Low Power Consumption, Long Life AC Fan âSan Ace 120ADâ9AD Type
New Products Introduction
Low Power Consumption, Long Life AC Fan “San Ace 120AD”9AD Type Haruka Sakai
Masafumi Yokota
Takashi Kawashima
Yasuhiro Maruyama
Toshiya Nishizawa
1. Introduction
Conventional AC fans has induction motors which were not so efficient. As such, in order to create a low power
In recent years, awareness of environmental protection
consumption fan which satisfied the abovementioned
has heightened, resulting in proactive energy conservation
market demands, it was necessary to devise a new method
activities across all markets. As such, AC fans are now
which parted from conventional technology.
required to consume less power and have longer life.
In contrast, the brushless DC motor has high efficiency in
Here we introduce features and performance of the
comparison with induction motors. So, if AC was input and
San Ace 120AD 9AD type; a 120 mm sq. 38 mm thick
a similar drive method to the brushless DC motor could be
AC fan with lower power consumption and longer life was
adopted, there would be significant improvement in AC fan
developed to respond to the needs stated above.
efficiency. Hence, this new model has an internal AC/DC converter which enables high efficiency.
2. Background of the Development
The new model achieves low power consumption and long life at the same time as maintaining high airflow and high
Sanyo Denki has produced and sold AC fans for many
static pressure characteristics of Sanyo Denki’s conventional
years. Sanyo Denki’s development of cooling fans began
AC fans. Moreover, in the case of the conventional models,
with the AC fan, which has become available in a variety of
it was necessary to choose a fan spec to the relevant input
sizes and voltages since its release in 1965. However, in 1982
voltage, however the new model is capable of a wide voltage
a DC fan was developed for the first time on which it was
range.
possible to create a circuit inside the fan. Since then, Sanyo Denki’s DC fan development has become the main focus, resulting in the increasing sophistication of performance and keeping on evolving. Meanwhile, development of new AC fans has been fallen behind due to the increase in DC fan applications. Given this situation, in order to enter into a new AC fan market, Sanyo Denki has developed the San Ace 120AD 9AD type; a 120 mm sq. 38 mm thick AC fan with lower power consumption and longer life.
3. Product Features Fig. 1 shows the San Ace 120AD 9AD type (hereinafter new model ) and below is a list of its features. (1) Low power consumption (2) Higher performance (3) Long life (4) Wider input voltage range (5) Lightweight
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SANYO DENKI Technical Report No.37 May 2014
Fig. 1:“San Ace 120AD”9AD type
Low Power Consumption, Long Life AC Fan“ San Ace 120AD”9AD Type
4. Product Overview
4.2 Characteristics 4.2.1 General characteristics
4.1 Dimensions
Rated voltage is 100 to 240 V AC, a frequency is 50/60 Hz, and rated speed is 3,250 min-1 regardless of input voltage and
Fig. 2 shows the dimensions of the new model.
a frequency. Table 1 shows the general characteristics for the new model. 120±0.8
38±0.5
104.8±0.3
（6）
104.8±0.3
（6）
120±0.8
4-Ø4.3±0.3
SANYO DENKI
Airflow direction
Rotating direction
Fig. 2: Dimensions of the new model (unit: mm)
Table 1: General characteristics for the new model Model No. 9AD1201H12
Rated voltage [V]
Operating voltage [V]
Frequency
100 to 240
90 to 264
[Hz]
Rated current [A]
Rated input [W]
Rated speed [min-1]
50/60
0.08
4.4
3,250
Note)
Max. airflow
Max. static pressure
[m3/min] [CFM] [Pa] [inchH2O] 3.0
106
84
0.34
SPL [dB(A)]
Operating temperature [˚C]
Expected life [h]
42
-20 to +75
60,000
Note: Common to 50/60 Hz
4.2.2 Airflow vs. static pressure characteristics
（InchH2O） （Pa）
0.35
Fi g. 3 s h o w s t h e a i r f l o w v e r s u s s t a t i c p r e s s u r e
（InchH2
90 80
characteristics for the new model.
0.30 70
the rated voltage under free air conditions and at normal humidity).
