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

3

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

7

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

11

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

13

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

14

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

15

Liebert NX600Dual or single input; optional input CB

16

Input JumpersFor single input

100 kAIC Withstand Rating Fuses provide a 100 kAIC withstand rating. 3 wire +G input/output only – no 4 wire

17

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

20

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

21

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

23

AC Input DC input

Draw out logic and customer

options

Fuse protected100kaic SCCR

EXL800Dual 400kW cores

24

Boast ChargerPhases A,B,C

Draw-out for ease of service

Core inductors

8 IGBT packs per phase/core

eXLOutput and Static switch

25

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

27

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%

30%

35%

40%

1 2 3 4 5 6 7 8 9 10

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

0.15

0.20

0.25

0.30

0.35

0.40

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

0

Integrating remote and on-site service: Remote Service – Centralized Technicians On-Site Service – Field Technician Monthly PM’s (1 on site / 11 Alber Monitoring)

33