WHITE paper
White
PAPER
High-voltage DC distribution is key to increased system
efficiency and renewable-energy opportunities
Written by: Stephen Oliver
Vice President, VI Chip Product Line
November 2012
A transition to 400 VDC in power distribution and conversion will help meet
greenhouse gas, efficiency, and renewable-energy goals.
The pressure throughout the energy supply chain to deliver electrical power more efficiently is intense and
growing. Most dramatically, the European Union’s response to the Copenhagen Accord puts forth a "20-20-20"
Energy Strategy, with goals of a 20% reduction in energy consumption, a 20% reduction in greenhouse gases,
and 20% reliance on power from renewable resources by 2020. These ambitious objectives are in place despite
the enormous growth in major power consumers such as data centers ("server farms") as voice, data, and
networks converge and merge, while user demands increase in the range of 5-10% annually.
Existing solutions within the AC-DC conversion-system topology are struggling to provide even a few
percentage points of large-scale improvement despite localized improvements in performance. The
answer may be to look instead to a very different AC-DC structure, based on new approaches rather
than merely incremental ones. Using high-voltage DC for power transmission, in conjunction with new
conversion approaches, offers tangible and significant benefits for both sourcing options and system
end-to-end performance. In fact, some work from France Telecom and China Mobile estimate that
between 8% and 10% across the board can be saved by going to DC distribution.
Ironically, this approach circles back to the 19th century and the earliest days of electric-power
generation and distribution. Edison favored DC generation and distribution while Tesla advocated AC,
with its availability of transformers for voltage step-up and step-down to reduce transmission (I2R)
losses. (Transformers were the only practical way to achieve needed voltage conversion despite their
efficiency of just 50-80%; cumbersome motor/generator combinations were a far-inferior alternative).
The battle was big and the stakes were high, with technical, economic, and political consequences.
As we all know, AC won that battle. But new technical developments in components and devices, along
with additional power-system objectives, are acting as catalysts to make DC-based systems a better
and available alternative. These developments include innovative conversion, control, and distribution
approaches, much of which is enabled by advanced semiconductors and conversion topologies which
function effectively in ways not previously possible. As a result, high-voltage DC (HVDC) systems are
now practical for distribution and use within a building, office park, warehouse, school, and factory.
Why use DC at all?
Why consider high-voltage DC (380 V nominal/400 V peak) instead of traditional AC, which is well
established and field proven for over 100 years? There are several aspects to the answer. DC does not
require source synchronization as AC does, and can draw upon wind, solar, and the grid as each source
is available. There are no phase balancing or harmonic issues, and no "stranded" equipment issues, all
costly investments in infrastructure which may become obsolete or redundant.
DC offers a lower total cost of ownership (TCO) in building wiring, copper, and connectors, along with
an increase in efficiency of between 8 and 10%–truly significant. A properly configured DC system
offers higher efficiency and more potential for power extraction from multiple available sources.
There are also benefits which are not as immediately apparent. Most backup-energy sources, such as
batteries and flywheels, are inherently DC. Further, telecom and server loads run on DC, so there are
fewer intermediate, efficiency-robbing stages, along with greater reliability due to fewer potential points
of failure with a DC-based approach.
vicorpower.com Applications Engineering: 800 927.9474
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The HVDC approach is not just a speculative dream or laboratory curiosity. It has industry-wide support
from critical component vendors, of course. It is also supported by industry consortia which are
developing essential standards and interoperability specifications, such as the DCG+C [DC Components
and Grid] consortium, the ITU [International Telecommunications Union] via standard L.1200, ETSI
[European Telecommunications Standards Institute] via EN 300 132-3-1, the IEC [International
Electrotechnical Commission], NTT/Japan [Nippon Telegraph and Telephone], and the IEEE.
Topology makes a difference
Before looking at the topology and implementation of a 400 VDC distribution approach, first look at the
existing approaches used for major power consumers such as data centers or telecom central offices.
In the data center, Figure 1, an incoming high-voltage AC line is stepped down, and then converted to
DC so it can be paralleled with a battery-backup system. The DC is then converted back to high-voltage
AC for distribution within the building, then converted yet again from AC down to lower-voltage DC,
and then to voltages for the circuitry rails via DC-DC converters. Thus, there are four major conversion
stages from incoming AC to final DC.
Figure 1.
A typical data center has
four major conversion stages
from incoming AC line
to final DC rails.
AC System
Conversion Steps: 4
1 UPS 2
AC/
DC
AC/
DC
AC 100
~ 200 V
Battery
3
4
AC/
DC
DC/
DC
CPU
ICT eq.
For the existing telecom system, there are just two major stages but with major points of inefficiency,
Figure 2. The line AC is converted to 48 VDC and combined with the backup batteries; this 48 VDC line
then supplies an array of DC-DC converters which provide the local, low-voltage rails needed for the circuitry.
The HVDC system also has just two major conversion stages, but there is more to the end-to-end
performance metric than the number of stages alone, as the efficiency of each stage is also critical. In
the HVDC approach, the stages are both more efficient and more reliable.
Figure 2.
For existing telecom systems,
the two major stages
of current telecom systems
are major points of inefficiency.