Static pressure
The new model has an expected life of 60,000 hours at 60˚C (survival rate of 90% with continuous operation at
0.25
0.20
0.15
100-240 V 50/60 Hz 60
Static pressure
4.3 Expected life
50 40 30
0.10 20 0.05
0
10
0 0
0.5
1.0 25
1.5 50
2.0 75
2.5
3.0 100
3.5（m3/min） 125（CFM）
Airflow
Fig. 3: New model airflow vs. static pressure
SANYO DENKI Technical Report No.37 May 2014
12
（InchH2O） （Pa）
0.7
80
160
Comparisons of the expected life, airflow versus static 0.30
140
100-240 V 50/60 Hz
new and 0.25 conventional models are as follows; Static pressure
50 0.20 5.1 Comparison of expected life
Table 2 shows comparison of the expected life and other 40
general 0.15 characteristics of the new model and conventional model.
0.05
0.4
0.3
30
10
-72%
120
5 New model: Power consumption
100
0
New model
80
Conventional model 109S075UL(At 60 Hz)
60
0.10
Table
Static pressure
0.5
15
Conventional model: Power consumption 109S075UL(At 60 Hz)
0.6
70 pressure characteristic and power consumption between the 60
20
180
Power consumption（W）
5. Comparisons with our Conventional 90 0.35 Models
（InchH2O） （Pa）
0.2 20 2: 10
0
New model and conventional model characteristic comparison
0 0
New model 9AD1201H12 Conventional model 109S075UL (At 60 Hz)
Max. Expected Max. static 0.5 life1.0 1.5airflow 2.0 2.5 3.0 pressure ［h］ ［m3/min］ ［Pa］ 25
50
75
100
Rated
input 3.5 （m3/min） ［W］
125（CFM）
60,000
Airflow 3.0
84.0
4.4
25,000
2.9
68.7
16.0
The new model has higher maximum airflow and
40 0.1
0
20
0 0
0.5
1.0 25
1.5 50
2.0
2.5
75
3.0 100
3.5（m3/min） 125（CFM）
Airflow
Fig. 4: Airflow vs. static pressure (New/conventional model comparison)
6. New Development Elements The new model is driven converting AC to DC inside the
maximum static pressure than the conventional model
fan. This means that an AC/DC converter is necessary and
having low power consumption. Furthermore, the expected
more space is required than the circuit for regular brushless
life (60˚C ambient temperature, 90% survival rate,
DC fan motors (motor drive circuit). Due to this, motor
continuous operation at rated voltage, free air state, normal
construction was reviewed and sufficient space was secured
humidity) of the new model with 60,000 hours is 2.4 times
to install the AC/DC converter.
longer than the conventional model with 25,000 hours.
Below lists are key things for the development to achieve the various characteristics of the new model.
5.2 Comparison of airflow vs. static pressure characteristic and power consumption Fig. 4 shows an example of the airflow versus static pressure characteristics for the conventional models and the new model.
(1) Low power consumption ・Adoption of a brushless DC motor ・Optimization of electronic components
In addition to a significant reduction in power
Compared to the conventional models, the new model
consumption by changing the drive method to brushless DC
has higher airflow versus static pressure characteristic in all
motor, the number of electronic components was reduced
areas. In addition, power consumption is reduced in all areas,
to the minimal necessary in order to reduce circuit loss.
achieving a 72% reduction in a free air state.
Moreover, higher efficiency was achieved by selecting the optimal item for each electronic components. (2) Higher performance ・Optimization of the impeller and frame shape
Fig. 5 gives a comparison between the impeller and the frame of the new and conventional models. The design of the impeller was sophisticated through repeated studies to achieve both low power consumption and high performance.
13
SANYO DENKI Technical Report No.37 May 2014
Low Power Consumption, Long Life AC Fan“ San Ace 120AD”9AD Type
Moreover, in order to increase fan efficiency, the shape of the frame has been optimized to suit the impeller shape. (3) Long life ・Reduced power consumption ・Optimization of electronic components in the AC/DC
converter By reducing power consumption through changing to a brushless DC motor and optimizing electronic components, the heat generation within the fan has been reduced, along
Fig. 6: Power terminal
with deterioration of components with life spans. (4) Wider input voltage range ・AC/DC converter study
7. Conclusion This document introduced some of the features
A study was made into the circuit for an AC/DC converter
and performances of the newly developed low power
so that suitable electronic components could be chosen
consumption, long life AC fan “San Ace 120AD” 9AD type.
