WO2014026840A2 - Electrical power distribution system for data centers - Google Patents

Electrical power distribution system for data centers Download PDF

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Publication number
WO2014026840A2
WO2014026840A2 PCT/EP2013/065754 EP2013065754W WO2014026840A2 WO 2014026840 A2 WO2014026840 A2 WO 2014026840A2 EP 2013065754 W EP2013065754 W EP 2013065754W WO 2014026840 A2 WO2014026840 A2 WO 2014026840A2
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WO
WIPO (PCT)
Prior art keywords
converter
voltage
distribution system
power distribution
power
Prior art date
Application number
PCT/EP2013/065754
Other languages
French (fr)
Other versions
WO2014026840A3 (en
Inventor
Drazen Dujic
Frederick Kieferndorf
Francisco Canales
Original Assignee
Abb Technology Ag
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Publication date
Application filed by Abb Technology Ag filed Critical Abb Technology Ag
Publication of WO2014026840A2 publication Critical patent/WO2014026840A2/en
Publication of WO2014026840A3 publication Critical patent/WO2014026840A3/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J1/00—Circuit arrangements for dc mains or dc distribution networks
    • H02J1/10—Parallel operation of dc sources
    • H02J1/102—Parallel operation of dc sources being switching converters
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J5/00—Circuit arrangements for transfer of electric power between ac networks and dc networks
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J9/00—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting
    • H02J9/04—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source
    • H02J9/06—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source with automatic change-over, e.g. UPS systems
    • H02J9/061—Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source with automatic change-over, e.g. UPS systems for DC powered loads
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/22—Conversion of dc power input into dc power output with intermediate conversion into ac
    • H02M3/24—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters
    • H02M3/28—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
    • H02M3/325—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal
    • H02M3/335—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/33507—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of the output voltage or current, e.g. flyback converters
    • H02M3/33523—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of the output voltage or current, e.g. flyback converters with galvanic isolation between input and output of both the power stage and the feedback loop
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/02—Conversion of ac power input into dc power output without possibility of reversal
    • H02M7/04—Conversion of ac power input into dc power output without possibility of reversal by static converters
    • H02M7/12—Conversion of ac power input into dc power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/21—Conversion of ac power input into dc power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/217—Conversion of ac power input into dc power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M7/219—Conversion of ac power input into dc power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only in a bridge configuration
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/4807—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode having a high frequency intermediate AC stage
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
    • H02M1/007—Plural converter units in cascade
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
    • H02M1/0074—Plural converter units whose inputs are connected in series
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/32—Means for protecting converters other than automatic disconnection
    • H02M1/325—Means for protecting converters other than automatic disconnection with means for allowing continuous operation despite a fault, i.e. fault tolerant converters
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/483—Converters with outputs that each can have more than two voltages levels
    • H02M7/49—Combination of the output voltage waveforms of a plurality of converters

Definitions

  • the present invention generally relates to electrical power supply for data centers, in particular data centers having a plurality of DC-operated loads such as servers, storage devices and the like.
  • data centers have an internal low-voltage three-phase AC electrical power distribution.
  • the power supply units provided in each of the servers usually include a switch mode power supply based on power factor correction stage followed by isolated DC-DC stage in order to adapt the voltage for the IT loads.
  • Electrical power provided to the data centers or similar facilities is usually taken from a three- phase medium-voltage AC line.
  • the medium AC voltage is stepped down using line frequency transformers to the low-voltage AC level, which usually is 380 VAC in Europe.
  • UPS uninterruptible power supply units
  • isolation devices for galvanic isolation such as power distribution units, are used to isolate the three-phase low-voltage AC distribution supply against a single-phase low AC voltage which is the input of the power supply units as used in the distant servers.
  • Document US 2006/0284489 A1 discloses a DC-based data center power architecture which has a four-stage system wherein low-voltage AC power is provided by low-frequency transformers. The low-voltage AC voltage is rectified and power is fed to a set of DC/DC converters that step down the DC voltage to bus bars to which DC loads are connected.
  • Document KR 201 1/003035 A discloses a DC power supply system for use in a data center having a plurality of servers.
  • the DC power supply system has a rectifier output that supplies DC power when alternating current power is supplied to the rectifier.
  • the servers store the DC power output from the rectifier.
