© 2015 eaton. all rights reserved.. xlm 62v supercapacitor module introduction for ups applications

© 2015 Eaton. All Rights Reserved..

XLM 62V Supercapacitor Module Introduction For UPS Applications

2© 2015 Eaton. All Rights Reserved..

XL60 Cells Available Accesories

Welded terminals to bus-bars Threaded terminals to bus-bars with washers&screws to build custom size modules

Threaded terminals to bus-bars with washers&screws and active balancing boards using Eaton’s patented balancing circuit


5.4V Modules With Connector

• P/N: PHV1245-5R4356-1• Base Cell: HV1245-2R7356-R• Configuration: 2 series x 2 parallel• Electronics: Active Balancing• 5.4V / 35F / 50mW, 510 J, 146W max. power•Connector: Molex 50-57-9406•Mating Conn: Molex 70018, 70543, 70545, 70553, 70555, 70107, 70541, 70551, 70634, 74099

• P/N: PHV1245-5R4176-2• Base Cell: HV1245-2R7356-R• Configuration: 2 series• Electronics: • Active Balancing, Temp. Sensor• 5.4V / 17F / 170mW, 248J, 43W max. power•Connector: Molex 51021-0600•Mating Conn: Molex 53261, 53047, 53398, 53048


Higher Voltage Module Examples• Application: UPS/Volt. Sag/SEMI F47

• P/N: XV3560-259R2425-1

• Base Cell: XV3560-2R7407-R

• Configuration: 96 cells in series

• Electronics: Passive Balancing + Fuse protection

• Module Ratings:

• 259.2V / 4.17F / 310mW

• 14.5 Wh, 55.9 kW max. power

• Common Platform with 300, 400 or 600F cells

• P/N: XBM3585-15R0207-1

• Base Cell: XB3585-2R5607-R

• Configuration: 2 parallel x 5 series

• Active Balancing

• 15V / 130F / 50mW, 6.3 Wh, 1100W max. power


Energy Storage In UPS Systems

• Static UPS: power converter using stationary power storage:

• Batteries: for backup time of minutes (typically 1 hour max)

• Supercapacitors: for backup time of seconds (typcially max 30 seconds)

• Dynamic/Rotary UPS: power converter using rotating energy source:

• Diesel/Jet generators: for backup times hours-days

• Flywheels: for backup times of seconds (typcially up to 2 minutes)

Strong competition against Eaton in EMEA


UPS Requirements For Seconds Backup

• Power level: 150kW-5MW

• 400VAC – 3phase outputs

• Backup time: 5-30s

• As small installation floorspace as possible

• Minimum maintanace time – chance for power loss during maintanace


Energy Storage Options For Short Bakcup UPS

Lead-acid battery Flywheel Supercapacitor

Volume for 250kW/15s 0.7m3 1.1m3 0.9m3

Total cost of installation for 20yrs

lifetime

0.8 (4 sets of batteries assumed to achieve 20yrs lifetime) 1.1 1 (supercap strings added

during the lifetime is included)

Cost of operation Not significant – just supply energy to keep batteries charged

Need constant power to keep flywheel running (1.8kW/flywheel)

Minimal – just supply energy to keep capacitors charged

Cost of maintainance Moderate – need battery pack replacement in 5yrs

High – mechanical components needs replacement acc to the

maintanace plan

Minimal – yearly dusting and cleaning or adding capacitor

strings during the life

Reliability

Moderate – batteries can get shorted and fail suddenly before expected

lifetime. Acid leakage may be an issue too.

High relibility if maintained properly

High reliability by constant cell degradation and multi string

redundancy. Overvoltage signal supplied for immediate action in

case of malfunction.

Environmental footprint

Heavy due to lead and acidsModerate – disposal is not a problem, but constant energy

needed

Minimal – charging losses are negligible and self discharge

rate is very low. No heavy metals, easy disposal.


Supercaps vs. Batteries: Pros and Cons

Battery solution advantages:• Lead acid batteries are still more cost competitive

against supercaps in case backup time is over 10s

• Batteries can store more energy in the same size

Supercap solution advantages:• Supercaps can support higher operating

temperatures up to +85C

• Supercaps can support UPS systems with frequent backup – even 10/hour due to the quick/seconds charge capability

• Supercap can be offered for „Pb allergic” customers/environments

• Supercaps can support the UPS lifetime without maintanace for 20yrs even


Supercaps vs. Batteries: Discharge Behaviour

Voltage drop due to ESR Battery discharge curve

Supercap discharge curve

Battery cannot deliver sufficient current below this point

Supercap can deliver sufficient current until it reaches almost 0 volts.