to support a wider input voltage range. Through this, it
By performing AC/DC conversion inside the fan, the
was possible to develop an AC fan with input voltage and
new model has incorporated the brushless DC motor drive
frequency characteristics which does not fluctuate and send
system despite being an AC fan. As a result, it achieves lower
a set amount of DC voltage to the motor drive circuit even if
power consumption and longer life having a higher airflow
AC input voltage fluctuates.
versus static pressure characteristic compared to Sanyo Denki’s conventional AC fans. Moreover, this product is
(5) Lightweight ・Motor size reduction ・Frame material change from aluminum die cast to resin
Conventional model frames were made from aluminum die cast however in order to reduce heat generation inside
extremely easy to use thanks to having characteristics not affected by input voltage and frequency. Regarding new AC fan with features of a brushless DC fan and difference from the conventional AC fan, we anticipate to play a major role in new market expansion.
the fan the motor was made smaller and lighter, therefore we could adopt a resin frame (See Fig. 5).
Fig. 5: Comparison of the impeller and frame between new model (left) and conventional model (right) The power is supplied to the AC fan through the plug cord. The configuration of the plug cord mounting area was modified on the new model. Fig. 6 shows the power terminal. The portion which mounts to the power terminal frame which joins with the plug cord has been made more reliable.
SANYO DENKI Technical Report No.37 May 2014
14
Low Power Consumption, Long Life AC Fan“ San Ace 120AD”9AD Type
Haruka Sakai Joined Sanyo Denki in 2011. Cooling Systems Division, Design Dept. Worked on the development and design of cooling fans.
Masafumi Yokota Joined Sanyo Denki in 1998. Cooling Systems Division, Design Dept. Worked on the development and design of cooling fans.
Toshiya Nishizawa Joined Sanyo Denki in 1999. Cooling Systems Division, Design Dept. Worked on the development and design of cooling fans.
Takashi Kawashima Joined Sanyo Denki in 2011. Cooling Systems Division, Design Dept. Worked on the development and design of cooling fans.
Yasuhiro Maruyama Joined Sanyo Denki in 2001. SANYO DENKI PHILIPPINES INC. Worked on the development and design of cooling fans.
15
SANYO DENKI Technical Report No.37 May 2014
Low Power Consumption, Long Life AC Fan “San Ace 120AD”9AD Type Haruka Sakai
Masafumi Yokota
Takashi Kawashima
Yasuhiro Maruyama
Toshiya Nishizawa
1. Introduction
Conventional AC fans has induction motors which were not so efficient. As such, in order to create a low power
In recent years, awareness of environmental protection
consumption fan which satisfied the abovementioned
has heightened, resulting in proactive energy conservation
market demands, it was necessary to devise a new method
activities across all markets. As such, AC fans are now
which parted from conventional technology.
required to consume less power and have longer life.
In contrast, the brushless DC motor has high efficiency in
Here we introduce features and performance of the
comparison with induction motors. So, if AC was input and
San Ace 120AD 9AD type; a 120 mm sq. 38 mm thick
a similar drive method to the brushless DC motor could be
AC fan with lower power consumption and longer life was
adopted, there would be significant improvement in AC fan
developed to respond to the needs stated above.
efficiency. Hence, this new model has an internal AC/DC converter which enables high efficiency.
2. Background of the Development
The new model achieves low power consumption and long life at the same time as maintaining high airflow and high
Sanyo Denki has produced and sold AC fans for many
static pressure characteristics of Sanyo Denki’s conventional
years. Sanyo Denki’s development of cooling fans began
AC fans. Moreover, in the case of the conventional models,
with the AC fan, which has become available in a variety of
it was necessary to choose a fan spec to the relevant input
sizes and voltages since its release in 1965. However, in 1982
voltage, however the new model is capable of a wide voltage
a DC fan was developed for the first time on which it was
range.
possible to create a circuit inside the fan. Since then, Sanyo Denki’s DC fan development has become the main focus, resulting in the increasing sophistication of performance and keeping on evolving. Meanwhile, development of new AC fans has been fallen behind due to the increase in DC fan applications. Given this situation, in order to enter into a new AC fan market, Sanyo Denki has developed the San Ace 120AD 9AD type; a 120 mm sq. 38 mm thick AC fan with lower power consumption and longer life.
