OCP Engineering Workshop 2015_San_Jose_

March9,2015SanJoseComputeEngineeringWorkshopENGINEERINGWORKSHOPOpenRackWorkshopSteveMillsFacebookMechanicalEngineerENGINEERINGWORKSHOPScheduleforToday▪FacebookOpenRackV21:00-1:20OverviewSteveMills1:20-1:30CubbySub-chassisReneeChu1:30-2:30PowerShelfSamirKala2:30–3:30BBUZohEbrahimzadeh3:30-4:00Break▪OpenRackStandardUpdate1.24:00-5:00UpdateSteveMillsENGINEERINGWORKSHOPOverviewofFacebookOpenRackV2SteveMillsFacebookMechanicalEngineerENGINEERINGWORKSHOP▪ComplieswithOpenRackStandardV1.1▪BackwardscompatiblewithallOpenRackV1ITGear▪IncreasedMaxITGearmassfrom950kgto1400kg▪Increasedheightfrom2100mm(82.6”)to2210mm(87”)2210mm(87”)FacebookOpenRackV2ENGINEERINGWORKSHOPRearView▪PDUsarelocatedinthebackunderthecanopy▪Capableofsupporting3busbarsbutFBplanstopopulateonly1atproductionENGINEERINGWORKSHOPFBV2PowerOverview1PowerZone=22OU1PowerZone=19OUENGINEERINGWORKSHOPFBV2PowerOverviewACINACPDUAC/DCPSUBBU12VBUSBAR54VDC48VDCTORSwitchDCPDU12VBUSBARENGINEERINGWORKSHOPFBV2PowerShelfShelfprovides6.6kWDC@12V2+1redundantwithintegratedBBU3xPSUactingasMaster3xBBUactingasSlaveACInputfromPDUOutput54VtoDCPDUMGMTtoDCPDUStatusLED12VOutputBusbarinterconnecttoRackENGINEERINGWORKSHOPFacebookCubbyRackSub-chassisReneeChuMechanicalEngineerFacebookENGINEERINGWORKSHOPFBCubbyProject▪Splitseachpowerzoneinto24slotsforITgear▪EachITslotis2OUtallx17.5cmx68cmandcansupport20kgofgear12ITSlots12ITSlots1PowerZoneENGINEERINGWORKSHOPSplitsPowerfrom12VDCtoeachSlotENGINEERINGWORKSHOPCubbywith1slotpopulated▪SpecificationwillbeincludedinOpenRackV2specificationsubmissiononOCPwebsite.ENGINEERINGWORKSHOPGeneralCompatibleNode▪SleddesignenvelopepopulatingoneITslotwithcubbymatingfeaturesENGINEERINGWORKSHOPBatteryBackupUnit(BBU)▪LithiumIonBatterySolutionZohEbrahimzadehFacebookHardwareEngineerENGINEERINGWORKSHOPAgenda▪V1Approach:▪BatteryCabinetw/LeadAcidbatteries▪V2BBU:Li-Ionbatteries▪Design▪Safety▪Aging▪StateofHealthTestV1BatteryCabinetENGINEERINGWORKSHOPElectricalOverview▪DataCenterDistribution▪ACInput▪480/277VACtoPSU▪PSUto12VDC▪DCInput▪48VDCtoPSU▪PSUto12VDCENGINEERINGWORKSHOPV1-BatteryCabinet▪56kWor85kW▪277VAC,3phaseinput▪20sealedVRLAbatteries▪3RectifiersforchargingandITswitches▪BatteryMonitoring(Vbatt,Ibatt,Temp,Impedance)▪90sbackuptimeoperationENGINEERINGWORKSHOPV1–LeadAcidBattery▪6Cellsperbattery▪12.98VDCperunit▪InternalImpedance3.77mOhm▪38KgperbatteryENGINEERINGWORKSHOP90sBackupOperationMainACBatteryDCGeneratorACGeneratorACBatteryDCMainACCase1:ACOutageCase2:ACReturnENGINEERINGWORKSHOPV2BBUDesignENGINEERINGWORKSHOPV2Design-Cell18650CylindricalCell:▪Nominal3.6V,4.2VMax@2Ah,30AMax▪18.5x65.3mm(DxH)▪46.2gpercell▪14.4KgofBattery/Rack▪Nomemoryeffect▪FlatVoltagecurveAnode:GraphiteonCuCathode:Li(Ni-Mn-Co)O2ENGINEERINGWORKSHOPV2Design–BBUPack52Cells:13Series4Parallel▪52.5VDCand120AMax▪3600WModule▪444x62x160mm(LxWxH)▪5.2KgSideViewTopViewENGINEERINGWORKSHOPV2Design-Shelf▪PSU(Master),BBU(Slave)ENGINEERINGWORKSHOPV2Design-Rack▪2Shelves,6BBUsENGINEERINGWORKSHOPV2Design–BBUFeatures▪Batterymonitoring:InternalBMSsystem▪ActiveCellBalancing:Cellbalancingduringcharge▪AutomatedSateofHealthcheck▪Redundantsafetymechanism:atleasttwolayers▪FullyenclosedmodulewithnoopeningsV2BBUSafetyENGINEERINGWORKSHOPV2BBU-SafetyShipping&StorageDuringOperationOver/abusivecharge,Over/abusivedischarge,OverTemperature,Shockandvibe,OvertemperatureUNDOTENGINEERINGWORKSHOPV2BBU-Safety,Cell12Protection3ENGINEERINGWORKSHOPBBUV2BBU–SafetyPSUAnalogMicroThermalSensors70°CCellBalancing1%ChargeFETsDischargeFuseChargeFuseThermalSensor85°CInternalVoltageSenseBBUUVP31.85VChargerOVP54VSoftShutdownHardShutdownBBUUVP27.3VAnalogNormalProtectionPrimaryProtectionSecondaryProtectionStepUpChargerV2BBUAgingENGINEERINGWORKSHOPV2Design–Aging▪Up20%increaseininternalimpedance▪Upto40%Capacityloss▪~6yearuntilEOL▪18-35COperation▪Max1dischargepermonthV2BBUStateofHealthTestENGINEERINGWORKSHOPV2Design–SoHTest▪Randomizedtestacrossthefleet▪Singletestpermittedinshelfatonce▪Minimum1500Watshelflevel▪Testrepeatedevery90daysENGINEERINGWORKSHOPV2Design–SoHTestMarch9,2015SanJoseComputeEngineeringWorkshop