  • the above object is achieved by the power distribution system for facilities having a plurality of low-voltage DC loads, such as data centers, according to claim 1 .
  • a power distribution system for supplying electrical power to a plurality of low-voltage DC loads in a data center, comprising:
  • a galvanically isolated converter arrangement for transforming a medium- voltage AC power provided on an utility line to a low/medium DC voltage provided on a first DC bus;
  • the converter arrangement has one converter unit per phase, wherein each of the converter units has a plurality of converter cells, and wherein each converter cell has an AC/DC converter stage followed by a DC/DC converter stage, wherein the DC/DC converter stage has a DC/AC converter and an AC/DC converter coupled to a medium- or high-frequency transformer for galvanic isolation.
  • One idea of the above power supply is to avoid and completely neutralize bulky low- frequency transformers which are configured to transform medium-voltage AC power to low- voltage AC power in cases where the AC power is mainly used for operating low-voltage DC loads, such as electronic circuits.
  • low-frequency transformers cannot provide any kind of power quality regulation alone, uninterruptable power supply is needed for power conditioning which leads to significant power losses across the distribution chain from the AC line to the loads, and the overall efficiency of a system is penalized.
  • Having multiple DC loads to be operated with very low voltages of 5 to 24 Volts implies advantages of having a distribution system that is realized with DC in order to match the load requirements and to reduce the number of conversions on the path of energy flow.
  • Avoiding the low-frequency transformer can be achieved by using a converter arrangement, such as a galvanically isolated medium-voltage rectifier, to transform the medium-voltage AC power to an intermediate-voltage DC power, wherein the intermediate-voltage DC power is then DC/DC converted to low/medium-voltage DC power as used by the loads and components of the data center.
  • a converter arrangement such as a galvanically isolated medium-voltage rectifier
  • the intermediate-voltage DC power is then DC/DC converted to low/medium-voltage DC power as used by the loads and components of the data center.
  • the above configuration has the advantage that no bulky low-frequency transformers are needed to transform the medium-voltage AC power at the input.
  • a converter arrangement instead of the low- frequency transformer a converter arrangement is used, the availability of the overall system can be increased and the up-time can be optimized due to the possibility of adding an additional layer of redundancy to the system, in particular by introducing redundancy inside the converter arrangement structure.
  • additional functionalities can be introduced since the converter arrangement incorporates a rectification function, which can be located centrally at the very input of the data center distribution system.
  • a further idea is to perform a power distribution throughout the data center with low-voltage DC power instead of low-voltage AC power. This may lead to a reduction of the number of conversion stages that are usually found in AC-supplied data centers by merely avoiding the double conversion performed within the uninterruptible power supply and inside the power supply units in, e. g., the server racks.
  • One of the benefits of having fewer conversions is simply a better efficiency as the power losses can be reduced. This may lead to a reduction of the need for cooling power, simpler system layout, smaller installation footprint and lower costs.
  • the converter arrangement may have one converter unit per phase, wherein each of the converter units has a plurality of converter cells which may have AC and DC terminals.
  • AC input terminals of the converter cells may be connected in series while their DC output terminals are connected in parallel.
  • one of the AC input terminals of the converter units may be connected to a common node, wherein the others of the AC input terminals of the converter units are input for a respective phase of the medium-voltage AC power, wherein the DC output terminals of the converter units are connected in parallel.
  • the AC input terminals of the converter units may be connected to each other in a delta configuration, wherein the output terminals of the converter units are connected in parallel.
  • each converter cell has an AC/DC converter stage followed by a DC/DC converter stage, wherein the DC/DC converter stage has DC/AC converter and an AC/DC converter coupled to a medium- or high-frequency transformer for galvanic isolation.
  • a first battery storage may be coupled to a DC link between the AC/DC converter stage and the DC/DC converter stage, in order to provide short term energy supply in case of a loss of AC power supply coming from the grid.
  • a second battery storage may be also coupled to the output of the converter arrangement.
  • Each converter cell may be provided with a bypass element to be activated in case of a failure to effectively decouple the respective converter cell from the serially connected converter cells. So redundancy can be introduced into the converter arrangement which increases availability of a whole power supply system.
