WO2012054227A2

WO2012054227A2 - High density uninterruptible power supplies and related systems and power distribution units

Info

Publication number: WO2012054227A2
Application number: PCT/US2011/054687
Authority: WO
Inventors: Robert William Johnson, Jr.
Original assignee: Eaton Corporation
Priority date: 2010-10-22
Filing date: 2011-10-04
Publication date: 2012-04-26
Also published as: US8587929B2; CN103181057A; WO2012054227A3; US20120098342A1; EP2630717A2; CN103181057B

Abstract

High density uninterruptible power supplies are provided including an enclosure and at least one uninterruptible power supply positioned in the enclosure. A battery associated with the at least one uninterruptible power supply is positioned in the enclosure. The at least one uninterruptible power supply and the associated battery are configured to provide at least thirty seconds of backup power to a load connected thereto. Related systems and power distribution units are also provided.

Description

HIGH DENSITY UNINTERRUPTIBLE POWER SUPPLIES AND

RELATED SYSTEMS AND POWER DISTRIBUTION UNITS

FIELD

[0001] The inventive subject matter generally relates to uninterruptible power supplies and, more particularly, to high density uninterruptible power supplies.

BACKGROUND

[0002] Uninterruptible power supply (UPS) systems are commonly used in installations such as data centers, medical centers and industrial facilities. UPS systems may be used in such installations to provide backup power to maintain operation of computer, medical devices and other critical equipment in event of failure of a primary utility supply. These UPS systems commonly have an "on-line" configuration including a rectifier and inverter coupled by a DC link that is also coupled to a backup power source, such as a battery. Other UPS configurations may also be used, such as standby and line-interactive configurations.

[0003] However, data centers are evolving from data centers having dedicated IT equipment for specific applications to data centers having managed IT equipment that is application insensitive, i.e. cloud computing. This fundamental change to the data centers may have an impact on the type of UPS system needed to provide backup power to maintain operations in the data centers in the event of failure of the primary utility supply.

SUMMARY

[0004] Some embodiments of the inventive subject matter provide high density uninterruptible power supplies including an enclosure and at least one uninterruptible power supply positioned in the enclosure. A battery associated with the at least one uninterruptible power supply is also positioned in the enclosure. The at least one uninterruptible power supply and the associated battery are configured to provide at least thirty seconds of backup power to a load connected thereto.

[0005] In further embodiments, the enclosure may be a first enclosure and the first enclosure may be configured to be connected to at least one power distribution unit. The at least one power distribution unit may be positioned in a second enclosure, separate from the first enclosure. [0006] In still further embodiments, the at least one power distribution unit may include a plurality of receptacles therein.

[0007] In some embodiments, first enclosure may include at least one utility input connection that is configured to provide power from a utility.

[0008] In further embodiments, the power distribution unit in the second enclosure may include a utility input connection. The at least one power distribution unit may further include a transfer relay positioned in the second enclosure.

[0009] In still further embodiments, the at least one uninterruptible power supply includes four uninterruptible power supplies positioned in the first enclosure and each of the four uninterruptible power supplies may have an associated battery. The four uninterruptible power supplies may provide up to 30 seconds of battery.

[0010] Some embodiments of the present inventive subject matter provide systems for providing backup power including a first enclosure including at least one uninterruptible power supply and a battery associated with the at least one uninterruptible power supply. The at least one uninterruptible power supply and the associated battery are configured to provide at least thirty seconds of backup power to a load connected thereto. The system further includes at least one second enclosure, separate from the first enclosure, which includes a power distribution unit and is configured to be connected to the first enclosure.

[0011] In further embodiments, the power distribution unit may include a plurality of receptacles on the second enclosure.

[0012] In still further embodiments, the first enclosure may further include at least one utility input connection that is configured to provide power from a utility.

[0013] In some embodiments, the second enclosure including the power distribution unit may further include a utility input connection therein. The power distribution unit may further include a transfer relay positioned in the second enclosure.

[0014] In further embodiments, the at least one uninterruptible power supply includes four uninterruptible power supplies positioned in the first enclosure, each of the four uninterruptible power supplies having an associated battery. The four uninterruptible power supplies may provide up to 30 seconds of battery.

