GE Digital Energy

Power Quality

UPS Application Guide

Digital Energy Uninterruptible Power Supply

19 EMERGENCY GENERATOR

GE Consumer & Industrial

General Electric Company
CH 6595 Riazzino (Locarno)
Switzerland
T +41 (0)91 / 850 51 51
F +41 (0)91 / 850 51 44
www.gedigitalenergy.com

Title:

EMERGENCY GENERATOR

Date of issue:

November 2008

File name:

APG_019_GENERAT_XGB_V010

Version:

1.0

Up-dating
Revision

Concerns

Date

Table of contents

Page

19 EMERGENCY GENERATOR ........................................................................................................................................................... 1

19.1
19.2
19.3
19.4
19.5
19.6
19.7

INTRODUCTION......................................................................................................................................................................................3
UPS AND EMERGENCY GENERATOR.............................................................................................................................................4
LOAD STEP................................................................................................................................................................................................4
FREQUENCY SYNCHRONIZATION...................................................................................................................................................4
BATTERY CHARGING ............................................................................................................................................................................4
SUMMARIZING........................................................................................................................................................................................4
GENERATOR SIZING .............................................................................................................................................................................5
19.7.1
19.7.2
19.7.3
19.7.4

Genset sizing example 1 (SG Series S1 Thyristor rect.) ........................................................................................................ 5

Genset sizing example 2 (SG Series S1 IGBT rect.) ................................................................................................................ 6
Genset sizing example 3 (SP500kVA vs SP500kVA with DCU) .......................................................................................... 6
Example UPS sizing ............................................................................................................................................................................. 7

COPYRIGHT 2008 by GE Consumer & Industrial

Data subject to change without prior notice.
All brands and product names are Trademarks or Registered Trademarks of their respective owners.
Reproduction only upon written consent by GE.

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19.1 INTRODUCTION
In many installations an engine generator set is used to supply either non-critical load and/or UPS
system. In this case the required batterys back-up time, in the event of a mains outage, could be only
few minutes. There is no general rule, but a minimal backup time should be ca. 10 minutes in order to
allow, even manual, start of the EG.
The solution with an EG will reduce the investment in large batteries, nevertheless, a careful analysis of
the specific characteristics of the installation it is recommendable in order to have the best
price/reliability compromise and to eliminate possible problems that could arise when a UPS and an
engine generator are put together in a system.
An Emergency Generator (EG) can be considered as a separated electrical energy source, which does
not comply with standard rules EN/IEC 61000-2-4. Furthermore we are confronted with the case where
the Mains has an high impedance and a relatively low short circuit power.
The output voltage of an EG depends on voltage regulation system of its alternator, which senses the
output voltage and compares the value with a reference value. If the load applied to an EG generate a
distortion, this would effect the voltage regulators.
The current harmonics, generated by non linear loads, flowing in the line impedance generates voltage
harmonics, which added to the fundamental wave, generates the voltage distortion.
From this consideration it is evident that all non linear loads, like the UPSs Rectifier, or SMPS which can
have a high harmonics distortion can cause serious EG operating problems like instability in the EG
regulation and overheating in the EG alternator windings.
Attention should be paid to the Sub-transient reactance (Xd) of the EG; its value varies between 10%
and 30%, depending of EG type. It is convenient to operate with EG which have the lowest possible Xdvalue, since the voltage distortion caused by current harmonics depends directly on this value.
It follows that in order to maintain the voltage distortion low, it is necessary that:
a)-THD (Total Harmonics Distortion) currents generated by non linear loads shall be low.
b)-The sub transient reactance Xd of the EG should be < 15%. (For good EG is 8 to 12%)
If points a) and b) are not satisfied the possibility to reduce the voltage distortion will be by over-sizing
the EG, so that it is only partly utilized.

Xd

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19.2 UPS AND EMERGENCY GENERATOR

If in the electrical installation an EG is used to supply a UPS, this could give rise problems which do not
arise when they are installed separately. When there are problems becomes difficult to establish which
of the two is the case. UPS manufacturer may say the UPS system is working perfectly and the problem
is the EG. The EG manufacturer may say in turn that the problem is related to the loads and there is
nothing that can be done with the EG.
The ability of a UPS and an EG to operate properly together, requires special consideration concerning
their compatibility.
GEs long standing experience, have identified the following common problems and relative solutions
when interfacing UPS and EG.
As previously mentioned, UPSs Rectifiers generate current harmonics, which flowing through the line
and EG impedances will cause voltage distortion.

