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»Energy efficiency«
in data processing?
Stefan Fassbinder
Deutsches Kupferinstitut
Am Bonneshof 5
D-40474 Düsseldorf
Tel.: +49 211 4796-323
Fax: +49 211 4796-310
sfassbinder@kupferinstitut.de
stf@eurocopper.org
www.kupferinstitut.de
The German Copper Institute, DKI, is
the central information and advisory
service dealing with all uses of copper
and copper alloys.
We offer our services to:
   Commercial companies    We can be contacted by:
   The skilled trades       post
   Industry                 phone
   R & D institutes         fax
   Universities             e-mail
   Artists and craftsmen    internet
   Students                 online database, or
   Private individuals      personally
An accidental finding:

Wanted:
The noise free living room PC

Found:
An energy glutton wasting energy for
lack of aluminium and copper
This brand new PC power supply
              unit




           at 39.95€




 promises to be 60% less noisy!   4
Well, 60% less noise
is at least a statement!

Though not really any more than that …

… as long as the question remains
unanswered:



Less than what?
This was not the way
Now what to do?
Loss heat can be
• either blown away
• or avoided!
So a different solution had to be found:
A fanless PSU (at 79.50€) works
totally noise free!
How is this reduction in
noise level achieved?
By improvement of passive cooling or by
reduction of cooling need, say losses?
By improvement of passive cooling and by
reduction of losses:
• Substantial enhancement of cooling
  surface on the aluminium heat sinks
• Substantial enhancement of copper cross
  sections in the windings of HF converters
But loss reduction holds
the greater share!
140W
                            Starting up a PC with
120W                       subsequent idle operation
       P
100W

80W

60W

40W
                Original PSU Antec True 380 SP
20W             Fanless PSU FSP ZEN (2009)

 0W
  00:00min         05:00min          t          10:00min
How to reduce losses? – Use more material!
Conventional                     Fanless




420 W                             300 W
Still, the actual net power
consumption of a common PC
(built in 2005, 800 MHz) is:

• 50 W when idling (whereas writing a text
  or composing an Excel table is idle for a
  PC!),
• 100 W at peak processor demand
  (gaming),
while the common power supply unit is very
much over-dimensioned!
Therefore the 300 W model
can quite conveniently
replace a 420 W unit.
  PC power              Antec   FSP ZEN
                      True 380 with active
 supply unit
                      SP with     PFC,
 comparison             active   fanless
    Power rating        380W      300W
            Weight      1995g     2223g
 Material intensity   5.250g/W 7.410g/W
            Factor      100%      141%
If this were not so the copper content would
have to be 41% higher rather than just 11%
Who else should have an
interest in this topic?
This is the reply to a request to the
colleagues from www.aluinfo.de sent
March 31, 2009:




I‘m still waiting…
Conventional PC power
unit, 420W
          PC power supply LC4620, S/N: 7J090402
                 Rated power                420W
 Input
            30.0A     28.0A      14.0A              Output
  P          3.3V      5.0V      12.0V        P      P /P N     η
   4.4W      0.0A      0.0A         0.0A       0.0W      0.0%    0.0%
  13.5W      0.0A      0.0A         0.0A       0.0W      0.0%    0.0%
  64.0W      0.0A      0.0A         3.3A     40.1W       9.5%   62.6%
  71.0W     17.5A      0.0A         0.0A     57.8W      13.8%   81.3%
 109.0W      0.0A      0.0A         6.7A     80.2W      19.1%   73.5%
 148.0W      0.0A      0.0A         9.4A    113.2W      26.9%   76.5%
 161.0W      0.0A     25.0A         0.0A    125.0W      29.8%   77.6%
 286.0W      0.0A      0.0A       18.8A     226.0W      53.8%   79.0%
 307.0W     28.5A     24.0A         0.0A    214.1W      51.0%   69.7%
 450.0W     28.5A     25.0A         7.0A    303.1W      72.2%   67.3%
 740.0W             PSU failure after ≈2s with <20% overload
Conventional PC power
unit, 300W
            PC power supply T.I.P. 300 ATX
               Rated power               218W
 Input
          14.0A     20.0A       6.0A             Output
  P        3.3V      5.0V      12.0V     P        P /P N     η
   0.0W    0.0A        0.0A      0.0A     0.0W        0.0%    0.0%
   3.1W    0.0A        0.0A      0.0A     0.0W        0.0%    0.0%
  21.4W    0.0A        0.0A      0.5A     6.1W        2.8%   28.6%
  43.3W    0.0A        2.2A      0.9A   21.7W         9.9%   50.0%
  56.8W    0.0A        0.0A      3.2A   38.9W        17.8%   68.5%
  70.0W    0.0A        0.0A      4.3A   51.4W        23.5%   73.4%
  97.0W    0.0A        5.0A      3.4A   66.1W        30.3%   68.1%
 122.0W    0.0A        5.0A      5.2A   87.2W        40.0%   71.5%
 148.0W    5.8A        5.0A      5.2A  106.0W        48.6%   71.6%
 181.0W    5.8A        9.5A      5.2A  129.0W        59.1%   71.3%
 226.0W   14.0A        9.5A      5.3A  157.4W        72.1%   69.7%
            Shut-off – no more measurements possible
Conventional PC power
unit, 380W
           PC power supply Antec True 380 SP
                Rated power            380W
 Input
           28.0A     35.0A    18.0A            Output
  P         3.3V      5.0V    12.0V    P        P /P N   η
   0.0W     0.0A     0.0A      0.0A     0.0W      0.0%    0.0%
   4.4W   Fanless PC power
            0.0A     0.0A      0.0A     0.0W      0.0%    0.0%
  28.3W     2.2A     0.0A      0.0A     7.1W      1.9%   25.1%
  64.8W   unit, 300W
            2.5A     0.0A      0.9A    19.1W      5.0%   29.4%
  90.0W     2.5A     4.0A      0.9A    39.1W     10.3%   43.4%
 109.0W
 148.0W
          Rated efficiency:
            6.1A
            6.1A
                     4.4A
                     4.6A
                               0.9A
                               3.3A
                                       53.3W
                                       82.6W
                                                 14.0%
                                                 21.7%
                                                         48.9%
                                                         55.8%
