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Learn how Refcool engineered a compact, high-capacity cooling unit (the i-ACE system) for a server cabinet manufacturer, enabling direct cooling of high-density server racks in confined spaces without sacrificing maintenance access.
As data centers and server rooms pack more computing power into each rack, traditional cooling methods can struggle to keep up – especially when space is limited. A leading server cabinet manufacturer approached Refcool to develop a direct cooling solution for high-density server racks. The challenge was to dissipate large heat loads from long rows of servers within a very narrow space, while still allowing easy maintenance of critical components. Refcool responded by designing the i-ACE (In-row Air Cooling Equipment) unit: a compact, high-efficiency cooler that can be installed alongside server cabinets to provide targeted cooling right at the heat source.
The client’s new line of server cabinets was pushing the envelope in terms of power density – essentially, more servers per cabinet meant more heat generated in a tight footprint. The cooling solution had to fit in the constrained aisle space (between or at the end of rows of cabinets) and remove heat effectively from each rack. The specific challenges included:
Limited Space: The cooling unit needed to be slim and modular to slide into narrow gaps or at the end of a row without requiring additional floor space that data centers could not spare.
High Heat Load: Each unit had to handle high thermal loads from multiple server racks, meaning efficient heat exchangers and fans were required to achieve the necessary cooling capacity in a small form factor.
Maintenance Accessibility: Despite the tight quarters, technicians must be able to access fans, filters, heat exchangers, and controls for servicing the cooling unit. Many compact designs falter by being hard to service; this was unacceptable to the client.
Scalability: The manufacturer wanted a range of cooler sizes to suit different server room configurations, implying that the design should be modular and scalable, not a one-off custom unit.
Refcool’s R&D and design teams collaborated to create a line of Server Room Coolers (i-ACE units) tailored for these requirements. The i-ACE unit is essentially an in-row precision cooling system. It installs directly adjacent to server cabinets, drawing in hot air from the servers and supplying cooled air back into the racks. Key features of the solution include:
Ultra-Slim Chiller Design: The i-ACE coolers have a narrow chassis that aligns with standard server rack dimensions, allowing them to be placed in close proximity to servers. They were designed in various heights and capacities so they can be deployed per rack or per row depending on need.
High-Efficiency Heat Exchangers: We incorporated advanced evaporator coils and arranged them to maximize heat transfer from the hot air within a compact volume. Paired with these coils are variable speed fans that can ramp up or down to match the cooling load of the servers, ensuring efficient operation.
Front and Rear Maintenance Access: Understanding the client’s maintenance concerns, Refcool’s design allows all critical components to be accessed from the front or rear of the unit (which remain accessible even when units are side-by-side with server racks). Fans, for example, are front-accessible and on slide-out rails; heat exchanger coils can be cleaned in situ with swing-open panels; and the electrical control box is mounted with a hinged door for easy reach. This means a technician can service the cooler without needing to remove it from its tight space.
Integrated Controls: Each i-ACE unit comes with smart controls that can interface with the data center’s environmental management system. The coolers can adjust cooling output based on server intake temperatures and can work in tandem – multiple units will communicate to balance the cooling load across a room. This ensures even cooling and avoids any single point of failure.
Scalable Range: From the initial project, Refcool and the client co-developed a comprehensive range of server room coolers. This range varies in cooling capacity and physical size, enabling deployment in small server closets up to large data halls. The scalability has become a selling point for the client, as they can now offer cooling-inclusive cabinets for various needs.
The resulting i-ACE cooling solution was a success for the server cabinet manufacturer and has since been rolled out as a product offering in their portfolio. With Refcool’s innovation, the client can directly cool high-density server racks even in narrow, confined data center aisles. Early deployments of the i-ACE units have demonstrated excellent performance: high-density server stacks that previously ran hot are now kept within optimal temperature ranges, preventing thermal throttling and improving hardware reliability. The direct, in-row cooling approach also proved to be energy-efficient – by targeting cooling exactly where it’s needed (at the rack), these units avoid the waste of chilling an entire room, which in turn lowers the overall power usage effectiveness (PUE) for the data center.
Maintenance personnel have praised the thoughtful design. They report that filter changes, fan swaps, and routine servicing on the i-ACE coolers are straightforward, in stark contrast to some legacy cooling units which were nearly impossible to service without shutting down equipment. This ease of maintenance means lower downtime and service costs for data center operators.
The project’s success has positioned Refcool as a preferred cooling partner for the client; in fact, the comprehensive range of Server Room Coolers that was developed has opened new business opportunities, allowing the client to market an integrated cooling-cabinet solution to other data center customers. For prospective B2B customers exploring similar needs, this case study is a persuasive example of how Refcool can deliver innovative, space-conscious cooling systems that solve modern IT challenges. It highlights our capability to co-develop products that not only meet technical specs but also provide commercial advantage.