[0015] Still further embodiments of the present inventive subject matter provide power distribution units including a power distribution unit enclosure and at least one uninterruptible power supply positioned in the power distribution unit enclosure. A battery associated with the at least one uninterruptible power supply is also positioned in the power distribution unit enclosure. The at least one uninterruptible power supply and the associated battery are configured to provide at least thirty seconds of backup power to a load connected thereto. A plurality of receptacles are also provided on the power distribution unit enclosure.

[0016] In some embodiments, the power distribution unit may occupy zero U-space in

IT racks.

[0017] Further embodiments of the present inventive subject matter provide high density uninterruptible power supplies including an enclosure; at least one uninterruptible power supply positioned in the enclosure; and a battery associated with the at least one uninterruptible power supply and positioned in the enclosure, wherein the enclosure does not contain any substantial means for cooling the at least one uninterruptable power supply and the battery in the enclosure.

[0018] In still further embodiments, a density of the high density uninterruptible power supply may be increased due to the absence of any substantial cooling means.

[0019] In some embodiments, the at least one uninterruptible power supply and the associated battery may be configured to provide at least thirty seconds of backup power to a load connected thereto.

[0020] In further embodiments, the enclosure comprises a first enclosure and wherein the first enclosure is configured to be connected to at least one power distribution unit, the at least one power distribution unit being positioned in a second enclosure, separate from the first enclosure. In certain embodiments, the at least one power distribution unit may include a plurality of receptacles therein.

[0021] In still further embodiments, at least one utility input connection may be included that is configured to provide power from a utility.

[0022] In some embodiments, the power distribution unit in the second enclosure may include a utility input connection. The at least one power distribution unit may include a transfer relay positioned in the second enclosure.

[0023] In further embodiments, the at least one uninterruptible power supply may be configured to provide no greater than about 30 seconds of battery.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a block diagram illustrating an uninterruptible power supply integrated in a power distribution unit in accordance with some embodiments of the present inventive subject matter.

[0025] Figure 2 is a block diagram illustrating uninterruptible power supply systems in accordance with some embodiments of the present inventive subject matter. [0026] Figure 3 is a diagram illustrating uninterruptible power supply systems in accordance with some embodiments of the present inventive subject matter.

[0027] Figure 4 is a block diagram of a universal power supply module in accordance with some embodiments of the present inventive subject matter.

[0028] Figure 5 is a block diagram of a power distribution unit in accordance with some embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

[0029] The inventive subject matter now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the inventive subject matter are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This inventive subject matter may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the inventive subject matter to those skilled in the art.

[0030] It will be understood that when an element is referred to as being "coupled" or

"connected" to another element, it can be directly coupled or connected to the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly coupled" or "directly connected" to another element, there are no intervening elements present. Like numbers refer to like elements throughout. As used herein the term "and/or" includes any and all combinations of one or more of the associated listed items.

[0031] In addition, spatially relative terms, such as "under", "below", "lower", "over",

"upper" and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "under" or

"beneath" other elements or features would then be oriented "over" the other elements or features. Thus, the exemplary term "under" can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0032] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the inventive subject matter. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein the expression "and/or" includes any and all combinations of one or more of the associated listed items.

[0033] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this inventive subject matter belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0034] As discussed above, data centers are changing from application-dedicated IT equipment to managed servers operating in a cloud environment. In a cloud environment, applications can be moved quickly to other groups of servers or different locations in a matter of minutes. Thus, the reduction in time to suspend or relocate the application reduces the need for the traditional UPS and associated backup times. In other words, the reduction in backup time requirement may allow the battery to be reduced in size and, thus, can be incorporated within the IT equipment. For example, one implementation severs having a battery therein. In this implementation, the battery backup does not require any additional space in the rack, but the server is not very dense. Customers that make high density servers may need a dense UPS solution without special server designs.

