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Phasing out AC - DIRECTLY

David E. Geary, P.E., Senior Member, IEEE
AbstractTodays technology in data center power is moving toward the perspective of the loads need for VDC (Volts Direct Current) Power and away from a focus on how to convert VAC (Alternating Current) Grid Power to something usable. BUT, converting to Data Center VDC Power Systems is not enough. This is not VAC verses VDC, not analog verses digital, not Westinghouse verses Edison. Simply put, it is the enhanced reliability, lower cost and maintenance expense, dramatic real estate reduction, and effective green power integration when focusing on the loads need for VDC Power. PLUS, increased efficiency is important and VDC does provide, in all cases an improvement. 380 VDC Power is the global format of choice. While we want to say Edison was right, we need to instead recognize that this world has evolved to where the demarcation line between VAC and VDC has made a shift. The VDC load is no longer just the chip, it is now 80% of the building enabled by power electronics and justified by the holistic business value of VDC.

I. INTRODUCTION Since the Current Wars fought between Westinghouse and Edison at the dawn of electricity there has never been a renaissance of interest in how electricity is generated, transported and used then exists today. The digital loads that continue to grow in todays societies have finally reached a growth pattern and density where it has become apparent that power generation and delivery, as we know it, must change. Digital loads should be supported by digital power. Todays power electronics, coupled with the need to expand the use of renewable energy sources, make it apparent that VDC power now has a place in our national power grid infrastructure. Some arguments in support for VDC power are as follows:

HE DIRECT CURRENT (VDC) POWER ADVANTAGE:

The data centers ability to adapt to current & future power generation systems (Solar, Wind, Fuel Cells, etc.) is here now in the form of reliable 380 VDC. The digital age demands that support systems such as power are focused on the chip systems that drive data center revenue. The managers, users, designers, and those financially responsible for data centers want to put their attention on the mission and require power support systems to be adaptable to new & evolving power generation techniques without affecting data center operations. Now considered large power consumers, data centers are focusing more on operations, which requires that power support systems must include flexible modularity, higher efficiency, more cost effective reliability, a smaller footprint, while enjoying the security of global safety listings. Chip2GridTM Intuitively it is better to design, adapt and optimize from chip (power use device) to the power grid, not from the power grid to the chip. If you are a data center person, the easy and intuitive answer is from the chip to the grid, which automatically embraces the unique concept of Chip2GridTM technology. Fundamentally, todays internal power supply first stage distribution for computers is at 380 VDC output, therefore all IT power supplies can easily migrate to this solution. Since the grid is a VAC source, the voltage must be changed to VDC only once (half a typical UPS system) rather than multiple conversions back and forth performed by legacy UPS and data center power system architectures. However, if the power grid is VDC, there is no need to change it back & forth. An example would be to power a computer directly from solar. The power supply for the server does not have to change VAC to VDC since it always sees 380 VDC. Designs are now available from the perspective of the chip to the server power supply to 380 VDC source. For data center designers, this provides a consistent methodology to allow them to invest more in their business systems and not the power support systems. Power supply providers who

Affiliation footnote: David Geary is a registered professional electrical engineer with over 30 years experience and is with Universal Electric Corp.; StarLine VDC Solutions Division, Canonsburg, PA 15317 USA (e-mail: dgeary@uecorp.com)

manufacture over 70% of servers globally embrace this technology. Chip2GridTM makes it happen. Chip2GridTM has a benefit for everyone associated with a Data Center. From the operations staff to the Chief Financial Officer Chip2GridTM contributes to data center operations and the bottom-line, as follows: 1. Higher Reliability fewer points of failure improves reliability studies indicate over 200% and to as much as 1,000%. 2. Higher Efficiency Start with an inherent energy savings (x) and work for more. 3. Smaller Footprint 33% space savings with electrical infrastructure. Also 36% lower lifetime real-estate costs per Validus/GE/ABB study 2010. 4. Lower Operation & Maintenance Costs- on average 35% less than VAC. 5. Lower Capital Expense- Reduce electrical facility capital costs by 15%. 6. Easier Data Center Conversions- no need to rip & replace just swap out. 7. Lower Heat Load overall cooling requirements are lower. 8. Easier Integration of Renewable Energy Most renewables are VDC to start. Components involved and aspects of electrical design engineering with this Chip2GridTM technology illustrate some of the additional positive realities of this approach as follows: IT power supplies accept 380 VDC input and uses what has been shown to be an optimal voltage level. The bus can be center grounded (+/- 190 VDC) to further reduce voltage exposure. Universal 380 VDC For existing power supplies not currently at 380 VDC all that is required is an off-theshelf receptacle and elimination of existing VAC power components. Safety connectors to the servers any arc is fully extinguished before opening of the connector and passes UL jointed finger probe touch-safe proof tests. Power Distribution System 380 VDC allows for more power delivery than VAC on the same amount of copper. Rack mount PDUs - modularity not previously available that allows easier design decisions. 380 VDC UPS no need to do an VAC-VDC conversion followed by a VDC-VAC conversion. Load balancing - not Chip2GridTM is the first data center power technology required for 380 developed from the perspective VDC, becoming a of the load (the chip) instead of bigger issue for the source (the grid) yielding to data center operators and VAC. managers significant benefits System overload, short not previously available until circuit and arc flash now. protection - 380 VDC offers new opportunities for new circuit protection technologies with the potential of providing for safer systems. As VAC data center distribution moves to higher RMS voltages (400vac, 415vac, 480vac) arc flash and circuit protection at the rack becomes a bigger issue;

