COOLING FAN REQUIREMENTS CALCULATIONS

Determining System Impedance

Determining the actual airflow produced by a fan mounted in an enclosure is much more
difficult than calculating the airflow required. Obstructions in the airflow path cause static
pressure within the enclosure, referred to as system impedance (expressed in static
pressure as a function of flow in CFM). To maximize airflow, any resistance should be
minimized, except for baffles that may be necessary to direct the airflow.

A typical system impedance curve for electronic equipment follows what is called the
"square law". This law states that static pressure changes as a square function of
changes in the CFM. The chart to the right displays typical impedance curves. Static
pressure through complex systems cannot be easily arrived at by calculation.

The experimental method of finding airflow through an enclosure is very accurate, but
costly, time consuming and cumbersome. In practice, empirical methods are normally
used to estimate airflow resistance. Experience shows that:

 An empty enclosure usually reduces airflow by 5 to 20%.

 A densely packed enclosure reduces airflow by 60% or more.
 Most enclosures have a static pressure between 0.05 and 0.15 in H2O.

Once you know the volume of air and the static pressure of the system to be
cooled, you can determine the fan specifications for your product.
  Required Air Flow
 DC or AC Power
 Voltage
 Speed
 Life Expectancy
 EMI/RFI
 Heat Dissipation
 Auto-restart
 Acoustic Noise

This guide will help you determine the best cooling sol
for your product.
Intake or Exhaust
Forced air-cooling for packaged electronic enclosures
can be achieved by either evacuation (with fan on
exhaust side) or pressurizing the enclosure with a fan
on the intake side. This choice should be made early
in the design process. Although both theoretically use
the same volume of air to dissipate the heat, they
have different effects on placement of components
within the enclosure.
When using an exhaust fan, the air distribution inside
the cabinet is flexible and heat from the fan itself is
not dissipated into the cabinet. Evacuation has the
disadvantage of reducing the pressure within the
enclosure, so airborne dust is drawn in through all the
vents and cracks in the enclosure. Filtering of the fan
on the exhaust side is extremely difficult. A further
benefit is that the enclosure is slightly pressurized so
that dust is not drawn into the enclosure from the
surrounding environment.
The disadvantage of intake fans is that filters must be
changed frequently to eliminate dust accumulation. A
clogged filter can
severely restrict
airflow, causing
elevated
temperatures in an
enclosure that may be
more of a problem
than the dust itself.
Another disadvantage
of a fan that
pressurizes the
system is that air dissipated by the fan motor can
slightly warm the incoming air. This can reduce the
air's cooling effect. Components that have the most
critical cooling requirements should be placed closest
to the air inlets. High temperature components should
be placed closest to the air outlets.
If exclusion of dust is required, it is better to use a fan
that pulls air into the enclosure. In this configuration, a
filter at the fan inlet can remove dust from the
incoming air.
Air that is drawn into the fan flows in a continuous,
non-turbulent movement called laminar flow, which
allows for a uniformly distributed airflow velocity in the
enclosure. This is important in eliminating stagnant air
and hot spots. Air exhausted from the fan is turbulent.
Heat dissipation in a turbulent airflow can be up to
twice that of a laminar flow with the same volumetric
flow rate, except that the turbulent airflow region near
a fan exhaust is normally limited.
Developing a well-defined airflow path through the
whole enclosure is essential to minimizing airflow
waste. Vents should be at least 50 percent larger than
the fan openings themselves. Care must also be
 taken to eliminate air re-
circulation in a fan, as
over ninety percent of the
airflow can be lost.
Baffles may be used to
eliminate re-circulation of
the same air since an
airflow path will always
take the path of least resistance (Figure Above).
Subassemblies and components within the enclosure
should be positioned to direct the airflow to places
that require cooling. Component placement should
always be considered in order to take advantage of
natural convection; for example, placing warm
components above cool components. Avoid placing
large components so that they shield smaller
components from the flow of air. Use baffles, where
necessary, to direct the airflow to critical hot spots.
Smaller systems usually use axial cooling fans, where
airflow is perpendicular to the fan blades. The airflow
required to dissipate the heat generated can either be
obtained by calculation or from a graph. This airflow
requirement will depend on the heat generated within
the enclosure and the maximum temperature rise
permitted. When estimating the power dissipated
within a system, use a worst-case estimate for a fully
loaded system to allow for the possibility of future
changes and additions of heat generating
subsystems.
In many applications, using an intake fan rather than
an exhaust fan can double or triple the life of the fan.
The heated air passing over an exhaust fan stresses
the fan's bearings much more than the 25°C air
flowing over an intake fan. This reduction in
temperature provides a dramatic increase on fan life,
as seen in the JMC Life Expectancy Curve (Chart
Above).
Power Parameters
In the past, the higher cost of DC fans led to the
almost exclusive use of AC fans. Today the price
differential between the two has disappeared and DC
fans have many advantages compared to AC fans.
For example, DC fans typically have a longer life and
consume almost 60% less power.
Brushless DC fans are usually available in four
nominal voltages: 5V, 12V, 24V, and 48V. If the
system has a regulated power supply with one of
these voltages, then a brushless DC fan may be
utilized. This fan will provide performance required,
without the input variables that plague AC fans.
The speed and airflow of a typical DC fan is
proportional to the voltage supplied. Therefore, a
single product may be utilized in different applications
by adjusting the supply voltage to provide the desired
airflow. The voltage range for satisfactory operation
depends on the individual fan design.
Brushless DC fans do not draw constant currents.
The choice of the power source, along with the
addition of other peripheral devices, will affect the
type and number of DC fans and their motor current
characteristics. Throughout blade rotation (particularly
at commutation), the current will fluctuate from
minimum to maximum. The wave form and level of
ripple current will vary significantly between fans and
motor designs, making specifications in narrow terms
difficult. An understanding of the power source
limitations and how they may be impacted by various
brushless DC fans early in the design phase will help
prevent problems and allow maximum system
flexibility.
What is Locked Rotor?
A locked rotor is a type of sensor output that
measures when the fan has completely stopped or
locked. It sends an alarm signal, at either high or low
voltage when the rotor locks. If the fan starts spinning
again, the alarm signal condition will stop.
What is Tach Output?
A tach output or "sensor output" indicates the speed
of the fan at different operating levels. Its purpose is
to identify when the fan drops below a certain RPM,
and to identify a potential problem with airflow. A tach
output fan will always have at least 3 wire leads.
 Variable
Speed Fan
in an
Electronics
Enclosure
A variable
speed fan is
automaticall
y controlled by the fan circuit, which
changes speed as the temperature
changes to provide optimum air flow at
all times.

