Efficiency + Modularity = the new Green UPS Design

Ed Spears

© 2010 Eaton Corporation. All rights reserved.

Data Centers – A Global Perspective

Wasted energy burdens the environment and increases operational expenses Carbon Footprint in IT Computing

» Only 3% of the energy entering a data center is used for net computing creating opportunities for efficiency improvements

(Source: IBM, 2009)

Item Units Delivered Generation 65 Steam 35 Electric The Grid 35 Data Center 33 (45% DCiE, 2.2 PUE) Server 15 Processor 5 Server Load 0.1- 4***

*Data source:

U.S. Department of Energy, May 18, 2007,

** Does not account approx 5 units to deliver coal or gas,

***

IBM, 2008 2 2

Challenges For Customers

Energy costs and regulatory compliance will continue to place organizations at risk Social, economic and regulatory pressures to reduce carbon emissions and energy costs globally Increasing Energy Costs

» Through 2009, Energy costs will emerge as the second highest operating cost (behind labor) in 70% of the Data Center facilities worldwide

(source: Gartner)

Sustainability

» 80% of CEO’s view sustainability as impacting brand value

(source: 2008, McKinsey)

» 31% say they want to reduce their environmental impact

(source: 2008, McKinsey)

» IT accounts for 2% of the global CO2 emissions, as much as the airline industry

(source: 2008, IBM, UK)

Regulations

» 82% of executives expect some form of climate change regulation within 5 years

(source: 2008, McKinsey)

» European Union Code of Conduct for Data Centers » UK Carbon Reduction Commitment (2010) 3 3

The Quest For Energy Efficiencies

The Key Challenge For Our Customers Energy Efficiency

» Reduced OpEx » Sustainability » Regulations

Source: CEMEP UPS

The Solution Energy Advantage Architecture

» Innovative proprietary technologies bringing new ways to maximize UPS energy efficiencies without compromising on reliability

Eaton 9395 UPS

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Energy Advantage Architecture

Two complementary Eaton-proprietary technologies to maximize UPS performance & efficiency Variable Module Management System (VMMS)

» Maximized efficiency in double conversion mode » Both in single- and multi-UPS systems applications

Energy Saver Systems (ESS)

» The ultimate savings: 99% efficiency » Automatic fast transfer to double conversion mode when needed (in less than 2 ms)

Energy Advantage Architecture

  Higher System Efficiency No Compromise On Reliability 5 5

Energy Advantage Architecture

Variable Module Management System (VMMS)

© 2010 Eaton Corporation. All rights reserved.

The Challenge For UPS’s

» • In double conversion mode, the efficiency of any UPS varies depending on the % of load Highest efficiency when close to full capacity » • UPS systems rarely loaded at full capacity This is a fact in redundant systems » How to maximize efficiency potential of UPS systems with lighter loads

The Solution: Eaton 9395 UPS and VMMS

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The Solution: Eaton VMMS

How to maximize efficiency with lighter loads in double conversion mode, especially in multi-UPS and redundant

system configurations?

Solution #1

(+)

Concentrate load on certain UPS’s to maximize

• •

UPS load level and overall system efficiency

» Some energy savings Limited to multiple-UPS systems (with several UPS in parallel) Still not optimal

Solution #2

(+++)

Eaton 9395 and its Variable Module Management System

• » Automatically optimize efficiency at UPM level Concentrate the load on certain UPM’s to maximize overall system efficiency • • » Only possible thanks to modularity of Eaton 9395 UPS Not limited to multiple-UPS systems Achieve even higher optimization thanks to UPM’s modularity 8 8

VMMS Principle

Example With Same Load Applied To Different Multi-UPS Configurations

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Fast Start VMMS/ESS Technology

INVERTER ON INVERTER IN SUSPENDED MODE

+DC +DC UPS RECTIFIER -DC A B C -DC A B C • •

Same Circuit with transistors off.

The pumpback diodes rectify the critical bus output and create appox. 700vdc on the pos and neg dc rails.

The pumpback diodes act as a 3phase bridge rectifier.

Pumpback Diode

A diode in the Inverter assembly that pumps excess energy back into the DC link during transistor turn off or transfers on and off line.