  • a generator may be coupled to the first DC bus by means of an AC/DC converter, in order to provide means for long term energy supply in case of a loss of AC power supply coming from the grid beyond the duration able to be supported by the battery storages.
  • an energy resource providing DC power e.g. photovoltaic panels
  • a second DC bus for carrying a low voltage may be provided which is coupled to the first DC bus by means of non-isolated DC/DC converters.
  • the system is provided with a plurality of galvanically isolated converter arrangements and a plurality of DC loads wherein the respective first DC buses for each of the plurality of galvanically isolated converter arrangements are coupled via bypass elements for system reconfiguration.
  • Figure 1 shows an architectural layout for a power distribution system for a data center connected to a medium voltage AC utility line
  • Figure 2 shows an illustration of a converter arrangement for an exemplary converter arrangement as a galvanically isolated medium-voltage rectifier. Detailed description of embodiments
  • Figure 1 shows an architectural layout for a power distribution system 1 for a data center connected to a medium-voltage AC utility line 2.
  • the utility line 2 provides a three-phase medium AC voltage which is isolated and stepped down using a converter arrangement 3.
  • a medium voltage is a voltage in a range between 1 kVAC to several tens of kVAC.
  • the converter arrangement 3 is configured as a galvanically isolated medium-voltage rectifier and provides a transformation using an AC/DC converter stage 31 followed by a DC/DC converter stage 32 including at least one medium frequency transformer for galvanic isolation.
  • the converter stages 31 , 32 are operated by means of a control unit 34.
  • the control unit 34 is configured to provide the converting function with an AC/DC converter stage 31 .
  • the control unit 34 may be configured to operate the AC/DC converter stage 31 to act as a DC/DC converter stage which is capable to convert a medium DC voltage to a lower DC voltage.
  • the two-part configuration of the converter arrangement 3 allows for the integration of a first battery storage 33 directly into the converter arrangement 3, thus allowing a great flexibility in system design due to close proximity of elements performing the functions of isolation, rectification and energy storage.
  • the first battery storage 33 serves for bridging a power outage such that the converter arrangement 3 can continue delivering regulated power and voltage to the underlying system during a short period of time.
  • a first distribution DC bus 5 providing a low/medium voltage level of e. g. 650 V to 750 V is provided.
  • An AC generator 6 can be used for backup power as this is common for conventional data centers in which the AC generator 6 is coupled to the first distribution DC bus 5 via an associated active or passive rectifier 7 in order to deliver an appropriate auxiliary DC voltage to the first distribution DC bus 5.
  • a plurality of DC/DC converters 8 may be used in order to provide a tightly regulated second bus voltage to second distribution DC buses 9.
  • the DC/DC converters 8 are configured as non-isolating converters, i. e. having no transformer, and can be designed in a modular form, so that the total power matches the typical power of groups of DC loads, such as a server rack 10, tapped from the same power distribution unit 1 1 which serves for distributing DC power to the connected server racks 10.
  • Each power supply unit 12 is provided that supplies the numerous DC loads 13.
  • Each power supply unit 12 may comprises a further DC/DC converter or may be realized as a DC/DC converter which receives a DC input voltage from the second distribution DC bus 9 via the power distribution unit 1 1 and directly feeds the DC loads 13 which are components of the server rack 10.
  • a second battery storage 15 can be integrated to provide electrical DC power directly to the first distribution DC bus 5 and/or directly to the second distribution DC bus 9.
  • the system can be realized as 2N-redundant, including a bypass element 16, e. g. a switch for system reconfigurations.
  • a bypass element 16 may be used to interconnect one or more redundant first distribution DC buses 5, respectively.
  • the elements of the converter arrangement 3, the generator 6, the active rectifier 7, the DC/DC converters 8, the first and second distribution DC buses 5, 9, the power distribution unit 1 1 and the further DC/DC converter 12 can be mirrored or multiplied.
  • another distributed energy resource 17 such as a renewable energy source, can easily be connected directly to the first or second distribution DC bus 5, 9, through appropriate interface converter 20.
  • photovoltaic modules can be provided as such a distributed energy resource.
  • Voltage adaption for supplying power to additional loads 18, such as motors or pumps, which are needed for the data center to operate, may be required.
  • the voltage adaption is provided by means of an auxiliary DC/DC or DC/AC converter 19.
