BATTERY –FREE DC ENERGY STORAGE FOR UPS

BILL WOLFE – NORTHEAST REGIONAL MANAGER

Expect More From An Energy Storage SolutionExpect More From An Energy Storage Solution

DC Energy Storage DC Energy Storage -- ReGen ReGen

Energy Re-cycle Markets / Applications

Energy Re-cycling Applications

VYCONVYCON

Battery Free UPS Battery Free UPS Flywheel Energy StorageFlywheel Energy Storage

MarketsMarkets

Mission Critical Protection for...

Small System Hospital / IT

300kW VDC XE

Electrical Room

House keeping pad

Top cable entry

480 VAC

300kW VDC XE

Electrical Room

House keeping pad

Top cable entry

480 VAC

20 year life span Small footprint

Eliminating hazards materials

Medium Size - Education Data Center

4 x 300kW VDC XEs

Easily expandable scalableHigh efficiency- 99.4%

24 x VDC XEs (7.2 MWs) High power density Simple installation Green / efficiency initiatives

DC Flywheel Storage – Large System

Modular Solution

5 x 300kW VDC XEsMinimal maintenance

No bearing changes

Insurance Data Center

Battery Hardening

A/B Bus 500KVA

AvailabilityRedundancy

Battery Free UPS Battery Free UPS

Source: Ponemon Institute

The Study:

•453 individuals in U.S. organizations who have responsibility for data center operations were surveyed

•41 data centers that experienced a complete or partial unplanned data center outage

Battery failure is Leading Cause (65%) of Unplanned Outages

Failures:

A single bad cell among thousands can take down a facility

Batteries have a limited life expectancy

False confidence; no indication of problems until needed

Source: Ponemon Institute

Average cost of the Unplanned Outage

Average cost of total or partial unplanned shutdown

Total cost by industry of unplanned shutdown

$397,362K$397,362K

$790,886K$790,886K

$1,017,746$1,017,746

Flywheel DC Energy Storage

A flywheel system stores energy by spinning a mass / flywheel.

Reliable DC power is delivered utilizing the kinetic energy stored in high speed flywheel.

Is a mechanical battery

Power Quality ApplicationsTypical UPS system block diagram

ATSRectifier AC/DC

Genset AC

Inverter DC/AC

Utility AC

Long-term AC alternate source

Critical AC output

Automatic Transfer

Switch 540 VDC480 VAC

VYCON DC Energy Storage

UPS System

UPS Applications – Typical Block Diagram

Rectifier AC/DC

Genset AC

Inverter DC/AC

Utility AC

Critical AC outputAutomatic

Transfer Switch

480 VAC

540 VDC

DC Energy Storage

Long-term AC alternate source

UPS System

UPS Applications – Typical Block Diagram

Rectifier AC/DC

Genset AC

Inverter DC/AC

Utility AC

Critical AC outputAutomatic

Transfer Switch

480 VAC

Long-term AC alternate source

540 VDC

DC Energy Storage

Flywheel Module

DCAC

Genset Start Signal

Bi-directional IGBT converter

Graphical Control

Interface

Remote Monitorin

g

Auxiliary Power(Protected AC source for flywheel controls and vacuum pump)

UPS System

Rectifier AC/DC

Genset AC

Inverter DC/AC

Utility AC

Critical AC outputAutomatic

Transfer Switch

480 VAC

VDC(flywheel and power converter)

Auxiliary Power(Protected AC source for flywheel controls and vacuum pump)

Bi-directional IGBT converter

Flywheel Module

DCAC

Basic Operation Sequence – Normal Operation

Genset Start Signal

Time Line

Graphical Control

Interface

Remote Monitorin

g

Long-term AC alternate source

UPS System

Basic Installation Sequence – Back-up Operation

Rectifier AC/DC

Inverter DC/AC

Utility AC

Critical AC outputAutomatic

Transfer Switch

480 VAC

Graphical Control

Interface

Remote Monitorin

g

VDC(flywheel and power converter)

Auxiliary Power(Protected AC source for flywheel controls and vacuum pump)

Bi-directional IGBT converter

Genset Start Signal

Genset AC

ATS Dela

y

2 sec.

Gense

t Star

t

and r

eady

to

acce

pt lo

ad

6 sec.

ATS Transfe

r

UPS Syn

c and

Rectifi

er Walk

-in

2 sec.

Flywhe

el

Recha

rging

2 to 15 min.

