Hitec UPS principles

Hitec Power Protection y UPS Academy

www.hitec-ups.com
Ride through systems Diesel UPS systems

Contents
       

Key functions of the UPS Build-up of the Hitec UPS Induction Coupling machine (IC) Power Generating Module (PGM) Hitec UPS principles UPS System y operation p (normal ( & diesel (emergency)) ( g y)) Sub components of the total UPS system UPS output measurements: doing what it should do?

Key function of the UPS

Mains

Customer

The problems
1. Spikes

The solution

The result:
7. Continuous Quality Power Uninterrupted Power Quality frequency: 50/60 Hz Quality voltage: 400/480 V Clean sine-wave

2. Frequency Variations 3. Voltage Sags 4. Outages 5. Harmonic Distortions 6. Transients

Basic build-up of the Hitec UPS

The Diesel-Generator (Genset) principle

At a utility failure a diesel engine has to take over the power supply

and that takes time .

The UPS principle

To bridge the time between the moment of utility failure and the moment the diesel engine can drive the generator

. an Induction Coupling is used to drive the generator so it can directly take over the energy supply to the load (Makes it an Un-interrupted Power Supply System (UPS))

The Induction Coupling (IC) principle

Like a battery, the induction coupling it is a device that stores energy.

In this case it stores kinetic energy via a flywheel. Enough to give the engine time for start-up and being able to deliver full power.

The Induction Coupling 2 rotors

Outer rotor with accelerating and decelerating windings

Free rotating inner rotor (flywheel) for the storage of energy

Construction of the Induction Coupling

Bearing shield Housing Outer rotor Inner rotor Fan Grease catch tray Shield & shaft Outer bearing Inner bearing

The Induction Coupling

. is an asynchronous motor.

With a rotating stator . (Outer rotor)

.. and a rotor
(Inner rotor)

IC outer rotor has two sets of windings

One to speed up the inner rotor (AC Windings).

and one to magnetically extract (regulated) the stored kinetic energy (DC Windings)

Supply for the 2 sets of windings of the induction coupling (AC & regulated DC)

Indirect, via a twin exciter that produces both the AC as the DC and then feed it in the windings (VQ type IC).

Direct, via two sets of brushes to feed AC or DC into the windings (XQ type IC).

Power Generating Module (XQ)

Induction coupling Slip-rings Generator outer rotor inner rotor t Freewheel clutch Diesel

Base frame

Power Generating Module (VQ)

Induction coupling inner rotor t Freewheel clutch Diesel

Brushless exciter Generator

outer rotor

Base frame

HITEC UPS principle

Q3 Utility OK Load Q1 Q2 Alternator in M t f Motor function ti Running 1500 / 1800 RPM @ 50 / 60 Hz

HITEC UPS principle

Q3 Utility Not OK Q1 opens Q2 Alternator direct in generating function Still running 1500 / 1800 RPM & so generating now directly 50 / 60 Hz ! (Sine wave continues) Load

HITEC UPS principle

Q3 Utility Not OK Q1 open

2 energy sources

Load Q2 Alternator in generating i f function i

Keep it running on 1500 / 1800 RPM & to generating ongoing 50 / 60 Hz !

HITEC UPS single system

Q3 Utility Q1 Diesel engine g Induction coupling Load Q2

Choke coil

Alternator lte ato

Freewheel clutch

HITEC UPS single system

Filtering / Voltage & PF improvement

Works like a band filter only 50/60 Hz will pass

Dynamic filter*; takes care of clean output sine wave. Voltage improvement*; takes care of stable output voltage. Power Factor improver*; takes care of different load types (PF/Cos) and compensates up to PF/Cos1 at the UPS input (no PF compensation needed)
*These functions are 24x365 available (UPS is running ongoing in parallel with the mains)

System operation

Speed (rpm)

Dependent system load

3n*

X
Normal Operation

Z
Diesel Operation

Time

Normal Operation
*RPM depend on system & IC type

Utility failure moment

Normal operation

Main power flow Q3 Q1 Q2 1500 RPM 50Hz 1800 RPM 60Hz

AC

Generator is running in motor mode. Reactor and generator functions as active filter & voltage stabilizer. The induction coupling keeps kinetic energy stored (AC windings energized).

