Max Protect – Max Efficiency Engineers Design Guide to Large UPS
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Transcript of Max Protect – Max Efficiency Engineers Design Guide to Large UPS
Max Protect – Max Efficiency Engineers Design Guide to Large UPS
C. Mayo Tabb Jr. Senior, 3-phase Regional Manager
June 2014
Availability (uptime)
Adequate monitoring / data center management capabilities
Heat density (cooling)
Energy efficiency (energy costs & equipment efficiency)
Power density
Space constraints / growth
Security (physical or virtual)
Technology changes / change management
Data center consolidations
Data storage
Regulatory compliance
Other
0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0%
38.8%
50.9%
32.1%
38.8%
22.4%
19.4%
15.8%
25.5%
21.2%
16.4%
9.7%
1.8%
33.6%
50.5%
42.1%
48.6%
28.0%
27.0%
18.7%
22.4%
24.3%
12.1%
9.3%
6.5%
What are your top three (3) facility / network concerns?
Spring 2013 Spring 2014
Customers want both: Efficiency without
Compromising Availability
DCUG Spring 2014 Survey Results
Efficiency
Protect
Capacity & Efficiency
Source: Uptime Institute / 2012 Symposium
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Capacity & Efficiency
driving data center change
Max Protect-Max Efficiency
Max Protect – Availability of power to load is top priority– Data is unique and cannot be recovered– Initial cost and operating cost are secondary– Configuration and batteries are equally important– Tier3 & 4 where every chance of failure must be eliminated– Typically wet cells or 20 year VRLA battery
Max Efficiency– Initial cost and operating cost are top priority– Data can be recovered or process repeated– Availability are secondary– Site and configuration redundancy
• Designed to tolerate a failure– Typically 5/10 year VRLA battery
Emerson Network Power Max Protection and Max Efficiency UPS
Capacity, kVA200 800
3phase In / 3phase Out
250, 300, 400kVA
500, 625, 750, 800, 900, 1100kVA
Liebert NXL
225, 250, 300kVA
1200
Eco-Mode, Intelligent Paralleling
SMS, 1+N, N+1
Eco-Mode, Capacity on Demand (Softscale)SMS, 1+N
Liebert NX
Liebert eXL 625, 750, 800 kVA
SMS
Eco-Mode, Capacity on Demand (Softscale)
400, 500, 600kVA
Maximum Efficiency
Maximum Protection
1200 kVA 1600 kVA
March 2014
June 2014
MIB
OutputMBB
3P
CB2
BFB
E
BIB
EG
FBO
AC
FBO
AC
GEC
MBJN N
EG
To Batteries
A
Trap DisconnectNon isolated other than 480V
isolated
What fails
What saves
Keep the load up
Isolation
“An isolation transformer hides many rectifier and inverter sins”“A transformer increases cost, footprint and lowers efficiency”
System AvailabilityUPS Design Engineer’s Quote
Characteristic Transformer-FreeMax Efficiency
Transformer-Based
AIC 65k,100k 65k,100k or 150k
Paralleling 1+N, (1+N &N+1) 1+N, N+1
PDU Start/bolted short
Input / DC / Output Isolation Alarm on Acid leak
Voltages 480v,HRG 480v,600v,HRG Opt.
Weight / SizeEfficiency – double conversion/eco-mode 95-97% / 98% 92-94% / 98%
Agency Listing UL1778 4th Edition, OSHPD,FCC
UL 1778 4th Edition, OSHPD,FCC
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Transformer and Transformer-Free UPS Liebert Products
NX - eXL NXLMax Protect
1125kVA/1125kW
Liebert NXL Enterprise-Scale UPS Protection for Medium/Large Data Centers
250kVA/225kW 480/575/600VAC
300kVA/270kW 480/575/600VAC
400kVA/360kW 480/575/600VAC
500kVA/450kW 480VAC
625kVA/625kW 480/575/600VAC
750kVA/675kW 480/575/600VAC
800kVA/800kW 480VAC
1100kVA/1100kW 480/575/600VAC Greater than 1,348 units under warranty and service contract, 24,683,136 Hrs.