 174.0W     5.6A     9.3A      3.3A   105.0W     27.6%   60.3%
 282.0W   89% (at full load)
           27.0A     9.3A      3.4A   176.2W     46.4%   62.5%
 381.0W    27.0A    17.0A      6.7A   254.5W     67.0%   66.8%
 463.0W    27.0A    17.0A     12.9A   328.9W     86.6%   71.0%
 561.0W    27.0A    17.0A     19.0A   402.1W    105.8%   71.7%
How high is the »efficiency« of a PC?
Much higher than earlier, anyway!
Ancient XT:               Latest model:
f = 4,7 MHz               f = 4,7 GHz
Pel ≈ 40 W                Pel <<400 W
This looks like an efficiency improvement by far
more than a factor of 100! With similar values for
• storage units,
• hard disks,
• graphic adaptors
you end up with improvement factors around 106!
Where will the journey
still take us?
A limit will be reached only when for one data bit
only more one electron needs to be moved.
So long, however, it‘s still 10,000 to 100,000
electrons that need to be employed for the smallest
occurring »elementary process« in data processing.
So the theoretical potential
• with miniaturisation,
• with acceleration of procedures,
• with reduction of energy demand
still lies somewhere near a factor of 104 … 105!
Hence the major part
of the job is done
• The first computer »Zuse Z1« had the
  dimensions of an electrical locomotive…
• …along with its power consumption…
• …and this with the performance of a credit
  card sized pocket calculator which you get
  as a giveaway nowadays and which is
  supplied from 2 cm² of solar cells or with a
  button cell battery for no less than a year!
But progress with
processors is continuing:
          PC built      upgraded
          2005          2011
Processor 2.6 GHz,      2*2.7 GHz,
RAM       512 MB,       4 GB,
          400 MHz       1.6 GHz
Idle power 59 W         45 W
measured with the same fanless PSU
Only what‘s the use of it all
if you do anything you can
think of in order to e. g. implement all
available efficiency techniques in a
modern diesel engine and then add a
gearbox with 30% of losses?
Nobody would do that in a car –
in a PC it‘s the usual approach!
For the PSU is sort of a
»gearbox for electricity«.
The noiseless operation
comes for free!
          Calculation of power consumption costs for a PC (built in 2005)
         before and after replacing the conventional PSU with a fanless one
                     Conventional PSU with fan                        Fanless PSU
  Output values     P      S       Q        LF      cosφ     P       S        Q        LF      cosφ
Full load 100h/a 135.5W 138.9VA 51.4var     0.975    0.977 113.0W 123.2VA    67.0var   0.890    0.940
No load 3000h/a    82.0W 87.1VA 29.3var     0.939    0.945  59.2W 70.5VA     38.1var   0.843    0.886
»off«      5660h/a  6.3W 24.5VA 23.6var     0.256    0.307   2.0W 24.1VA     24.0var   0.080    0.112
          PSU                   39.95 €                                     79.50 €
Price
          Power                                      14.0c/kWh
Consumption                   294.91kWh/a                               200.36kWh/a
Electricity costs               41.29€/a                                  28.05€/a
Payback time                                           2.99a