10 10

VMMS Principle

VMMS maximizes % load of each UPM

Optimizing overall system efficiency

100% 95% System Efficiency gain thanks to 9395 and VMMS System Efficiency gain using legacy UPS efficiency optimization 90% 85% Higher Efficiency with 9395 and VMMS 80% EATON UPS LEGACY UPS 20% % load of each UPM in Case1 when using Eaton 9395 UPS without VMMS % load of each legacy UPS in Case1 (no multi-UPS efficiency optimization) 40% 60% 80% 100% % load of each UPS in Case2 (legacy UPS with some multi-UPS efficiency optimization) % load of each active UPM in Case3 when using Eaton 9395 and VMMS

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VMMS In A Nutshell

VMMS allows to shift to higher efficiency curves

(according to system’s redundancy

up to

N+0 VMMS 84 82 80 78 96 94 92 90 88 86 9395 UPS Efficiency

Eaton 9395 1100kVA UPS Eaton 9395 825kVA UPS Eaton 9395 275kVA UPS

Typical Operations Range 9395 275kVA 9395 550kVA 9395 825kVA 9395 1100kVA 9395 VMMS N+0 Load kVA Notes: - Scaled drawing - VMMS and N+0 curves using VMMS default max UPM % load level @ 80% (*)

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VMMS Applications

VMMS can be used in all multi-module (multiple-UPM) 9395 systems

» Single 9395 units from 550kVA to 1100kVA » Distributed parallel systems SBM Systems

Typical Applications Where VMMS Particularly Efficient

» Redundant N+1 and 2N systems UPS’s • Lightly loaded: typically operate at loads < 45% load level where efficiency is not optimal » Data Centers, especially when UPS system feeds dual corded servers » Any applications when load is not constant 13 13

VMMS Example:

9395 / 825kVA Units in Dual Corded Load with A & B feeds

“A”

Example with 440kVA load

(A 220kVA + B 220kVA) Single / Dual Source “B” Data Center with

Dual Corded

Servers

UPS Configuration Efficiency @ 440kVA load

Without VMMS 91.2% VMMS on N+1 Redundancy VMMS on N+0 Redundancy 92.8% 94.3%

UPS Energy Savings Additional Benefits & Comments

Used as reference for savings calculation

 Industry-leading UPS efficiency in double conversion 56 MWh / year 108 MWh / year  Additional energy savings from reduced cooling in VMMS (typically +30-40% to UPS energy savings)  UPM’s in VMMS ready state available for redundancy A Feed 220kVA A Feed 220kVA A Feed 220kVA B Feed 220kVA B Feed 220kVA 14 B Feed 220kVA 14

VMMS – How Can I Get It?

Variable Module Management System is available:

»

on Eaton 9395 UPS

»

Earlier installations can also be upgraded with VMMS capability

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Energy Saver System

The game-changing UPS technology

16 16

UPS inefficiencies are a significant contributor to energy costs

Example – 2009

$1M buys approximately 50 5kW racks Cost of UPS electrical losses per year – $28k * Underlying figures from

The Invisible Crisis in the Data Center: The Economic Meltdown of Moore’s Law,

Uptime Institute, 2007 17 17

The Answer — Energy Saver System



Efficient

99% efficiency across entire operating range 

Intelligent

Detects incoming power quality and engages modules as needed 

Reliable

Proven double conversion topology ensures continuous load availability 18 18

Engage subsystems in real time, based on input power quality

Input Power Quality Active Modules

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Energy Saver System is Fast

Computer system tolerance.

20 mSec…..1/50 th of a second Digital Static Transfer Switch (STS).

4 mSec…..1/250 th of a second Energy Saver System.

1.2 mSec total…1/830 th of a second

(Inverter is engaged in 620 micro-seconds!)

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DVT Testing - Three Phase Outages

Source Output • • • •

Test Setup

Source Channels -> 3,5,&7 Output/Load Channels -> 4,6,&8 Load -> 100KW Resistive Unit -> 275KVA IR (Internal Redundant) with Common Battery •

Test Description

1/2 cycle 0% dropout sequence (All Phases) (0% is a low impedance (short) source fault) •

Test Result

1.2ms Transfer Time (600us detection time plus 600us SCR clearing time).

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DVT Testing - Three Phase Outages Continued

Source Output • • • •

Test Setup

Source Channels -> 3,5,&7 Output/Load Channels -> 4,6,&8 Load > 225KVA ∆Y Transformer with 100KW Resistive Load Unit -> 275KVA IR (Internal Redundant) with Separate Batteries •

Test Description

40 cycle 40% dropout sequence (All Phases) •

Test Result

1.6ms Transfer Time (1ms detection time plus 600us SCR clearing time).