19.3 LOAD STEP

When the EG is on, the instantaneous application of the load to the EG, result in high inrush currents
which can cause voltage and frequency swings. To avoid such problems, GEs UPS has a soft start
system so that the power draw from the UPSs Rectifier can gradually be applied to the EG. The power
walk in is ca. 30 sec.

19.4 FREQUENCY SYNCHRONIZATION

EG have a limitation on how closely and how fast they can control frequency response due to sudden
changing loads. On the other hand the frequency tolerance to synchronize to bypass, so that the critical
load can be transferred to EG, can be much tighter. The result would be a continuous alarm: UPS not
synchronized. Therefore a UPS system shall have the possibility to block the synchronization, modify
the Slew Rate and/or to enlarge the synchronization window if the critical load would accept a wider
frequency tolerance.

19.5 BATTERY CHARGING

The electrical energy produced by an EG is expensive. In UPS systems with large battery, it would be
worth to recharge the battery whit the electrical mains. Therefore the UPS shall have the possibility to
block the batterys charging when the Rectifier draw energy from an EG.

19.6 SUMMARIZING
In a system which includes UPS and EG a careful analysis should be made considering the electrical
installation and the equipments compatibility.
1) UPS might have:
a) Soft start system.
b) Different solutions to reduce the harmonics.
c) Possibility, via bypass, to block the synchronization with EG.
d) Possibility to automatically adapt the frequency slew rate.
e) Possibility to block the recharging of the battery.
2) EG might have :
a) Power rating able to supply the UPS, other loads and a certain power reserve
b) Small sub transient (<12%) reactance to ensure low voltage distortion and not to
oversize significantly the EG.

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3) Cables might be sized considering currents harmonics and if the cables length is significant a voltage
drops of 5% should be considered for the EG output nominal voltage.
4) For large installation must also to verify whether compensating power factor capacitors are installed.
These capacitors form a resonant circuit with the mains a resonant circuit with one or more harmonics
generating a distortion.

19.7 GENERATOR SIZING

The following information are useful to determine the size of an EG by means of its sub transient
reactance Xd, the acceptable voltage distortion d and Rectifier input power. (Rectifier input power is
ca. 10% more than UPS nominal power)
Note: Norm EC/IEC 61000-2-2 allowed max. 8% THD voltage distortion.
However, it is advisable to contact the EG supplier for the compatibility of the EG and the UPS system
and other loads, if any, if the size of the EG is less than 2 times the applicable loads.
A simplify and indicative formula to calculate the size of a GenSet is the following.
PG = PR * C * Xd / d
where
GenSet power;
- PG
- PR
Rectifier input power;
- Xd GenSet sub-transient reactance;
-d
acceptable THDv voltage distortion at GenSet terminals;
-C
constant, which value depends from the number of rectifier pulses and the total line impedance
of the electrical system. Extrapolate values:
thyristor rectifier
C= 1.3 to 1.6
Clean Input Module
C= 0.8 to 1
Given the GenSet, the formula can be used to calculate the maximum UPS applicable
PR = PG *d /(C * Xd)
An indicative evaluation of GenSet size related to UPS rectifier power is as follows:
6-pulse rectifier
PG = 2.5 ~ 3 times PR
CIM Clean Input Module
PG = 1.5 ~ 2 times PR

19.7.1

Genset sizing example 1 (SG Series S1 Thyristor rect.)

Project data
UPS type
UPS nominal power
Rectifier input power factor
UPS efficiency
Acceptable voltage distortion
GenSet sub-transient reactance

SG-CE S1 thyristor rect.

300kVA
PFrect = 0,8
EffUPS = 93,3%
d = 8%
Xd = 12%

GenSet sizing

Load power
Load power factor
Load active power
Rectifier input active power
Rectifier input apparent power
GenSet sizing 6 pulses rectifier configuration
GenSet oversize (related to UPS load)
Modifications reserved

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Sload = 300kVA
PFload = 0,8
Pload = Sload x PFload = 300 x 0,8 = 240kW
Prect = Pload / EffUPS = 240 / 0,933 = 257,2 kW
Srect = Prect / Pfrect = 257,2 / 0,80 = 321,5 kVA
SGenSet = Srect x C x Xd / d = 319,1 x 1,5 x 0,12 / 0,08
= 723kVA
SGenSet / Sload = 723 / 300 = 2,4 240%

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19.7.2

Genset sizing example 2 (SG Series S1 IGBT rect.)