MTBF = 6,170,784 Hrs.* Best field MTBF of any Liebert UPS
4 times improvement over Legacy UPS
Units in Blue provide DC isolation
1100kVA/1100kW
Transformer-Based
Monolithic Constructio
n
Maximum Protection UPS System
Liebert NXL Ratings to 1100kVA/kW Transformer-based
– 600v without add-on transformers on DC isolation versions
Efficiency – 94+% Dual Conversion
– 98+% Active Inverter
Intelligent Ecomode– System level Intelligent Paralleling
MIB
OutputMBB
3P
CB2
BFB
E
BIB
EG
FBO
AC
FBO
AC
GEC
MBJN N
EG
A
Trap Disconnect
CB1
12P isolated
12P non isolated
or
To Batteries
NXL800 Rectifier
Liebert NXL Industry Leading Performance
Leading Power Factor Capability
Handles Faults
High, Flat Efficiency Curve
Superior Stack up
Performance
User Friendly DSP Controls
UL STD. 1778 4TH Edition
Intelligent EcoMode– Increases efficiency
by running the bypass in parallel with the inverter.
– If poor quality AC detected, switches to full dual conversion mode
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Bypass AC Input
Rectifier AC Input
Rectifier Inverter
Static Switch
Battery
Bypass AC Input
Rectifier AC Input
Rectifier Inverter
Static Switch
Battery
Double Conversion Operation
Intelligent EcoMode
• Bypass source is monitored• Inverter in on• Inverter matches bypass• Load harmonics profiled• Efficiency gain
Liebert NXL High Efficiency Modes of Operation,“Intelligent EcoMode”
• Outage• Transfer
NXL,NX,eXL Configurations System Level Static Switch and Controls
Cos
t Effe
ctiv
e D
esig
n
Hig
hest
MTB
F D
esig
n
Distributed Bypass (1+N)NXL,Nx,eXL
Centralized Static Switch (N+1)NXL,eXL
Single Module System (SMS)NXL,NX,eXL
Prod
uct L
ine
Scop
e
SS
R I
SS
R I
SS
R I
BB
BB
BB
SS
R I
BB
R I
BB
R I
BB
R I
BB
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3200-5000 amp Continuous-duty Static Switch SCCC 1000% Overload rating De-rates at 1600,2000,2500,3000
amps but costly N+1 UL-1558 & UL-891 to 200 kaic 1+N UL-15558 &UL-891 to 100 kaic
ASCO
1+N (Distributed Static Switch) N+1 (Central Static Switch)NXL and eXL share N+1 SCCC
Slightly more reliable
Slightly less costly
225kVA/225kW 480V (Fixed Capacity or SoftScale to 300 kVA/kW)
250kVA/250kW 480V (Fixed Capacity or SoftScale to 300 kVA/kW)
300kVA/300kW 480V (Fixed Capacity ) Best price point
400kVA/400kW 480V (Fixed Capacity or SoftScale to 600 kVA/kW)
500kVA/500kW 480V (Fixed Capacity or SoftScale to 600 kVA/kW)
600kVA/600kW 480V (Fixed Capacity ) Best price point
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Liebert NX, Transformer-free UPS System
8500 units installed in Europe since 2007
Liebert NX,Large Transformer-free System Transformer-free, 480 Volt, 3-wire design Unity PF rating, kW = kVA Leading/Lagging PF load support Configurations:
Single-module systems Parallel 1+N systems, to 6 Modules Dual bus systems Common Battery option for 2 modules
95% efficient in dual conversion 98-99% efficient in eco-mode High overload capability
(125 %10 min, 150% 1 min) High power density / small footprint UL 1778 Edition 4 listed Liebert Service coverage/capability Life.net automatic “call home” monitoring Field mtbf 1.2M hours,8500 installed since
2007 by European methodology OSPHD tested
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Liebert NX600Dual or single input; optional input CB
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Input JumpersFor single input
100 kAIC Withstand Rating Fuses provide a 100 kAIC withstand rating. 3 wire +G input/output only – no 4 wire
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NX600 starting 800kVA
PDU w SS pulse
NX600 3phase bolted fault w/o
bypass –unit kept running after
breaker opened No output breaker or option for one Unit will always be with external MBC MIB or MOB/IOB provides disconnect
Input fuses
S610 450/500 798 amps inputNXL 450/500 804 amps inputNX600 761 amps input
Combined effect of efficiency and advanced PWM rectifier optimized to VRLA Batteries
25% battery recharge obsolete10x recharge rate obsolete – 20X VRLA batteries life is shortened if fast recharge – 5% is typical max
NX600 Technical Data
Max Efficiency Liebert eXL UPS!