DC System (48 V)
Conversion Steps: 2
1 RF
AC/
DC
DC 48 V
Battery
2
vicorpower.com DC/
DC
CPU
ICT eq.
Applications Engineering: 800 927.9474
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The HVDC topology begins with the line AC rectified to 380 V-DC (nominal), with the battery backup
also operating at that voltage, Figure 3. The DC voltage is then distributed throughout the facility and
stepped down by local DC-DC converters to supply the rails of the processor and various loads. The
system can draw on the outside AC line, batteries, and even onsite renewable sources such as wind and
solar simultaneously or individually, in case there is a failure (such as grid problems due to a storm).
Figure 3.
The line AC is rectified to
380 VDC (nominal),
while the battery backup
also operates at that voltage
in the HVDC topology.
HVDC System (380 V)
• High efficiency
(Few conversion
steps)
• High reliability
(Batteries directly
supply power)
1
Conversion Steps: 2
RF
2
AC/
DC
DC 380 V
DC/
DC
CPU
• Low Copper
(Small current)
• Flexibility for
placing ICT
equipment
(Long distance)
ICT eq.
Battery
t
t
Getting down to single volts
The reality is that most circuitry operates from DC voltages below 12 V, and even down to the 1 V
region. The challenge for any distribution/conversion system is to develop and deliver those low
voltages (and their high currents) efficiently and reliably.
HVDC can meet this requirement, as well, using several available building blocks. One is a Sine
Amplitude Converter™ (SAC™), used in the form of a BCM®Bus Converter, which is an isolated, nonregulated DC-DC converter which uses a Zero-Voltage/Zero-Current Switching architecture, Figure 4.
The SAC is like a traditional AC transformer except that it is DC input/output, and has an input/output
voltage ratio which is fixed by design. For example, with a transformer ratio (K) of 1/8, it produces a 50 VDC output from a 400 VDC input, and 47.5 V from a 380 V input.
Figure 4.
To support the HVDC topology,
designers can use a
Sine Amplitude Converter™
(SAC™) or
BCM® Bus Converter
(an isolated, non-regulated
DC-DC converter).
+IN
T2
1
Q1
2
T1
T2
2
Q2
1
Q5
1
2
2
1
T2
+OUT
2
V
T2
Q3
T1
1
V
–OUT
T2
Q6
Frequency
Lock/Control
T2
T2
1
Q4
2
–IN
vicorpower.com Applications Engineering: 800 927.9474
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The SAC reaches over 96% efficiency partially due to its fixed, high frequency (>1 MHz), soft-switching
topology. The result is a power density of 70 W/cm3 ; a Vicor full-chip bus converter measuring just
3.25×2.2×0.67 cm (1.28×0.87×2.265 in.)—comparable to a standard RJ-45 Ethernet plug, Figure 5—can
deliver up to 330 W. The second block is the non-isolated buck-boost regulator, also using Zero-Voltage
Switching and 1 MHz operation, Figure 6, resulting in small size and high efficiency of 97%.
Figure 5.
This Vicor bus converter is
the size of a standard RJ-45
Ethernet plug, yet deliver
up to 330 W.
Figure 6.
Using Zero-Voltage Switching at
1 MHz operation,
the non-isolated buck-boost
regulator offers small size
and 97% efficiency.
+OUT
+IN
IL
ZVS B-B
Control
GND
GND
Working together, the SAC/BCM and buck-boost regulator provide an equalizer (adapter) function over
the full span of input voltages for the normal service range as defined by ETSI, Figure 7. At the normal
380 V point, the bus converter can drop the line down to 48 V, with the equalizer operating in a powerthrough mode (with a bypassed buck-boost). Thus, system efficiency is enhanced because the unit
converts only when needed. If the DC voltage from the line or battery drops towards 260 V, the buckboost converter "kicks in" and maintains the fixed 48 V rail.
In either case, the architecture maintains high efficiency and allows for seamless, dynamic use of
multiple sources—a rectified DC line, battery, and renewables—as they become available.
vicorpower.com Applications Engineering: 800 927.9474
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Figure 7.
Meeting the normal service
range, as defined by ETSI,
requires understanding
of corner-case design
considerations and
uses multiple functional blocks.
410 V
Abnormal Range
(400 – 410 V)
400 V
380 V +/- tolerance
350 V
300 V
365 – 400 V
Normal operating voltage
Normal Service Range (260 V – 400 V)
380 V
If...
BCM 1/8
98%
45-50 V
98%
Buck-Boost
“Equalizer”
48 V +/–5%
(~45-50 V)
Adapter
If...
260 – 365 V
BCM 1/8
98%
32-50 V
96%
Buck-Boost
“Equalizer”
Adapter
48 V +/–5%
(~45-50 V)
98%
Abnormal Range (0 – 260 V)
260 V
0V
Legacy equipment is fully supported as well, starting with today's architecture of AC to 48 VDC
rectification, followed by a 48 VDC power-distribution unit (PDU), and then DC-DC and DC-AC modules
for the lower voltages as needed, Figure 8. In the transition phase, Figure 9, the rectification would be at
line voltage producing 380 VDC, followed by a HV PDU, and then a mix of 380 VDC, 48 VDC, and lowervoltage AC (if needed) outputs, along with 48 V/12 V DC (or 9.6V) bus converters for the final rails.