[0035] Accordingly, some embodiments discussed herein provide a high density UPS solution suitable for use in evolving data centers. As will be discussed further below with respect to Figures 1 through 5, there are several implementations/form factors that may be used for high density UPS systems in accordance with embodiments discussed herein.

Furthermore, in some embodiments, the high density UPS systems may not include any forced air flow from front to back to cooling during a discharge period, i.e. no substantial cooling means may be included in the system. It will be understood that "no substantial means of cooling" can include a small fan or similar device to provide some cooling without departing from the scope of the present inventive subject matter. The absence of any substantial cooling means may allow provision of increasingly dense UPS systems as discussed further herein. [0036] Referring first to Figure 1, a block diagram of a UPS integrated with a power distribution unit (PDU) in accordance with some embodiments will be discussed. As discussed above, in the changing data center environment, five or more minutes of backup time to suspend or relocate the application may not be necessary. For example, in a cloud environment, only a minute or less, for example, 30 seconds, of backup time may be needed to switch from one group of servers to a duplicate server group. Furthermore, the nature of the load being backed up by the UPS has also changed, i.e. the load is more tolerant to wide variations of utility voltage because they have power factor corrected power supplies. The combination of these changes has reduced the need for any regulation in the UPS, thus allowing an offline UPS topology to fill the need for backup power in the new data center environment.

[0037] As illustrated in Figure 1, some embodiments combine the UPS/battery 130 and the PDU 110 in a single enclosure. As illustrated, in the embodiments illustrated in Figure 1, the output receptacles 120 may be provided at one end of the PDU 110 and the UPS/battery 130 in accordance with embodiments discussed herein may be provided at the opposite end of the PDU 110. The UPS/battery 130 may support its full load for about 30 seconds to no more than about a minute. In these embodiments, the UPS/battery 130 may be 3kW modules. The use of a fan may be limited and thermal mass may be the dominate temperature control for the semiconductor switches.

[0038] IT racks with provision to mount electronic chassis are commonly used in telecommunications and computer networking applications. A typical data center, for example, may include multiple racks in which equipment chassis, e.g., servers, storage units, power supplies and the like, are inserted and mounted. The amount of space a piece of equipment occupies in the IT rack can be expressed in "U" units, which is a unit of measure equal to 1.75. The PDU 110 including the receptacles 120, the UPS/battery 130 and various other circuitry not shown in Figure 1 may be installed in IT racks in zero-U format, i.e. not occupying any space on the IT racks. However, due to the battery 130 and electronics (not shown) included in the combined PDU/UPS illustrated in Figure 1, this implementation may have a significantly larger cross section than a conventional PDU, which may make the configuration illustrated in Figure 1 less desirable. Furthermore, typically PDUs are placed in the rear of the IT rack where the temperature is typically higher. Thus, placing the combination PDU/UPS in this position may cause the battery to experience a very short operational life. [0039] Referring now to Figure 2, a block diagram illustrating UPS systems in accordance with some embodiments of the present inventive subject matter will be discussed. As illustrated in Figure 2, the UPS system includes a UPS/battery module 235 and one or more PDU/receptacles 215A through 215D including one or more individual receptacles 220 thereon. As illustrated, the UPS and battery are provided in a first enclosure 235 and the output receptacles 215A through 215D are provided in a second enclosure 215 A through 215D, separate from the first enclosure 235.

[0040] It will be understood that although four output receptacles/PDUs 215A through 215D are illustrated in Figure 2, embodiments of the present inventive subject matter are not limited to this configuration. More or less than four receptacles 215A through 215D may be provided without departing from the scope of the present invention subject matter.

[0041] The output receptacles 215A through 215D can be mounted in the traditional zero-U space of the IT racks. The output receptacles 215A through 215D will have a smaller cross section than embodiments discussed above with respect to Figure 1 as the UPS and battery are provided in a separate enclosure 235. In some embodiments, the PDUs 215A through 215D illustrated in Figure 2 may be standard/conventional PDUs/output receptacles, which occupy zero-U space in the rear of the IT rack.

[0042] Although some embodiments are discussed herein as occupying a certain amount of space in the IT racks, embodiments of the present inventive subject matter are not limited to this configuration. For example, embodiments discussed herein can occupy more or less space than discussed without departing from the scope of the subject matter discussed herein.

