Modern data centres consume huge amounts of energy. One recent report estimates that they will consume one-fifth of the world’s electricity by 2025[i]. UPS power supplies, as major equipment items, contribute significantly to this demand; accordingly, any strategy that improves the energy efficiency of UPS will have a major impact on both sustainability and cost-saving within data centre operations.
Fortunately, various techniques are available to optimise UPS efficiency under all conditions, as demonstrated in modern, modular UPS systems like Kohler Uninterruptible Power’s Kohler PW9250DPA.
Below, Alex Emms, Operations Director at Kohler Uninterruptible Power, looks at these techniques. He starts by discussing the fundamental design approach that optimises the energy efficiency of UPS under normal operating conditions. Next, he explores a smart module switching function that maintains high efficiency levels even when UPS loads drop below 25 percent. Finally, he covers eco-mode and explains that, while it achieves extremely high efficiencies, it is not suitable for all data centre solutions.
The move to modular UPS systems – and its impact on efficiency
When double-conversion online UPS power supplies first appeared in the seventies, they used transformer-based UPS designs. However, advances in power semiconductor technology have facilitated a general industry move towards transformerless UPS solutions. This has brought several advantages, including some related to efficiency.
Firstly, the topology is inherently more efficient. Even at optimal, near full load conditions, transformer-based UPS designs remain well below 95 percent – and as the load reduces towards 25 percent, UPS efficiency approaches just over 85 percent. By contrast, the Kohler PW 9250DPA UPS system can achieve efficiencies up to 97 percent with loads from 25 to 75 percent of nominal UPS capacity.
However, the benefits extend further; the considerable size and weight reductions achieved by transformerless UPS designs mean that a complete UPS solution can be implemented as small, rack-mounting modules rather than as large, monolithic UPS units. The advantages of this can be explained by considering a PowerWAVE 9250DPA example.
This comprises the uninterruptible power supply supporting, say, a 200 kW load; it would use four of its 50 kW modules – or five, to provide N+1 redundancy. Then, if the load increases, incrementing the UPS’s capacity by plugging in another 50 kW module (vertical scaling) is cost-effective, easy, and can be done without even interrupting power to the load. Further capacity can be provided by horizontal scaling, i.e. adding more UPS battery racks in parallel.
Note that both benefits – redundant capacity and scalability – are achieved with minimal excess capacity, space and cost, due to the modules’ granularity.
By contrast, a monolithic UPS system typically has to be significantly oversized for future-proofing. Additionally, N+1 redundancy must be implemented using two complete UPS power systems, so neither can ever be more than 50 percent loaded even in the best case. These factors force the monolithic UPS system to work with low loads, where UPS efficiency drops away sharply.
Maintaining high UPS efficiency under all conditions
We have seen how modular topology improves UPS efficiency, but it’s important to maintain these high efficiency levels under low loads. One way to facilitate this is to use a smart module switching technique called Xtra VFI.
Xtra VFI is an intelligent feature that minimises loss and improves efficiency on double-conversion modular UPS systems like the Kohler PW 9250DPA. With this mode enabled, the uninterruptible power supply automatically adjusts the number of active modules to match changing load requirements. Surplus modules are switched to standby but remain ready to transfer to active mode if the load increases or the mains fails. The active modules share the load equally.
The efficiency improvements are particularly significant when the load is less than 25 percent of full UPS capacity. Power availability is protected, as the UPS system allows for desired redundancy levels in its module-switching calculations. Xtra VFI operation is summarised in Fig.1 below.
Fig.1: UPS Xtra VFI operating mode
In eco-mode, power flows directly from the utility mains supply to the load during normal operation, so bypassing the rectifier and inverter inefficiencies. If a mains problem is detected, the critical load is switched to the inverter output.
While eco-mode UPS efficiency can reach 99 percent or more, it exposes the load to any incoming mains problems during normal operation. Accordingly, users should weigh the benefits of increased UPS operating efficiency against the risk created by operating in eco-mode.
To meet ever-increasing pressure to curb power consumption, UPS power supply users must avail themselves of every technique to improve energy efficiency. Their best option is to choose a UPS solution that not only benefits from modern, modular transformerless UPS topology, but also offers a smart module switching capability like Xtra VFI to maintain high efficiency levels under all load conditions.
Whether or not to use eco-mode depends on each site’s particular circumstances.
In any case, consultation with experienced suppliers of UPS systems like Kohler Uninterruptible Power is always worthwhile, as they can advise on the options and suggest the optimum UPS solution.
To discover how KUP can help you find a UPS solution with great UPS efficiency, contact us here.