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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. DCUG Spring 2014 Survey Results. Protect. Efficiency. Customers want both: Efficiency without Compromising Availability.

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Max Protect – Max Efficiency Engineers Design Guide to Large UPS

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  1. Max Protect – Max Efficiency Engineers Design Guide to Large UPS C. Mayo Tabb Jr. Senior, 3-phase Regional Manager June 2014

  2. DCUG Spring 2014 Survey Results Protect Efficiency Customers want both: Efficiency without Compromising Availability

  3. Capacity & Efficiency Capacity & Efficiency driving data center change Source: Uptime Institute / 2012 Symposium

  4. 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

  5. June 2014 March 2014 Emerson Network Power Max Protection and Max Efficiency UPS 500, 625, 750, 800, 900, 1100kVA Liebert NXL 250, 300, 400kVA SMS, 1+N, N+1 Eco-Mode, Intelligent Paralleling Maximum Protection 400, 500, 600kVA Liebert NX 225, 250, 300kVA SMS, 1+N Eco-Mode, Capacity on Demand (Softscale) Maximum Efficiency Liebert eXL 1200 kVA 1600 kVA 625, 750, 800 kVA SMS Eco-Mode, Capacity on Demand (Softscale) 200 800 1200 3phase In / 3phase Out Capacity, kVA

  6. System Availability UPS Design Engineer’s Quote • “An isolation transformer hides many rectifier and inverter sins” • “A transformer increases cost, footprint and lowers efficiency” What saves What fails Keep the load up Isolation

  7. Transformer andTransformer-Free UPS Liebert Products Max Protect NXL NX - eXL

  8. Liebert NXL Enterprise-Scale UPS Protection for Medium/Large Data Centers 1100kVA/1100kW • 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 1125kVA/1125kW Units in Blue provide DC isolation 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

  9. 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 InverterIntelligent Ecomode • System level Intelligent Paralleling NXL800 Rectifier Transformer-Based Monolithic Construction

  10. UL STD. 1778 4TH Edition Liebert NXL Industry Leading Performance Superior Stack up Performance Handles Faults High, Flat Efficiency Curve User Friendly DSP Controls Leading Power Factor Capability

  11. Liebert NXL High Efficiency Modes of Operation,“Intelligent EcoMode” Double Conversion Operation • Intelligent EcoMode • Increases efficiency by running the bypass in parallel with the inverter. • If poor quality AC detected, switches to full dual conversion mode Bypass AC Input Static Switch Inverter Rectifier Rectifier AC Input Battery Intelligent EcoMode • Outage • Transfer Bypass AC Input Static Switch Inverter Rectifier Rectifier AC Input • Bypass source is monitored • Inverter in on • Inverter matches bypass • Load harmonics profiled • Efficiency gain Battery

  12. NXL,NX,eXLConfigurations • System Level Static Switch and Controls SS SS R I R I BB Single Module System (SMS) NXL,NX,eXL BB R I SS BB Highest MTBF Design Product Line Scope R I R I BB Cost Effective Design BB SS R I R I BB BB Centralized Static Switch (N+1) NXL,eXL Distributed Bypass (1+N) NXL,Nx,eXL

  13. 1+N(Distributed Static Switch) N+1 (Central Static Switch)NXL and eXL share N+1 SCCC • 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 Slightly less costly ASCO Slightly more reliable

  14. Liebert NX, Transformer-free UPS System 8500 units installed in Europe since 2007 • 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

  15. 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

  16. Liebert NX600Dual or single input; optional input CB Input Jumpers For single input 16

  17. 100 kAIC Withstand Rating • Fuses provide a 100 kAIC withstand rating. • 3 wire +G input/output only – no 4 wire Input fuses NX600 3phase bolted fault w/o bypass –unit kept running after breaker opened NX600 starting 800kVA PDU w SS pulse • No output breaker or option for one • Unit will always be with external MBC • MIB or MOB/IOB provides disconnect

  18. NX600 Technical Data S610 450/500 798 amps input NXL 450/500 804 amps input NX600 761 amps input Combined effect of efficiency and advanced PWM rectifier optimized to VRLA Batteries 25% battery recharge obsolete 10x recharge rate obsolete – 20X VRLA batteries life is shortened if fast recharge – 5% is typical max

  19. 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

  20. 2 level vs 3 Level NPC2 2 Level NPC1

  21. Inverter Topology Comparison 400VAC2L, NPC1, and NPC2 2L, Legacy, NX, Powerware 9395, MGE G7K – 94-95% IGBT Losses NPC1, APL, APM, Mitsubishi <250kVA, -95-96% NPC2, eXL, Mitsubishi >250kVA, GE – 96-97% Switching Frequency

  22. UPS System Efficiencies Liebert eXL Active Inverter Intelligent EcoMode* Liebert eXL Dual Conversion** Efficiency Load *Current Estimate **Subject to upward revision

  23. Liebert eXLInput section AC Input DC input Draw out logic and customer options Fuse protected 100kaic SCCR 23

  24. EXL800Dual 400kW cores Draw-out for ease of service Boast Charger Phases A,B,C 8 IGBT packs per phase/core Core inductors 24

  25. eXLOutput and Static switch Static switch SCR Output Bypass input Output and BFB breakers 25

  26. EXL800Cooling design for maximum efficiency • 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

  27. UPS DC Systems Remember the batteryIt is responsible for half the load losses!

  28. Battery Life ComparisoneXL800 * * * Replacement cost at 75% in year 4-5, 8-10 etc.

  29. Alber – individual cell monitoring

  30. 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 Resistance Trend • AC impedance testing will detect a bad cell • Only when very close in time to when the cell is failing or has failed Impedance Trend

  31. 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 How many cell failures before replacement ?

  32. Liebert Battery Mean TimeBetween Failure (MTBF) Study Battery Maintenance(No Monitoring) Experience: High reliability Alber On-siteExperience: Significantly longer runtime before a failure Ntegrated MonitoringExperience: No outages due to bad batteries 2010* Study based on batteries under Liebert contract from battery strings with a total of 9.5 million run hoursprior to the end of their expected service life. *Updated 2013 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)

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