AI and the Big Data Boom
AI and social media have reached the widest possible audience in recent years, triggering a tremendous flood of data. Today’s data centre technology is no longer sufficient—new approaches are on the horizon.
Good advice: Check out REGATRON—the right solution for your future development and test equipment needs, today!
Abstract
The incredible increase in data density, especially in AI servers, means that both server power supplies and energy distribution must be adapted and optimized to this new situation. Where is this journey headed?
- Power supplies: Today’s standard 3 kW server power supplies will soon have 50 to 100 kW of power and be strictly optimized for low loss. More and more server bus voltages will increase up to ±400/800 VDC.
- The energy path from the building’s power connection to the server power interface will be optimized: It should be short, low-loss, and with as few voltage changes as possible. Direct connection to medium grid voltages up to 35 kV AC will yield energy benefits.
This concept is called “Grid-to-Chip” and requires new standards to be set in both the development of power supply units and the physical design of energy distribution.
Scalability and Future-Proofing
There is no question that this concept imposes extraordinary demands both on the development of components and on the testing of whole systems. REGATRON provides a modular testing architecture designed to grow alongside technological advancements. Both the G5 (DC) and TC.ACS (AC) systems allow for the seamless integration of units into parallel, series, or mixed-mode matrices, reaching capacities of 5,000+ kW and currents exceeding 20,000 A. This approach enables an enterprise to start up with a single 54 kW module for initial component validation and subsequently expand to a multi-megawatt system for full “Grid-to-Chip” rack verification.
Sophisticated Software-Defined Control
In contrast to conventional resistive/dissipative loads, REGATRON G5 and TC.ACS systems are highly advanced software-defined instruments. The internal control loops are remarkably adaptable, ensuring high stability even when faced with complex coupling network impedances or challenging Device Under Test (DUT) characteristics. This ensures that the resulting test data reflects the authentic performance of the PSU or Power Shelf.
Optimal Operational Efficiency and TCO
For 24/7 testing operations, energy consumption represents the most significant operational cost. REGATRON’s regenerative technology ensures that up to 95% of the energy utilised during testing is recovered and returned to the facility’s grid. A comprehensive Total Cost of Ownership (TCO) analysis confirms that this efficiency provides a notably faster Return on Investment (ROI) and a reduced environmental footprint compared to the high electricity and cooling costs of traditional air-cooled dissipative loads.
Overview of Grid-to-Chip Power Infrastructure
To support next-generation AI factories, power infrastructure is evolving through three distinct stages to manage escalating GPU/TPU energy demands efficiently:
Generation 1: Integrated Rack (100–200 kW)
Compute and power modules share a single enclosure. Multiple PSUs deliver 50V DC via a common busbar, supporting rack power up to ~200 kW. While currently standard, increasing densities eventually exceed the spatial and thermal limits of this integrated design.
Generation 2A: Power Sidecar & HVDC (200 kW – 1 MW)
To overcome space constraints and distribution losses, power components (PSUs, BBUs, and CBUs) are moved to a dedicated ‘Power Sidecar’. This distributes 400 V or 800 V High-Voltage DC (HVDC) to the IT rack, where a final side-mounted conversion stage steps it down to 50 V. This architecture maximises compute capacity while reducing energy waste.
Generation 2B: MW-Scale SST & Direct Conversion (MW+)
For megawatt-scale efficiency, Solid-State Transformers (SST) convert 10…34.5 kV utility power directly into an 800 V HVDC microgrid, eliminating redundant conversion stages. Final voltage step-down is integrated within the server tray via Intermediate Bus Converters (IBC), minimising losses from the grid to the processor core.
