Data centers need a reliable source of power. That power must be distributed throughout the data center in a way that ensures a consistent flow of electricity with no deviations in voltage. It might sound simple, but achieving this objective requires a complex interplay of components.
We’ve written a lot about growing data center power demands. The average data center cabinet consumes 7 kW of power, hyperscale data centers consume 10 kW to 14 kW per rack, and AI data centers can consume 60 kW per rack or more. Power requirements are increasing exponentially. Data centers consumed 4.4% of all US electricity in 2023. Actual projections vary greatly due to differing growth prediction models, but the industry consensus is that data center power consumption will at least double by 2028, with many aggressive estimates predicting growth hitting 12% of the total US electricity supply by 2030.
With many megawatts of power coming into their facilities, data center operators need a safe and efficient way to deliver it to individual racks and cabinets. That’s the role of the data center power whip.
What Is a Power Whip?
A power whip (also known as a “PDU whip”) is a heavy-duty, high-voltage cable that connects a primary power source to a power distribution unit (PDU) to bring power to rows of racks or cabinets in a data center. It’s called a “whip” because it has a whip tail that is typically hardwired into a breaker on the power panel. The other end of the power whip is a connector that plugs into a PDU.
Benefits of Power Whips in the Data Center
A primary benefit of PDU power whips is ease of installation. Power whips add a layer of modularity to a process that would otherwise require custom on-site assembly. Power whips come pre-assembled and pre-terminated. That means all an electrician will need to do on-site is connect the tail to the power source. Power whips also help reduce operating costs by distributing electricity efficiently.
Another key benefit is safety. UL-listed power whips have been thoroughly tested to meet strict requirements. By distributing power evenly, power whips also help protect IT equipment.
Locations of Power Whips
There are two options for routing power whips throughout the data center: underfloor or overhead. Each has benefits and drawbacks in terms of cost, manageability, and cooling efficiency.
Underfloor Power Whips
Underfloor power whips require a raised floor data center buildout. The raised floor concept started with mainframes in the 1960s. A grid of pedestals is installed on the structural floor, raising the floor surface of the data center 6 inches to 4 feet or more. Typical raised floor installations are 12 inches to 18 inches in height. The void between the raised floor and structural floor, called the “plenum,” provides space for power whips as well as other cables, HVAC ducts, and plumbing.
Advantages
Underfloor power whip systems are concealed. They keep the data center floor clean and clear of hazards. Whenever a move, add, or change is necessary, the floor tiles can be lifted and removed.
Underfloor power whip installations also carry significant cooling and airflow advantages. The main reason being airflow is isolated in underfloor systems. Less chilled air is lost to the ambient environment. Additionally, cool air doesn’t rise. By nature, underfloor systems limit cooling loss.
Disadvantages
Installing raised floors in a data center is a time-consuming and expensive endeavor that requires specialist support to modify. Additionally, troubleshooting issues with underfloor power whips is more time-consuming and disruptive, given that each tile along the pathway needs to be lifted to be examined.
It’s also worth noting that raised floor facilities have weight restrictions. Racks and cabinets must not exceed specific weight thresholds and must be laid out to conform to the building’s design.
Nevertheless, most data center operators consider it a worthwhile investment that will pay for itself in the long run.
Overhead Power Whips
Overhead power whips distribute power from above. They drop into equipment via cable pathway. Most data centers will have an element of overhead cable management for traditional network cables like copper and fiber, but some take the same approach for power distribution.
Advantages
Overhead power whip’s main benefits are accessibility and price. Retrofitting raised floors into a data center requires heavy construction, long lead times, and significant costs, all of which are modest when installing overhead cable runways. In some cases, less cabling material is required for overhead installations. The distance between the distribution panel and the server cabinet is often shorter in overhead busway systems than in underfloor. Additionally, overhead power whips are typically exposed, making installation, maintenance, and reconfiguration easier. Ease of access can be crucial for minimizing downtime in the event of an emergency.
