BATTERY –FREE DC ENERGY STORAGE
FOR UPS
BILL WOLFE – NORTHEAST REGIONAL MANAGER
Expect More From An Energy Storage Solution
DC Energy Storage - ReGen
Energy Re-cycle Markets / Applications
Energy Re-cycling Applications
VYCON
Battery Free UPS
Flywheel Energy Storage
Markets
Mission Critical Protection for...
Small System Hospital / IT
300kW VDC XE
 20 year life span
 Small footprint
 Eliminating hazards
materials
Electrical Room
House keeping pad
Top cable entry
480 VAC
Medium Size - Education Data Center
4 x 300kW VDC XEs
Easily expandable scalable
High efficiency- 99.4%
DC Flywheel Storage – Large System
24 x VDC XEs (7.2 MWs)
 High power density
 Simple installation
 Green / efficiency initiatives
Modular Solution
Minimal maintenance
No bearing changes
5 x 300kW VDC XEs
Insurance Data Center
Availability
Redundancy
Battery Hardening
A/B Bus 500KVA
Battery Free UPS
Battery failure is Leading Cause (65%) of
Unplanned Outages
The Study:
Failures:
•453 individuals in U.S. organizations
who have responsibility for data center
operations were surveyed
A single bad cell among thousands
can take down a facility
•41 data centers that experienced a
complete or partial unplanned data center
outage
Source: Ponemon Institute
Batteries have a limited life
expectancy
False confidence; no indication of
problems until needed
Average cost of the Unplanned Outage
$1,017,746
Total cost by industry of
unplanned shutdown
$790,886K
Average cost of total or
partial unplanned shutdown
$397,362K
Source: Ponemon Institute
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 Applications
Typical UPS system block diagram
Long-term AC alternate source
Genset
AC
480
VAC
Automatic
Transfer
Switch
Utility
ATS
Rectifier
Inverter
AC/DC
DC/AC
540 VDC
AC
VYCON DC Energy Storage
Critical
AC
output
UPS Applications – Typical Block Diagram
Long-term
AC alternate
source
Genset
AC
Automatic
Transfer Switch
UPS System
Rectifier
Inverter
AC/DC
DC/AC
540 VDC
480
VAC
Utility
AC
DC Energy Storage
Critical
AC
output
UPS Applications – Typical Block Diagram
Long-term
AC alternate
source
Genset Start Signal
Genset
AC
Automatic
Transfer Switch
UPS System
Rectifier
Inverter
AC/DC
DC/AC
Critical
AC
output
540 VDC
480
VAC
Utility
AC
Bi-directional IGBT
converter
DC
AC
Auxiliary Power
(Protected AC source
for flywheel controls
and vacuum pump)
Graphical
Control
Interface
Flywheel Module
DC Energy Storage
Remote
Monitorin
g
Basic Operation Sequence – Normal Operation
Long-term
AC alternate
source
Genset Start Signal
Genset
AC
Automatic
Transfer Switch
480
VAC
UPS System
Rectifier
Inverter
AC/DC
DC/AC
Critical
AC
output
Utility
AC
Bi-directional IGBT
converter
DC
AC
Auxiliary Power
(Protected AC source
for flywheel controls
and vacuum pump)
Time Line
Graphical
Control
Interface
Flywheel Module
VDC
(flywheel and power converter)
Remote
Monitorin
g
Basic Installation Sequence –
Long-term
AC alternate
source
Genset Start Signal
Genset
AC
UPS System
Automatic
Transfer Switch
480
VAC
Back-up Operation
Rectifier
Inverter
AC/DC
DC/AC
Critical
AC
output
Utility
Bi-directional IGBT
converter
AC
DC
AC
Auxiliary Power
(Protected AC source
for flywheel controls
and vacuum pump)
Utility Outage
Time Line
2 sec.
6 sec.
2 sec.
Graphical
Control
Interface
2 to 15 min.
