Power Electronics: The latest industrial UPS systems ensure constant power with the highest flexibility

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Home Splash—ePower FocusFebruary 3, 2015: Modern industrial UPS systems are laden with advanced features like power conditioning, swappable batteries and data line protection

By Shweta Sengar

Uninterrupted power supply (UPS) systems have become an indispensable part of any organisation’s infrastructure, given the power conditions in the country. A UPS system offers a degree of insurance or security for users who are concerned about data safety. The use of computer-based control systems in manufacturing and process control has led to the need for UPS systems in industrial facilities too. Typical applications vary from distributed programmable logic controller (PLC) based controls to absolute distributed control systems (DCS), with power requirements ranging from 3kVA to 50kVA.

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The latest in the market

Industrial UPS systems these days offer outstanding performance with constant power supply, high power efficiency and yet require a low investment. Most of the industrial UPS systems are now user friendly and offer easy to use controls. A variety of industrial UPS models are now available for diverse applications. These UPS systems offer specific input and output power requirements, and most of them are also laden with advanced features like power conditioning, swappable batteries and data line protection.

Three phase UPS systems with a wide input voltage range: Delta Power Solutions’ Ultron DPS series caters to the industrial segment. It is available in the 60–400kVA range and is scalable up to 3200kVA in parallel. This is a double conversion IGBT rectifier three-phase UPS system. With state of the art TLI (triple level inverter) and three phase PFC (power factor correction) topology, the Ultron DPS features industry leading performance of up to 96 per cent AC-AC efficiency, an input power factor of >0.99, an output power factor of up to 0.9 and a low iTHD of <3 per cent. It has an enhanced special design for battery management, swappable fans and is easy to maintain. Speaking about the innovative features of the product, Suhas Joshi, vice president, Delta Power Solutions, says, “The excellent power performance and high system availability of the Ultron DPS provides customers with the benefits of a stable power supply, high power efficiency, low capital investment and low overall operation costs. This series is available in full power ratings ranging from 60kVA to 400kVA in a single unit to fit each specific application requirement. There are three different cabinets for the Ultron DPS series with an optimised footprint. Customers can save valuable space from the series’ industry leading power density yet compact design. Being lightweight, it also reduces transportation and installation costs.”

Delta Power Solutions’ Ultron DPS’ key features include X redundancy or hot standby configuration that increases system reliability, a wide input voltage range (DPS 60~120kVA: -45 per cent ~+20 per cent; DPS 160~400kVA : -40 per cent~+20 per cent) allowing the UPS system to work in harsh electrical environments, a high AC-AC efficiency even at light load levels reducing energy loss and saving operating costs, a high input power factor (>0.99) and low input harmonic distortion (iTHD<3 per cent) that eliminates the need to have an over sized genset (and hence saving on capital investments), 38~42 battery units in one battery cabinet that optimises investments (applicable for models 160~400kVA), hot-swappable fans which reduce maintenance lead time (applicable for models 160~400kVA), and built-in manual bypass that allows zero downtime to ensure system availability even during maintenance.

SMPS technology-based UPS systems: Emerson offers a repertoire of solutions that provide reliable efficiency in the field of industrial grade UPS systems, battery chargers, inverters and rectifiers for heavy duty industrial use. Shashank Paranjpe, senior director, presales and product management, industrial systems, Emerson Network Power, informs, “Energy efficiency and reliability are key to the smooth functioning of a DC UPS power system and Emerson Network Power’s new generation of DC power products embody these features. This product portfolio is based on the UtilitySure platform, utilising SMPS (switched mode power supply) technology. This technology provides high power conversion efficiency while converting electrical power and enables us to create products that are substantially lighter and smaller in size. Due to this technology, energy consumption is minimised, resulting in reduced overheads and expenditure.”

Highlighting the key factors that differentiate Emerson’s UPS systems from other brands, Shashank Paranjpe says, “Emerson has introduced a host of new DC power system products for industrial applications in diverse segments including power generation, transmission and distribution (T&D), oil and gas, etc. One of the key products from this line is the UtilitySure power system. It is a flexible and compact power system for 24V, 48V, 110V and 220V DC critical power applications, ideal for easy deployment in power generation, T&D as well as oil and gas. It is simple to install, and is designed to reduce operating expenses and improve reliability. Models of various capacities with 90 per cent efficiency are available. This power system delivers network and financial flexibility by adapting to new technologies and architectures that improve reliability, while reducing maintenance and operating costs.”