Disadvantages
One of the benefits of overhead power whip installation is also a drawback. Being that overhead power whips are exposed, they’re more susceptible to accidental damage and can make the data center appear more “cluttered”. Not to mention, cooling systems are often less efficient due to the exposed nature of the overhead whip.
Overhead installations must also make accommodations for other overhead systems such as ductwork, lighting, and fire suppression.
Types of Power Whips
PDU power whips are made of several different types of cable, and the choice depends on the specific application and environmental conditions.
Liquid-Tight Flexible Metal Conduit (LFMC)
The name of this power whip explains its features. LFMC cables have a flexible inner core made of heavy-gauge, corrosion-resistant steel. The steel is spiral wound and includes a copper bonding strip to reduce electromagnetic interference. The PVC jacketing material is impervious to liquids and moisture and resistant to mild acids, oils, and sunlight. LFMC cables are cost-effective and popular among data center operators.
SOOW Cable
The “SOOW” in the name of this cable isn’t an initialism. It stands for the cable’s properties:
- Service
- Oil-resistant insulation
- Oil-resistant jacket
- Water resistance
It is made of multiple strands of flexible copper, with a rubber jacket that has chlorinated polyethylene elastomer. (It is also called an SEOOW cable.) SOOW cables are rated for 600 volts, making them suitable for heavy-duty industrial applications. In addition to oil and water resistance, they can withstand sunlight and a wide range of temperatures.
Tray Cables
As the name suggests, tray cables are designed for use in cable trays or raceways. There is a wide range of options. Power and control tray cables (Type TC) have at least two and as many as 37 metal conductors with thermoplastic, high-heat nylon coating (THHN) for insulation. Also called vinyl nylon tray cables (VNTCs), these power whips are rated for 600 volts.
Feeder Cables
Feeder cables can connect one area of the data center’s power distribution to another part within the same area. They’re often used to provide temporary power connections during construction, but they can also provide an extra power supply connection for particularly power-intensive equipment or route power from PDUs back to the remote power panel (RPP) for added efficiency. They can also connect power from equipment like the main switchboard and transformer. Feeder cables can also be used for load bank testing to ensure backup generators work correctly with the facility’s UPS system.
Selecting the Right Cabling Products
Whether a data center chooses to route electrical cables under the floor or overhead, it pays to invest in electrical cabling products that will deliver the highest levels of performance and reliability. The right products will quickly pay for themselves with reduced maintenance, troubleshooting and downtime.
Preassembled cables can dramatically reduce deployment time and installation costs. Assembling just one connector can take up to five minutes — valuable time that can be saved with a preassembled solution. Ready-to-install cables are also pretested to minimize the risk of errors and installation problems.
Why Choose Enconnex Power Whips?
Enconnex manufactures power whips on a dedicated assembly line in our Reno, Nev., facility and partners with a best-in-class manufacturer of cable runway and tray.
We use the highest quality components and assemble each power whip to meet the highest standards for performance, reliability and safety. Here are some of the benefits of Enconnex Power Whips.
Fast Delivery
We assemble our power whips in-house to reduce lead times. We also offer power whip kits for customers who want to assemble their power whips onsite.
Fully Customized
We build each power whip to meet the customer’s requirements. A variety of lengths, connectors, conduit diameters, jacketing, labeling and color options are available.
Easy Installation
We ship each power whip preassembled and ready to connect data center equipment to the main power supply. Preassembled power whips simplify installation for faster time to value.
Tested for UL Safety Standards
We ensure that all the components in our power whips are tested and meet UL listing requirements. This ensures proper functionality and safe use in the data center.
Cost-Saving Solutions
We help reduce installation costs by delivering power whips that are ready to install. This reduces personnel hours, parts and tools required in the field.
We assemble our power whips in-house to reduce lead times. We also offer power whip kits for customers who want to assemble their power whips onsite.
Total Engineering Support
We assist with specifying power whips at no additional cost. Customers are assured that each power whip will precisely meet their needs.
Enconnex power whips are manufactured to meet the most demanding electrical distribution requirements. Contact one of our specialists to discuss your specific needs.
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