Project data
UPS type
UPS nominal power
Rectifier input power factor
UPS efficiency
Acceptable voltage distortion
GenSet sub-transient reactance

SG-CE S1 IGBT rect.

300kVA
PFrect = 0,99
EffUPS = 92,3%
d = 8%
Xd = 12%

GenSet sizing

Load power
Load power factor
Load active power
Rectifier input active power
Rectifier input apparent power
GenSet sizing IGBT rectifier configuration
GenSet oversize (related to UPS load)

Sload = 300kVA
PFload = 0,8
Pload = Sload x PFload = 300 x 0,8 = 240kW
Prect = Pload / EffUPS = 240 / 0,923 = 260 kW
Srect = Prect / Pfrect = 260 / 0,99 = 262,7 kVA
SGenSet = Srect x C x Xd / d = 262,7 x 0,85 x 0,12 /
0,08 = 334,8kVA
SGenSet / Sload = 334,8 / 300 = 1,11 111%

Note: SG-CE Series Clean Input Module configuration has a double benefit effect on GenSet sizing
respect to a traditional thyristors rectifier:
- higher rectifier input power factor 0.99 (respect to 0.8)
- lower harmonics contents, that means a C factor lower (0.8-1) respect to thyristor
rectifier (1.3-1.6)

19.7.3

Genset sizing example 3 (SP500kVA vs SP500kVA with DCU)

Project data
UPS type
UPS nominal power
Rectifier input power factor
UPS efficiency
Acceptable voltage distortion
GenSet sub-transient reactance

SitePro 500kVA 12pulses rectifier

500kVA
PFrect = 0,8
EffUPS = 90,1%
d = 8%
Xd = 12%

GenSet sizing

Load power
Load power factor
Load active power
Rectifier input active power
Rectifier input apparent power
GenSet sizing IGBT rectifier configuration
GenSet oversize (related to UPS load)

Modifications reserved

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Sload = 500kVA
PFload = 0,8
Pload = Sload x PFload = 500 x 0,8 = 400kW
Prect = Pload / EffUPS = 400 / 0,901 = 444 kW
Srect = Prect / Pfrect = 444 / 0,8 = 555 kVA
SGenSet = Srect x C x Xd / d = 555 x 0,85 x 0,12 / 0,08
= 707,5kVA
SGenSet / Sload = 707,5 / 500 = 1,41 141%

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UPS type
UPS nominal power
Rectifier input power factor
UPS efficiency
Acceptable voltage distortion
GenSet sub-transient reactance

SitePro 500kVA 12pulses rectifier with DCU

500kVA
PFrect = 0,98
EffUPS = 89,7%
d = 8%
Xd = 12%

GenSet sizing

Load power
Load power factor
Load active power
Rectifier input active power
Rectifier input apparent power
GenSet sizing IGBT rectifier configuration
GenSet oversize (related to UPS load)

19.7.4

Sload = 500kVA
PFload = 0,8
Pload = Sload x PFload = 500 x 0,8 = 400kW
Prect = Pload / EffUPS = 400 / 0,897 = 445.9 kW
Srect = Prect / Pfrect = 445,9 / 0,98 = 455 kVA
SGenSet = Srect x C x Xd / d = 455 x 0,85 x 0,12 / 0,08
= 580,12kVA
SGenSet / Sload = 580,12 / 500 = 1,16 116%

Example UPS sizing

Project data
GenSet nominal power
UPS efficiency
Acceptable voltage distorsion
GenSet sub-transient reactance

300kVA
92%
d = 8%
Xd = 15%

UPS sizing
rectifier sizing 6 pulses rectifier configuration PR = PG x d / (C x Xd) = 300 x 0,08/(1,5 x 0,15) = 107 kVA
UPSsize S=PR / efficiency = 107 / 0,92 = 116kVA SGSeries 120kVA
rectifier sizing IGBT rectifier configuration
PR = PG x d / (C x Xd) = 300 x 0,08/(0,9 x 0,15) = 178 kVA
UPSsize S=PR / efficiency = 178 / 0,92 = 193kVA SGSeries 200kVA

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