiency curve, regardless of load, optimizes the overall efficiency of the HVAC system. Infinitum motors run at variable speeds to save energy at off-peak times, and efficiency is maintained with precise, demand-based controls.

Motor improvements can save upwards of 65 percent of energy depending on the application area. For example, variable frequency drives (VFDs) with silicon carbide MOSFETS can operate at higher switching frequencies and temperatures with fewer losses because their breakdown strength is ten times that of the standard components used in legacy VFDs. This provides precise control over power, and by extension, energy savings for the motor system. A motor running at 80 percent of its rated speed uses 51 percent of the electricity of a motor running at 100 percent speed. Even greater savings are realized at lower speeds; a motor + VFD running at 50 percent of rated speed uses only 12.5 percent of the full-speed energy. With an efficient fan, the right motor can improve wire-to-air efficiency too.

Rightsizing for Fans

Selecting a custom motor that delivers high levels of efficiency across a fan’s peak power and normal operating speeds can have a meaningful impact on the system’s overall performance. Infinitum’s advanced EC motors can be customized to meet horsepower, speed and torque requirements for high efficiency across a wide range of load conditions.

With a PCB stator design, Infinitum motors are innately more efficient because there are no core losses. Most traditional motors feature a heavy iron core with copper windings. This configuration causes eddy currents, and by extension, losses.

Infinitum makes it easy to rightsize motors on an application-by-application basis. The Aircore EC Motor Selection Tool helps fan OEMs select a properly optimized motor to fit the fan system. Custom nameplating allows designers to get close to the exact motor configuration needed, and it reduces input current requirements, which can add up to significant energy and electrical equipment savings for the whole system. A savings of 5.6 amps for a motor that fits system requirements amounts to 22.4 amps for a single four-fan array module. For 100 fan arrays, that adds up to a savings of 2,2240 amps, which could reduce electrical infrastructure requirements.

For a detailed example of motor rightsizing, read How to Exceed Customer Expectations by Rightsizing the Motor for Your Fan System and explore different configurations with our motor selection tool. There, you’ll find information on torque, speed, input amperage, efficiency and size.

Rightsizing for Pumps

Many of the benefits conveyed above apply to pumps too. With the United States Department of Energy (DOE) proposing new energy conservation standards for circulator pumps, there’s urgency to design for higher efficiency and better reliability. Circulator pumps are usually overlooked for energy efficiency upgrades due to long, expensive design cycles, but new technologies are making these upgrades worthwhile. For more information on pump efficiency, read Five Ways to Maximize Energy Conservation in Circulator Pumps with Electronically Commutated Motors.

Operating the Motor

In the context of data center infrastructure, server cooling, and by extension, motor operation is one of the largest contributors to carbon emissions, so prioritizing a more efficient motor leads to significant savings over time. For example, using the highest efficiency motors available (which corresponds to IE5 or NEMA Premium levels) could save 5,800 gigawatts of electricity—the equivalent of taking 16 million cars off the road. A motor that is more efficient, even by a few percentage points, makes a difference over a 20-year lifespan.

For Infinitum motors, energy consumption during operation is based on standard and published data on power, operating time and the efficiency of the motor + VFD. Compared to a 10HP AC induction motor + VFD with IE1 efficiency, the Infinitum motor system was found to produce 10 percent fewer CO₂emissions over a 20-year period of operation (Figure 1). That amounts to $30,000 in energy cost savings.

Figure 1: Over 20 years, a 10HP Infinitum motor system uses 1,440 Gigawatt-hours (GWh). This amounts to an energy cost savings of $30,000 compared to a 10HP AC induction motor + VFD in this example.

Running 1,000 Infinitum motors for one year alone reduces carbon emissions by 80,000 metric tons of CO₂, which is equivalent to the electricity use of 15,000 homes over the course of a year. The compounding impacts of motor improvements underscore the importance of implementing even smaller changes as early as possible.