[0043] As illustrated in Figure 4, the UPS and battery enclosure 435 may include one or more UPS 480A-480D and battery 485A-485D pairs, each having an associated PDU cord 450 and utility cord 440. The UPS and battery enclosure 435 may be mounted in a 2U chassis, i.e, the UPS and battery enclosure 435 occupies 2U of space in the IT racks. The UPS 480A-480D in accordance with some embodiments may be a 3kVA UPS. The 3KVa UPS and the associated battery may only occupy one quarter of the IT rack width, allowing up to four UPS/battery pairs to fit in a 2U IT rack enclosure 435 as illustrated in Figure 4. Thus, combined the four UPS/battery pairs provide a 12kW UPS having about 30 seconds of battery in 2U IT rack space. The individual 3kVA UPS modules 480A-480D may or may not be interconnected without departing from the scope of embodiments discussed herein.

[0044] Although embodiments of the present invention illustrated in Figure 4 include four UPS/battery pairs in the enclosure 435, it will be understood that embodiments of the present inventive subject matter are not limited to this configuration. For example, more or less than four pairs may be included in the enclosure 435 without departing from the scope of embodiments discussed herein. It will be understood that if more than four pairs are included in the enclosure 435, the enclosure may occupy more than the 2U of rack space discussed above.

[0045] As further illustrated in Figure 4, in some embodiments, the battery 485A-

485D is placed facing toward the input side of the enclosure 435 where it is cooler to preserve operational life of the battery and the UPS 480A-480D is provided in the rear of the enclosure 435.

[0046] Referring again to Figure 2, a cord 250 is attached to the UPS enclosure 235 and the receptacles/PDUs 215 A through 215D are plugged into the UPS enclosure 235. The UPS/battery enclosure 235 may also include a plurality of inputs for power from the utility 240 as shown.

[0047] Referring now to Figure 3, a UPS system in accordance with some

embodiments will be discussed. As illustrated in Figure 3, the UPS system includes a UPS/battery enclosure 335 and at least one PDU/receptacle 315 A' through 315D'. The UPS/battery module 335 and the PDUs 315 A' through 315D' including one or more receptacles 320 are provided in separate enclosures as shown. Figure 5 illustrates the PDUs 315 A' through 315D' in detail. As illustrated therein, an input cord 360/560 is attached to each of the PDUs 515 A' through 515D' and each PDU enclosure 515 A' through 515D' includes a transfer relay 590 therein.

[0048] Referring again to Figure 3, the input cord 360 is used to connect the PDUs

315 A' through 315D' to the utility power. As shown, similar to embodiments illustrated in Figure 2, the UPS and battery module 335 is attached to the PDUs 315 A' through 315D¹ using a cord 350. Since the PDUs 315A' through 315D' are directly attached to the utility power using the input cord 360, the UPS and/or battery in enclosure 335 may be replaced without interruption of power to the load connected to the output receptacles of the PDUs 315 A' through 315D'. Thus, the modified PDUs 315 A¹ through 315D' provide a "power pass" PDU that allows UPS and battery servicing without load interruption.

[0049] As discussed above, some embodiments of discussed above with respect to

Figures 1 through 3 provide a UPS associated with a battery that will provide a minute or less, for example, 30 seconds, of backup time that may be needed to switch from one group of servers to a duplicate server group. Embodiments of the UPS, PDUs and systems discussed above may provide five times more density over existing systems and products. [0050] In the drawings and specification, there have been disclosed exemplary embodiments of the inventive subject matter. Although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the inventive subject matter being defined by the following claims.

Claims

THAT WHICH IS CLAIMED:

1. A high density uninterruptible power supply comprising:

an enclosure;

at least one uninterruptible power supply positioned in the enclosure; and

a battery associated with the at least one uninterruptible power supply and positioned in the enclosure, the at least one uninterruptible power supply and the associated battery being configured to provide at least thirty seconds of backup power to a load connected thereto.