The lower the allowed discharge voltage for supercaps the more cost efficient is the use


Supercaps vs. Flywheel Energy efficiency

Advantages of supercaps:

• Supercaps have higher efficiency than flywheels

• Supercaps can be easily and cost effectively be configured to support smaller power levels and shorter backup times while flywheels are not easy to adopt

Example


Supercap vs. Flywheel Total Cost Of Operation

Advantage of supercaps:

• Total cost of operation is lower for supercapacitor solution

• Due to the modularity of the supercaps, the required capacitance to achieve the needed UPS autonomy time can be kept by adding capacitors during the lifetime based on the cell degradation – see CAPEX scenario

Example


EATON UPS Solution PN: XLM-62R1137-R

Features:• Lowest ESR UPS module (<0.8mOhm)

• Longest lifetime 16yrs@25C with 20% capacitance degradation

• Patented active cell balancing circuit makes sure that there is no voltage imbalance between the single cells

• Built-in cell overvoltage monitoring – signal given through standard Molex connector

• 8 mounting holes for safe and easy fixation into cabinets – sustains earthquakes if properly mounted


EATON UPS Solution PN: XLM-62R1137-R

Ratings:

• 62V Maximum operating voltage - typical 56V – 10 pcs connected in series are ideal for 3ph UPS solutions

• 130F, 8 mOhm max

• Total stored energy: 70 Wh/251 kJ

• Peak power: 72 kW

• Lifetime: 20% capacitance loss in 16yrs@25C operating temperature

Certificates:

• Agency information UL810A

• Shock and vibrations Telcordia GR- 63 Zone 4

• Environmental IP30, RoHS, lead free, halogen free

• Altitude, Operating 10,000 ft / 3,000 meters Altitude, Non- operating 40,000 ft / 12,000 meters


XLM-62R1137-R Dimensions

• 4U height

• 6.9”” width fits 3 wide in 24” rack

• All front connections


Rack Implementations As Per Today2 wide in 19” telecom or server rack

3 wide in 24” UPS rack

Secure modules with strap; or for Zone 4 earthquake safety, bolt to shelf

Series Connected Modules: Higher VoltageParallel Connected Modules: Longer Time


UPS Apps Requiring Short Backup: Data Centers

• Data centers: banks, stock exchange and cloud computing data centers require zero power down time due to processing critical data which can be lost or wrongly processed in case of power interruptions

• UPS system consists of optional power generators & short time bridging UPS’ to provide 10-30s full power until the generators are not up to speed and capable to provide the required power/voltage level or the data processing is not routed to an other datacenter

optional


UPS Apps Requiring Short Backup: Hospitals

• Hospitals needs immediate power backup in case of blackout. Some countries allow max 10s without power, but during surgeries it can be critical. Investment of seconds bridging UPS is neglidgible compared to the total investment cost.

• UPS system consists of power generators & short time bridging UPS’ to provide 10-20s full power until the generators are not up to speed and capable to provide the required power/voltage level


UPS Apps Requiring Short Backup: IC Fabs• 24/7 running factories such as chemical or IC manufacturing locations needs power without

interruption in case of smaller power outages or power factor problems. Since there are large power consuming equipments, the stationary UPS unit serves as power conditioner, voltage stabilizer in case of heavy load peaks and ridehtough in case of seconds power interruptions.

• UPS system consists of high power short time bridging UPS’ to provide 5-10s ride/through time acc to Semi F47.


UPS Apps Requiring Short Backup: Transportation• Airport runway lights or highway tunnel lights are critical to help pilots and drivers to have a clear

vision of the route and minimize the chance for accidents. During blackout time these critical lights needs to be powered. Also on airports landed airplanes and docking tunnels are needed to be powered as well not to allow interruption of the plane landing and takeoffs.

• UPS system consists of power generators & short time bridging UPS’ to provide 10-30s full power until the generators are not up to speed and capable to provide the required power/voltage level


Supercap Bank Sizing Example

UPS requirements:

• 500kW power delivery for 20s – 400VAC 3phase

• Energy storage float (charge) voltage: 560VDC, min voltage: 360VDC

• System efficiency: 94%

• Lifetime requirement: 20yrs

• Ambient temperature: 25C constant, kept in controlled enviroment



• 500kW x 1.06 (eff) = 532kW

• 10x10pcs XLM 130F modules required by the new installation

• Min voltage by end of discharge is 373.5V...it will degrade during the lifetime



• 10x10pcs capacitor bank discharge curve after installation – NEW parts

• Meets system requirements

• Autonomy time: 21s > 20s

• 10x10pcs capacitor bank discharge curve after 20yrs lifetime

• Doesnt meet system requirements

• Autonomy time: 14s < 20s => need additional capacitance installation during the lifetime!!!


To ensure 20yrs of lifetime 10x14pcs capacitors can be installed at the initial installation, but they will all degrade due to voltage and temperature starting from day1


To ensure 20yrs of lifetime 10x10pcs capacitors can be installed at the initial installation and capacitor strings are added during the lifetime to ensure that the autonomy time is guaranteed. In this case 1-1 string is added after 2yrs, 6ry and 14yrs of operation.

This way 10 capacitors and rack, protection devices are saved + initial installation cost is lower significantly than installing 10x14 caps by the beginning.


Engine Starting – For Start-Stop Engines

• Smart Start

• Start from battery, supercap or combination

• Optimize starting and system capability

• Utilize energy for other functions to optimize performance and lifetime

Existing

Vehicle

Batteries

Supercap Module

Start

Switch

Starter/

Solenoid

Capacitor Bank

Vehicle power: cab, chassis, steering

Bidirectional

DC-DC Converter

Controller


Supercap + Battery Hybrid Test

The test was to simulate a system with repeated peak power requirements

© 2015 eaton. all rights reserved.. xlm 62v supercapacitor module introduction for ups applications

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