Power Distribution Units: High-Density PDUs for AI Data Center Infrastructure

Updated December 11, 2025

December 2025 Update: Rack power densities jumping from 8.2kW (2020 avg) to 500-1000kW for AI Factory deployments. Global PDU market growing from $2.2B (2024) to $3.2B by 2030. Busway systems expanding 40%+ YoY—fastest growing DC physical infrastructure segment. 100A+ PDUs mandatory for modern GPU servers. HVDC distribution at 600-800V gaining traction for efficiency.

Rack power densities have jumped from 8.2kW average in 2020 to projections of 500-1000kW for AI Factory deployments.¹ GPUs like NVIDIA's Blackwell B100 and B200 cross the 1,000-watt threshold per chip, pushing rack power beyond 100kW and approaching 1MW in some configurations.² The humble power distribution unit has evolved from a simple power strip into a sensor-rich platform delivering actionable insight, operational resilience, and the agility required for the AI era.³

The global PDU market grew from $2.2 billion in 2024 to a projected $3.2 billion by 2030 at 6.4% CAGR, with intelligent PDU adoption accelerating as AI and machine learning workloads demand higher power capacities.⁴ Allied Market Research projects the broader market reaching $7.9 billion by 2030.⁵ Power distribution has become the fastest-growing segment of data center physical infrastructure, with busway systems expanding over 40% year-over-year.⁶ For organizations deploying AI infrastructure, PDU selection determines whether expensive GPU investments achieve full utilization or bottleneck on power delivery.

AI workloads transform PDU requirements

Traditional data centers operated at 20-30kW per rack. AI training clusters require 40-60kW racks. Large language models demand at least 70kW.⁷ Supercomputing applications for national security and AI research draw 100kW or more.⁸ The escalation fundamentally changes PDU specifications.

Higher amperage becomes mandatory. PDUs designed for high density accommodate 100A and above, with higher breaker and fuse counts delivering more power on a per-outlet basis.⁹ Standard 30A or 60A PDUs cannot support modern GPU servers regardless of other specifications.

Three-phase distribution optimizes high-power delivery. Each phase operates with its own current path, reducing stress on wiring and enabling smaller, cost-effective conductors.¹⁰ Three-phase configurations also improve power factor and reduce harmonic distortion compared to single-phase alternatives.

Temperature tolerance addresses thermal challenges. Vertiv's PowerIT PDU operates in temperatures up to 140°F (60°C) and humidity up to 95%, critical for high-density deployments where cooling struggles to maintain traditional comfort ranges.¹¹

Medium voltage distribution emerges for extreme densities. For rack layouts of 100-300kW, the most efficient approach delivers medium voltage directly to PDUs at the rack row.¹² Higher voltage distribution reduces current, enabling air cooling and lighter infrastructure than traditional approaches.¹³

High-voltage DC architectures gain traction. HVDC distribution at 600-800V reduces conversion stages and improves efficiency.¹⁴ Keeping power to the rack at 400V eliminates virtually all transmission loss compared to the 4% loss from 480V to 208V/120V step-down conversion.¹⁵

Intelligent PDU monitoring capabilities

Modern intelligent PDUs deliver far more than power distribution. They measure, analyze, and report power consumption in real time, transforming from commodity components into strategic infrastructure platforms.¹⁶

Granular power monitoring provides visibility into rack-level consumption. Intelligent PDUs offer monitoring of current (amps), voltage, power (kVA, kW), power factor, and energy consumption (kWh) to ±1% accuracy.¹⁷ The precision enables accurate capacity planning and chargeback calculations.

Power quality analysis identifies potential problems before they cause outages. Voltage, harmonics, crest factors, and power factor data reveal anomalies that could stress equipment or indicate failing components.¹⁸ Early detection prevents costly unplanned downtime.

Environmental monitoring extends beyond power. Built-in sensors track temperature and humidity at the rack level, triggering immediate alerts when conditions exceed thresholds.¹⁹ The granular visibility complements facility-level environmental systems.

DCIM integration creates unified infrastructure visibility. Intelligent PDUs feed data into Data Center Infrastructure Management systems, correlating power consumption with compute workloads, environmental conditions, and capacity utilization.²⁰ The integration enables data-driven optimization across the entire facility.