Flywheel Module
S
AT
D
a
el
y
t
ar
St t o
t
y
se ad ad
en re lo
G nd pt
a cce
a
d
a n -i n
c alk
n
Sy r W
Tr
S ifie
S
P
U ect
AT
R
sf
an
er
el ng
he rgi
w
a
y
Fl ech
R
VDC
(flywheel and power converter)
Remote
Monitorin
g
Basic Installation Sequence –
Long-term
AC alternate
source
Genset
AC
UPS System
Automatic
Transfer Switch
480
VAC
Normal Operation
Rectifier
Inverter
AC/DC
DC/AC
Critical
AC
output
Utility
Bi-directional IGBT
converter
AC
DC
AC
Auxiliary Power
(Protected AC source
for flywheel controls
and vacuum pump)
Utility Outage
Time Line
2 sec.
6 sec.
2 sec.
Graphical
Control
Interface
2 to 15 min.
Flywheel Module
S
AT
D
a
el
y
t
ar
St t o
et dy ad
s
a
en re lo
G nd pt
e
a cc
a
d
a n -i n
c alk
n
Sy r W
Tr
S ifie
S
P
U ect
AT
R
sf
an
er
el ng
he rgi
w
a
y
Fl ech
R
VDC
(flywheel and power converter)
Remote
Monitorin
g
Basic Installation Sequence – Genset operation
Long-term
AC alternate
source
Genset
AC
UPS System
Automatic
Transfer Switch
480
VAC
Rectifier
Inverter
AC/DC
DC/AC
Critical
AC
output
Utility
Bi-directional IGBT
converter
AC
DC
AC
Auxiliary Power
(Protected AC source
for flywheel controls
and vacuum pump)
Utility Outage
Time Line
2 sec.
6 sec.
2 sec.
Graphical
Control
Interface
2 to 15 min.
Flywheel Module
S
AT
D
a
el
y
t
ar
St t o
et dy ad
s
a
en re lo
G nd pt
e
a cc
a
d
a n -i n
c alk
n
Sy r W
Tr
S ifie
S
P
U ect
AT
R
sf
an
er
el ng
he rgi
w
a
y
Fl ech
R
VDC
(flywheel and power converter)
Remote
Monitorin
g
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
Flywheel Technology Evolution
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
High Speed, Steel Flywheel Module
Permanent Magnet Motor-Generator
Magnetic Levitation
VDC – Simplified One Line
Flywheel Module
IGBT Power Converter
Soft Start
To UPS
Battery
Input
DC Monitoring
Motor Generator Controls
Power Conversion Module Controller
Control
Panel
Magnetic Levitation
Controller
VDC and VDC-XE Module Layout
IGBT Bi-Directional
Converter Module
DC – Disconnect
Breaker
Mag Levitation
Controller Module
Flywheel Module
Field Serviceable
Vacuum Pump
VDC and VDC-XE at a Glance
Max Power Rating:
VDC : 215kW VDC-XE: 300kW
Max Energy Storage Rating:
VDC : 3000kW secs @ 100kW
VDC-XE:
4000kW secs @ 100kW
Foot Print / Weight:
6.25 sq ft / 1554 lbs
Standard features include:
DC Breaker included
4 line display
Top or bottom cable entry
Options include:
Mod Bus
Touch Screen
Auto Restart
Customer interface board
OSHPD Seismic Certification
73.7”
30”
30”
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…
OSHPD - SEISMIC CERTIFICATION
Office of Statewide Health Planning and Development (State of California)
AUTO-RESTART OPERATION
Configurations
Battery Free UPS System
UPS
Back up
Generator
Automatic Transfer Switch
Rectifier
Inverter
AC/DC
DC/AC
ATS
DC Bus
Utility
208 – 600V AC
VYCON Flywheel
DC Energy Storage
Critical Load
Configurations
VYCON DC Flywheel + Battery Hardening
UPS
Back up
Generator
Automatic Transfer Switch
Rectifier
Inverter
AC/DC
DC/AC
Critical Load
ATS
DC Bus
Utility
208 – 600V AC
VYCON Flywheel
DC Energy Storage
+
-
+
-
+
-
+
-
VDC XEB Hybrid
DC 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
Value
VDC XE High Speed Flywheel ‐ Primary First line of defense – (EPRI 98% source of back up power
outages < 10 seconds)
Increased energy availability and reliability
Full magnetic levitation system ‐
Provides 100% levitation & sustains flywheel rotor during operation
Eliminates cost and downtime associated with bearing changes
No bearing replacement
Smart Monitoring ‐ Flywheel “walks‐in” Mitigation of Coup de fouet / Reduces cost and frequency the battery whiplash and extends battery life of battery replacement Reliability (VDC XE) ‐ Reduced number Extends battery life
of cycles and frequency of battery discharge
Low cost of ownership
Integrated Breaker / Single Power Feed Ease of installation
Lowers cost and footprint of installation
VDC XEB System Operation-Battery Hardening
Float Voltage
UPS DC Bus Voltage (dc)
Grid Disturbance
Gen
Coup de fouet = Whiplash
98% of disturbances
< 10 sec.