The saved losses pay back for the price
premium within 3 years. The global savings
potential in 1 bn PCs would be 100 TWh/a!
Morals: I am a fan of the fanless design!
Then why do portable PCs provide
 the same computing performance
  with that much less electricity?
This notebook PC
is equipped with an integrated
55 Wh battery and an additional
95 Wh battery and runs for about
13 hours on these, corresponding to
12 W net DC power requirement!
Metering conditions:
• WLAN off,
• no UMTS device,
• no »action games«,
• moderate screen brightness.
Whereas it is remarkable with the laptop PC
• that the screen is already included
• and the whole PC uses less power …
… than a desktop flat screen uses
         for itself alone!
So in the end there is one
question remaining open:
Why can this technique not be built
into a desktop PC?
Energy is still way too cheap.
The availability of electricity from the
accumulator is a reason to save
energy – the electricity price obviously
is not.

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Fan noise

  • 1. »Energy efficiency« in data processing? Stefan Fassbinder Deutsches Kupferinstitut Am Bonneshof 5 D-40474 Düsseldorf Tel.: +49 211 4796-323 Fax: +49 211 4796-310 sfassbinder@kupferinstitut.de stf@eurocopper.org www.kupferinstitut.de
  • 2. The German Copper Institute, DKI, is the central information and advisory service dealing with all uses of copper and copper alloys. We offer our services to:  Commercial companies We can be contacted by:  The skilled trades  post  Industry  phone  R & D institutes  fax  Universities  e-mail  Artists and craftsmen  internet  Students  online database, or  Private individuals  personally
  • 3. An accidental finding: Wanted: The noise free living room PC Found: An energy glutton wasting energy for lack of aluminium and copper
  • 4. This brand new PC power supply unit at 39.95€ promises to be 60% less noisy! 4
  • 5. Well, 60% less noise is at least a statement! Though not really any more than that … … as long as the question remains unanswered: Less than what?
  • 6. This was not the way Now what to do? Loss heat can be • either blown away • or avoided! So a different solution had to be found: A fanless PSU (at 79.50€) works totally noise free!
  • 7. How is this reduction in noise level achieved? By improvement of passive cooling or by reduction of cooling need, say losses? By improvement of passive cooling and by reduction of losses: • Substantial enhancement of cooling surface on the aluminium heat sinks • Substantial enhancement of copper cross sections in the windings of HF converters
  • 8. But loss reduction holds the greater share! 140W  Starting up a PC with 120W subsequent idle operation P 100W 80W 60W 40W Original PSU Antec True 380 SP 20W Fanless PSU FSP ZEN (2009) 0W 00:00min 05:00min t  10:00min
  • 9. How to reduce losses? – Use more material! Conventional Fanless 420 W 300 W
  • 10. Still, the actual net power consumption of a common PC (built in 2005, 800 MHz) is: • 50 W when idling (whereas writing a text or composing an Excel table is idle for a PC!), • 100 W at peak processor demand (gaming), while the common power supply unit is very much over-dimensioned!
  • 11. Therefore the 300 W model can quite conveniently replace a 420 W unit. PC power Antec FSP ZEN True 380 with active supply unit SP with PFC, comparison active fanless Power rating 380W 300W Weight 1995g 2223g Material intensity 5.250g/W 7.410g/W Factor 100% 141% If this were not so the copper content would have to be 41% higher rather than just 11%
  • 12. Who else should have an interest in this topic? This is the reply to a request to the colleagues from www.aluinfo.de sent March 31, 2009: I‘m still waiting…
  • 13. Conventional PC power unit, 420W PC power supply LC4620, S/N: 7J090402 Rated power 420W Input 30.0A 28.0A 14.0A Output P 3.3V 5.0V 12.0V P P /P N η 4.4W 0.0A 0.0A 0.0A 0.0W 0.0% 0.0% 13.5W 0.0A 0.0A 0.0A 0.0W 0.0% 0.0% 64.0W 0.0A 0.0A 3.3A 40.1W 9.5% 62.6% 71.0W 17.5A 0.0A 0.0A 57.8W 13.8% 81.3% 109.0W 0.0A 0.0A 6.7A 80.2W 19.1% 73.5% 148.0W 0.0A 0.0A 9.4A 113.2W 26.9% 76.5% 161.0W 0.0A 25.0A 0.0A 125.0W 29.8% 77.6% 286.0W 0.0A 0.0A 18.8A 226.0W 53.8% 79.0% 307.0W 28.5A 24.0A 0.0A 214.1W 51.0% 69.7% 450.0W 28.5A 25.0A 7.0A 303.1W 72.2% 67.3% 740.0W PSU failure after ≈2s with <20% overload
