Executive Summary 4G WiMax Radio Access Cabinet

Transcription

1 Executive Summary 4G WiMax Radio Access Cabinet

2 From Napkin to Network 4

3 Development Team-Goals Partner in Design, Concept and Manufacturing of Next Gen-Radio Access Cabinet Design a Cabinet Environment that Increases Equipment Efficiencies Improve on time delivery for increased national deployment Reduce Overall CAPEX Reduce OPEX for Site Maintenance Reduce Utility Costs or Eliminate all together-* With Thermal Enhanced Engineering *Note: Majority of Utility Costs come from Air Conditioning and cooling of Radio Equipment! 5

4 Design a Cabinet Environment that Increases Equipment Efficiencies First of it s kind enhanced Equipment Layout Thermally Enhanced Design Challenge in design with Energy/Equipment Efficiencies as paramount 6

5 Proven Manufacture with substantial capabilities Enjoy the full resources of Nu-Way Industries Enclosure Development and Integration for the programs success 7

6 Reduce Overall CAPEX- Unique Business Model The Scenario Expert in thermal and Outside Plant solutions. Thermal spend in Outside Plant ranges from 40+% of the total spend. Enclosure Companies must purchase thermal at market pricing. Integration of thermal into the solution demands a margin multiplier. The Solution- create a unique business relationship to reduce this multiplier. Nu-Way Engineers Designs the Thermal and Cabinet together from conception to finish product. Designedt o accommodate thermal, applications and standards requirements. Provides service support, warranty and aftermarket support for thermal. 8

7 Reduce OPEX Through Thermally Enhanced Equipment Design Strategy Majority of Utility Costs come from Air Conditioning and cooling of Radio Equipment! Challenges of Fresh Air Cooling Simple Design- less failure modes than traditional ACU applications Highest Energy Efficiency of ALL Cooling Modes DC Powered, Continues to Cool During Power Outage Requires Temperature Rise Above Ambient to Operate Telcom normally requires hardening to 65C Some equipment is only rated to 50C intake Requires Hydrophobic Media to Protect Electronics- 9

8 Reduce Utility Costs- With thermally Enhanced Engineering New Variable Speed Air Conditioning Technology-Designed Exclusively for the telecommunications 4G WiMax / LTE Launch Advantages of variable compressor speed control Stable enclosure temperature no thermal cycling Accurate enclosure temperature control Improved MTBF Immediate response to changes in enclosure thermal load Reduced power consumption / improved COP & EE Reduced OPEX Reduced operation of Air Conditioner Compressor and ambient fan. Provides Emergency backup cooling when AC power is not available. Extends Run Time by increasing time to Max Thermal conditions. Disadvantages-Periodic Filter Maintenance 10

9 Thermal Climate Map-Logistics Deployment Pin Key Green= Never above 40c DAC Red= Above 43c ACU Mandated An interactive map with thermal characteristics by area has been developed for all deployment cities. Push pins are color coded to indicate climate conditions. Min, max and altitude data are presented with a mouse click on any pin. A hot link to yearly data is also presented under each pin. 13

10 1P M 2P M Thermal Data-CFD Model Solar load on the cabinet at different times of the day <144 W <272 W <192 W <186W <962 W <932 W Geographical location: Arizona ambient temperature: 46 C Max solar load on top panel is 962 W Max solar load on panel facing the sun is 192 W Max solar load on top panel is 932 W Max solar load on panel facing the sun is 272 W 3P M <662W <120W <803 W Max solar load on top panel is 803 W Max solar load on panel facing the sun is 662 W 4P M <645W <32W <613 W Max solar load on top panel is 613 W Max solar load on panel facing the sun is 645 W 14

11 Is Roof Top Installation a Thermal Concern? <81 C Concrete painted black <115 C Concrete (gray) Concrete <113 C Cabinet 2 above ground <136 C Grass (green) Grass <134 C Cabinet 2 above ground Conditions: 2:00PM, July 1 st Phoenix Arizona Simulated ambient temp to be 46 C No internal load or cooling Results: When the cabinet sits on a black painted concrete slab the cabinet envelope will reach an maximum temperature of 81 C (average temp of 58 C). On unpainted concrete the cabinet envelope maximum temperature will reach 115 C (average temp of 96 C). On concrete but 2 feet above the ground the max temperature on the envelope is 113 deg C (average temp is 95 deg C) On a grass field the cabinet skin can reach temperatures as high as136 C (average temp of 122 C). On a grass field 2 feet elevated, the max temp is 134 C (average temp of 121 C). Conclusion: When cabinet is sitting on a dark surface the temperature rise on its skin from radiation is lower since the surface doesn t deflect any energy. If cabinet is floating above the ground it will receive some extra radiant heat from some angles but more surface area is in contact with the ambient air so the extra affect of radiation is negligible. 15