Sustainable Design

Physical space is at a premium for data center designers, so equipment size and footprint are central considerations. With a more compact, axial-flux design and a thin PCB stator, motors can be up to 50 percent smaller and lighter. Selecting this kind of design reduces the overall space required for air handling and other cooling infrastructure. When cooling systems are closer to the computing equipment that creates heat, they’re more effective at removing it. Smaller, lighter motors also make for easy installation and maintenance.

These designs also reduce the use of raw materials and incorporate end of life (EOL) management to minimize waste. Infinitum uses information about the procurement and refinement of the materials used in our electric motors as a proxy for the carbon footprint that results from production. The most common materials used in motor manufacturing are copper, iron/steel, aluminum and magnets. Unlike other motors, Infinitum also leverages printed circuit boards (PCBs). Each of these materials is assigned an emissions factor that indicates how much energy it takes to transform it from a raw material to a fabrication-ready state. Our current impact reporting methodology shows an overall CO₂reduction of 18 percent for a 10HP [AL1] Infinitum motor compared to a traditional 10HP AC induction motor (Figure 2).

Figure 2: Infinitum’s methodology shows an overall CO₂reduction of 18 percent for a 10HP Infinitum motor² compared to a traditional 10HP AC induction motor.

Considering the end of life for equipment is also a key aspect of a sustainable data center. Operators are tasked with managing refrigerants and gasses along with valuable materials like aluminum, steel and magnets that shouldn’t end up in a landfill.

At the end of the day, the right motor can help bolster your sustainability claims, improve efficiency and minimize energy costs for data centers. For an overview of mounting schemes for Infinitum motors in fan arrays, read Fan Cube & Fan Array Design Asset.

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Apr 13 2023

Evaluating Sustainability Claims of Electric Motors

There’s no disputing it. Every company should prioritize mindful stewardship of natural resources, including those of us in the industrial sector. To help us do that, we need standards and methodologies that can help us assess the life cycle of the products we deploy. With more knowledge, we can look for ways to lower emissions.

One industry that’s championed standards development and implementation is building and construction. Leadership in Energy and Environmental Design (LEED), the WELL Building Standard, the Living Building Challenge, and Energy Star are comprehensive certifications that account for a building’s lifecycle including, but not limited to, energy, lighting, acoustics, materials and site management. Some existing certifications, like the Living Building Challenge, go beyond reducing footprint. They demand that a building has a net positive impact.

Each of these certifications feature methodologies to assess carbon footprint. For example, LEED includes whole-building life cycle assessment (LCA)—a quantitative approach to comparing the environmental impacts of the products, processes and systems that go into constructing and maintaining a building. While these certifications aren’t perfect solutions, they establish a framework for the building and construction industry to better understand the impact of their work and act on behalf of the environment.

Industrial products and processes are starting to leverage LCA methodologies too. Rochester Institute of Technology defines an industrial LCA as “a systematic analysis of environmental impact over the course of the entire life cycle of a product, material, process, or other measurable activity.” They identify a linear production model that includes:

Material extraction
Production
Packaging and distribution
Use
End of use and waste treatment / recovery, which we’ll refer to as end of life (EOL)

Infinitum is starting down the path to identify baselines for motor production and operation because we believe that once we understand where we are, we can make better decisions on how to improve. Here’s how we’re starting to create a methodology and establish benchmarks.

Making the Infinitum Motor

To start, we’re using information about the procurement and refinement of the materials used in our electric motors as a proxy for the carbon footprint that results from making them. Over time, we aim to be able to assess the production, packaging and delivery processes as well.

The most common materials used in motor manufacturing are copper, iron/steel, aluminum and, sometimes, magnets. Unlike other motors, Infinitum also leverages printed circuit boards (PCBs). Each of these materials is assigned an emissions factor that indicates how much energy it takes to transform from a raw material to its fabrication-ready form.

