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UNIBLOCK UBTD Diesel Rotary UPSNothing protects quite like Pillerpiller.com
UNIBLOCK UBTD Piller headquarters, Osterode, Germany.About PillerManufacturing in a state-of-the art facility whereFounded in Hamburg, Germany over 100 yearsall products can be seen in the making, from rawobligation to end users to develop a technicalago by Anton Piller, the company has a long historymaterial through to finished goods. In 2016 Pillersolution which minimises risk whilst optimisingin the manufacturing of exceptionally high qualityPower Systems Inc., the US subsidiary of Pillerwhole life costs. At the same time, the finalelectrical machines and power quality equipment.Group GmbH, acquired the business and assets ofsolution must be practical for maintenance andActive Power Inc., a US kinetic energy storageversatile enough to be future proofed.Today, Piller is a world leader and innovator in anumber of power protection technologies,specialising in UPS systems for ‘mission critical’applications and Frequency Converters for AircraftUBTD has the highest design flexibility:n Low and medium voltage systemsn Ride-through energy from batteries orkinetic storagen Cooling by air or chilled watern Containerised solutionsn Delayed or instant diesel startingn Sophisticated load-dependentmanagement optionsUK based engineering and industrial group,Langley Holdings PLC. (www.langleyholdings.com).Ground Power amongst other uses. For the pastPower around the clock, around the world30 years, the company has designed andPower quality varies dramatically around the world.manufactured static technology products along-In some regions, adverse weather leads to regularside its rotary counterparts, giving it a uniquepower supply disturbances and total failures. Inposition with widespread specialist capabilitiesothers, poor infrastructure causes voltage drops,for today’s power protection clients.frequency instability and outages. In addition, thePiller UPS systems are found in colocation datacentres, financial institutions, broadcasting, telecommunication networks, airports, healthcarefacilities, continuous process production sites andapplications where high quality power is paramount.The new Piller UNIBLOCK UBTD family is exactlythat kind of UPS, combining state of the art machinetechnology and electronics to deliver outstandingreliability, efficiency, flexibility and performance.Introducing the UNIBLOCK UBTD The UBTD is unlike any other UPS. Consistingof a special combination of proprietary motorgenerator and choke, this UPS provides a veryelectrical characteristics of loads place a varietysimple and highly reliable uninterruptible powerof demands on the power source.solution with exceptionally high efficiencies.For industrial applications, there will often beThe technology employed provides an extremelyextremely high power requirements spread acrossrobust, small footprint, high power solution designedlarge sites, rapidly changing high current loads orthe need for long term outage support. Not only that,to give over 20 years of dependable operation.The UBTD is available in single module sizesPiller Frequency Converters and related productsownership and running costs of any solutionare prevalent in both military and civil applications,from 500kW to 2700kW with options available inhave to be factored in to the manufacturing orproviding 400Hz ground power at airports,terms of energy storage and diesel engineprocessing costs.thereby offering versatility to meet the specificIT applications like data centres, on the other hand,often have a different focus, with loads that areconditions and load requirements. With theUNIBLOCK UBTD multiple system configurationsless dynamic but where performance specificationsare readily possible. Paralleling is simple, modularSince 1919, Osterode in Germany has been theare more precise and high operational efficiencyexpansion is easy and there are solutions forhome of Piller Research, Development andcombined with maximum uptime is paramount.every size of installation.50/60Hz ship-to-shore supplies in ports and onboard power systems for both submarine andsurface vessels.2specialist. Piller Group GmbH is a division of theWhatever the situation, facility designers have an