  • AC loads these can be operated by connecting them directly to the first distribution DC bus 5 using inverters to convert the DC power at the first distribution DC bus 5 into AC power to be provided to the respective AC load 18.
  • the converter arrangement 3 have to serve the purpose of providing a secure galvanic isolation from the medium voltage utility line 2 as well as the necessary rectification to provide the first DC voltage on the first distribution DC bus 5, with a possibility to integrate the first battery storage 33.
  • converter arrangement 3 as may be used in the architectural layout of Figure 1 is shown. As shown, converter arrangement 3 is configured using a arrangement of three single-phase converter units 21 each having a plurality of converter cells 22. Each converter cell 22 has an AC/DC converter stage 23 followed by a DC/DC converter stage 24.
  • the converter arrangement 3 can be built in a modular manner, wherein one AC/DC converter stage 23 and one DC/DC converter stage 24 together form the converter cell 22 which might be seen as a basic building block for the converter arrangement 3.
  • a number of such converter cells 22 may be stacked and connected in series on their AC side and in parallel on their DC side, respectively.
  • the required number of cells 22 mainly depends on the type of semiconductors used, the utility line voltage and the required first DC voltage on the first distribution DC bus 5.
  • the isolated DC/DC converter stages 24 provide the required galvanic isolation between the utility side and the load side, so that they can be designed to include a transformer that operates at medium or high frequency.
  • the converter arrangement 3 uses a star-connected topology for the single-phase converter units 21 , so that the single-phase converter units 21 are connected such that one of their input terminals is connected at one node and their respective other input terminals are inputs for a respective phase of the AC voltage.
  • the output terminals of the single-phase converter units 21 are connected in parallel.
  • the converter arrangement 3 can be made fault- tolerant by increasing the number of converter cells 22 per phase. In case of a failure of any component within one cell and provided the means to decouple the faulty cell from the system, the system can continue to operate without derating and a very high up-time can be guaranteed. This introduces another layer of redundancy into the system that is already redundant on the system level, as mentioned above.
  • the first battery storage 33 can be integrated into the DC link of each single-phase converter unit 21 of the converter arrangement 3. In one embodiment, this can be done in a conventional fashion on the output side of the converter arrangement 3, so that the whole converter arrangement 3 is stopped once the voltage at the utility line is lost such that the power supply is replaced by the first battery storage 33.
  • the first battery storage 33 can be arranged among the floating DC links at the input of each DC/DC converter stage 24 of the converter arrangement 3. In this case, when power on the utility line is lost, the converter arrangement 3 is still partially operational and continues to deliver energy to the first distribution DC bus 5.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Business, Economics & Management (AREA)
  • Emergency Management (AREA)
  • Dc-Dc Converters (AREA)
  • Rectifiers (AREA)
  • Direct Current Feeding And Distribution (AREA)

Abstract

The present invention relates to a power distribution system (1) for supplying electrical power to a plurality of low-voltage DC loads in a data center, comprising: -a galvanically isolated converter arrangement (3) for transforming a medium-voltage AC power provided on an utility line (2) to a low/medium DC voltage provided on a first DC bus (5); and -a plurality of DC loads to be supplied with a low DC voltage generated from the low/medium DC voltage on the first DC bus (5) by means of one or more additional DC/DC converters, characterized in that the converter arrangement (3) has one converter unit (21) per phase, wherein each of the converter units (21) has a plurality of converter cells (22), and wherein each converter cell (22) has an AC/DC converter stage (23, 31) followed by a DC/DC converter stage (24, 32), wherein the DC/DC converter stage (24, 32) has a DC/AC converter and an AC/DC converter coupled to a medium-or high-frequency transformer for galvanic isolation.

Description

Electrical power distribution system for data centers
Technical field
The present invention generally relates to electrical power supply for data centers, in particular data centers having a plurality of DC-operated loads such as servers, storage devices and the like.
Related art
At present, data centers have an internal low-voltage three-phase AC electrical power distribution. As the processing units and other parts used in servers of data centers are operated with a low-voltage DC power, the power supply units provided in each of the servers usually include a switch mode power supply based on power factor correction stage followed by isolated DC-DC stage in order to adapt the voltage for the IT loads. Electrical power provided to the data centers or similar facilities is usually taken from a three- phase medium-voltage AC line. The medium AC voltage is stepped down using line frequency transformers to the low-voltage AC level, which usually is 380 VAC in Europe. The low-voltage AC level is distributed throughout the data center, where also uninterruptible power supply units (UPS) are provided that usually perform a double conversion from AC to DC followed by DC to AC as the auxiliary power is supplied and stored in an intermediate battery which is connected to intermediate stage of the UPS.