3n*

n 0

Transfer from Normal into Diesel/Emergency operation

Q3 Q1 Q2 Main power flow

DC

Utility problem; Q1 opens, energy from the inner rotor goes, via the generator, to the load. The diesel engine starts up and takes over the power supply.

3n*

n 0

Diesel/Emergency operation

Synchronizing

Q3 Q1 Main power flow Q2

The speed of the engine is controlled ensuring a constant output frequency. The outer rotor of the IC is re-energized to speed up the inner rotor (AC). When utility is OK the UPS synchronizes to it.

AC

3n*

n 0

Transfer from Diesel/Emergency back into Normal operation

Main power flow Q3 Q1 Q2

AC

3n*

After the mains acceptance time** Q1 closes. The diesel engine ramps down 50 rpm and the free-wheel clutch disengages. It will continue 3 minutes for cool down purposes.
** Time depend on type of System 10-20 min.
n 0

Normal operation

Main power flow Q3 Q1 Q2 1500 RPM 50Hz 1800 RPM 60Hz

Generator is running in motor mode. Reactor and generator functions as active filter & voltage stabilizer. The induction coupling keeps kinetic energy stored (AC windings energized).

AC

3n*

n 0

Total UPS System

The sub components of the UPS System

Generator

Diesel engine

Choke coil

Switchgear Cooling system

Dicon

Induction coupling

Freewheel clutch Control panel

Diesel Engine Start

Starting is only ramping up of the diesel engine as the generator is already running. The quick start of the diesel engine takes 1 1.2 2 to 2 2.5* 5* seconds and it will deliver full power after again 5* seconds.

The engine should therefore be ongoing ready for quick starting: - hourly* pre-lubricated - ongoing pre-heated (ongoing)

* Depends on type of diesel

Diesel Engine

A gravity fed fuel system is used for the flow from the day tank to the engine (gravity works always!). For filling the day tank from the bulk tank* fuel pumps are used. Starting g redundancy y options*: p - Redundant batteries - Redundant starter motors - RSP system (makes 24 DC of the UPS 400/480 AC output voltage)
* Depends on project & diesel engine

Cooling System

UPS system needs two cooling functions: - Engine cooling (radiator). - UPS Room cooling. These functions can be integrated or via separate equipment.

Free-Wheel Clutch (GMN type)

Diesel engine

IC outer rotor

When the dieselengine speed reaches the outer rotor speed of the induction p g, the freecoupling, wheel clutch automatically engages.

Free-Wheel Clutch (Stieber type)

Outer race connected to the induction coupling Inner race connected to the diesel engine

When the dieselengine speed reaches the outer rotor speed of the induction coupling, the free-wheel clutch automatically engages.

UPS Module key panels (Analog HMI)

Unit Control Panel (UCP) Unit Reactor Panel (URP)

Main Power Board (MPB) Human Machine Interface (HMI)

UPS Module key panels (Touch Screen HMI)

Unit Control Panel (UCP) Unit Reactor Panel (URP)

Main Power Board (MPB) Human Machine Interface (HMI)

Measuring Hitec UPS performance

Utility failure with 100% load
Moment Mo e t of o mains failure Mains voltage Mains Voltage

Diesel engine RPM Output voltage 1500/1800

50/60 Hz -1% / -1,5% Hz*

Free-wheel clutch engaging

50/60 Hz line

Output frequency 1 sec. Diesel start *Specification depends on type of system & type of induction coupling

Test field example recording

All Hitec UPS modules are tested on the testfield & on site under full load condition.

50 Hz

1 = Output voltage 2 = Output frequency

1 cm = 200 ms

3 = Mains voltage 4 = Diesel speed 5 = DC current IC

UPS internal measurement function

At every utility failure, the UPSs reaction is recorded and can be used for analyzing

1 cm = 0,5 Hz

Hitec UPS principles

Hitec Power Protection y UPS Academy

www.hitec-ups.com
Ride through systems Diesel UPS systems