3. Product Features Fig. 1 shows the San Ace 120AD 9AD type (hereinafter new model ) and below is a list of its features. (1) Low power consumption (2) Higher performance (3) Long life (4) Wider input voltage range (5) Lightweight
11
SANYO DENKI Technical Report No.37 May 2014
Fig. 1:“San Ace 120AD”9AD type
Low Power Consumption, Long Life AC Fan“ San Ace 120AD”9AD Type
4. Product Overview
4.2 Characteristics 4.2.1 General characteristics
4.1 Dimensions
Rated voltage is 100 to 240 V AC, a frequency is 50/60 Hz, and rated speed is 3,250 min-1 regardless of input voltage and
Fig. 2 shows the dimensions of the new model.
a frequency. Table 1 shows the general characteristics for the new model. 120±0.8
38±0.5
104.8±0.3
（6）
104.8±0.3
（6）
120±0.8
4-Ø4.3±0.3
SANYO DENKI
Airflow direction
Rotating direction
Fig. 2: Dimensions of the new model (unit: mm)
Table 1: General characteristics for the new model Model No. 9AD1201H12
Rated voltage [V]
Operating voltage [V]
Frequency
100 to 240
90 to 264
[Hz]
Rated current [A]
Rated input [W]
Rated speed [min-1]
50/60
0.08
4.4
3,250
Note)
Max. airflow
Max. static pressure
[m3/min] [CFM] [Pa] [inchH2O] 3.0
106
84
0.34
SPL [dB(A)]
Operating temperature [˚C]
Expected life [h]
42
-20 to +75
60,000
Note: Common to 50/60 Hz
4.2.2 Airflow vs. static pressure characteristics
（InchH2O） （Pa）
0.35
Fi g. 3 s h o w s t h e a i r f l o w v e r s u s s t a t i c p r e s s u r e
（InchH2
90 80
characteristics for the new model.
0.30 70
the rated voltage under free air conditions and at normal humidity).
Static pressure
The new model has an expected life of 60,000 hours at 60˚C (survival rate of 90% with continuous operation at
0.25
0.20
0.15
100-240 V 50/60 Hz 60
Static pressure
4.3 Expected life
50 40 30
0.10 20 0.05
0
10
0 0
0.5
1.0 25
1.5 50
2.0 75
2.5
3.0 100
3.5（m3/min） 125（CFM）
Airflow
Fig. 3: New model airflow vs. static pressure
SANYO DENKI Technical Report No.37 May 2014
12
（InchH2O） （Pa）
0.7
80
160
Comparisons of the expected life, airflow versus static 0.30
140
100-240 V 50/60 Hz
new and 0.25 conventional models are as follows; Static pressure
50 0.20 5.1 Comparison of expected life
Table 2 shows comparison of the expected life and other 40
general 0.15 characteristics of the new model and conventional model.
0.05
0.4
0.3
30
10
-72%
120
5 New model: Power consumption
100
0
New model
80
Conventional model 109S075UL(At 60 Hz)
60
0.10
Table
Static pressure
0.5
15
Conventional model: Power consumption 109S075UL(At 60 Hz)
0.6
70 pressure characteristic and power consumption between the 60
20
180
Power consumption（W）
5. Comparisons with our Conventional 90 0.35 Models
（InchH2O） （Pa）
0.2 20 2: 10
0
New model and conventional model characteristic comparison
0 0
New model 9AD1201H12 Conventional model 109S075UL (At 60 Hz)
Max. Expected Max. static 0.5 life1.0 1.5airflow 2.0 2.5 3.0 pressure ［h］ ［m3/min］ ［Pa］ 25
50
75
100
Rated
input 3.5 （m3/min） ［W］
125（CFM）
60,000
Airflow 3.0
84.0
4.4
25,000
2.9
68.7
16.0
The new model has higher maximum airflow and
40 0.1
0
20
0 0
0.5
1.0 25
1.5 50
2.0
2.5
75
3.0 100
3.5（m3/min） 125（CFM）
Airflow
Fig. 4: Airflow vs. static pressure (New/conventional model comparison)
6. New Development Elements The new model is driven converting AC to DC inside the
maximum static pressure than the conventional model
fan. This means that an AC/DC converter is necessary and
having low power consumption. Furthermore, the expected
more space is required than the circuit for regular brushless
life (60˚C ambient temperature, 90% survival rate,
DC fan motors (motor drive circuit). Due to this, motor
continuous operation at rated voltage, free air state, normal
construction was reviewed and sufficient space was secured
humidity) of the new model with 60,000 hours is 2.4 times
to install the AC/DC converter.
longer than the conventional model with 25,000 hours.