Furthermore, isolation devices for galvanic isolation, such as power distribution units, are used to isolate the three-phase low-voltage AC distribution supply against a single-phase low AC voltage which is the input of the power supply units as used in the distant servers.
Document US 2006/0284489 A1 discloses a DC-based data center power architecture which has a four-stage system wherein low-voltage AC power is provided by low-frequency transformers. The low-voltage AC voltage is rectified and power is fed to a set of DC/DC converters that step down the DC voltage to bus bars to which DC loads are connected.
Document US 2010/026094 A1 discloses a power supply that distributes DC voltage in a building.
Document KR 201 1/003035 A discloses a DC power supply system for use in a data center having a plurality of servers. The DC power supply system has a rectifier output that supplies DC power when alternating current power is supplied to the rectifier. The servers store the DC power output from the rectifier.
In document EP 2 290 799 A1 a bi-directional multi-level AC/DC converter is disclosed. Summary of the invention
It is an object of the present invention to provide a flexible, modular, scalable and reliable power distribution system for data centers which does not require low frequency transformer at the input and has a reduced number of conversion stages, in particular a power supply which reduces energy losses in data centers.
The above object is achieved by the power distribution system for facilities having a plurality of low-voltage DC loads, such as data centers, according to claim 1 .
Further embodiments are indicated in the depending subclaims.
According to one aspect, a power distribution system for supplying electrical power to a plurality of low-voltage DC loads in a data center, comprising:
a galvanically isolated converter arrangement for transforming a medium- voltage AC power provided on an utility line to a low/medium DC voltage provided on a first DC bus; and
a plurality of DC loads to be supplied with a low DC voltage generated from the low/medium DC voltage on the first DC bus by means of one or more additional DC/DC converters, characterized in that
the converter arrangement has one converter unit per phase, wherein each of the converter units has a plurality of converter cells, and wherein each converter cell has an AC/DC converter stage followed by a DC/DC converter stage, wherein the DC/DC converter stage has a DC/AC converter and an AC/DC converter coupled to a medium- or high-frequency transformer for galvanic isolation.
One idea of the above power supply is to avoid and completely neutralize bulky low- frequency transformers which are configured to transform medium-voltage AC power to low- voltage AC power in cases where the AC power is mainly used for operating low-voltage DC loads, such as electronic circuits. As low-frequency transformers cannot provide any kind of power quality regulation alone, uninterruptable power supply is needed for power conditioning which leads to significant power losses across the distribution chain from the AC line to the loads, and the overall efficiency of a system is penalized. Having multiple DC loads to be operated with very low voltages of 5 to 24 Volts, implies advantages of having a distribution system that is realized with DC in order to match the load requirements and to reduce the number of conversions on the path of energy flow.
Avoiding the low-frequency transformer can be achieved by using a converter arrangement, such as a galvanically isolated medium-voltage rectifier, to transform the medium-voltage AC power to an intermediate-voltage DC power, wherein the intermediate-voltage DC power is then DC/DC converted to low/medium-voltage DC power as used by the loads and components of the data center. Naturally, this implies simplification of the switch mode power supplies used inside the servers, as these now can be realized as DC-DC converters without power factor correction stage.
The above configuration has the advantage that no bulky low-frequency transformers are needed to transform the medium-voltage AC power at the input. As instead of the low- frequency transformer a converter arrangement is used, the availability of the overall system can be increased and the up-time can be optimized due to the possibility of adding an additional layer of redundancy to the system, in particular by introducing redundancy inside the converter arrangement structure. At the same time additional functionalities can be introduced since the converter arrangement incorporates a rectification function, which can be located centrally at the very input of the data center distribution system.
Furthermore, as there is no need for physically providing large and costly AC filters, an increased power quality can be provided at the input of the data center, thanks to the high quality resolution of a voltage waveform at the input of a converter arrangement.
