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POWER SUPPLY PROTECTION

TABLE OF CONTENTS
Introduction Customized power supply protection (UPS) solutions UPS Basics UPS system and main functions UPS system applications The different industrial applications and requirements GUTOR UPS technology The concept AC UPS system description AC Inverter system description DC system description Bypass transformer and stabilizer System design, features and benefits Man-Machine Interface Intelligent system ventilation UPS system configurations Single unit AC & DC Parallel Redundant AC & DC Full Dual AC & DC Battery configurations Common versus single configuration Complete system solutions More than just a product Standards & Quality Worldwide recognised standards Planning & Installation System expertise and support Batteries Getting the suitable battery type for your requirements Sizing of batteries Battery Monitoring 19 20 18 17 16 4 15 3 2 1

INTRODUCTION
CUSTOMIZED POWER SUPPLY PROTECTION (UPS) SOLUTIONS
GUTOR is a leading worldclass industrial UPS Company. The depth of our technical understanding combined with the experiences gained by working closely with customers from various industrial sectors, qualify us to provide customized solutions for uninterruptible power supply protection (UPS) of superior technical quality standards. The objective of this brochure is to guide you through the world of GUTOR UPS technology. In addition to a general overview of the main functions and important aspects of UPS systems, this brochure highlights some of the main GUTOR UPS features and benefits. We are pleased to discuss your power supply protection needs and evaluate the best possible solution. Our ultimate goal is to provide a full range of comprehensive services for as long as you require.

UPS BASICS
UPS SYSTEM AND MAIN FUNCTIONS

The continuous supply of quality power is critical to commercial and industrial process installations. A power failure, or even minor disturbances in the power supply, will interrupt the process chain and eventually result in system shutdown. This could cause substantial financial losses or even jeopardizing the safety of human lives.

The key function of UPS systems is therefore the protection of electrical power supplies to installations (also called consumers or loads), which cannot tolerate even the slightest voltage interruption or inconsistencies. Unfiltered electrical power supplied by utilities may contain harmonics, sags, spikes or other noise. Introducing one or more UPS systems along the power supply chain will effectively eliminate these kinds of disturbances. Most importantly, during power failure conditions, the UPS will bridge the critical power supply gap. In these instances, the system automatically switches to large battery banks to draw the required electrical power until mains is again available. This occurs without affecting the load performance. The size of the battery banks and eventual alternative power source (bypass, diesel power generator), depend on system and battery configurations.

Additionally, UPS systems are often installed to support the safe shutdown and reboot of critical process installations. Modern UPS systems provide auxiliary functions such as automatic monitoring, system performance testing and alarm displays.

Custom single line diagramm

UPS SYSTEM APPLICATIONS


THE DIFFERENT INDUSTRIAL APPLICATIONS AND REQUIREMENTS

Many factors must be considered when choosing a UPS system. Cost-benefit considerations oftentimes outweigh the ability to undertake the task for which the system is required. While it may be acceptable to make compromises in non-critical applications, in critical ones this could have catastrophic consequences. GUTOR UPS systems are primarily designed to meet requirements for applications in the Oil & Gas, Petrochemical, Chemical, and Power Generation industries.

Our systems are typically designed for production process plants, offshore installations, refineries, pipeline control centres, gas-gathering plants, LNG and GTL plants, or storage tanks. UPS systems ensure quality power supplies for pumps, control devices, fire-fighting systems,

emergency lighting, air conditioning and other essential equipment. We further specialize in the design of power protection solutions applied in conven-

tional and nuclear power plants, or substations. In installations such as these UPS systems guarantee quality power supply for switchgear controls, shaft-turning devices, or protection drives.

Safety qualifications For certain applications, such as in Nuclear Power Station it is imperative that UPS systems meet strict safety regulations. The GUTOR system design complies with IEEE standards for the qualification of Class 1E equipment. Where seismic qualification of our systems is required we follow the recommended practice.

GUTOR UPS TECHNOLOGY


THE CONCEPT
GUTOR UPS technology is based on the following key technical criteria:

Double Conversion: AC to DC current, by means of a 6- or 12-pulse thyristor, and DC to AC current by means of an IGBT pulse width modulated (PWM) inverter module.

Modular Design: Consists of galvanic isolated transformers; inverter-, rectifier- and static switch modules. This design offers the highest flexibility in terms of configuring input-, DC- and output voltage parameters, and power ratings (kVA). Most importantly, rectifier and inverter modules can individually be sized according to requirements. This also allows the oversizing of rectifier and inverter, on the one hand for re-charging larger batteries, or the supply of DC loads, and on the other hand to deal with any overload profile and increased short circuit current.

Highlights: Automatic monitoring and testing of system performance.

No switchover time (bypass / inverter).