Remote management reduces operational overhead. Switched PDUs enable remote power cycling of individual outlets, reducing truck rolls for simple restart operations. The capability proves particularly valuable for edge deployments and remote facilities.

The European Union's Energy Efficiency Directive now requires comprehensive power monitoring in all new data center builds.²¹ Similar regulations in North America and Asia-Pacific compel operators to replace basic PDUs with intelligent monitoring versions.²² Regulatory requirements accelerate the transition from commodity PDUs to monitored platforms.

415V versus 480V distribution considerations

Voltage selection impacts efficiency, cost, and compatibility throughout the power chain. Different regions standardize on different voltages, but AI deployments increasingly evaluate alternatives to traditional local standards.

480V distribution represents the traditional US approach. Three-phase 480V enters data centers and converts to 208V/120V through step-down transformers.²³ The conversion causes approximately 4% transmission loss.²⁴ Some large data centers, including Google, distribute 480V AC directly to racks with three-phase rectifiers converting to DC within the rack, eliminating intermediate conversion losses.²⁵

415V distribution predominates outside the United States. US facilities can convert to 415V at the UPS level, achieving 85-90% efficiency depending on load.²⁶ The voltage enables direct 240V single-phase distribution to servers.

240V versus 120V efficiency differences compound at scale. At 240V, typical server power supplies operate at 85.5% efficiency. At 120V, efficiency drops to 82%, a full 3.5% difference.²⁷ Comparing 208V with 240V shows a 1.5% efficiency gap.²⁸ For megawatt-scale deployments, these percentage points translate to substantial power and cooling savings.

Transformer considerations favor higher voltages. A 277/480V to 240/415V step-down autotransformer measures 90% smaller and costs less than 120/208V PDU isolation transformers.²⁹ Eliminating large PDU transformers reduces cooling requirements and floor space consumption.

ABB's MegaFlex 415V UPS launched in June 2025 specifically for colocation, hybrid, hyperscale, and neocloud data centers.³⁰ The product complements ABB's 480V MegaFlex, giving operators flexible options for different deployment requirements.³¹

Organizations planning greenfield deployments should evaluate 415V distribution for efficiency gains, while brownfield upgrades may find 480V more practical given existing infrastructure.

Leading PDU manufacturers for AI workloads

The competitive landscape concentrates among a few major vendors, with Schneider Electric and Vertiv dominating global market share separated by just a tenth of a percentage point according to Dell'Oro Group.³²

Vertiv PowerIT rack PDU launched in 2025 specifically targeting AI and HPC workloads. The system provides advanced power management, flexible configurations, and enhanced internal components for reliability at scale.³³ Three-phase distribution in both 208V Delta and 240/415V WYE configurations evenly distributes electrical load across phases.³⁴ Operating temperature tolerance to 60°C and humidity tolerance to 95% address high-density deployment environments.³⁵

Schneider Electric NetShelter Rack PDU Advanced updated to support high-current power needs of AI servers. Compact vertical and horizontal models offer higher counts of dedicated circuits for efficient rack layouts.³⁶ Schneider developed a rack system specifically supporting the NVIDIA GB200 NVL72, integrating into NVIDIA's HGX and MGX ecosystems for the first time.³⁷

Server Technology (a brand of Legrand) focuses on intelligent rack PDU solutions with switched capabilities enabling granular power management. The company emphasizes efficiency for high-density deployments and offers extensive monitoring capabilities.

Raritan (also Legrand) provides intelligent PDU platforms with integrated environmental monitoring and DCIM integration capabilities. The company offers extensive documentation on power distribution optimization strategies.

Eaton competes across the full power infrastructure stack, with PDU solutions integrating into broader UPS and power management ecosystems. The company participates in the European market where PDU and PSU revenue projects to reach $20.05 billion by 2035.³⁸

Sizing PDUs for AI rack configurations

Proper PDU sizing requires understanding both peak and sustained power requirements across the equipment lifecycle.

GPU server power consumption continues escalating. Current AI servers draw 30kW compared to 8kW for conventional servers.³⁹ Next-generation systems push even higher as chip TDPs exceed 1,000W.