Pushing Double Conversion Efficiency to 97% Leading power factor loads without de-rating -
0.7 leading to 0.7 lagging
2 level vs 3 Level
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NPC2
NPC1
2 Level
2L, Legacy, NX, Powerware 9395, MGE G7K – 94-95%
NPC1, APL, APM, Mitsubishi <250kVA, -95-96%
NPC2, eXL, Mitsubishi >250kVA, GE – 96-97%
IGBT Losses
Switching Frequency
Inverter Topology Comparison 400VAC2L, NPC1, and NPC2
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UPS System EfficienciesEf
ficie
ncy
Load
Liebert eXLActive Inverter Intelligent EcoMode*
Liebert eXLDual Conversion**
10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0% 80.0% 90.0% 100.0%80.0%
85.0%
90.0%
95.0%
100.0%
*Current Estimate **Subject to upward revision
Liebert eXLInput section
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AC Input DC input
Draw out logic and customer
options
Fuse protected100kaic SCCR
EXL800Dual 400kW cores
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Boast ChargerPhases A,B,C
Draw-out for ease of service
Core inductors
8 IGBT packs per phase/core
eXLOutput and Static switch
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Static switch SCR
OutputBypass input
Output and BFB breakers
High Efficiency is increasingly effected by fan losses– Fan kW are a larger portion of total losses at higher efficiency
4 x 600 cfm ball bearing 50,000 hour fans per core Fan failure is alarmed via tack signal from fan Shutdown/bypass determined by temperature 100% load – 35 degrees C at 800 kW
– Continuous operation requires all fans Up to 90% load- 35 degrees C at 800 kW
– Continuous operation with one failed fan Above 90% load
Operates until temperature bypass/shutdown on failed fan
EXL800Cooling design for maximum efficiency
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UPS DC Systems
Expected Yearly Replacement
0%
5%
10%
15%
20%
25%
30%
35%
40%
1 2 3 4 5 6 7 8 9 10
Years
Perc
enta
ge
Remember the batteryIt is responsible for half the load losses!
Battery Life ComparisoneXL800
* Replacement cost at 75% in year 4-5, 8-10 etc.
**
Battery Technology Minutes Warranty Life Cost
4x HR540 VRLA 6 3 yr 3-5 yr $87k
4x HX5500 VRLA 5 3 yr 3-5 yr $87k
4x XE-95 Pure lead 3 2 yr 2-4 yr $102k
5x XE-95 Pure lead 6 5 yr 5-6 yr $127k
5x HR7500 VRLA 17 4 yr 4-6 yr $150k
4x HX925 VRLA 16 3 yr 3-6 yr $156k
AVR95-33 VRLA - stack 6 5+15 12-15 yr $176k
DXC-23 san wet 1.250 15 3+17 12-18 yr $178k
DXC-27 poly Wet 1.215 15 3+17 12-18 yr $237k
AVR4100 VRLA - stack 27 5+15 12-15 yr $253k
5x Li-on LiFeMgPO4 6 10 yr 10+ yr $311k
Alber – individual cell monitoring
Impedance Trend
Resistance Trend
The Difference – Early Detection of Failures Typically, internal resistance
increases slowly over time and use
Early detection allows for cell replacement to avoid load loss
AC impedance testing will detect a bad cell
Only when very close in time to when the cell is failing or has failed
Why is it 4 yearsfor a 10 year VRLA?
10 year design life in telecom float test– 24 cells16 amps for 8 hours versus 240 cells 450 amps for 5 minutes– Warranty – 3 years full+7 years pro-rata
Year 4 – 2%x240 cells=5 cells– One fails every 2-3 months for 1 string– For two strings one every month– For 4 strings one every two weeks - 5 cells between 90 day PM’s– IT will barely tolerate this number of service calls
Year 5 – 15%x240 cells=36 cells– One fails every 10 days for 1 string– For two strings one every 5 days– For 4 strings one fails every 2 days – 36 cells between 90 day PM’s– IT will Not tolerate this number of service calls
Expected Yearly Replacement at 77 F
0%
5%
10%
15%
20%
25%
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Years
Perc
enta
ge
How many cell failures before replacement ?
Liebert Battery Mean TimeBetween Failure (MTBF) Study
Battery Maintenance(No Monitoring) Experience: High reliability
0.00
0.05
0.10
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0.25
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0.35
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0.45
On-Site PMs On-Site PMs with Alber
Ntegrated Monitoring
Outages Per Million Hours
2010* Study based on batteries under Liebert contract from battery strings with a total of 9.5 million run hours prior to the end of their expected service life. *Updated 2013
Alber On-siteExperience: Significantly longer runtime before a failure
Ntegrated MonitoringExperience: No outages due to bad batteries
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Integrating remote and on-site service: Remote Service – Centralized Technicians On-Site Service – Field Technician Monthly PM’s (1 on site / 11 Alber Monitoring)
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