Galvanic isolation.

Highest technical flexibility. Benefits: Ultimate protection of critical load. Possible paralleling of UPS systems. Extended lifetime. Ultimate security and functionality. On-Line: By contrast to off-line technology, where the load is supplied through the bypass and only in the event of a power failure the inverter is activated the GUTOR UPS inverter is continuously supplying the load. This is an important aspect especially for critical loads where even 5 10 ms switchover time from bypass to inverter could be critical. Parallel Redundant / Active Load-Sharing: Allows paralleling of two or more units whereby each unit supplies its own share of the required output power. This provides ultimate security and functionality. Consequently the lifetime is extended due to lower operation temperature.

50% Load

50% Load

Loads

AC UPS SYSTEM DESCRIPTION

AC UPS system main components include rectifier-, inverter- and static switch modules, a manual bypass switch, transformers, controller, and a man-

machine interface (front panel) with display.

Inverter Modules

Manual Bypass Switch

Static Switch Charger Module

UPS Main Cabinet Main Controller

Main Switches Bypass / Incoming Cabinet Terminals

External Connections Alarm Relay Board

AC INVERTER SYSTEM DESCRIPTION

AC Inverter system main components include inverter-, static switch modules, and a manual bypass switch, transformers, a controller, and a man-machine interface (front panel with display).

Inverter module GUTOR uses pulse-widthmodulated (PWM) inverter technology with IGBTs. This inverter type can be run in parallel of up to 9 inverter units, with active load sharing.

PWM IGBT Inverter


+

DC Input from Rectifier and/or Battery +

Output

Manual Bypass Switch Inverter Modules

Static Switch

Main Switches Inverter Main Cabinet Main Controller Bypass / Incoming Cabinet

Terminals External Connections

DC SYSTEM DESCRIPTION

DC Rectifier / battery charger system main components include, transformers, charger module, a controller, and a man-machine interface (front panel with display).

6-pulse / 12-pulse rectifier module Its function is to rectify AC to DC current. It is designed in such a way that it can achieve boost voltage for a fast charging of the batteries and finally supplying the necessary

current to the inverter, even if the mains input voltage is at a minimum of 10% of the nominal value. By applying a 12-pulse unit the mains current distortion can be reduced by more than 60%.

Rectifier 6-Pulse Configuration

Rectifier 12-Pulse Configuration

+ 0 Mains Mains current distortion ~28%


o

30

DC-Load/Inverter +

Charger Module

Ventilation

Charger Main Cabinet

Distribution Cabinet Distribution

BYPASS

When a system is in bypass mode, the load is supplied directly by the bypass mains. The switchover from normal to bypass operation could be performed manually, or in case the power supplied by the inverter becomes

insufficient, it would occur automatically without disturbing the loads.

BYPASS TRANSFORMER AND STABILIZER

When differences exist in input and output voltage in the bypass mains, some systems may contain a bypass transformer or stabilizer. The transformer adapts the input to the output voltage; the stabilizer

compensates the input mains variations and keeps the output voltage stable.

Typical installation of high power stabilizer

Typical installation of small power stabilizer

SYSTEM DESIGN, FEATURES AND BENEFITS

GUTOR UPS technology is designed to respond to system functionality, safety and reliability our customers main concerns. It offers a lot of flexibility in system designs and in complying with customers

specific technical specifications. We build all our products in accordance with international and national recognized standards and guarantee top quality standard with ISO 9001: 2000.

Some of the main system design features and benefits are as follows:

Clear system operation and controlling of system function.

Safe operation and maintenance.

High protection against weather influences and harsh environment.

Highest system availability and reliability.

Modular design

System design that allows access to all components from the front and top of the cabinet. In typical GUTOR system designs, a separate safety disconnect cabinet houses the input circuit breaker and the manual bypass switch. For easy maintenance some of the components are mounted on sliding drawers, or hinged structure parts.

High integrated control logic

All systems are equipped with microprocessor electronics (controller), which offer digital processing and setting of all parameters. To ensure a reliable operation, two independent sources, the mains and the battery power the controller.

MAN-MACHINE INTERFACE
GUTOR AC and DC systems are equipped with a comprehensive front panel, a flexible manmachine interface, which displays and facilitates the systems parameter settings and monitoring. This front panel is divided into four main sections:

1. The user-specific mimic


diagram showing the systems current operation status, indicating which system part is supplying the load at the moment and which is in standby mode.

2. Operation for turning

on and off the system and a lamp test button.

3. The display unit

consists of a LC display showing Event log Alarm list Measurement Operational modes, an alarm LED, an acoustic alarm and a keypad.

4. The alarm indication

panel contains LEDs which signal specific alarm occurrences.