Util

ity O

utag

e

Time Line

Flywheel Module

DCAC

Long-term AC alternate source

UPS System

Basic Installation Sequence – Normal Operation

Rectifier AC/DC

Genset AC

Inverter DC/AC

Utility AC

Critical AC outputAutomatic

Transfer Switch

480 VAC DC

AC

VDC(flywheel and power converter)

Auxiliary Power(Protected AC source for flywheel controls and vacuum pump)

Bi-directional IGBT converter

Graphical Control

Interface

Remote Monitorin

g

Flywheel Module

DCAC

Long-term AC alternate source

ATS Dela

y

2 sec.

Gense

t Star

t

and r

eady

to

acce

pt lo

ad

6 sec.

ATS Transfe

r

UPS Syn

c and

Rectifi

er Walk

-in

2 sec.

Flywhe

el

Recha

rging

2 to 15 min.

Util

ity O

utag

e

Time Line

UPS System

Basic Installation Sequence – Genset operation

Rectifier AC/DC

Genset AC

Inverter DC/AC

Utility AC

Critical AC outputAutomatic

Transfer Switch

480 VAC DC

AC

VDC(flywheel and power converter)

Auxiliary Power(Protected AC source for flywheel controls and vacuum pump)

Bi-directional IGBT converter

Graphical Control

Interface

Remote Monitorin

g

Flywheel Module

DCAC

Long-term AC alternate source

ATS Dela

y

2 sec.

Gense

t Star

t

and r

eady

to

acce

pt lo

ad

6 sec.

ATS Transfe

r

UPS Syn

c and

Rectifi

er Walk

-in

2 sec.

Flywhe

el

Recha

rging

2 to 15 min.

Util

ity O

utag

e

Time Line

The Principles of Kinetic Energy

KE ~ m (rpm)² (for rotational motion)

Low Speed • More mass means more energy• Double mass = double energy• “Low-speed” 1800 to 8000RPM

High Speed• More energy by higher rpm• Double rpm = quadruple energy• “High-speed” 36000 to 55000RPM

VYCON - Next Generation Design High speed - 36900 RPM• Air cooled• Small steel alloy flywheel mass (120lbs)• Annual service requirement

• 15 mins. - No down time

• High power density (300kVA)• Full recovery from drop out event• OSHPD seismic certification • Scalable

Flywheel Technology Evolution

High Speed, Steel Flywheel Module Permanent Magnet Motor-Generator

Magnetic Levitation

VDC – Simplified One Line

To UPS Battery Input

IGBT Power Converter

Magnetic LevitationController

Control Panel

Flywheel Module

Soft Start

DC Monitoring Motor Generator Controls

Power Conversion Module Controller

VDC and VDC-XE Module Layout

IGBT Bi-Directional Converter Module

Field Serviceable Vacuum Pump

DC – Disconnect Breaker

Mag LevitationController Module

Flywheel Module

VDC and VDC-XE at a GlanceMax Power Rating:

VDC : 215kW VDC-XE: 300kW Max Energy Storage Rating:

VDC : 3000kW secs @ 100kWVDC-XE: 4000kW secs @ 100kW

Foot Print / Weight: 6.25 sq ft / 1554 lbs

Standard features include:DC Breaker included4 line displayTop or bottom cable entry

Options include:Mod BusTouch ScreenAuto RestartCustomer interface boardOSHPD Seismic Certification

30”

30”

73.7”

Customer Interface

Standard 4-Line LCD Display

STATUS OPERATING PARAMETERS EVENT HISTORY START/STOP UNIT

Communications

Customer Interface Board (CIB) Option

MODDBUS (RTU Protocol) Interface Option

More Options…

AUTO-RESTART OPERATION

OSHPD - SEISMIC CERTIFICATIONOffice of Statewide Health Planning and Development (State of California)

Battery Free UPS System

ATS

Back up

Generator

Utility

208 – 600V AC

Critical Load

Automatic Transfer Switch

DC Bus

VYCON FlywheelDC Energy Storage

UPS

Configurations

Rectifier

AC/DC

Inverter

DC/AC

VYCON DC Flywheel + Battery Hardening

ATS

Back up

Generator

Utility

208 – 600V AC

Critical Load

Automatic Transfer Switch

DC Bus

VYCON FlywheelDC Energy Storage

UPS

Configurations

Rectifier

AC/DC

Inverter

DC/AC

+ -

+ -

+ -+ -

VDC XEB HybridDC Energy Storage

VDC XEB Overview

Integration of VYCON’s highly reliable flywheel technology with a High Rate Discharge VRLA battery