Redundancy configurations affect total PDU capacity requirements. N+1 or 2N redundancy doubles or more the number of PDU circuits needed. Plan capacity based on redundancy strategy rather than just equipment nameplate ratings.

Future growth headroom prevents premature infrastructure replacement. Deploying PDUs sized for current requirements risks stranded capacity when servers upgrade to higher-power models. Industry guidance suggests sizing for expected rack density growth over the deployment lifetime.

Outlet types and counts must match equipment requirements. Different GPU servers use different power inlet configurations. Verify PDU outlet types match server requirements before procurement.

Circuit allocation requires careful planning. Higher outlet counts per PDU reduce the number of units required but may concentrate failure risk. Balance consolidation against fault domain considerations.

The International Energy Agency projects data center electricity consumption surging from 415TWh in 2024 to 945TWh by 2030.⁴⁰ PDU infrastructure deployed today must scale for this trajectory.

Installation and operational considerations

Proper PDU deployment extends beyond product selection to installation practices and operational procedures.

Vertical versus horizontal mounting affects rack space utilization. Vertical PDUs in zero-U configurations preserve full rack space for equipment. Horizontal PDUs consume rack units but may simplify cable routing in certain configurations.

Cable management integration prevents airflow obstruction. PDU placement affects how power cables route through the rack. Plan PDU location alongside cable management strategy rather than treating them as separate decisions.

Phase balancing maximizes capacity utilization. Unbalanced loads across three-phase PDUs reduce available capacity and can trigger overcurrent protection on heavily loaded phases while other phases remain underutilized.

Monitoring baseline establishment enables anomaly detection. Configure intelligent PDU monitoring immediately upon deployment to establish normal operating baselines. Anomaly detection requires historical data for comparison.

Firmware management ensures security and functionality. Intelligent PDUs run firmware requiring periodic updates. Include PDU firmware in regular vulnerability management and patching processes.

Introl's global field teams deploy power infrastructure for AI installations across 257 locations, from single-rack GPU servers to 100,000-accelerator clusters. PDU selection and installation directly impact power delivery reliability and efficiency.

The power distribution evolution

PDU technology evolution continues accelerating to match AI workload demands. Liquid cooling integration adds complexity as rack PDUs must coexist with coolant distribution units. Higher voltages reduce current and simplify conductor sizing. Intelligent monitoring enables predictive maintenance and capacity optimization.

Organizations planning AI infrastructure should evaluate PDUs as strategic components rather than commodity accessories. The power distribution layer determines whether expensive compute resources receive reliable, efficient power delivery or face capacity constraints and reliability risks.

High-density PDUs with intelligent monitoring, three-phase distribution, and appropriate voltage selection form the foundation for AI-ready power infrastructure. The investment in proper power distribution compounds returns across the entire compute stack by ensuring GPUs and accelerators operate at full capacity without power-related constraints or interruptions.

References

1. Vertiv, "Data Center Trends 2025: Vertiv Predicts Industry Efforts to Support, Enable, Leverage and Regulate AI," November 2024.

2. Data Center Frontier, "Powering the AI Era: Innovations in Data Center Power Supply Design and Infrastructure," 2025.

3. Server Technology, "Driving Data Center Efficiency with High-Density Rack PDUs," 2025.

4. Globe Newswire, "Data Center Rack Power Distribution Unit (PDU) Business Report 2025-2030," December 4, 2025.

5. Globe Newswire, "Data Center Power Distribution Units (PDUs) and Power Supply Units (PSUs) Market Research 2025-2035," May 20, 2025.

6. Lightwave Online, "Schneider Electric and Vertiv dominate the data center physical infrastructure market," 2025.

7. Chatsworth Products, "Considerations for Power Distribution Units for Artificial Intelligence / GPU-Based Applications," 2025.

8. Chatsworth Products, "Considerations for PDUs," 2025.

9. Server Technology, "Driving Data Center Efficiency with High-Density Rack PDUs," 2025.

10. Raptor Power, "Understanding the Benefits of 3 Phase 415V in Data Centers," 2025.

11. Data Center Dynamics, "Vertiv launches new power distribution unit for AI data centers," 2025.

12. Voltage Correction, "Medium Voltage UPS Systems in High Density AI Data Centers," 2025.

13. insideHPC, "Adaptive Power Systems for the 100kw-Rack AI Data Center," May 2025.

