Annual Meeting. Task 4.8: DC Data Center with High Voltage isolation Virginia Tech Fred C Lee, Qiang Li and Shishuo Zhao.

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1 Annual Meeting Task 4.8: DC Data Center with High Voltage isolation Virginia Tech Fred C Lee, Qiang Li and Shishuo Zhao January December

2 MV Utility Power Distribution in Data Center 480V 2500 kva cable conduction consume 2% total power 60Hz transformer 99% efficiency Server Hall 1Hall Server Hall Hall 2 480V AC 480/277V AC 208V AC 400V DC 12V DC DC/AC DC/DC PSU Server er x Cable 98% x UPS PDU PSU s 95% x 96% x 94% x 88% =73% Data center will consume 10% of electricity by % efficiency improvement = 4.6 Nuclear Power Plants

3 MV Utility Future DC Data Center 4160V 2500 kva Cable conduction consume 0.2% total power HF HF SST Server Hall Server Hall 1 Server Hall 2 MV 4160V AC Eff. 400V DC PDU DC/DC PSU 12V DC Server Rack x 97% x99% x 97% x90% =84% 98 % 99.5 % 97.5 % 90 % >85 % 86% copper cost saved 12% efficiency improvement

4 Future DC Data Center 4160VAC 480V/277V AC 380VDC DC /DC 12 V DC PSU Solid-State Transformer AC/ DC DC/ DC Module 4160VAC 380VDC 4160VAC. DC/DC Module DC/ DC Module A /DC C AC /DC DC/ DC Module DC/DC Module DC/DC

5 WBG Switching Losses 800V DC 2:1;1 2:1:1 400V DC 800VDC L lk1 L lk2 380VDC L m L lk2 1200V SiC 600V GaN E sw (uj) Energy Loss per switching event SiC Turn on GaN Turn on GaN Turn off SiC Turn off I off (A) ZVS 500KHz

6 Magnetic Material Selection kHz 100 C P v kw/m F45 -- Ferroxcube 3C98-- Ferroxcube PC95 TDK P61 ACME 3F36 Ferroxcube B max (mt) 3F36 is best fit for 500kHz

7 MMF High Frequency Transformer Magnetic Field Distribution MMF Pri winding l d Bobbin Bobbin Bobbin N*I l d N*I/2 Bobbin Bobbin Bobbin Sec winding Magnetic Field L kp =12 uh; L ks =5.8 uh L kp =6.1 uh; L ks =3.6 uh

8 Electrical Field Distribution under 30kV Lighting Voltage 30kV Dielectric Strength Insulation Bobbin Insulation Tape Encapsulate material 19.7 kv/mm 62.8 kv/mm 22.6 kv/mm << Maximum Electrical field: 5.5 kv/mm

9 Transformer Loss vs Volume Core loss density P v = 300kW/m N=20 N=6 Loss /W Volume /L

10 Impact of Core Loss Density (P V ) kw/m kw/m 3 Prequency:500kHz Wire numbers:825 Strand AWG:44 Loss /W kw/m kw/m kw/m 3 70 P v =300 kw/m 3 Total loss=74w Volume=1.02Liter Volume /L P v =100 kw/m 3

11 Lightning Impulse Test 30kV Impulse Generator Equivalent Connection Circuit Impulse generator Pri. Sec. 30kV for 4160V voltage level Test voltage waveforms Transformer under Test [2] IEEE STANDARD GENERAL REQUIREMENTS FOR DRY-TYPE DISTRIBUTION AND POWER TRANSFORMERS INCLIJDING THOSE WITH SOLID CAST AND/OR RESIN-ENCAPSULATED WINDINGS

12 Transformer Applied Voltage Test Line Frequency transformer to generate 12kV Equivalent Connection Circuit Line Frequency 12kV MV Pri. Sec. Gradually increase to 12kV RMS line frequency voltage and hold for 60s without any voltage collapse [1] IEEE STANDARD GENERAL REQUIREMENTS FOR DRY-TYPE DISTRIBUTION AND POWER TRANSFORMERS INCLIJDING THOSE WITH SOLID CAST AND/OR RESIN-ENCAPSULATED WINDINGS

13 Transformer Partial Discharge Test Line Frequency transformer Partial Discharge Measurement Line Frequency MV Pri. Sec. Voltage 7.4kVAC 30 sec 180 sec 5.4kVAC 1.8V r 1.3V r V r : Rated working voltage Time Maximum intensity of partial discharge should be below 50 pc under 5.4kV RMS AC Maximum level of partial discharge 3.8 pc << 50pC under 5.4kV RMS AC

14 Efficiency Test Result 98% Peak Efficiency 98.0% 96% 94% Efficiency Power Level /W 92%

15 V gs 20V/div Experimental Waveforms Output Power: 15 kw I pri 20A/div V ds 500V/div

16 10 6 Research Goal for SST Target: 500kHz, 15kW F s (Hz) khz Module Power level (kw)

17 MV Utility Future DC Data Center 4160V 2500 kva Cable conduction consume 0.2% total power HF HF SST Server Hall 1 Server Hall 2 MV 4160V AC Eff. 400V DC PDU DC/DC PSU 12V DC Server Rack x 97% x99% x 97% x90% =84% 250KVA 98 % 99.5 % 97.5 % 90 % >85 % 86% Copper cost saved 12% total efficiency improvement

18 INEMI International Electronics Manufacturing Initiative 380VDC 900 W/in KW on-board power Server Blade

19 Current design practice Comparison 400V/12V, 100W/in 3 400V/12V, 97.6%, 900W/in 3 9X

20 Thank You

21 Core Material Selection kHz kHz Pv kw/m B m (mt) 3F45 -- Ferroxcube 3C98-- Ferroxcube PC95 TDK P61 ACME 3F36 Ferroxcube Pv kw/m B m (mt) 100 3F45 Ferroxcube P61 ACME 3F36 Ferroxcube PC95 TDK 3C98-- Ferroxcube kHz Pv kw/m F45 -- Ferroxcube 3F36 Ferroxcube P61 ACME ML95s-Hitachi 3C98 is selected for f s < 500kHz ML95s is selected for f s > 500kHz B 100 m (mt)

22 Impact on Different Material Loss VS Frequency Volume VS Frequency Total loss/w 90 P v =300kW/m C F36 75 ML95S Frequency /khz Volume/ L 1.3 P 1.25 v =300kW/m C F ML95S Frequency /khz

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