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DVT Testing - Single Phase Outages

Source Output • • • •

Test Setup

Source Channels -> 3,5,&7 Output/Load Channels -> 4,6,&8 Load -> 100KW Resistive Unit -> 275KVA IR (Internal Redundant) with Common Battery •

Test Description

1 cycle 0% dropout sequence (phase L1) (0% is a low impedance (short) source fault) •

Test Result

1ms Transfer Time 23 23

DVT Testing - Single Phase Outages Continued

Source • • • •

Test Setup

Source Channels -> 3,5,&7 Output/Load Channels -> 4,6,&8 Load -> 100KW Resistive Unit -> 275KVA IR (Internal Redundant) with Common Battery •

Test Description

12 cycle 40% dropout sequence (phase L2) •

Test Result

1.2ms Transfer Time Output 24 24

DVT Testing - Single Phase Outages Continued

Source Output • • • •

Test Setup

Source Channels -> 3,5,&7 Output/Load Channels -> 4,6,&8 Load > 225KVA ∆Y Transformer with 100KW Resistive Load Unit -> 275KVA IR (Internal Redundant) with Separate Batteries •

Test Description

1 cycle 0% dropout sequence (Phase L2) •

Test Result

1.6ms Transfer Time 25 25

What about power line transients?

» In either ESS or VMMS mode the inverter filter is continuously “on-line” – it works with an inline inductor to filter out any abnormal line transients. Need proof?

Inverter Filter Inline inductor

27 27

ESS Technology

~ =

“Typical” Surge IT Equipment tolerance UPS output with Surge Filter

28 28

High Alert Mode

High Alert Mode: Continued Storm Detection:

Storm detection is the setting in which the UPS locks into double conversion mode when three power line disturbances have forced three transfers from ESS to double conversion mode within an hour. The system will then remain in high alert mode for one hour after the last line disturbance (before transferring back to ESS). Any power strategy command from the front display will reset the one hour ESS lockout period. Note: the one hour timer is EEP configurable.

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Operation during faults (short circuits)

ESS Output Fault Detection (Breaker Clearing)

While in ESS the UPS is capable of detecting the difference between a load fault and an upstream short. If a load fault is detected, the UPS will try to clear the fault/breaker by remaining in ESS. If the fault is a short upstream from the UPS, it will immediately perform a forward transfer. The forward transfer time is less than 2 ms (due to the DSP control)

ESS Overload Behavior

If the load exceeds 110% of the UPS capacity while in Energy Saver System, the UPS will transfer to bypass and will remain there until the overload clears. Once the overload clears, the unit transitions back to Energy Saver System (except for output faults – see above). 30 30

Energy Saver System saves even more at lower loadings

ESS Efficiency — 99% across the complete operating range

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Energy Saver System — the bottom line

The energy savings from ESS typically recovers 100% of the UPS cost over a 2-3 year period.

» At 250 kW of critical load, the savings is equivalent to $4000 per year per point of efficiency gain.

Backing up your 250 kW load with an ESS UPS is equivalent to pulling 29 cars off the road.

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Energy Saver System – The Bottom Line – 250kW

Critical Load Electric Costs

(energy + demand) per kW hr

Legacy UPS efficiency Eaton ESS UPS efficiency 50 kW

$0.11 92.5%

99% Summary Table 125 kW 250 kW

$0.11 92.5%

99%

$0.11 93%

99% 500 kW

$0.11 93%

99% 700 kW

$0.11 93%

99% 3-Year energy savings 3-Year CO 2 savings Cars off the road

145 MW hr 104 metric tons 6 cars 363 MW hr 261 metric tons 16 cars 670 MW hr 481 metric tons 29 cars 1340 MW hr 962 metric tons 59 cars 1876 MW hr 1347 metric tons 82 cars

3-Year electric cost savings $15,972 $39.929 $73,715 $147,431 $206,403

• •

The energy savings from ESS typically recovers 100% of the UPS cost over a 2 - 3 year period Every 250kW with ESS is equivalent to pulling 29 cars off the road.

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Summary — Energy Saver System

Energy costs are overwhelming equipment costs in data centers.

» UPS electrical losses account for 5 –10% of the overall electrical expenditure.*

Eaton’s Energy Saver System drives these losses down to nearly zero.

The energy savings recovers the cost of the UPS in less than five years.

* Underlying figures from

The Invisible Crisis in the Data Center: The Economic Meltdown of Moore’s Law,

Uptime Institute, 2007 34 34

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