From a materials standpoint, Infinitum motor emissions are estimated by multiplying the embodied energy (MJ/kg) of each individual material in the motor by its emissions factor. The same process is repeated for a baseline 10HP AC induction motor^[1] for a point of comparison. Emissions are calculated based on type and quantity of materials used, and all emissions are measured in quantity of CO₂. Our current methodology shows an overall CO₂reduction of 18 percent for a 10HP Infinitum motor^[2] compared to a traditional 10HP AC induction motor (Figure 1). 75 percent of the aluminum Infinitum uses for motor housings is recycled material, and in this methodology, we assume the reference motor uses the same ratio.

Figure 1: Infinitum’s methodology shows an overall CO₂reduction of 18 percent for a 10HP Infinitum motor² compared to a traditional 10HP AC induction motor. Key assumptions listed at the end of the page.

Running the Infinitum Motor

With our current methodology, energy consumption during operation is based on standards and published numbers. Energy consumption is based on power, operating time and the efficiency of the motor + VFD. For the sake of comparison, the same calculation is performed for a 10HP AC induction motor + VFD with IE1 efficiency.

For this calculation, emissions avoided from energy consumption are considered for both motor systems^[1] over a 20-year period, and the cost of energy is estimated using U.S. Bureau of Labor statistics. The Infinitum motor system was found to produce 10 percent fewer CO₂emissions in operation.

In a practical example, over a period of 20 years, a 10HP AC induction motor + VFD uses 1,615 Gigawatt-hours (GWh) of energy while a 10HP Infinitum motor system uses 1,440 Gigawatt-hours (GWh). In this scenario energy cost savings amount to $30,000 (Figure 2). Over 20 years, every 100,000 Infinitum motors in service reduces CO₂emissions by 8 million metric tons. That’s the equivalent of pulling 1.5 million homes off the grid for a year.

Figure 2: In a practical example, over 20 years, a 10HP Infinitum motor system uses 1,440 Gigawatt-hours (GWh). This amounts to an energy cost savings of $30,000 compared to a 10HP AC induction motor + VFD.

It’s worth noting that there are a couple of well-known efficiency standards in the industrial space today. Standard IEC/EN 60034-30-1 and the National Electrical Manufacturers Association (NEMA) are typically used to compare one motor to another in terms of operational energy use. IEC, spanning from IE1 to IE5, focuses on application-specific performance. NEMA, spanning from “standard efficiency” to “super premium,” rewards motor designs with broader applicability across applications.

Managing End of Life (EOL) for the Infinitum Motor

At the end of a motor’s operational life, there are three main options: landfill, recycling of materials or remanufacturing (i.e., reuse of components). Infinitum motor components can be reused, so in each generation of manufacturing, CO₂reduction compounds, resulting in a 59 percent CO₂ reduction for the second-generation Infinitum motor compared to the second generation 10HP AC induction motor (Figure 3). Assuming a useful lifetime of 10 years for a conventional 10HP AC induction motor, in 20 years, the conventional motor will have been manufactured twice. In the same amount of time, an Infinitum motor can be manufactured once and remanufactured from reused components. Our current methodology accounts for landfill and remanufacturing. Recycling materials like steel can save energy; however, we can’t confirm that recycled material is used to make the next motor, so that scenario has been omitted.

Figure 3: Infinitum’s methodology shows that CO₂reduction compounds, resulting in a 59 percent CO₂ reduction for the second-generation Infinitum motor compared to the 10HP AC induction motor, which has to be manufactured from scratch both times. Key assumptions listed at the end of the page.

Matters of Methodology

The capacity to compare motors objectively is important. We need to explore the materials used in the motor, the manufacturing processes that turn those materials into components, the assembly process, transportation and distribution, operation and end of life (EOL). As we gain a better understanding of lifecycle emissions, we’ll be able to make informed decisions at each phase in a motor’s life and compare motors more holistically. At Infinitum we’ve begun this journey by measuring and benchmarking several of those methodology process steps.

In 2023, Sustainalytics, a Morningstar Company evaluated our methodology and deemed it “good practice” for impact reporting. We’re committed to making meaningful assessments and finding ways to improve.