Predictable and reliable backup power / energy storage for critical loads

Extended system design life and warranty

VDC XEB Features - Benefits - Value

Feature  / Function Benefits ValueVDC XE High Speed Flywheel

‐

Primary 

source of back up power

First line of defense

– (EPRI 98% 

outages < 10 seconds)

Increased energy availability 

and reliability

Full magnetic levitation system

‐

Provides 100% levitation & sustains 

flywheel rotor during operation

No bearing  replacementEliminates cost

and downtime 

associated with bearing 

changes

Smart Monitoring ‐

Flywheel

“walks‐in”

the battery 

Mitigation of Coup de fouet

/ 

whiplash and extends battery life

Reduces cost

and frequency   

of battery replacement 

Reliability (VDC XE) ‐

Reduced number 

of cycles

and frequency of  battery 

discharge

Extends battery life Low cost of ownership

Integrated Breaker / Single Power Feed Ease of installationLowers cost and footprint of 

installation

98% of disturbances < 10 sec.

10

Coup de fouet = Whiplash

Float Voltage

Grid Disturbance

0 20

Time (Seconds)

VDC XEB System Operation-Battery Hardening

Flywheel provides voltage support eliminating battery whiplashIncreasing battery life, Improving UPS reliability & Reducing serviceReduces number of batteries cycles

UPS

DC

Bus

Vol

tage

(dc)

Gen

Block Diagram

VDC XEB integrated flywheel & battery system

VYCON VDC XE FlywheelVYCON VDC XE Flywheel Technical and Reference MaterialTechnical and Reference Material

02

4

6

12

8

10

Utility Outage

ATS Signal Genset Start

Genset Start, Voltage Stabilizes

UPS Synchronizes with Genset

UPS Rectifier walk-in, Starts to recharge energy storage 10 to 12 seconds typical

Continuous Power Sequence

Seconds

Run Times – General Reference

40 60 80 100 120 160 225 275 450 550 750 1100

1 99.8 67.0 50.3 40.3 33.6 21.9 11.7 6.4

2 80.0 65.0 48.8 34.8 26.6 11.3 6.2

3 72.3 51.5 42.2 23.2 16.8 8.54 Run Time in Seconds 55.6 34.1 26.1 16.0 6.0

5 34.8 23.0 11.7

    VDC Run Times*UPS Output Power Rating (kVA)

Number of Flywheels

40 60 80 100 120 160 225 275 450 550 750 1100

1 133.3 88.9 66.7 53.3 44.4 32.9 20.5 14.12 102.4 85.3 64.0 45.5 37.3 19.7 13.6 6.73 95.0 67.6 55.3 33.6 26.3 16.2 6.94 Run Time in Seconds 72.9 44.6 36.5 25.3 13.35 45.6 33.3 20.0

    VDC‐XE+ Run Times*UPS Output Power Rating (kVA)

Number of Flywheels

*Back-up times are typical using .9 Output Power Factor, 80% Full Load Rating, 96% Inverter Efficiency

Run Time CalculatorParameter Value Unit

UPS kVA Output 400 kVA

Load Power Factor 0.80 number

UPS kW Output 320 kW

Inverter Efficiency 96 %

Flywheel kW Output 333 kW

Rectifier Walk-in Time 0.0 seconds

Percent Load on UPS 100 %

Quantity of Flywheel units 2 number

Minimum Run Time Required 18.0 seconds

20.1 seconds @ 100 % Load

27.7 seconds @ 80 % Load

30.0 seconds @ 75 % Load

38.4 seconds @ 60 % Load

46.1 seconds @ 50 % Load

57.6 seconds @ 40 % Load

92.2 seconds @ 25 % Load

ADD VDC seconds @ 100 % Load

ADD VDC seconds @ 80 % Load

19.9 seconds @ 75 % Load

29.4 seconds @ 60 % Load

35.2 seconds @ 50 % Load

44.0 seconds @ 40 % Load

70.1 seconds @ 25 % Load

4 - 40

VDC XE (300kW)

Variable Input Parameters

0 - 15

25 - 100

1 - 8

VDC (215kW)

Available Run Time

Range

40 - 1100

0.7 - 1

Calculated

80 - 100

Calculated

Average cost of unplanned 

shutdown $250 ‐$680K

Average cost of unplanned 

shutdown $250 ‐$680K

ROI Calculator

VYCON DC Flywheel Success Stories

SUMMARY

Lowest cost of ownershipOSHPD listed / Certified20 year life spanHigh efficiency- 99.4% Small footprintMinimal maintenance

Green technologyHigh reliability / predictabilityHigh power densitySimple installationNo bearing changes

Vycon VDC Energy Storage System

http://www.vyconenergy.com/

Thank you