12 Thermal Data CFD Model Cabinet Temperatures at equilibrium under solar load with internal cooling Grass (green) Grass (green) Conditions: 2:00PM, July 1 st Phoenix Arizona Simulated ambient temp to be 46 C Surface: Grass field No internal heat load 600 W of cooling To simulate the air flow the air on the cabinet the model circulates air front to back at 200 CFM and returning on top and sides. Results: Under the described conditions the average temperature of the cabinet skin is 55 deg C and the inside air temperature in the cabinet will stay under 45 deg C. Conclusion: If the cabinet is designed to GR-487-CORE the calculated solar load takes into account all direct and indirect radiation and exceeds the worst case situation encountered in the natural environment. 16

13 Mechanical Integrity-Water Egress Test 17

14 Thermal Design Challenge Create robust thermal environment for equipment hardened to 50C inlet temperatures Minimize Failure Modes Minimize operating costs Establish benchmark acoustic performance Consider that heat loads will increase with new equipment adds and designs 18

15 Thermal Strategy and Testing Philosophy Establish cooling solution with lowest possible energy consumption Establish worst case testing conditions to include: Maximum Internal Heat Load (1840W) Maximum Solar Loading per GR-487 (calculated) Worst case ambient conditions per GR-487 Ensure substantial thermal margin: Covers single fan failure Covers decreased performance as filters clog Covers future equipment adds with potential for higher thermal loading Covers unique situations (close to heat generating source) Establish cooling capacity with lowest possible acoustic results Ensure continued cooling during power failure using only DC reserve power 19

16 Thermal Design Approach Strong influence on front end design Establish best case air flow, take advantage of the natural convection Front to back, by creating hot column, cold column Bottom to top, by locating fan tray above equipment stack Avoid re-mixing, by locating exhaust in rear of enclosure Utilize fresh air cooling for highest possible cooling efficiency High efficiency, Hydrophic filter for equipment protection Create large surface area for consistent air flow, longevity Utilize proven dual fan system with backward curved impeller approach Utilize DC powered controller and fans for power fail cooling coverage Establish ACU solution for highest temperature environments 20

17 Thermal Design Results Top Mount Fan Tray Provides direct exhaust of hot column to back Of enclosure Solar Shield, Hoods and Telco box Serve to Reduce Radiation Heat Loads Ambient Intake Air Is evenly distributed to All Rack Mount Elements Mid Mount Rack Rails 21

18 Thermal Design Results Top Mount Fan Tray Provides direct exhaust of hot column to back Of enclosure Front Filter Hoods Provide wind driven rain protection And improve acoustic performance Large, Dual Filter Cassettes Provide 95% Clean Air At.3 Micron Particle Size Sealed and potted frame for water Ingress protection Cold Front Column Allows space for intake of cool air into rack equipment Rack equipment creates front to back air flow Rear Exhaust Hood Protects against wind driven rain and improves Acoustic performance 22

19 Energy Conservation Current in DC Amperes " Enclosure Current Draw Versus Fan Speed Current Draw Note: we are cooling 2,000 Watts of Heating using 8/10 th Amperage 54Vdc Observations: Target speed to cool equipment is 1200 RPMs, Current Draw -54 VDC Worst cast power consumption is 43W Typical power draw will be substantially lower with reduced duty cycle. Typical 4000 BTU Air Conditioner draws 874W 23