0
10
20
Time
(Seconds)
Flywheel provides voltage support eliminating battery whiplash
Increasing battery life, Improving UPS reliability & Reducing service
Reduces number of batteries cycles
Block Diagram
VDC XEB integrated
flywheel & battery
system
VYCON VDC XE Flywheel
Technical and Reference Material
Continuous Power Sequence
Utility Outage
0
2
ATS Signal Genset Start
4
Genset Start, Voltage Stabilizes
6
Seconds
UPS Synchronizes with
Genset
8
10
12
UPS Rectifier walk-in, Starts
to recharge energy storage
10 to 12 seconds typical
Run Times – General Reference
VDC‐XE+ Run Times*
UPS Output Power Rating (kVA)
Number of
Flywheels
1
40
60
80
100
120
160
225
275
133.3
88.9
66.7
53.3
44.4
32.9
20.5
14.1
102.4
85.3
64.0
45.5
95.0
67.6
2
3
4
Run Time in Seconds
450
550
750
37.3
19.7
13.6
6.7
55.3
33.6
26.3
16.2
6.9
72.9
44.6
36.5
25.3
13.3
45.6
33.3
20.0
5
1100
VDC Run Times*
UPS Output Power Rating (kVA)
Number of
Flywheels
1
2
40
60
80
100
120
160
225
275
99.8
67.0
50.3
40.3
33.6
21.9
11.7
6.4
80.0
65.0
48.8
34.8
72.3
51.5
3
4
5
Run Time in Seconds
450
550
750
1100
26.6
11.3
6.2
42.2
23.2
16.8
8.5
55.6
34.1
26.1
16.0
6.0
34.8
23.0
11.7
*Back-up times are typical using .9 Output Power Factor, 80% Full Load Rating, 96% Inverter Efficiency
Run Time Calculator
Variable Input Parameters
Parameter
Value
Unit
Range
UPS kVA Output
400
kVA
40 - 1100
Load Power Factor
0.80
number
0.7 - 1
UPS kW Output
320
kW
Calculated
Inverter Efficiency
96
%
80 - 100
Flywheel kW Output
333
kW
Calculated
Rectifier Walk-in Time
0.0
seconds
0 - 15
Percent Load on UPS
100
%
25 - 100
Quantity of Flywheel units
2
number
1 - 8
Minimum Run Time Required
18.0
seconds
4 - 40
Available Run T ime
VDC XE
VDC
(300kW)
(215kW)
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
ROI Calculator
Average cost of unplanned shutdown $250 ‐$680K
VYCON DC Flywheel Success Stories
SUMMARY
Lowest cost of ownership
OSHPD listed / Certified
20 year life span
High efficiency- 99.4%
Small footprint
Minimal maintenance
Green technology
High reliability /
predictability
High power density
Simple installation
No bearing changes
Vycon VDC Energy Storage System
Thank you
http://www.vyconenergy.com/