14. insideHPC, "Adaptive Power Systems," May 2025.

15. 42U, "Data Center Power Topology," 2025.

16. Server Technology, "Driving Data Center Efficiency," 2025.

17. Raritan, "Manage Data Center Power Usage," 2025.

18. Server Technology, "Driving Data Center Efficiency," 2025.

19. Yosun PDU, "PDU Manufacturer Showdown The Best Power Distribution Units for Data Centers in 2025," 2025.

20. Raritan, "Manage Data Center Power Usage," 2025.

21. Business Wire, "Data Center Power Distribution Units (PDUs) and Power Supply Units (PSUs) Market Research 2025-2035," May 21, 2025.

22. Business Wire, "Data Center PDUs and PSUs Market Research 2025-2035," May 2025.

23. 42U, "Data Center Power Topology," 2025.

24. 42U, "Data Center Power Topology," 2025.

25. Encor Advisors, "Data Center Power Design: The Electrifying Guide [2025]," 2025.

26. Team Silverback, "Data Center Power Series 1 – Selecting the Right Voltage," 2025.

27. Mirus International, "415V Distribution for Green Data Centers," white paper.

28. Mirus International, "415V Distribution," white paper.

29. Mirus International, "415V Distribution," white paper.

30. ABB, "ABB launches AI-optimized 415V 3-phase UPS for large-scale data centers," June 2025.

31. ABB, "ABB launches AI-optimized 415V UPS," June 2025.

32. Lightwave Online, "Schneider Electric and Vertiv dominate," 2025.

33. Data Center Dynamics, "Vertiv launches new power distribution unit for AI data centers," 2025.

34. Data Center Dynamics, "Vertiv launches new PDU," 2025.

35. Data Center Dynamics, "Vertiv launches new PDU," 2025.

36. Digital Infra Network, "Schneider targets high-density AI challenges with new data center solutions," 2025.

37. Digital Infra Network, "Schneider targets high-density AI challenges," 2025.

38. Globe Newswire, "Europe Data Center PDUs and PSUs Market Report 2025-2035," August 13, 2025.

39. Mitsubishi Electric, "How AI in Data Centers Increases the Demand for a Reliable UPS," 2025.

40. Data Center Frontier, "High-Voltage DC Power: The Future of Data Center Power Architecture," 2025.

Key takeaways

For operations teams: - Rack densities evolved from 8.2kW average (2020) to 500-1000kW projections for AI Factory deployments - 100A+ PDUs now standard for AI; three-phase distribution mandatory; temperature tolerance to 60°C critical - Medium voltage distribution for 100-300kW racks enables air cooling; HVDC 600-800V reduces conversion stages

For procurement teams: - PDU market grows from $2.2B (2024) to $3.2B (2030) at 6.4% CAGR; busway systems expanding 40%+ YoY - Vertiv and Schneider dominate with market share separated by 0.1%; Vertiv PowerIT (2025) specifically targets AI workloads - Schneider developed rack system specifically supporting NVIDIA GB200 NVL72, integrating into HGX/MGX ecosystems

For infrastructure architects: - 415V distribution achieves 3.5% better efficiency than 120V (240V PSU = 85.5% vs 120V = 82%) - 277/480V to 240/415V autotransformers 90% smaller than 120/208V isolation transformers - Google distributes 480V AC directly to racks with three-phase rectifiers, eliminating 4% transmission loss

For finance teams: - IEA projects data center electricity consumption: 415TWh (2024) → 945TWh (2030) - EU Energy Efficiency Directive requires comprehensive power monitoring in all new builds; North America/APAC following - Intelligent PDU monitoring enables accurate capacity planning and chargeback calculations at ±1% accuracy

Squarespace Excerpt (158 characters): PDU market grows to $3.2B by 2030 as AI racks hit 100kW+. Intelligent monitoring, 415V distribution, and high-amperage designs power GPU-intensive workloads.

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