XLM 62V Supercapacitor Module Introduction
For UPS Applications
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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
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5.4V Modules With Connector
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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
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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
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Higher Voltage Module Examples
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Application: UPS/Volt. Sag/SEMI F47
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P/N: XV3560-259R2425-1
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Base Cell: XV3560-2R7407-R
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Configuration: 96 cells in series
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Electronics: Passive Balancing + Fuse protection
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Module Ratings:
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259.2V / 4.17F / 310mW
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14.5 Wh, 55.9 kW max. power
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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
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Energy Storage In UPS Systems
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Static UPS: power converter using stationary power storage:
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Batteries: for backup time of minutes (typically 1 hour max)
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Supercapacitors: for backup time of seconds (typcially max 30 seconds)
Dynamic/Rotary UPS: power converter using rotating energy source:
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Diesel/Jet generators: for backup times hours-days
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Flywheels: for backup times of seconds (typcially up to 2 minutes)
Strong competition against
Eaton in EMEA
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UPS Requirements For Seconds Backup
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Power level: 150kW-5MW
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400VAC – 3phase outputs
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Backup time: 5-30s
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As small installation floorspace as
possible
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Minimum maintanace time – chance
for power loss during maintanace
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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.
Heavy due to lead and acids
Moderate – 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.
Environmental
footprint
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Supercaps vs. Batteries: Pros and Cons
Battery solution advantages:
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Lead acid batteries are still more cost competitive
against supercaps in case backup time is over 10s
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Batteries can store more energy in the same size
Supercap solution advantages:
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Supercaps can support higher operating
temperatures up to +85C
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Supercaps can support UPS systems with frequent
backup – even 10/hour due to the quick/seconds
charge capability
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Supercap can be offered for „Pb allergic”
customers/environments
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Supercaps can support the UPS lifetime without
maintanace for 20yrs even
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Supercaps vs. Batteries: Discharge Behaviour
Voltage drop
due to ESR
Battery discharge curve
Supercap discharge curve
The lower the allowed
discharge voltage for
supercaps the more cost
efficient is the use
Battery cannot deliver sufficient
current below this point
Supercap can deliver sufficient
current until it reaches almost 0 volts.
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Supercaps vs. Flywheel Energy efficiency
Advantages of supercaps:
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Supercaps have higher
efficiency than flywheels
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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
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Supercap vs. Flywheel Total Cost Of Operation
Advantage of supercaps:
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Total cost of operation is lower
for supercapacitor solution
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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
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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
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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:
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Agency information UL810A
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Shock and vibrations Telcordia GR- 63 Zone 4
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Environmental IP30, RoHS, lead free, halogen free
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Altitude, Operating 10,000 ft / 3,000 meters Altitude, Non- operating
40,000 ft / 12,000 meters
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XLM-62R1137-R Dimensions
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4U height
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6.9”” width fits 3 wide in 24” rack
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All front connections
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Rack Implementations As Per Today
2 wide in 19” telecom or server rack
3 wide in 24” UPS rack
Series Connected Modules: Higher Voltage
Parallel Connected Modules: Longer Time
Secure modules with strap; or for Zone 4 earthquake safety, bolt to shelf
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UPS Apps Requiring Short Backup: Data Centers
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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
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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
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UPS Apps Requiring Short Backup: Hospitals
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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.
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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
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UPS Apps Requiring Short Backup: IC Fabs
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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.
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UPS system consists of high power short time bridging UPS’ to provide 5-10s ride/through time acc to
Semi F47.
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UPS Apps Requiring Short Backup: Transportation
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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.
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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
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Supercap Bank Sizing Example
UPS requirements:
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500kW power delivery for 20s – 400VAC 3phase
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Energy storage float (charge) voltage: 560VDC, min voltage: 360VDC
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System efficiency: 94%
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Lifetime requirement: 20yrs
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Ambient temperature: 25C constant, kept in controlled enviroment
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Supercap Bank Sizing Example
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500kW x 1.06 (eff) = 532kW
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10x10pcs XLM 130F modules
required by the new installation
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Min voltage by end of
discharge is 373.5V...it will
degrade during the lifetime
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Supercap Bank Sizing Example
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10x10pcs capacitor bank discharge
curve after installation – NEW parts
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10x10pcs capacitor bank discharge
curve after 20yrs lifetime
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Meets system requirements
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Doesnt meet system requirements
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Autonomy time: 21s > 20s
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Autonomy time: 14s < 20s => need
additional capacitance installation
during the lifetime!!!
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Supercap Bank Sizing Example
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.
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
This way 10 capacitors and rack, protection
devices are saved + initial installation cost is
lower significantly than installing 10x14 caps by
the beginning.
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Engine Starting – For Start-Stop Engines
Start
Switch
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Smart Start
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Start from battery, supercap or
combination
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Optimize starting and system
capability
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Utilize energy for other
functions to optimize
performance and lifetime
Controller
Existing
Vehicle
Batteries
Bidirectional
DC-DC Converter
Capacitor Bank
Supercap Module
Starter/
Solenoid
Vehicle power:
cab, chassis,
steering
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Supercap + Battery Hybrid Test
The test was to simulate a system with repeated peak power requirements
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Supercap + Battery Hybrid Test
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Supercap + Battery Hybrid Test
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