A further idea is to perform a power distribution throughout the data center with low-voltage DC power instead of low-voltage AC power. This may lead to a reduction of the number of conversion stages that are usually found in AC-supplied data centers by merely avoiding the double conversion performed within the uninterruptible power supply and inside the power supply units in, e. g., the server racks. One of the benefits of having fewer conversions is simply a better efficiency as the power losses can be reduced. This may lead to a reduction of the need for cooling power, simpler system layout, smaller installation footprint and lower costs.
Furthermore, the converter arrangement may have one converter unit per phase, wherein each of the converter units has a plurality of converter cells which may have AC and DC terminals.
Moreover, AC input terminals of the converter cells may be connected in series while their DC output terminals are connected in parallel.
According to one embodiment, one of the AC input terminals of the converter units may be connected to a common node, wherein the others of the AC input terminals of the converter units are input for a respective phase of the medium-voltage AC power, wherein the DC output terminals of the converter units are connected in parallel.
In an alternative embodiment, the AC input terminals of the converter units may be connected to each other in a delta configuration, wherein the output terminals of the converter units are connected in parallel.
It may be provided that each converter cell has an AC/DC converter stage followed by a DC/DC converter stage, wherein the DC/DC converter stage has DC/AC converter and an AC/DC converter coupled to a medium- or high-frequency transformer for galvanic isolation.
Moreover, a first battery storage may be coupled to a DC link between the AC/DC converter stage and the DC/DC converter stage, in order to provide short term energy supply in case of a loss of AC power supply coming from the grid. Furthermore, a second battery storage may be also coupled to the output of the converter arrangement.
Each converter cell may be provided with a bypass element to be activated in case of a failure to effectively decouple the respective converter cell from the serially connected converter cells. So redundancy can be introduced into the converter arrangement which increases availability of a whole power supply system.
According to another embodiment, a generator may be coupled to the first DC bus by means of an AC/DC converter, in order to provide means for long term energy supply in case of a loss of AC power supply coming from the grid beyond the duration able to be supported by the battery storages.
It may be provided that an energy resource providing DC power (e.g. photovoltaic panels) may be coupled directly to the first DC bus by means of an appropriate interface in order to achieve maximum power extraction.
A second DC bus for carrying a low voltage may be provided which is coupled to the first DC bus by means of non-isolated DC/DC converters.
It may be provided that the system is provided with a plurality of galvanically isolated converter arrangements and a plurality of DC loads wherein the respective first DC buses for each of the plurality of galvanically isolated converter arrangements are coupled via bypass elements for system reconfiguration.
Brief description of the drawings
Preferred embodiments of the present invention are described in more detail in conjunction with the accompanying drawings, in which:
Figure 1 shows an architectural layout for a power distribution system for a data center connected to a medium voltage AC utility line; and
Figure 2 shows an illustration of a converter arrangement for an exemplary converter arrangement as a galvanically isolated medium-voltage rectifier. Detailed description of embodiments
Figure 1 shows an architectural layout for a power distribution system 1 for a data center connected to a medium-voltage AC utility line 2. The utility line 2 provides a three-phase medium AC voltage which is isolated and stepped down using a converter arrangement 3. A medium voltage is a voltage in a range between 1 kVAC to several tens of kVAC. The converter arrangement 3 is configured as a galvanically isolated medium-voltage rectifier and provides a transformation using an AC/DC converter stage 31 followed by a DC/DC converter stage 32 including at least one medium frequency transformer for galvanic isolation. The converter stages 31 , 32 are operated by means of a control unit 34.
The control unit 34 is configured to provide the converting function with an AC/DC converter stage 31 . In alternative environments the control unit 34 may be configured to operate the AC/DC converter stage 31 to act as a DC/DC converter stage which is capable to convert a medium DC voltage to a lower DC voltage.
The two-part configuration of the converter arrangement 3 allows for the integration of a first battery storage 33 directly into the converter arrangement 3, thus allowing a great flexibility in system design due to close proximity of elements performing the functions of isolation, rectification and energy storage. The first battery storage 33 serves for bridging a power outage such that the converter arrangement 3 can continue delivering regulated power and voltage to the underlying system during a short period of time.