General Overview of a typical Data Center Architecture
LFT: Low Frequency Transformer
SST: Solid State Transformer
BBU: Battery Backup Unit
PSU: Power Supply Unit
IBC: Intermediate Bus Converter
VRM: Voltage Regulator Module
GPU: Graphics Processing Unit
TPU: Tensor Processing Unit
CBU: Capacitor Backup Unit
SSCB: Solid State Circuit Breaker
Powershelf & PSU Testing
Grid Simulator: TC.ACS series
– Recommended Model: ACS.150.528.216 (150 kVA, 528 VAC L-L, 216 A/phase)
DC Load Simulator: G5.RSS and G5.RLD Series
– Recommended Model: G5.RSS.216.1000.1296 (216 kW, 1000 V, 1296 A)
BBU and CBU Testing
Battery Cycler: G5.BT Series and EIS Testing Function
– Recommended Model: G5.BT.54.80.2028 (54 kW, 80 V, 2028 A)
Battery Simulator: G5.BAS Series
– Recommended Model: G5.BAS.54.80.2028 (54 kW, 80 V, 2028 A)
Power Sidecar Testing
Grid Simulator: TC.ACS Series
– Recommended Model: ACS.150.528.216 (150 kVA, 528 VAC, 216 A/phase)
DC Load Simulator: G5.RSS Series and G5.RLD Series
– Recommended Model: G5.RSS.216.1000.1296 (216 kW, 1000 V, 1296 A)
HVDC DC-DC Testing
HV DC Link Simulator: G5.RSS Series and G5.SRC Series
-Recommended Model: G5.RSS.216.1000.1296 (216kW, 1000V, 1296A)
LV DC Link Simulator: G5.RSS Series and G5.RLD Series
– Recommended Model: G5.RSS.216.1000.1296 (216 kW, 1000 V, 1296 A)
SSCB, SST, Bus Bar Testing
High Current Power Source: G5.SRC Series
– Recommended Model: G5.SRC.216.80.8112 (216 kW, 80 V, 8112 A)
DC Grid Simulation: G5.RSS Series
– Recommended Model: up to 5000+ kW / ±500…1500 (3000) V
AC Load Simulation: ACS Series
– Recommended Model: up to 2000+ kVA / 528 VAC L-L or higher
Why REGATRON
Select REGATRON for AI infrastructure validation to secure a high-precision, future-proof, and economically efficient testing environment.
- Future-Proof Scalability: Scale seamlessly from a 54 kW module to 5,000+ kW and 20,000+ A using modular G5 (DC) and TC.ACS (AC) matrices.
- Extreme Dynamics & Precision: Achieve microsecond-grade rise times (20–100 µs) and ultra-low current ripple, providing the precision required for validating SSCBs, CBUs, and high-power busbars.
- High-Voltage & P-HIL Capability: Support for 3,000 VDC series configurations enables SST semiconductor testing, while low-latency (60 µs) of optical RegaLink RT interface with Aurora protocol facilitate high-fidelity Power Hardware-in-the-Loop (P-HIL) simulation.
- Software-Defined Stability: Highly adaptable control loops compensate for complex cabling impedances, ensuring test results reflect authentic DUT performance independent of equipment limitations.
- Maximized ROI: Recover up to 95% of testing energy to dramatically lowering TCO and facility cooling costs compared to traditional dissipative loads.
Suitable Products
G5.RSS Series
The G5.RSS series integrates Regatron’s cutting-edge technology in a compact, space-saving design. It features rapid transient response (50…100 µs), ripple modulation up to 10 kHz, and high-precision current and voltage regulation. Its switchable output capacitance ensures stability and maximum dynamic response in both CV and CC modes. Ideally suited for a wide range of demanding laboratory and industrial applications, including testing compliant with automotive and industry standards EIS, P-HIL, and more.
- Power Range: 0…9 to 0…5000+ kW
- Voltage Range: 0…60 to 0…3000 VDC
G5.BT Series
Specialized 1- to multi-channel tester/cycler for battery modules and packs, offering adjustable, high dynamics (50…100 µs), outstanding accuracy, and application-specific safety features. It includes a dual measurement range for maximum accuracy and G5.BatControl software. Mobile racks with IP20 or IP54 ratings are available. Optimized for various battery testing applications and EIS.
- Power Range: 0…9 to 0…5000+ kW
- Voltage Range: 0…60 to 0…3000 VDC
AC Grid Simulation
The TC.ACS series can be used as a full 4-quadrant grid simulator, offering multiple programmable operating modes: Power mode, RLC load mode, and current mode. Its flexibility makes it ideal for testing inverters (PV, V2G, ESS), chargers, OBC (11/22 kVA), drives (e.g., for elevators), grid impedance simulation, and anti-islanding testing.
- Power Range: 0…30 to 0…2000+ kVA
- Voltage Range: 0…528 Vrms (L-L) (higher on request)
Three-Phase Power Amplifier
The TC.ACS series can be used as power amplifier, featuring different operating modes (CV/CC), an analog high-speed interface, and an optional digital high-speed interface based on the Aurora protocol. The fast response capability of TC.ACS provides minimum time delays and phase errors, making it ideally suited as P-HIL-amplifier for power hardware-in-the-loop simulation.
- Power Range: 0…30 to 0…2000+ kVA
- Voltage Range: 0…528 Vrms (L-L) (higher on request)
We Are Here to Support You
Experience our commitment to outstanding customer support at every stage — before, during, and after your purchase. Benefit from our complimentary consultation services from the very beginning to ensure the
ideal solution for your needs. For added flexibility, selected power supplies may also be available for rent. Please contact REGATRON to discuss your specific requirements and to check availability for your application.
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