Short answer: design for much higher rack power density, modular redundancy, and flexible voltage distribution (including newer DC options) — then size transformers, switchgear, PDUs, and cooling around those needs so your site can scale from tens to hundreds of kilowatts per rack without costly rework.
AI-first deployments change the rules. Here’s a concise, practical guide that covers what to plan for and how to keep your build scalable and serviceable.
1. Start with realistic power-density forecasts
AI racks can range from ~10 kW per rack (earlier GPU systems) to modern, liquid-cooled racks and hyperscale designs pushing dozens to >100 kW per rack. Use a tiered forecast (conservative / expected / aggressive) and plan main feeders, busways, and UPS capacity to the aggressive scenario to avoid expensive retrofits.
2. Choose the right distribution architecture
Consider these options depending on scale and density:
3. Transformers, switchgear, and redundancy strategy
Size transformers from utility MV (e.g., 13.8 kV) down to facility voltages (480V/400V) sized with headroom — data centers commonly use 500–2,500 kVA transformer banks depending on campus scale. Use dual A/B distribution paths, N+1 or 2N UPS topologies for critical AI training clusters, and synchronous transfer/static transfer switches where needed to maintain uptime.
4. PDUs, monitoring, and protection
Use rack PDUs capable of high current three-phase feeds, per-outlet metering, and branch protection sized to actual GPU power supply needs (many GPU servers list per-system kW specs — e.g., common H100/DGX figures). Add fused sections and select transformers/secondary protection coordinated for selective clearing so a fault trips only the nearest protective device.
5. Cooling & power are two halves of the same problem
Power consumed becomes heat to be removed. For high-density GPU racks, air cooling may be insufficient; liquid cooling and close-coupled heat exchange are increasingly common in hyperscale AI rooms. Coordinate electrical sizing with mechanical design early.
Quick checklist for a scalable design
- Forecast 3 scenarios of kW/rack and site load.
- Design transformers and main switchgear with 20–30% headroom and modular add-on capability.
- Use dual feeds (A/B) to racks and separate UPS strings for redundancy.
- Specify PDUs that support three-phase high-current feeds and per-outlet monitoring.
- Plan for liquid cooling or 800 VDC distribution if projected density exceeds 50 kW/rack.
At High Power Products (HPP) we engineer systems with the transformers, switchgear, and fused distribution equipment that make scalable AI deployments possible. Whether you need medium-voltage step-down transformers, custom switchgear, or coordinated fuse and protection schemes to support high-density racks and busway feeds, we can engineer for long life and fast delivery — and we also offer Arcteq protection solutions for added personnel and equipment safety.
Ready to make your AI infrastructure future-proof? Request a quote and speak with our engineers today.