Below lists are key things for the development to achieve the various characteristics of the new model.
5.2 Comparison of airflow vs. static pressure characteristic and power consumption Fig. 4 shows an example of the airflow versus static pressure characteristics for the conventional models and the new model.
(1) Low power consumption ・Adoption of a brushless DC motor ・Optimization of electronic components
In addition to a significant reduction in power
Compared to the conventional models, the new model
consumption by changing the drive method to brushless DC
has higher airflow versus static pressure characteristic in all
motor, the number of electronic components was reduced
areas. In addition, power consumption is reduced in all areas,
to the minimal necessary in order to reduce circuit loss.
achieving a 72% reduction in a free air state.
Moreover, higher efficiency was achieved by selecting the optimal item for each electronic components. (2) Higher performance ・Optimization of the impeller and frame shape
Fig. 5 gives a comparison between the impeller and the frame of the new and conventional models. The design of the impeller was sophisticated through repeated studies to achieve both low power consumption and high performance.
13
SANYO DENKI Technical Report No.37 May 2014
Low Power Consumption, Long Life AC Fan“ San Ace 120AD”9AD Type
Moreover, in order to increase fan efficiency, the shape of the frame has been optimized to suit the impeller shape. (3) Long life ・Reduced power consumption ・Optimization of electronic components in the AC/DC
converter By reducing power consumption through changing to a brushless DC motor and optimizing electronic components, the heat generation within the fan has been reduced, along
Fig. 6: Power terminal
with deterioration of components with life spans. (4) Wider input voltage range ・AC/DC converter study
7. Conclusion This document introduced some of the features
A study was made into the circuit for an AC/DC converter
and performances of the newly developed low power
so that suitable electronic components could be chosen
consumption, long life AC fan “San Ace 120AD” 9AD type.
to support a wider input voltage range. Through this, it
By performing AC/DC conversion inside the fan, the
was possible to develop an AC fan with input voltage and
new model has incorporated the brushless DC motor drive
frequency characteristics which does not fluctuate and send
system despite being an AC fan. As a result, it achieves lower
a set amount of DC voltage to the motor drive circuit even if
power consumption and longer life having a higher airflow
AC input voltage fluctuates.
versus static pressure characteristic compared to Sanyo Denki’s conventional AC fans. Moreover, this product is
(5) Lightweight ・Motor size reduction ・Frame material change from aluminum die cast to resin
Conventional model frames were made from aluminum die cast however in order to reduce heat generation inside
extremely easy to use thanks to having characteristics not affected by input voltage and frequency. Regarding new AC fan with features of a brushless DC fan and difference from the conventional AC fan, we anticipate to play a major role in new market expansion.
the fan the motor was made smaller and lighter, therefore we could adopt a resin frame (See Fig. 5).
Fig. 5: Comparison of the impeller and frame between new model (left) and conventional model (right) The power is supplied to the AC fan through the plug cord. The configuration of the plug cord mounting area was modified on the new model. Fig. 6 shows the power terminal. The portion which mounts to the power terminal frame which joins with the plug cord has been made more reliable.
SANYO DENKI Technical Report No.37 May 2014
14
Low Power Consumption, Long Life AC Fan“ San Ace 120AD”9AD Type
Haruka Sakai Joined Sanyo Denki in 2011. Cooling Systems Division, Design Dept. Worked on the development and design of cooling fans.
Masafumi Yokota Joined Sanyo Denki in 1998. Cooling Systems Division, Design Dept. Worked on the development and design of cooling fans.
Toshiya Nishizawa Joined Sanyo Denki in 1999. Cooling Systems Division, Design Dept. Worked on the development and design of cooling fans.
Takashi Kawashima Joined Sanyo Denki in 2011. Cooling Systems Division, Design Dept. Worked on the development and design of cooling fans.
Yasuhiro Maruyama Joined Sanyo Denki in 2001. SANYO DENKI PHILIPPINES INC. Worked on the development and design of cooling fans.
15
SANYO DENKI Technical Report No.37 May 2014