  • 14. Conventional PC power unit, 300W PC power supply T.I.P. 300 ATX Rated power 218W Input 14.0A 20.0A 6.0A Output P 3.3V 5.0V 12.0V P P /P N η 0.0W 0.0A 0.0A 0.0A 0.0W 0.0% 0.0% 3.1W 0.0A 0.0A 0.0A 0.0W 0.0% 0.0% 21.4W 0.0A 0.0A 0.5A 6.1W 2.8% 28.6% 43.3W 0.0A 2.2A 0.9A 21.7W 9.9% 50.0% 56.8W 0.0A 0.0A 3.2A 38.9W 17.8% 68.5% 70.0W 0.0A 0.0A 4.3A 51.4W 23.5% 73.4% 97.0W 0.0A 5.0A 3.4A 66.1W 30.3% 68.1% 122.0W 0.0A 5.0A 5.2A 87.2W 40.0% 71.5% 148.0W 5.8A 5.0A 5.2A 106.0W 48.6% 71.6% 181.0W 5.8A 9.5A 5.2A 129.0W 59.1% 71.3% 226.0W 14.0A 9.5A 5.3A 157.4W 72.1% 69.7% Shut-off – no more measurements possible
  • 15. Conventional PC power unit, 380W PC power supply Antec True 380 SP Rated power 380W Input 28.0A 35.0A 18.0A Output P 3.3V 5.0V 12.0V P P /P N η 0.0W 0.0A 0.0A 0.0A 0.0W 0.0% 0.0% 4.4W Fanless PC power 0.0A 0.0A 0.0A 0.0W 0.0% 0.0% 28.3W 2.2A 0.0A 0.0A 7.1W 1.9% 25.1% 64.8W unit, 300W 2.5A 0.0A 0.9A 19.1W 5.0% 29.4% 90.0W 2.5A 4.0A 0.9A 39.1W 10.3% 43.4% 109.0W 148.0W Rated efficiency: 6.1A 6.1A 4.4A 4.6A 0.9A 3.3A 53.3W 82.6W 14.0% 21.7% 48.9% 55.8% 174.0W 5.6A 9.3A 3.3A 105.0W 27.6% 60.3% 282.0W 89% (at full load) 27.0A 9.3A 3.4A 176.2W 46.4% 62.5% 381.0W 27.0A 17.0A 6.7A 254.5W 67.0% 66.8% 463.0W 27.0A 17.0A 12.9A 328.9W 86.6% 71.0% 561.0W 27.0A 17.0A 19.0A 402.1W 105.8% 71.7%
  • 16. How high is the »efficiency« of a PC? Much higher than earlier, anyway! Ancient XT: Latest model: f = 4,7 MHz f = 4,7 GHz Pel ≈ 40 W Pel <<400 W This looks like an efficiency improvement by far more than a factor of 100! With similar values for • storage units, • hard disks, • graphic adaptors you end up with improvement factors around 106!
  • 17. Where will the journey still take us? A limit will be reached only when for one data bit only more one electron needs to be moved. So long, however, it‘s still 10,000 to 100,000 electrons that need to be employed for the smallest occurring »elementary process« in data processing. So the theoretical potential • with miniaturisation, • with acceleration of procedures, • with reduction of energy demand still lies somewhere near a factor of 104 … 105!
  • 18. Hence the major part of the job is done • The first computer »Zuse Z1« had the dimensions of an electrical locomotive… • …along with its power consumption… • …and this with the performance of a credit card sized pocket calculator which you get as a giveaway nowadays and which is supplied from 2 cm² of solar cells or with a button cell battery for no less than a year!
  • 19. But progress with processors is continuing: PC built upgraded 2005 2011 Processor 2.6 GHz, 2*2.7 GHz, RAM 512 MB, 4 GB, 400 MHz 1.6 GHz Idle power 59 W 45 W measured with the same fanless PSU
  • 20. Only what‘s the use of it all if you do anything you can think of in order to e. g. implement all available efficiency techniques in a modern diesel engine and then add a gearbox with 30% of losses? Nobody would do that in a car – in a PC it‘s the usual approach! For the PSU is sort of a »gearbox for electricity«.
  • 21. The noiseless operation comes for free! Calculation of power consumption costs for a PC (built in 2005) before and after replacing the conventional PSU with a fanless one Conventional PSU with fan Fanless PSU Output values P S Q LF cosφ P S Q LF cosφ Full load 100h/a 135.5W 138.9VA 51.4var 0.975 0.977 113.0W 123.2VA 67.0var 0.890 0.940 No load 3000h/a 82.0W 87.1VA 29.3var 0.939 0.945 59.2W 70.5VA 38.1var 0.843 0.886 »off« 5660h/a 6.3W 24.5VA 23.6var 0.256 0.307 2.0W 24.1VA 24.0var 0.080 0.112 PSU 39.95 € 79.50 € Price Power 14.0c/kWh Consumption 294.91kWh/a 200.36kWh/a Electricity costs 41.29€/a 28.05€/a Payback time 2.99a The saved losses pay back for the price premium within 3 years. The global savings potential in 1 bn PCs would be 100 TWh/a! Morals: I am a fan of the fanless design!
  • 22. Then why do portable PCs provide the same computing performance with that much less electricity? This notebook PC is equipped with an integrated 55 Wh battery and an additional 95 Wh battery and runs for about 13 hours on these, corresponding to 12 W net DC power requirement!
  • 23. Metering conditions: • WLAN off, • no UMTS device, • no »action games«, • moderate screen brightness. Whereas it is remarkable with the laptop PC • that the screen is already included • and the whole PC uses less power …
  • 24. … than a desktop flat screen uses for itself alone!
  • 25. So in the end there is one question remaining open: Why can this technique not be built into a desktop PC? Energy is still way too cheap. The availability of electricity from the accumulator is a reason to save energy – the electricity price obviously is not.