Partner POV | Custom PDUs: Enabling the future of data centers beyond standard solutions

Article written by Felix Escobar, Offering Manager, Vertiv. 

The rise of artificial intelligence (AI) and high-performance computing (HPC) applications is driving the rapid adoption of custom power distribution units (PDUs), with the market projected to grow at 23.8% through 2028—far outpacing standard rack PDUs at 5.3%.

The increased densification from AI and HPC workloads requires significant power consumption, with global data center energy use expected to double by 2030. This evolution brings unique challenges in maintaining reliable and efficient power distribution, requiring solutions beyond standard offerings.

PDU customization can help data center operators meet these dynamic demands and maintain a competitive edge. However, successful custom PDU deployment hinges on collaborating with partners who can deeply analyze unique customer challenges and deliver adaptable solutions.
 

The evolution of power distribution units (PDUs)

Traditional PDUs served a straightforward purpose – stepping down the voltage from commercial levels (typically 480 volts (V)) to IT-compatible voltages while maintaining reliable power delivery. However, as data centers have evolved from standard enterprise facilities to complex, multi-tenant environments supporting AI workloads, the resulting increase in power consumption (see Figure 1) has necessitated more sophisticated and flexible power distribution solutions to handle these higher kilovolt-amps (kVA) ratings without sacrificing efficiency or reliability.

Varying requirements of data center power distribution

Data centers supporting AI workloads require significantly higher power capacities, with some facilities needing up to 50 kilowatts (kW) per cabinet. According to McKinsey, global demand for data center capacity could rise from 19% to 22% annually from 2023 to 2030, potentially reaching 171 to 219 gigawatts (GW) by 2030. The exponential growth of AI and multi-tiered workloads creates unique challenges for enterprises, colocation providers, and hyperscalers, requiring solutions beyond standard offerings.  
 

PDU customization use cases for modern data centers

While PDU customization isn't new, modern data center challenges—like evolving power needs and minimal downtime requirements—demand it to achieve increased reliability, scalability, and efficiency. This discussion will explore two cases that exemplify the intersection of engineering and practical application.

Voltage flexibility for scalable PDU deployments

There has been an increasing trend of data center infrastructure providers procuring PDUs in bulk to mitigate supply chain uncertainties and extended lead times, allowing units to be available for rapid deployment as soon as sites are built.

However, stockpiling PDUs presents a challenge: operating voltage requirements, dictated by site-specific factors and customer needs, are often finalized only during deployment. If the procured units do not match these requirements, redesigning or modifications may be necessary, extending timelines and complicating the deployment process.

• Solution: The "deploy anywhere" transformer - The triple-output voltage transformer addresses varying voltage requirements by providing three different voltage outputs—208V, 400V, and 415V—from a single unit. As the industry shifts toward more efficient configurations, the design also offers flexibility to support higher voltages as needed, such as 480V.
  The triple-output transformer features multiple taps on the secondary windings, which can be connected to different terminals to change the output voltage after deployment.
• Key benefits - Colocation environments benefit from the flexibility of multi-output voltage transformers, as voltage requirements often remain undetermined during procurement. The custom PDU's post-deployment reconfiguration delivers three key advantages:
  • Cost-efficiency: Bulk purchasing multi-output voltage transformers can reduce procurement costs, which is crucial for large-scale operations.
  • Flexibility: The ability to reconfigure voltage outputs post-deployment enables PDUs to adapt to various facilities and stockpiled units to be deployed with minimal delays or modifications. Streamlined inventory management and simplified deployment processes reduce complexity and allow units to remain readily available for rapid installation.
  • Adaptability: This design allows colocation providers to adapt to changing voltage requirements without needing new equipment, which is essential in the rapidly evolving data center landscape.