INTELLIGENT SYSTEM VENTILATION

Independent of requirements, we offer N+1 redundant ventilation concept. In case one fan fails the remaining fans are sufficient for the cooling of the entire system. Additionally, by means of an internal speed sensor, the rotation of each individual fan is monitored. In the event the number of rotations falls below the pre-set value, an alarm is signaled. The fans can be exchanged during normal operation without any danger to personnel and load.

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UPS SYSTEM CONFIGURATIONS

GUTOR provides a range of UPS system configurations that suit the respective load types. We group the various load types into three major categories.

Typical load types:

AC Linear Type A Type B


~ ~ =
M

Unlinear Type C

= ~ =

AC 1 or 3 phase motors Passive load Various

Power supply with one single input Drives

Power supply with dual inputs for AC

Typical load types:

DC Linear Type A Type B


= = =
M

Unlinear Type C

= = =

DC motors DC loads

Power supply with one single input

Power supply with dual inputs for DC

Total reliability of an installation depend on:

Up-stream configuration, meaning the number of up-stream sources.

UPS system configuration.

Down-stream design, meaning the redundancy of the consumer side.

Lets look at some specific UPS system configurations and their characteristics in relation to the respective load types.

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AC Unit basic components: Rectifier- and Inverter modules. Batteries. Static bypass switches. Manual bypass. Characteristics: Preferable for A+B load types.

Single Unit Configuration

LOAD

BYPASS MAINS STATIC SWITCHES EN

MANUAL BYPASS SWITCH Q050


BYPASS TEST AUTO

RECTIFIER
RECTIFIER INVERTER

MAINS
MAINS EA

C
BATTERY

BATTERY

DC Unit basic components: Rectifier module. Batteries. Characteristics: Preferable for A+B load types.

Single Unit Configuration

LOAD

B
RECTIFIER

MAINS

C
BATTERY

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AC Unit basic components: Rectifier- and Inverter modules. Common, or individual batteries. Static bypass switches. Common manual bypass. Characteristics: Preferable for A+B load types. Highest reliability and system availability. Load sharing facility, meaning that each unit supplies its own share of total output. Redundant. High MTBF. High overload capability. Up to 9 units in parallel operation for higher performance.

Parallel Redundant Configuration

LOAD
MANUAL BYPASS SWITCH Q050

BYPASS MAINS

STATIC SWITCHES EN RECTIFIER 1 MAINS 1 INVERTER 1

BYPASS TEST AUTO

B
EA

RECTIFIER

MAINS
MAINS 2

BATTERY 1 RECTIFIER 2

BATTERY 2 INVERTER 2

EN

C
EA

BATTERY

DC Unit basic components: Rectifier module. Common, or individual batteries. Characteristics: Preferable for A+B load types, in particular for ultimate reliability and availability requirements. Load sharing facility, meaning that each unit supplies its own share of total output. More units in parallel operation for higher performance.

Parallel Redundant Configuration

LOAD
RECTIFIER 1

MAINS 1

BATTERY 1
RECTIFIER 2

MAINS 2

C
BATTERY 2

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AC Unit basic components: Rectifier- and Inverter modules. Common, or individual batteries. Static bypass switches. Manual bypass. Characteristics: Preferable for C load types.

Full Dual Configuration


MANUAL BYPASS SWITCH Q050
BYPASS TEST AUTO

BYPASS MAINS STATIC SWITCHES EN


RECTIFIER INVERTER

LOAD

A B C

MAINS EA

BATTERY MANUAL BYPASS SWITCH Q050


BYPASS TEST AUTO

BYPASS MAINS STATIC SWITCHES EN


RECTIFIER INVERTER

A B

MAINS EA

BATTERY

DC Unit basic components: Rectifier module. Individual batteries. Characteristics: Individual, separate unit set-up. Preferable for C load types.

Full Dual Configuration

LOAD

A
RECTIFIER

MAINS

B
BATTERY

MAINS
RECTIFIER

A B

MAINS

BATTERY

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BATTERY CONFIGURATIONS
For Parallel / Redundant and Full Dual UPS system configurations, where two and more units are combined, a common battery configuration is possible. While on one hand this configuration offers space and cost advantages, on the other, the same could be a common failure point. A breakdown of the DC circuit in one UPS unit influences the DC circuit of the combined unit.

Mains
+

Load

Short-circuit in the DCcircuit in one unit has an influence in the DC-circuit of the second unit

Mains
+

Load

Shortcircuit Common Batteries

Mains
+

Load

Short-circuit in the DCcircuit in one unit has no influence in the DC- circuit of the second unit

With this configuration the same arguments like those mentioned above, such as higher battery costs, apply. In this way, the risk of a common failure point in the DC circuit can be avoided.