UPS systems with isolation transfer: Makvolt Power Pvt Ltd recently introduced advance PFC online UPS system, especially for DGS&D, ATM machines and government requirements. The models that Makvolt offers are 3kVA UPS systems (48/72/96 VDC with isolation transformer) and 5kVA UPS systems (120 VDC with isolation transformer). The UPS systems are equipped with an LCD/LED display to monitor power and specifications, along with DSC based controls using free scale, a 17-nano second correction period with an in-built sensor, and an output THD of <2 per cent. They also have advanced PFC technology, an EMI/RFI noise filter and come with an in-built static bypass. Sandeep Agarwal, director, Makvolt Power Pvt Ltd, informs, “The new ST series of UPS systems have a single PCB, which is easily serviceable and has the latest protection with alarms and metering. It is also customisable as per customer requirements, i.e., the output voltage can be customised to 110V and the output frequency can be modified to 60Hz.”

Double conversion UPS systems: General Electric recently launched the TLE series of UPS systems that focus on high efficiency. They offer the latest power conversion technology that uses a three level inverter design and a multi mode architecture that makes real time decisions between premium protection mode and premium efficiency mode. The TLE UPS systems from GE are designed using GE’s Six Sigma (DFSS) technology to ensure that the products meet customer demands for dependability and other major attributes. The TLE UPS is a double conversion system, which means that the failure of the input AC does not activate the transfer switch, because the input AC is not the primary but the backup source. Therefore, during an input AC power failure, online operation results in no transfer time. TLE UPS systems offer up to 97 per cent efficiency in double conversion mode and 99 per cent efficiency in eco-mode, the highest in the class. They have a compact and sturdy design and offer front access only. Apart from these features, the industrial UPS systems from GE offer less than 5 per cent input current harmonic distortion.

MPPT based UPS: UTL UPS recently launched online PCU which is MNRE approved. The UPS is of 10kVA rating with versatile specifications. New user interface allows to control the charging current and output voltage any time with ease, when attached to a solar panel, MPPT is used to track the maximum power from the panel. The PCU works on an excellent power sharing technique used to share grid and solar in such a way that reduce your electricity consumption by up to 50 per cent. The DSP based single card (charger+inverter+MPPT) is used in the system which reduces the size of the UPS and makes it compact. The SNMP (simple network management protocol) facility helps to monitor it remotely with 30 days data logging at customer place as well.

Choosing the right product

A few key aspects should be borne in mind while investing in a power backup system. One must make sure that the product has accurate specifications with regard to technical and physical descriptions. Before zeroing in on an industrial UPS system, one should keep in mind the following important points:

  • One must thoroughly check for product efficiency. Besides being an environment-friendly green product, the UPS should also consume less power and result in substantial savings in energy bills.

  • Another extremely important aspect is the extended battery life. Even for unitary UPS systems with entry level cost differences, the long term pay back or ROI assured should be considered.

  • A good UPS system should not only support the requisite load factor, but should also go light on the power being drawn. Such systems can easily be supported by smaller DG sets, input cables and switches.

  • A reduced footprint and the use of minimal physical space should also be ensured to save on rental expenditure. It should also be easy for facility managers to monitor and control the system remotely.

  • Yet another critical aspect is the mean time to repair, or MTTR. One needs to always ensure that the system has the advanced hot swapping technology, which enables extremely quick module exchange, repair or upgradation, without any load interruptions, thereby increasing the total availability.

  • Last but not the least, is the scalability factor. Apart from power costs, the right kind of modular UPS systems also contribute a lot towards reducing the total cost of ownership, making the ROI much more attractive. One can easily curtail initial investments with the ‘pay as you grow’ format.

Apart from the above parameters, the user should focus on the availability or mean time between failures (MTBF), total cost of ownership (TCO) and adaptability of the solution. Customers should look into the vendor’s credentials as well as strong after sales record/service capabilities. They should consider additional options such as feeder level insulation monitoring and battery health monitoring, which offer an edge in optimising maintenance costs.

Boxes

Delta’s Ultron DPS series

  • IGBT rectifier three-phase UPS system

  • Triple level inverter and three-phase PFC (power factor correction)

  • 96 per cent AC-AC efficiency

  • Input power factor >0.99

  • Low iTHD <3 per cent

  • Swappable fans

Makvolt’s Advance PFC Online UPS System

  • Input power factor 0.99

  • Input current THD < 10 per cent

  • Overall efficiency > 90 per cent

  • Inbuilt isolation transfer

  • As per DGS&D specification

GE’S TLE SERIES OF UPS SYSTEMS

  • Up to 97 per cent efficiency in double conversion mode

  • 99 per cent efficiency in eco-mode

  • 0.99 input power factor

  • Less than 5 per cent input current harmonic distortion

  • High MTBF; low MTTR

Emerson’s UtilitySure power system

  • Available in 24V, 48V, 110V and 220V

  • 90 per cent efficiency

  • Silicon controlled rectifier

  • SMPS technology

UTL’s online PCU

  • DSP based single card

  • Automatic relay and static by pass

  • IP 20 protection available

  • Smart mode and auto equaliser

  • SNMP and 30 days data logging

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