2. The high density uninterruptible power supply of Claim 1, wherein the enclosure comprises a first enclosure and wherein the first enclosure is configured to be connected to at least one power distribution unit, the at least one power distribution unit being positioned in a second enclosure, separate from the first enclosure.

3. The high density uninterruptible power supply of Claim 2, wherein the at least one power distribution unit includes a plurality of receptacles therein.

4. . The high density uninterruptible power supply of Claim 2, further comprising at least one utility input connection that is configured to provide power from a utility.

5. The high density uninterruptible power supply of Claim 2, wherein the power distribution unit in the second enclosure comprises a utility input connection.

6. The high density uninterruptible power supply of Claim 5, wherein the at least one power distribution unit further comprises a transfer relay positioned in the second enclosure.

7. The high density uninterruptible power supply of Claim 2:

wherein the at least one uninterruptible power supply comprises four uninterruptible power supplies positioned in the first enclosure, each of the four uninterruptible power supplies having an associated battery.

8. The high density uninterruptible power supply of Claim 7, wherein the four uninterruptible power supplies are configured to provide up to 30 seconds of battery.

9. A system for providing backup power comprising:

a first enclosure including at least one uninterruptible power supply and a battery associated with the at least one uninterruptible power supply, the at least one uninterruptible power supply and the associated battery being configured to provide at least thirty seconds of backup power to a load connected thereto; and

at least one second enclosure, separate from the first enclosure, including a power distribution unit, the second enclosure configured to be connected to the first enclosure.

10. The system of Claim 9, wherein the power distribution unit includes a plurality of receptacles on the second enclosure.

11. The system of Claim 9, wherein the first enclosure further comprises at least one utility input connection that is configured to provide power from a utility.

12. The system of Claim 9, wherein the second enclosure including the power distribution unit further comprises a utility input connection therein.

13. The system of Claim 12, wherein the power distribution unit further comprises a transfer relay positioned in the second enclosure.

14. The system of Claim 9:

15. The system of Claim 14, wherein the four uninterruptible power supplies provide up to 30 seconds of battery.

16. A power distribution unit comprising:

a power distribution unit enclosure; at least one uninterruptible power supply positioned in the power distribution unit enclosure;

a battery associated with the at least one uninterruptible power supply and positioned in the power distribution unit enclosure, the at least one uninterruptible power supply and the associated battery being configured to provide at least thirty seconds of backup power to a load connected thereto; and

a plurality of receptacles on the power distribution unit enclosure.

17. The power distribution unit of Claim 16, wherein the power distribution unit occupies zero U-space in IT racks.

18. A high density uninterruptible power supply comprising:

an enclosure;

at least one uninterruptible power supply positioned in the enclosure; and

a battery associated with the at least one uninterruptible power supply and positioned in the enclosure, wherein the enclosure does not contain any substantial means for cooling the at least one uninterruptable power supply and the battery in the enclosure.

19. The high density uninterruptible power supply of Claim 18, wherein a density of the high density uninterruptible power supply is increased due to the absence of any substantial cooling means.

20. The high density uninterruptible power supply of Claim 18, wherein the at least one uninterruptible power supply and the associated battery are configured to provide at least thirty seconds of backup power to a load connected thereto.

21. The high density uninterruptible power supply of Claim 20, wherein the enclosure comprises a first enclosure and wherein the first enclosure is configured to be connected to at least one power distribution unit, the at least one power distribution unit being positioned in a second enclosure, separate from the first enclosure.

22. The high density uninterruptible power supply of Claim 21, wherein the at least one power distribution unit includes a plurality of receptacles therein.

23. The high density uninterruptible power supply of Claim 21, further comprising at least one utility input connection that is configured to provide power from a utility.

24. The high density uninterruptible power supply of Claim 21, wherein the power distribution unit in the second enclosure comprises a utility input connection.

25. The high density uninterruptible power supply of Claim 24, wherein the at least one power distribution unit further comprises a transfer relay positioned in the second enclosure.

26. The high density uninterruptible power supply of Claim 7, the at least one uninterruptible power supply is configured to provide no greater than about 30 seconds of battery.