20 0:00:00 0:00:20 0:00:40 0:01:00 0:01:20 0:01:40 0:02:00 0:02:20 0:02:40 0:03:00 0:03:20 0:03:40 0:04:00 0:04:20 0:04:40 0:05:00 0:05:20 0:05:40 0:06:00 0:06:20 0:06:40 0:07:00 0:07:20 0:07:40 0:08:00 0:08:20 0:08:40 0:09:00 0:09:20 0:09:40 0:10:00 0:10:20 0:10:40 0:11:00 0:11:20 0:11:40 0:12:00 0:12:20 0:12:40 0:13:00 0:13:20 0:13:40 0:14:00 0:14:20 0:14:40 Air Temperature Degrees Celcius Thermal Test Data Moderate Climate 60 66" Enclosure Direct Ambient Cooling Thermal Results Fan Speed 1200 RPMS, Ambient Temperature 22C Average IDU1 IDU5 RAS Top Site Boss RAS In Exhaust 0 Observations: Fans set to half speed Fully redundant cooling All data was taken with maximum internal load of 1840W Input temperature to equipment is less than a 2 degrees Celsius increase over ambient Current draw -54 VDC = 38 Watts of Energy Consumption! During Power Failure, the system continues to cool on battery back up Acoustic noise performance measures 51.2 dba per GR487 method 24

21 0:00:00 0:00:20 0:00:40 0:01:00 0:01:20 0:01:40 0:02:00 0:02:20 0:02:40 0:03:00 0:03:20 0:03:40 0:04:00 0:04:20 0:04:40 0:05:00 0:05:20 0:05:40 0:06:00 0:06:20 0:06:40 0:07:00 0:07:20 0:07:40 0:08:00 0:08:20 0:08:40 0:09:00 0:09:20 0:09:40 0:10:00 0:10:20 0:10:40 0:11:00 0:11:20 0:11:40 0:12:00 0:12:20 0:12:40 Air Temperature Degrees Celsius Thermal Test Data Hot Climate 60 66" Enclosure Direct Ambient Cooling Thermal Results Fan Speed 1200 RPMs, Ambient Temperature 42C Average IDU1 IDU5 RAS Top Site Boss RAS In Exhaust 10 0 Observation: The direct ambient cooling approach results in consistent delta T, independent of ambient conditions DAC Approach is recommended to 43C ambient conditions 25

22 Sound Level dba or Temperature Degrees Celsius Acoustic Performance Direct Ambient System " Enclosure GR487 Acoustic Test Results Sound Level Versus Fan Speed db A Front db A Side db A Rear Average db A - 3m Temperature Observations: Target speed to cool equipment is 1200 RPMs, Average sound level is 51.2 dba Night time performance will be less than 50 dba with reduced ambient temperature 26

23 Thermal Design Extreme Environment VC-2900-E All In One Variable Speed Air Conditioner Matches Cooling Capacity to Heat Load Cooling Range is 6000 to BTUs Includes DC Powered, Fresh Air System 27

24 Time 0:01:30 0:03:10 0:04:50 0:06:30 0:08:10 0:09:50 0:11:30 0:13:10 0:14:50 0:16:30 0:18:10 0:19:50 0:21:30 0:23:10 0:24:50 0:26:30 0:28:10 0:29:50 0:31:30 0:33:10 0:34:50 0:36:30 0:38:10 0:39:50 0:41:30 0:43:10 0:44:50 0:46:30 0:48:10 0:49:50 0:51:30 0:53:10 0:54:50 0:56:30 0:58:10 0:59:50 1:01:30 1:03:10 1:04:50 1:06:30 1:08:10 1:09:50 1:11:30 1:13:10 Air Temperature Degrees Celsius Thermal Test Data Extreme Climate " Enclosure VC-2900-E All-In-One Air Conditioner Thermal Results Chamber Target Temperature 52 Degrees Celsius IDU 1 IDU 5 RAS Top RAS In Site Boss Battery Chamber Ambient 10 0 Observations: System fully covers maximum thermal load of 1840 Watts The ACU compressor is variable speed and eliminates thermal cycling A built-in Economizer begins to function reduced ambient temperatures During Power Failure, the system continues to cool using the economizer function 28

25 Thermal Conclusions DAC Approach Covers 90% of US Climate Conditions. OPEX and CAPEX are substantially lower than ACU cooling approaches Acoustic performance is sub 60 dba for most operating conditions, sub 50 dba for night time The VC-2900 provides a stable thermal environment for the remaining 10%, extreme temperature applications Both options were design with substantial thermal margins. 29