Two options are available:

1. A remotely mounted thermistor on a

third lead wire (thermistor not
provided).
2. A thermistor mounted on the fan
PCB (thermistor provided).

With the three lead wire fan, varying the

voltage on the third lead from 0 to 6
volts can also control speed variation.
Variable and Two Speed Fan
Information
Specially designed variable-speed and
two-speed fans can be used to
significantly reduce noise generation
and power consumption. With standard
single speed fans, the DC fan rpm and
air output can be controlled by varying
the input voltage or by switching
between power supply circuits.
However, these methods limit the range
of low speed operation; and they may
involve switching the motor IC on and
off when changing speeds. Fan motor
damage or malfunction is possible. To
overcome these problems, two speed
fan motors and variable speed fans are
available from JMC.
These specially designed JMC fan
motors offer a wide variation of fan rpm
while keeping the supply voltage
constant. Two speed fans can be used
in many cooling applications. When
extra heat is generated in an
application, the fan can switch from idle
mode to high-speed operation for extra
cooling.
Important: Bearing type and temperature
matter

The life and reliability of all DC fans,

regardless of manufacturer, depends on a
combination of voltage, frequency, ambient
temperature, and airflow restrictions. The
normal failure mode is in the bearing system,
which is usually related to the total
temperature that the bearings are subjected
to, although other factors may apply.

In general, there is not much difference in life

between sleeve and ball bearings when the
total temperature is relatively low. As this
total temperature increases, however, ball
bearings will give a progressively longer life
than sleeve bearings.
 Equations and
Variables:
Maximum static
pressure and
maximum air
volume
measurements must
be taken separately.