as well as, higher cost, non-commodity parts driven by peak voltages above 560 VAC. Server fans can run off 380 VDC and inherently provide a reduction in power consumption with simpler and more precise control. Cooling systems can utilize 380 VDC motors. Harmonics can be treated at the VDC source thus allowing for the elimination of filtering at the component level. Green Power VDC Micro-Grids: Sources such as wind, solar, batteries, ultracaps & fuel-cells are already VDC and by removing the VAC conversion there is improved efficiency and ROI.

Todays VAC industry focuses too much attention on the efficiency gains, (or lack there-of), when transitioning to a VDC infrastructure topology. This paper focuses on the multiple engineering issues and ideas that will make VDC power the power topology of the future because the future benefits will be shown to be too compelling to think otherwise. This paper includes a Chip2GridTM journey through a 380 VDC infrastructure and covers engineering oriented topics and ideas such as: power supply details, connectors, wire and cords, power distribution units/PDUs, branch circuit protection, metering, bus way, distribution level circuit protection and control, grounding, load balancing, equipment space, reliability, short circuit and arc flash protection, voltage drop, VDC motors and control, and cross industry collaboration. A Chip2GridTM PERSPECTIVE

II. VDC POWER ENGINEERING The electrical engineering characteristics of VAC verses VDC power needs to be examined in detail before a final conclusion can be made regarding the impetus to change anything. VAC power has been the topology of choice since the beginning of electricity, and there were technical reasons why.

So why consider VDC power again:

We can provide VDC power at a voltage already native to power supplies today. As we investigate the details of how this is done we can also realize that the legacy VAC power environment that power supplies have lived in since the beginning have caused many things to be added to these power supplies in order to function in the pre-defined constraints dictated by the VAC power system operational specifications. If we remove these constraints and offer a very stable, narrow range voltage (380 VDC +/- 5%) then what will that allow the power supply to evolve into? Reduced or elimination of hold-up requirements, no harmonic filtering required, other opportunities? So what are the engineering challenges that will allow for optimized power supply design? B. The 380 VDC topology: a) Codes & Standards: First of all we are not talking about High Voltage DC! (380v VDC is actually classified as Low Voltage by IEEE). Per the Emerge Alliances, (www. Emergealliance.org), Standard for VDC Power Distribution Systems for Data & Telecom Centers AND ETSI Standard EN 300 132-3; Power Supply Interface at the Input to Telecom & Data (ICT) Equipment; Direct Current up to 400 V Solution, the nominal voltage is 380v VDC. Both of these standards will be completed by mid-year 2012. The recommended topology is a center tap ground that will limit voltage to ground to + 190v VDC and 190v VDC.

A. VDC Power for VDC loads The Power Supply Story: More and more of our everyday power loads are inherently VDC. In data centers that is especially true and data center load growth has resulted in industry looking different ways of doing things to increase efficiency and reliability. So let us start here inside the data center. The primary load in the date center is the processor chip, data storage, communication interfaces and data transmission all inherently VDC power loads fed through a VAC to VDC power supply. So the story begins with the power supply:

Other code and standard activities are in process with NFPA 70, (The National Electrical Code (NEC)), NEMA, UL, IEEE and others to integrate and develop verbiage for the design, installation and operation of VDC power systems with VDC power rated devices. Europe and Asia are also developing and editing standards for a 380v VDC topology. b) Short circuit, arc flash, circuit protection, load flow: VDC power has distinctive characteristics that differ from VAC power. As such there are multiple opportunities to do things differently regarding circuit protection, system coordination and control, arc flash protection and load flow control. New and existing technologies can be applied to take advantage of these characteristics to make this VDC topology more reliable, safer, and easier to monitor and maintain. Load Balancing De-rating Example

e) Voltage drop: If everything is equal VDC has less voltage drop than VAC:

c) Harmonics No harmony in the VAC world: Harmonics can be addressed at the bulk conversion point from VAC to VDC power. This feature allows for the elimination of the burden for point-of-use treatment at each stage of power conversion that exists in todays VAC power system. d) Load Balancing: Load balancing within a VAC system where multiple single phase loads are used is critical, and more often then not, not easily achieved. The lack of complete load balancing within a VAC system results in a built-in, ever changing derating effect that must be addressed.

