ORv3 High Power Rack (HPR) Ecosystem Solution
Major rack & power upgrades to the
ORV3 ecosystem to support the needs of
upcoming AI platforms
POWER AND COOLING
RACK & POWER
ORv3 High Power Rack (HPR) Ecosystem Solution
Glenn Charest, Mechanical Design Engineer, Meta
Rich Banyard, Mechanical Engineer, Rittal
Dmitriy Shapiro, Mechanical Design Engineer, Meta
David Sun, Power Engineer, Meta
Overview
• ORv3 was originally designed to support ~18-36kW of power. With AI driving increasing
power requirements, a new iteration called HPR (High Power Rack) is being designed at
Meta in conjunction with rack, power, and cable partners
ORv3 ORv3 HPR
Rack Depth 42” 48”
Busbar Capacity 18kW+ 92kW+
PSU Shelf 18kW (6*3kW PSUs) 33kW (6*5.5kW PSUs)
BBU Shelf 18kW (6*3kW BBUs, 90sec) 33kW (6*5.5kW BBUs, 90 sec)
Grounding Path ORv3 Standard Improved to avoid overcurrent
PSU/BBU Shelves/Rack 2/Rack 3/Rack +
AC WHIPs / PSU Shelf NA: 2x 20A, 12AWG Wire, L22-20P NA: 2x 30A, 8AWG Wire, L22-30P
EU: 1x 32A, 4mm^2 Wire, IEC309 EU: 2x 32A, 4mm^2 Wire, IEC309
Blind Mate Manifold Compatible Compatible w/ room for expansion
ORv3 HPR Rack
Extension
Frame*
• Leverages existing ORv3 rack with additional
extension frame and deeper busbar
• Extension frame allows mounting of all
ORv3 accessory kits (doors, etc)
• Up to 6x AC WHIPs can be routed through
side of extension frame
• Modular cross braces to ensure busbar &
frame rigidity
Modular
Mounting Braces*
Locations
*Colors shown for differentiation.
Actual components are powder coated black Rack Rear View *Busbar
ORv3 HPR Rack Manifold
Mounting
• New ORv3 HPR-specific TORC/BORC (Top/Bottom of Rack
Containment) kits to seal off airflow between hot and cold aisle in
data center.
• Same blind mate manifold mounting locations as ORv3, but extension
frame now provides protection for potential deeper manifolds
TORC
Manifold
BORC Mounting
ORv3 HPR Rack
• Frame ballasts to offset increased
busbar & extension frame. These
are designed to increase the angle
needed to potentially tip over the
rack.
• Angled extension frame bottom to
overcome ramp angle requirements
*Colors shown for differentiation.
Actual components are powder coated black Rack Bottom View
ORv3 HPR Busbar
• 35mm width remains to minimize impacts to system designs
• Depth increased by 125mm, weight increased by 65kg
• Increased busbar to rack mounting robustness
• Improved grounding (see ORV3 HPR Grounding Scheme)
ORV3 HPR
ORV3
Top of Rack Mounting Bottom of Rack Mounting Busbar Top View
ORv3 HPR Busbar
• Simulations were conducted to validate
the following potential configurations
Config 1 2 3 4
PSU Shelves 3 3 3 3
PSU Shelf Top Top Top, Bottom
Location Bottom
Load Qty 16 12 16 31
Load 5.7kW 11.7kW 8.75kW 18x 5.8kW
9x 1.5kW
2x 2kW
2x 3kW
Load Location Bottom Top Center See Layout
Busbar Capability 92kW 140kW 140kW 128kW (1) 92kW (2) 140kW (3) 140kW (4) 128kW
ORv3 HPR Grounding Scheme
• Alternative ground current paths could potentially cause overrating of the IT gear connector
ground contacts and power return pins, leading to overheating. Grounding scheme changes will
mitigate the risk
• Current ORV3 ground scheme:
ORv3 HPR Grounding Scheme Changes
1. Connect 50V_RTN busbar (copper) to busbar cage (steel) through metal ground blocks on top and bottom of the rack
ORv3 HPR Grounding Scheme Changes
2. Change the aluminum ground bar material to low conductivity metal such as steel to increase contact resistance.
ORv3 HPR Grounding Scheme Changes
3. Create a new SKU of IT gear input busbar clip without ground bracket.
a) New Option: Busbar clip WITHOUT the ground bracket shall be used for IT gears with non-isolated 50V input, i.e., where
50VRTN is connected to the chassis in the IT gear.
b) Existing Standard: Busbar clip WITH the ground bracket shall be used for IT gears with isolated 50V input, i.e., where
50VRTN is floating from the IT gear chassis.
ORv3 HPR Grounding Scheme Changes
4. The ground bonding of the PDB/MB board in non-isolated input IT gear shall be designed to carry the full fault current
when there is a 50V short to the chassis.
ORv3 HPR AC WHIP
• Tapbox plug: NA L22-20P -> L22-30P, EU Remains IEC309
• AC Input connector keying feature flipping 180° for 30A Keying Feature Flipping
shelf & WHIP
• NA power cord changing from 12AWG (18mmOD) to
8AWG (27mmOD) to comply with UL817. EU power cord
remains the same
• 90° overmolded bend to overcome bend radius
challenges 90° Bend
• To be routed along the extension frame
ORv3 HPR PSU + Shelf
ORv3 ORv3 HPR
Max Power Output 18kW (6*3kW PSUs) 33kW (6*5.5kW PSUs)
PSU Module Length 520mm 640mm
Shelf Depth 787mm 787mm
Busbar Output Connector 500A 700A
Busbar Connector Temp None Yes, with thermistor
Monitoring
Peak Power 130%, 20ms 136%, 50ms and 160%, 400us
AC Connections / PSU NA: 2x 20A, 12AWG, L22-20P NA: 2x 30A, 8AWG, L22-30P
Shelf EU: 1x 32A, 4mm2, IEC309 EU: 2x 32A, 4mm2, IEC309
• AC Loss & Pulse Management signal cable connections
• Removed 3V gap (48V-51V) between PSU and BBU output voltages
• Power Monitoring Module (PMM) to monitor system status,
connected to upstream rack management device
•
ORv3 HPR BBU + Shelf
ORv3 ORv3 HPR
Max Power Output 18kW (6*3kW BBUs) 33kW (6*5.5kW BBUs)
BBU Module Length 672mm 702mm
Shelf Depth 787mm 787mm
Busbar Output Connector 500A 700A
Backup Time 3kW, 90sec / 3kW, 240sec 5.5kW, 90sec / 4kW, 240sec
Battery Life 6 years 6 years
Peak Power 130%, 20ms 136%, 50ms and 160%, 400us
• AC Loss & Pulse Management signal cable connections
• Removed 3V gap (48V-51V) between PSU and BBU output voltages
• Power Monitoring Module (PMM), same as on PSU
Call to Action
• PSU, BBU, PMM, and AC WHIP specs are in OCP Rack and
Power Wiki under “High Power ORV3 System Specs Folder”.
• Rack and Power call, 2nd Wed 9am. Check site for times.
Thank you!