Maximum Static Pressure Measurement:

When the nozzle is closed, the pressure in chamber
A will reach a maximum. The pressure difference Ps
represents the maximum static pressure achievable
by the fan.

Maximum Air Volume Measurement:

The nozzle is opened and the auxiliary blower is
used to lower the pressure in chamber A to Ps = 0.
The maximum air volume can then be calculated
using Pn, D and the air volume equation below. Q
represents the maximum achievable airflow with the
fan in free air.

Heat Transfer is represented by:

Q = 3.16W / Tf or Q = 1.76W / Tc
Where:
Q = Airflow required in CFM (cubic feet per minute)
W = Heat dissipated in watts
Tc = Temperature rise above inlet temp °C
Tf = Temperature rise above inlet temp °F

Using the chart to the left, one can estimate the

airflow required. The vertical axis represents the
heat to be removed and the horizontal axis
represents the airflow. Notice that both axes are
logarithmic. The sloping lines define the
 temperature rise in °C. First find the sloping line that
represents the permitted rise, and then find the
point on this line that corresponds to the heat to be
removed. The horizontal position of this point shows
the required airflow.

For example, 35 CFM of airflow is required for a

system that dissipates 200W, which results in a
10°C temperature rise.

Noise has no effect on a fan's cooling performance,

but it makes a big difference to the people working
nearby. Audible noise originates from several
sources, some of which can be controlled by the
enclosure designer. Others are a result of a fan
manufacturer's design. Read below to find out more
about the causes of fan noise and what you can do
to minimize it.

Causes of Fan Noise

Noise emanating from axial fans is a function of

many variables and causes:

 Whirl pooling: This is a broadband noise source

generated by air separation from the blade surface
and trailing edge. It can be partially controlled by
good blade profile design, proper pitch angle and
notched or serrated trailing blade edges.
 Turbulence: Also a broadband noise, generated
within the airflow stream itself. Inlet and outlet
disturbances, sharp edges and bends in the
airflow will cause increased turbulence and noise.
 Speed: Speed of rotation is a major contributor to
fan noise.
 Fan load: Noise varies with the system load; fans
are generally quieter when operated near their
peak efficiency.
 Structure vibration: This can be caused by the
components and mechanism within the fan, such
as residual unbalance, bearings, rotor to stator
eccentricity, and by motor mounting. Cooling
fans are basically motors and should be treated as
such when mounted.
 System disturbance: System disturbances are
the biggest cause of fan noise. When a fan is
designed for low noise operation, it can be very
sensitive to inlet and outlet disturbances caused
by card guides, brackets, capacitors, transformers,
cables, finger guards, filter assemblies, walls or
panels, etc. Trial and error, combined with
common sense and intuition, are often the best
tools for determining fan selection and
component placement for low noise operation.
How to Minimize Fan Noise
The following design actions will help produce a
system with minimal fan noise:

 Reduce system impedance at the inlet and outlet

ports. If a large part of the fan's flow potential is
used up by the impedance of the inlet and outlet,
a larger, faster, noisier fan will be required.
 Avoid obstructions to the airflow, especially in
the critical inlet and outlet areas. When turbulent
air enters the fan, noise is increased by as much
as 10 dB, usually in a discrete tone form that is
particularly annoying.
 Use a larger, slower fan rather than a faster,
smaller version whenever possible. Often, this
solution will produce less noise for the same
airflow.
 Relax the temperature rise limits where possible,
to reduce the airflow required. This will allow
you to use a smaller, slower fan that produces less
noise.
 Isolate the fan to avoid vibration transmission.
Because fans operate at a low frequency and are
light in weight, vibration isolators must be soft
and flexible. Since the transmission is dependent
on the system, trial and error is the best approach
to a quiet system/fan interaction. In systems that
require 20 CFM or less, cabinet vibration is the
predominant source of noise, and isolation of the
fan is the only practical solution.

Cooling fan noise is expressed in decibels (dBA).

The dBA rating is determined directly by a sound
level meter equipped with a filtering system which
de-emphasizes both the low and high frequency
portions of the audible spectrum. This measurement
is recorded at a distance of 1 meter from the
source.