Mains
+

Load

Shortcircuit Individual Batteries

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COMPLETE SYSTEM SOLUTIONS


MORE THAN JUST A PRODUCT
GUTOR provides complete power supply protection solutions. These include consulting during early stage of a project, engineering, assembly, testing, commissioning of the system(s) and batteries. Most importantly, we are committed to a reliable long term after sales service.

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STANDARDS & QUALITY


WORLDWIDE RECOGNISED STANDARDS
GUTOR supplies products that are designed and manufactured based on recognised worldwide technical and safety standards, such as EN, IEC, IEEE, VDE, SEV, NEMA, ANSI, CSA, UL, FCC. We guarantee quality assurance by means of internal and external controls conducted by our quality management and Bureau Veritas our external auditor. In addition, our systems and processes have undergone customer assurance programs to assure qualification for special applications. Available reports are accessible to our customers and inspectors.

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PLANNING & INSTALLATION


SYSTEM EXPERTISE AND SUPPORT
When planning or installing an UPS system, GUTORs Sales, Engineering and Service teams offer their expertise and support. There are a few important aspects that must be considered, such as:

Safety regulations

IP protection

Placing of system

Cable inlet

Ventilation

Earthing

Fuse coordination (Selectivity)

Connections

Detailed recommendations and instructions including maintenance are provided in customized operation instruction manuals.

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BATTERIES
GETTING THE SUITABLE BATTERY TYPE FOR YOUR REQUIREMENTS
Batteries are a key element in the concept of the UPS power protection solution package. They are used to store the energy required to feed the load (Inverter) during a mains failure. The choice of battery type is therefore critical. GUTOR has many years of experience in working closely with well-known battery manufacturers, advising and sizing optimal batteries for various applications. GUTOR systems are designed for Lead Acid as well as Nickel-Cadmium battery types.

SIZING OF BATTERIES
GUTOR advises and supports customers with issues related to sizing of all sorts of batteries. We size batteries for individual load profiles, according to IEEE standards.

BATTERY MONITORING

In case of a power failure it is crucial that the back-up batteries are in optimal working condition. Battery monitoring is an effective way to ensure their good performance and full capacity. Ultimately monitoring facilities extend availability of the entire installation.

GUTOR systems provide standard built-in capacity test facility for safe discharge and load testing of the batteries. This can be manually initialised through keypad commands on the front panel. When the system is initialised, it switches to battery operation

mode while the rectifier is kept on stand-by for immediate restart if necessary. The total discharge time is recorded in the system for statistic purposes.

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Optional GUTOR provides an (ABM) Advanced Battery Monitoring that can be integrated in all systems. Compared to above capacity test facility, ABM offers various advantages:

Performance & Capacity testing of battery.

Manual or programmed automatic initialisation possibility.

More detailed monitoring Estimated battery back-up time according to actual load Total battery voltage.

Detailed recording for statistic purposes.

Higher safety for the system as only 25% discharge of the total battery capacity is required.

Built in Battery Monitoring and Testing Facilities ABM

VBAT
VBAT at 25% of expected Battery back-up time VBAT at 50% of expected Battery back-up time

Advanced Battery Monitor

Ex. 2

Ex. 1

= Expected discharge curves

VBAT at 75% of expected Battery back-up time

At 10% load At 10% load

Load = 100% 90% 75%

50%

10%

Expected Battery back-up time

Example 1: Battery weak: VBAT falls below VBAT 25% time before 25% of the time is reached Example 2: Battery defective: VBAT falls below VBAT 50% time before 25% of the time is reached

Upon request GUTOR provides advice to customers, and installs third party battery monitoring facilities.

These offer individual, or cell monitoring (lead acid battery types only). Compared to GUTORs ABM, these

facilities generally require additional equipment and engineering and as a result are more costly.

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GUTOR offices:

Headquarters GUTOR Electronic Ltd Hardstrasse 72 74 CH-5430 Wettingen Switzerland Phone: +41 (0)56 437 34 34 Fax: +41 (0)56 437 34 44 e-mail: gutor.info@apcc.com www.gutor.com

Asia-Pacific GUTOR Electronic Asia Pacific Sdn. Bhd. 6th Floor, Wisma Genting Jalan Sultan Ismail 50250 Kuala Lumpur Phone: +603 2161 3440 Fax: +603 2161 3441 e-mail: gutor.asia-pacific@apcc.com www.gutor.com

Malaysia

North America GUTOR North America 40 Catamore Blvd. 02914 East Providence RI USA Phone: +1 (401) 435 9800, ext 6638 Fax: +1 (888) 726 8448 e-mail: gutor.usa@apcc.com www.gutor.com
410.126GB1

Representative offices in Brazil, Emirates, Germany, India, Saudi Arabia