At the output of the converter arrangement 3 a first distribution DC bus 5 providing a low/medium voltage level of e. g. 650 V to 750 V is provided. An AC generator 6 can be used for backup power as this is common for conventional data centers in which the AC generator 6 is coupled to the first distribution DC bus 5 via an associated active or passive rectifier 7 in order to deliver an appropriate auxiliary DC voltage to the first distribution DC bus 5.
To step down the voltage of the first distribution DC bus 5 to an appropriate voltage level, a plurality of DC/DC converters 8 may be used in order to provide a tightly regulated second bus voltage to second distribution DC buses 9. The DC/DC converters 8 are configured as non-isolating converters, i. e. having no transformer, and can be designed in a modular form, so that the total power matches the typical power of groups of DC loads, such as a server rack 10, tapped from the same power distribution unit 1 1 which serves for distributing DC power to the connected server racks 10.
In each of the server racks 10, a power supply unit 12 is provided that supplies the numerous DC loads 13. Each power supply unit 12 may comprises a further DC/DC converter or may be realized as a DC/DC converter which receives a DC input voltage from the second distribution DC bus 9 via the power distribution unit 1 1 and directly feeds the DC loads 13 which are components of the server rack 10.
For improved operational capabilities, a second battery storage 15 can be integrated to provide electrical DC power directly to the first distribution DC bus 5 and/or directly to the second distribution DC bus 9.
Furthermore, the system can be realized as 2N-redundant, including a bypass element 16, e. g. a switch for system reconfigurations. One or more bypass elements 16 may be used to interconnect one or more redundant first distribution DC buses 5, respectively. Hence, the elements of the converter arrangement 3, the generator 6, the active rectifier 7, the DC/DC converters 8, the first and second distribution DC buses 5, 9, the power distribution unit 1 1 and the further DC/DC converter 12 can be mirrored or multiplied.
In addition, another distributed energy resource 17, such as a renewable energy source, can easily be connected directly to the first or second distribution DC bus 5, 9, through appropriate interface converter 20. For example, photovoltaic modules can be provided as such a distributed energy resource. Voltage adaption for supplying power to additional loads 18, such as motors or pumps, which are needed for the data center to operate, may be required. The voltage adaption is provided by means of an auxiliary DC/DC or DC/AC converter 19. In case of AC loads, these can be operated by connecting them directly to the first distribution DC bus 5 using inverters to convert the DC power at the first distribution DC bus 5 into AC power to be provided to the respective AC load 18.
One main aspect of the above-described architectural layout is the absence of bulky low- frequency transformers and their replacement by the converter arrangement 3. The converter arrangement 3 have to serve the purpose of providing a secure galvanic isolation from the medium voltage utility line 2 as well as the necessary rectification to provide the first DC voltage on the first distribution DC bus 5, with a possibility to integrate the first battery storage 33.
In Figure 2, converter arrangement 3 as may be used in the architectural layout of Figure 1 is shown. As shown, converter arrangement 3 is configured using a arrangement of three single-phase converter units 21 each having a plurality of converter cells 22. Each converter cell 22 has an AC/DC converter stage 23 followed by a DC/DC converter stage 24.
The converter arrangement 3 can be built in a modular manner, wherein one AC/DC converter stage 23 and one DC/DC converter stage 24 together form the converter cell 22 which might be seen as a basic building block for the converter arrangement 3.
A number of such converter cells 22 may be stacked and connected in series on their AC side and in parallel on their DC side, respectively. The required number of cells 22 mainly depends on the type of semiconductors used, the utility line voltage and the required first DC voltage on the first distribution DC bus 5. The isolated DC/DC converter stages 24 provide the required galvanic isolation between the utility side and the load side, so that they can be designed to include a transformer that operates at medium or high frequency. The converter arrangement 3 uses a star-connected topology for the single-phase converter units 21 , so that the single-phase converter units 21 are connected such that one of their input terminals is connected at one node and their respective other input terminals are inputs for a respective phase of the AC voltage. The output terminals of the single-phase converter units 21 are connected in parallel.
To increase the availability of the system, the converter arrangement 3 can be made fault- tolerant by increasing the number of converter cells 22 per phase. In case of a failure of any component within one cell and provided the means to decouple the faulty cell from the system, the system can continue to operate without derating and a very high up-time can be guaranteed. This introduces another layer of redundancy into the system that is already redundant on the system level, as mentioned above.