Figure 8.
The use of multiple modules
ensures that legacy equipment
is supported
AC
Switch
board
48
VDC
RF
ICT equip.
(48 Vdc)
PDU
ICT equip.
(48 Vdc)
D/A
ICT equip.
(AC input)
}
Current
Status
}
Transient
Status
Figure 9.
The transition phase uses a
combination of rectifier,
step-up, and step-down stages.
AC
Switch
board
380
VDC
RF
vicorpower.com ICT equip.
(380 Vdc)
PDU
D/D
ICT equip.
(48 Vdc)
D/A
ICT equip.
(AC input)
Applications Engineering: 800 927.9474
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In this way, HV DC can be phased in without ripping "everything" out, which would be a costly and
impractical requirement. After the transitional period, the intermediate voltage conversion after the
PDU could be unnecessary: the 380 VDC would go directly to the loads to be converted down to the
final needed voltages in a single step, Figure 10.
Figure 10.
As the technology and approach
becomes established and
accepted, the 380 V high
voltage DC would go directly to
the loads, and then converted
to the lower-voltage rails
in a single stage.
AC
Switch
board
380
VDC
RF
ICT equip.
(380 Vdc)
PDU
ICT equip.
(380 Vdc)
ICT equip.
(380 input)
}
100%
380 Vdc
Loads
A tangible demonstration
Block diagrams and proposed architectures are good, but a working model is better, as shown by a
complete 400 VDC system built using available, appropriate connectors, fuses, and distribution, Figures
11 and 12. This collaboration between Emerson, Vicor, Anderson Electric, and Fujitsu powered multiple
loads including an Intel VR12 processor, a LAN switch, a 1U server, a PC, and a monitor. As further
testimony to the concept's validity, the 48 V was directly down-converted using a buck-boost plus busconverter-like unit to 1 V without additional intermediate steps for the processor, yielding about 5%
greater efficiency than the traditional approach.
Figure 11 & 12.
ANDERSON
Connectors
This working model shows
a complete 400 VDC system
built using commercially
available connectors, fuses, and
distribution cabling.
FUJITSU 400 V DC power strip
A
120 V,
15 A
wall outlet
AC/DC
Converter
0.7-1.2 V Intel VR 12
ZVS 20-55 V
SAC
CPU/memory
B-B
HV IBC 1:8
WLAN Switch
HV IBC 1:32
1U Server
Un-regulated
48 V Load
Un-regulated
48 V Load
VICOR
Regulated
48 V Load
Industrial PC
Standard
48 V Load
24” LED Monitor
Standard
48 V Load
380 V - 400 V
LED monitor
Emerson Network
Power Ac-DC Converter
vicorpower.com Equalizer
ZVS-BB
A
EMERSON Network Power
380 V Load
380 V - 400 V DC LED Lighting fixtures
VICOR
VICOR Intel VR12.0
reference design
LED lighting fixture
1U Server
VICOR Test Board
WLAN Switch
Industrial PC
Applications Engineering: 800 927.9474
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The challenges and opportunities ahead
A combination of factors is making high voltage DC a very attractive solution to the energy
consumption dilemma. The merging of voice-centric telecom with data-centric networking (voice,
video, data) is driving increased power usage from information sources through end users. At the same
time, we face climate-change issues, limits on fossil fuels, and a need to integrate renewable sources.
Initiatives such as the Kyoto Protocol (1997), the Copenhagen Accord (2009) and the European Council
20-20-20 Energy Strategy provide a regulatory framework and set of ambitious goals for reducing
emissions of greenhouse gases, lowering energy consumption, and increasing use of renewable sources.
The electronics industry will be a big part of responding to these initiatives and meeting these goals. It
must be inventive, with radical, dramatic solutions rather than just incremental upgrades. It must be
proactive, at the leading edge of the transition, while using proven, safe, demonstrable technologies
which can shorten time to market. It must also collaborate on an industry-wide basis with alliances
among various vendors and organizations to set comprehensive standards, define commonalities, and
minimize barriers to adoption.
At the same time, the plan, process, and products must be commercially viable to encourage worldwide
involvement and adoption. Yes, these big challenges require big thinking and transformations, but this
industry has repeatedly shown it can act to meet and even lead them, as demonstrated by its many
radical transitions in process, products, and implementation over the years.
About the author
Stephen Oliver is Vice President of VI Chip® Product Line for Vicor Corporation. Steve has been in
the electronics industry for eighteen years, with experience as an applications engineer, product
development, manufacturing and strategic product marketing in the AC-DC, telecom, defense,
processor power and automotive markets. Previously with International Rectifier, Philips Electronics
and Motorola, Steve holds a BSEE degree from Manchester University, U.K. and an MBA in Global
Strategy and Marketing from UCLA and holds several power-electronics patents.
The Power Behind Performance
Rev 1.1
09/13
vicorpower.com Applications Engineering: 800 927.9474
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