Electric motors serve a variety of industries and functions, including HVAC operations where our LCA overlaps with the building and construction industry. Understanding how a well-designed motor can contribute positively to existing and emerging environmental certifications is important to us. By working with Infinitum, customers have access to state-of-the-art motors, but they also gain a sustainability partner for life. We’re always looking for ways to hold ourselves to a higher standard.

For further information on how to reduce the energy requirements of a motor, see How to Exceed Customer Expectations by Rightsizing the Motor for Your Fan System. For more information about how Infinitum can deliver sustainable motors for your application, reach out to our engineering team.

Key assumptions for Carbon Footprint Comparison

Motor compares are for 10 HP – 1800 configurations
AC induction motor weighs 85kg. Infinitum motor weighs 45kg. No VFD
Aluminum for both motors is assumed to be 75% recycled
Useful lifetime for motors assumed = 10 years

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Mar 27 2023

How to Exceed Customer Expectations by Rightsizing the Motor for Your Fan System

Companies that develop fan systems for the HVAC market have a variety of requirements to consider; chief among them are performance and size. Achieving performance targets is the first order of business, but rightsizing the motor for the task at hand can lead to additional benefits.

Finding the right motor is critical for delivering on these requirements at the systems-level.
Here, we’ll:

Walk through the motor selection process
Dive into a few central ways motor design and selection can support overall fan system performance
Provide insights surrounding motor rightsizing and how it can be beneficial in applications with a large number of fans or fan arrays (e.g., data centers)

Unlocking the Potential in the Motor Selection Process
The motor selection process starts early in the fan system design cycle. Performance requirements are dictated by customers in the form of flow targets (cfm) and pressure targets (in-wg). With that knowledge, the fan design team makes two important selections:

A fan model that can deliver on flow rate expectations
A motor with the requisite torque and speed to drive the fan at the customer’s desired operating parameters

Take the example of a data center. These facilities require well-designed fan systems to cool servers, maintain airflow between aisles and sustain appropriate humidity levels.

Our example data center application requires an operating point of 10,000 cfm at 2.5 in-wg of static pressure. The fan OEM uses that operating information as input for an in-house selection software that specifies an appropriate fan model and a motor that provides the brake horsepower (bhp) and motor speed (rpm) required to drive that fan. Rather than using a software tool, for illustrative purposes, we’ll use a fan curve.

Based on our example application parameters, fan model ABC was selected. Once fan model selection is complete, the fan curve, shown in Figure 1, is used to determine the combination of motor power and speed that can deliver the requisite operating conditions.

*Figure 1: Example fan curve; a tool used to visualize a fan’s flow rate and static pressure performance, which can be used to determine motor horsepower and speed requirements*.

In this example, assume the motor that meets customer requirements is a 5.4 hp motor at 1208 rpm with a torque requirement of 23.5 lb-ft (31.8 Nm). Knowing the fan’s power and speed requirements are accounted for, the fan OEM looks for a motor with the best efficiency throughout the fan’s operating range.

Prioritizing Fan Performance and Efficiency in Motor Selection
Motor efficiency benefits the entire fan system, so motor selection is central to energy savings—a focus area for customers and regulators alike. Matching a motor’s peak efficiency with a fan system’s peak efficiency provides the optimal efficiency for the system overall. Motor efficiency curves are helpful for visualizing motor performance across a variety of loads and speeds.

Assess Motors at Partial, Optimal and Full Loads
While it’s important to know the system’s optimal duty point, there will be times when the motor runs at full or partial loads, so it’s equally important to consider how it’ll perform under those circumstances. For instance, when cooling demand decreases in an office building over the weekend, the system may run at a partial load. Alternatively, in a redundancy situation where one fan in an array fails, the others will work harder to maintain airflow and static pressure.