Downtime risks in multi-tenant PDU modifications

In colocation and multi-tenant data center (MTDC) environments, multiple tenants are often connected to a single PDU, with some units operating at partial capacity due to varying power demands. When a new tenant requires connection to an already operational PDU, operators must de-energize the entire unit to maintain the safety of service personnel during installation. This temporary shutdown disrupts the power of existing tenants, risking SLA breaches, and potentially compromising uptime commitments.

• The always-on solution: Isolated PDU data center design - An innovative isolated PDU design addresses downtime risks in MTDCs caused by multi-tenant configurations. By physically isolating field connection terminals from any live parts within the unit, the custom PDU keeps modifications or maintenance activities on one part of the system from affecting the broader power distribution network and disrupting the operation of other tenants. Key technical specifications include:
  • K-factor options: Range from K4 to K20 for enhanced harmonic filtering, reducing the effects of harmonic distortion.
  • Configurable impedance specifications: Allow fault current control, managing and limiting the impact of electrical faults on the IT infrastructure.
  • Multiple subfeed configurations: Support up to 8 outputs, enabling tailored power distribution for diverse tenant needs.
  • Advanced operational features: Include options such as 80% or 100% rated output breakers, third-party monitoring support, and thermal scanning options for enhanced performance and adaptability.
• Key benefits
  • Higher reliability ratings: Targets high uptime, crucial for meeting high availability demands.
  • Maintenance without compromising redundancy: Allows maintenance activities without affecting the power supply to other tenants.
  • Safe load modifications: Enables operators to safely modify specific customer loads while maintaining power to others, enhancing flexibility in dynamic colocation environments.
  • Reduced white-space impact: Minimizes footprint and clearance restrictions, optimizing data center space utilization.
  • Custom transformers: Supports tailored solutions for specific operational needs.

Evolving data center power distribution demands

As AI and HPC workloads reshape data centers, power distribution must evolve, requiring larger power blocks, flexible configurations, and tailored solutions. Modern power densities are pushing beyond conventional boundaries, requiring:

• Enhanced power quality management: AI workloads can cause power transients that surge up to 150% of a computing cluster's steady-state maximum power level. Maintaining stable and clean power delivery to sensitive equipment is critical to avoid disruptions.
• Sophisticated harmonic filtering: Electrical noise from harmonics can lead to overheating and equipment malfunctions.
• Greater flexibility in voltage delivery options: AI and HPC data centers often have diverse loads throughout the facility, requiring flexible voltage configurations to maintain efficiency and reliability.
• Improved fault isolation capabilities: Advanced mechanisms are necessary to minimize downtime during maintenance or fault conditions.
   

Enterprise PDU solutions for modern data centers

Power distribution unit customization becomes effective when supported by extensive manufacturing capabilities and expertise. Experience and innovation intersect critically in this context. With a long history of transformer manufacturing and integrated research and development and product management teams, rapid advancement and implementation of these solutions at scale is achievable:

• Custom transformer winding: Allows optimal performance and compatibility with diverse data center environments. This customization is crucial for addressing the unique power needs of AI and HPC applications.
• Comprehensive testing facilities: Simulate real-world load conditions, allowing rigorous evaluation of the performance and reliability of custom PDUs before deployment. This process tests products' capability to handle demanding AI/HPC data center environments.
• Decades of quality control: Maintain the highest standards of reliability and efficiency of custom PDUs.
   

Embrace the future of data centers

The exponential growth of AI and HPC workloads has pushed data centers to an inflection point in power distribution. Adapting to evolving power requirements while maintaining reliability demands tailored solutions, with increasing complexity driving the need for precision. Engineering expertise and flexible manufacturing enable power distribution systems to deliver scalability, efficiency, and uninterrupted operations.

Vertiv's commitment to innovation and excellence positions us to address the challenges and opportunities of the AI-driven data center landscape. With deep engineering expertise and flexible manufacturing, our customization capabilities enable precise adaptation to unique demands—from stable power delivery to harmonic filtering and flexible voltage configurations—enhancing reliability and minimizing downtime.