Comment Re:Why? (Score 1) 260
Bah, just use the chassis as return; the frames might only be steel, but there's a good amount of it. That and I suggest 600V for truly limiting the amount of power lost through cables.
;)
You'd end up with servers welded to the rack.
Power losses increase with the square of the current - going from 5A to 10A means your cable losses quadruple. These are known as IIR losses (or I^2R losses).
Steel (iron) is an OK conductor of electricity - not great, but OK, so you'd have large losses of energy from the chassis itself (if you thought your racks were hot, well, now imagine the rack itself emitting heat!).
And unless the servers are contacted on practically every surface evenly, point-heating will take place that will weld the chassis to the server.
In fact, that's how an electrical welder works - a low-voltage high current source is all you need. Pass that current through a steel rod and it'll heat up and melt. (You want high current - voltage doesn't really matter - IIR remember? Double the current, quadruple the power).
Heck, it's a nifty physics demonstration when you take a step down transformer that takes line voltage of 120V and step it to 1.2V - that can get you 100A easily (with only a 1A draw at the other end) and that's sufficient for a demonstration. Remember, in welding, you're really creating a dead short.
it's why big racks often do get 208V, 240V or more into them - it's much easier to use thinner cables.