Understanding the reality of fan system operation, Infinitum motors are designed to deliver some of the highest levels of efficiency on the market across a wide range of load conditions and speeds. A flat efficiency curve across loads means the motor delivers higher levels of efficiency during the actual operating conditions of the fan system. Figure 2 shows that the Infinitum Aircore EC motor delivers better efficiency than two leading choices: Super Premium AC Induction Motor & VFD and a Leading EC Fan Motor.

*Figure 2: Fan efficiency curve comparing Super Premium AC Induction Motor & VFD , a Leading EC Fan Motor and Infinitum’s Aircore EC motor*.

Infinitum’s Aircore EC is built with an innovative PCB stator architecture which eliminates core losses and delivers high efficiency levels. The Aircore EC is a motor system that includes the motor and an integrated variable frequency drive (VFD). Each Infinitum motor system comes with a “Final Motor Verification and Test Report” which includes a motor efficiency curve like the one shown in Figure 3.

*Figure 3: Example of Infinitum’s “Final Motor Verification and Test Report”*.

How Infinitum Supports Motor Selection for Fan System Applications
To support the selection process, Infinitum offers the Aircore EC Motor Selection Tool to help fan OEMs select a properly optimized motor to fit their fan system. Returning to our fan system example, Figure 4 shows which motors best fit the 5.4 hp at 1208 rpm combination established using the fan curve. In this case, the motor selection tool provided two options. Fan OEMs can compare these motor recommendations, including rated power, rated speed, motor system efficiency, rated amps and rated torque.

*Figure 4: Example results from* *Infinitum’s motor selection tool*.

Then, fan OEMs select either:

A customized motor system configuration that is provided with a certified nameplate complete with the custom selection’s FLA, rated power, and rated speed
A motor with standard settings and nameplate that can be operated at the specified operating point

Custom Nameplating Services
With custom nameplating, motors like Infinitum’s can be rated with a lower amp rating. The motor selection tool includes the rated amps for each motor option. For the 5.4 hp motor, rated amps is 6.4 A. For the 10 hp motor, rated amps is 12.0 A. A lower input current allows the customer—in our case, a data center designer—to save on upstream electrical infrastructure costs by reducing the amount and size of wiring, circuit breakers and transformers.

In our example, input current savings would amount to 5.6 amps per motor. In a fan array composed of six fans, this amounts to 33.6 amps. The savings become significant when you consider that data centers usually require many fan arrays to prevent servers from overheating, allowing them to stay online for long periods of time. If, for example, the data center required 100 fan arrays (comprised of six fans each), the electrical infrastructure for the 5.4 hp motors would need to handle 3,840 amps (100 arrays x 6 fans x 6.4 amps) where the 10 hp motor would drive a requirement of 7,200 amps (100 arrays x 6 fans x 12 amps).

Size Optimizations at All Levels of Motor Design
Another important factor in motor selection is size. For many fan applications, the length of the motor is a crucial dimension in determining the width of the cabinet that houses the fan system. The Aircore EC motor series is shorter in length than an AC induction motor with comparable horsepower, due to its axial-flux motor design. For example, with the integrated VFD, a 10 hp Aircore EC motor at 1800 rpm is 8.9” in length, including the motor and drive. At 19.8”, a comparable AC induction motor from TECO-Westinghouse (10 hp / 1800 rpm) is more than twice the length. Optimizing the cabinet width to be as small as possible saves precious space in the data center mechanical room and simplifies transport and installation.

Because of the axial-flux motor design, the Aircore EC has a larger diameter than the typical AC induction motor. The larger diameter can be advantageous for centrifugal fan applications if it is close to the diameter of the wheel; in that case, there is less air turbulence through the fan array, so there is smoother airflow through the fan.

In summary, as we saw with our data center example, the ability to pinpoint the motor that best fits the actual power and speed needs of a given fan application will provide downstream benefits. Focusing on performance as early as the motor selection process results in reduced input power per motor, meaning fewer electrical infrastructure needs, reduced energy consumption and significant financial savings up front and over time.

To talk performance requirements with our team or try our motor selection tool for yourself, visit our website.

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