The first battery storage 33 can be integrated into the DC link of each single-phase converter unit 21 of the converter arrangement 3. In one embodiment, this can be done in a conventional fashion on the output side of the converter arrangement 3, so that the whole converter arrangement 3 is stopped once the voltage at the utility line is lost such that the power supply is replaced by the first battery storage 33. Alternatively, the first battery storage 33 can be arranged among the floating DC links at the input of each DC/DC converter stage 24 of the converter arrangement 3. In this case, when power on the utility line is lost, the converter arrangement 3 is still partially operational and continues to deliver energy to the first distribution DC bus 5.
Reference list power distribution system
utility line
converter arrangement
first distribution DC bus
generator
active or passive rectifier
further DC/DC converter
second distribution DC bus
server rack
power distribution unit
power supply unit
server loads
second battery storage
bypass element
distributed energy resource
AC load
auxiliary DC/DC or DC/AC converter interface converter
single-phase converter unit
converter cell
AC/DC converter stage
DC/DC converter stage
AC/DC converter
DC/DC converter
first battery storage
control unit

Claims

Patent claims
1 . Power distribution system (1 ) for supplying electrical power to a plurality of low- voltage DC loads in a data center, comprising
a galvanically isolated converter arrangement (3) for transforming a medium- voltage AC power provided on an utility line (2) to a low/medium DC voltage provided on a first DC bus (5); and
a plurality of DC loads to be supplied with a low DC voltage generated from the low/medium DC voltage on the first DC bus (5) by means of one or more additional DC/DC converters, characterized in that
the converter arrangement (3) has one converter unit (21 ) per phase, wherein each of the converter units (21 ) has a plurality of converter cells (22), and wherein each converter cell (22) has an AC/DC converter stage (23, 31 ) followed by a DC/DC converter stage (24, 32), wherein the DC/DC converter stage (24, 32) has a DC/AC converter and an AC/DC converter coupled to a medium- or high-frequency transformer for galvanic isolation.
2. Power distribution system (1 ) according to claim 1 , wherein AC input terminals of the converter cells (22) are connected in series and DC output terminals of the converter cells (22) are connected in parallel.
3. Power distribution system (1 ) according to claim 1 or 2, wherein one of the AC input terminals of each converter units (21 ) is connected to a common node, wherein the others of the AC input terminals of the converter units (21 ) are input for a respective phase of the medium-voltage AC power, wherein the output terminals of the converter units (21 ) are connected in parallel.
4. Power distribution system (1 ) according to claim 1 or 2, wherein the AC input
terminals of the converter units (21 ) are connected to each other in a delta configuration, wherein the output terminals of the converter units (21 ) are connected in parallel.
5. Power distribution system (1 ) according to claim 1 , wherein a first battery storage (33) is coupled to a DC link between the AC/DC converter stage (23, 31 ) and the DC/DC converter stage (24, 32).
6. Power distribution system (1 ) according to any one of claims 1 to 5, wherein each converter cell (22) is provided with a bypass element to be activated in case of a failure to effectively decouple the respective converter cell (22) from the serially connected converter cells (22).
7. Power distribution system (1 ) according to any one of claims 1 to 6, wherein a
generator (6) is coupled to the first DC bus (5) by means of a further AC/DC converter (7).
8. Power distribution system (1 ) according to any one of claims 1 to 7, wherein an energy resource (17) providing DC power is coupled through a converter (20) to the first DC bus (5).
9. Power distribution system (1 ) according to any one of claims 1 to 8, wherein a
second DC bus (9) for carrying a low voltage is provided which is coupled to the first DC bus (5) by means of non-isolated further DC/DC converters (8).
10. Power distribution system (1 ) according to any one of claims 1 to 9, wherein a
second battery storage (15) is coupled to a first DC bus (5).
1 1 . Power distribution system (1 ) according to any one of claims 1 to 10, wherein the system (1 ) is provided with a plurality of galvanically isolated converter
arrangements (3) and a plurality of DC loads wherein the respective first DC buses (5) for each of the plurality of galvanically isolated converter arrangements (3) are coupled via bypass elements (16) for system reconfiguration.
PCT/EP2013/065754 2012-08-16 2013-07-25 Electrical power distribution system for data centers WO2014026840A2 (en)

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