VDC has a distinct advantage when considering this requirement.

f) Connectors: Power connectors have been developed and some are UL listed for 380 VDC use. Additionally there are new cord/connectors that insure the computer load is turned off prior to physical connections and disconnections.

h) Metering/monitoring: Power quality metering for VAC systems have become very costly when WAVE FORM CAPTURE and high-speed measurements are required to figure out has happened, in hind site, during a power quality event. The constant nature of VDC voltage and current allows for a simpler metering requirement and with the ability to decide more quickly when a problem occurs. i) Busway distribution: VDC is inherently a 2-wire system as proposed with a ground that could be run separately or accommodated by a busway frame. As such, VDC presents various options with system distribution configurations that VAC power cannot compete with.

Additionally there are new solid state technologies that will supplement connectors which will automatically open the VDC circuit as connectors are made and un-made. g) Wires and cords: According to American manufactures of wire and cable all are inherently rated for both VAC and VDC. Also, since VAC power is rated as an RMS voltage and not a peak-peak voltage, VDC wire and cable has a higher voltage rating and thus a higher power rating. 3-Phase, 4-Wire (VAC) verses 2-wire (VDC): Beside the obvious comparison of 4-wire verses 2-wire and the amount of labor and material when comparing the two, there is another thing to consider. Per NEC requirements adjustment/de-rating factors must be applied to conductors when four or more conductors are installed in a single raceway, (see NEC table).

j) Cross industry collaboration: "Semi-conductors began to evolve in the 1940s and 1950s and have become the predominant means of using power, and about 80 percent of power used in commercial buildings must go through some form of power electronics so it can be converted to VDC," quote from studies conducted by the Center of Power Electronics Systems at Virginia Tech. As the world continues to grow towards a native VDC load existence, and as other industries embrace this topology as well, there is great opportunity to share designs, development and opportunities to invent/develop when cross industry collaboration occurs.

Chip2Grid System Diagram C. Abbreviations and Acronyms AC - alternating current DC - direct current EMC - electromagnetic compatibility ETSI - European Telecommunications Standards Institute HVDC - NOT HIGH VOLTAGE VDC only higher voltage direct current (100 to 600 volts) IEC International Electrotechnical Commission IEEE - Institute of Electrical and Electronics Engineers NEC - National Electrical Code (NFPA 70) NEMA -National Electrical Manufacturers Association NFPA - National Fire Protection Association (United States) PDU - power distribution unit PE - protective earthing PPE - personal protective equipment PSU - power supply unit TCO - total cost of ownership UPS - uninterruptible power supply (or uninterruptible power system) VAC - Volts Alternating Current VDC - Volts Direct Current VRLA - valve-regulated lead-acid (battery)

k) Equipment size, space and cost: VDC power is not a new idea, but the way it can now be deployed and the innovation potential that exists in relation, will prove to be a positive factor when relating equipment size, space and cost. As industry volume increases, volume pricing and system optimization will occur. Recent studies have confirmed a possible cost savings of approximately 15%, and a space savings of approximately 35% when compared to Uptime Institute verified Tier 4 level legacy designs. l) Efficiency & Reliability: Less equipment required within a power path/chain that gets usable power to point-A (the load/chip) from point-B (the source/grid) means higher efficiency and more reliability. This is an engineering fact. Actual numbers will vary based on the many perspectives that are possible but that fact remains. Chip2Grid Technology has powerful benefits using currently available technologies and with great potentials for new technologies to address power consumption, real estate, cost & expense reduction, increased focus on the chip, reduced real estate, and easy green power integration. Plus you get increased efficiency as part of the package.

III. REFERENCES Books:

[1] [2] [3] [4] J. Jones, The Empires of Light, New York, Random House, 2003

Papers Presented at Conferences (Unpublished):

P.Barker, Nova Energy Specialists, LLC, Use of VDC for Micro-grids and Power Distribution, presented at the EPRI VDC Power Workshop, Washington VDC, 2006 C. Gellings, EPRI, Are we at the Threshold of a New Era of VDC Systems?, presented at the EPRI VDC Power Workshop, Washington, VDC, 2006 Pratt, A.; Kumar, P.; Aldridge, T.V., "Evaluation of 400V VDC distribution in TELCO and Data Centers to Improve Energy Efficiency," Telecommunications Energy Conference, 2007. INTELEC 2007. 29th International, pp. 32-39, Sept. 30 2007 - Oct. 4 2007. Aldridge, T.; Pratt, A.; Kumar, P.; Dupy, D.; AlLee, G., "Evaluating 400V Direct-Current for Data Centers," May 2010, http://blogs.intel.com/research/Direct%20400VDC%20White%20Paper. pdf

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Patents:
[6] M. Baldwin & D. Geary, High Reliability VDC Power Distribution System, U.S. Patent 7,492,057, Feb. 17, 2009