Mission Critical PowerPrinciple of OperationThe UNIBLOCK machine’s motor and generatorSystem ReliabilityUBTD Diesel Rotary UPSwindings share a common stator and a singleA design free of power capacitors eliminates thePower Quality ImprovementThe UBTD will compensate for the supply of verycombines all the benefits of a rotary UPS with abrushless rotor to provide a highly compactcommon failure component generally found in staticlow input voltages, including voltage sags to 50% ofdouble winding machine with unique electricalUPS. The durable rotary machine technology isnominal voltage, without disconnection. It cancharacteristics. The combination of special electricfar less sensitive to damage from overload andprotect against brownouts to -30% without evensteel and combined stator windings gives rise toother electrical disturbances and uses no brushes,having to use the ride-through stored energy.a machine with exceptionally high efficiency whilstslip rings or complex bearing arrangements.The UNIBLOCK diesel engine in one integrated unit.The system consists of the UNIBLOCK motorgenerator (MG) connected via a free wheel clutchto a diesel engine, all mounted on a single shortbase frame. The load is normally fed via anisolating and coupling choke connected to theutility supply. The choke has a second tappedconnection to the motor-generator. In the eventof short interruptions or complete outages, theload is supported initially by a ride-through sourcewhich can be either a conventional battery systemor a Piller POWERBRIDGE electrically-coupledkinetic energy store – alternatives unique to thePiller design and providing the longest ride-throughexhibiting the sub-transient reactance requiredfor low harmonic distortion and high fault clearingcapacity. An incorporated damper cage reducesharmonics and the standard bearing designensures long operational performance with minimalmaintenance. The machine is manufactured andbalanced by hand at the Piller factory to ensureextremely long service life.The unit easily handles 100% non-linear loads asThe power electronics employ rugged semi-well as 100% step loads while maintaining a stableconductor technology with no need for internaloutput. Acting as a bi-directional filter inside thedevice paralleling or multiple power capacitors.UPS, the choke eliminates the passage of nearly allBypass operation is not required for any aspectharmonics between load and source.of the UPS function and in most cases, electriccooling fans are eliminated by using the impellerof the UNIBLOCK machine for the systemcooling. All of these factors combine to provide aUPS which exhibits a level of reliability that cannotBypassbe matched by other technologies.Coupling Choketimes available in the market. With the load safelysupported, the diesel engine is then given acommand to start. Once up to speed, the systemhands over the long-term support of the load toBypassCoupling ChokeM/Gthe engine by seamlessly engaging the clutch.UNIBLOCK The UNIBLOCK Motor-GeneratorAt the heart of every Piller Rotary UPS lies thepre-eminent UNIBLOCK synchronous motor-M/Ggenerator with its unique low-distortion, highfault-clearing characteristics.DieselEngineBatteryPOWERBRIDGE UNIBLOCK UBTD with POWERBRIDGE kinetic energy store.UBTD with external battery ride-through.3
UNIBLOCK UBTD Power Factor Correctionsupply transformer impedances, ensuring fault-Power factor correction is automatic with theUBTD . The MG and choke combinationclearing current can be generated internally bythe UPS. This capability represents a stepcompensates for poor power factor loads so thatimprovement in fault tolerance of the power systemthe utility sees near unity across all load levels.when compared for example, to a conventionalThis means no electricity tariff penalties needstatic UPS solution.apply and additional power factor correction unitsare not required.Simple MaintenanceNothing in the standard UBTD design requiresFault Handlingoff-site refurbishment and the maintenanceThe UBTD is inherently capable of clearing shortrequirements are less than most alternativecircuit faults by virtue of extremely low sub-transienttopologies, with no power capacitors or fans toreactance, that approximates towards normalbe periodically changed. Life expectancy of theUNIBLOCK easily exceeds 20 years.Motor and Generator Windingsin a common StatorCommon Rotorwith Damper windingBrushlessExcitationBearing4System FanBearingUNIBLOCK UBTD featuresn Single machines sized 500kWup to 2700kWn Paralleling up to 40MWn Higher reliability than other technologiesn Highest partial and full load efficiencieswith energy store connectedn Total design flexibilityn Medium and low voltage optionsn Battery or kinetic energy store versionsn Typically 3 times longer bridging timefrom the POWERBRIDGE compared withother UPSn Fastest recharge time withPOWERBRIDGE n Wide leading and lagging load powerfactor without de-ratingn Inherent fault clearing ability fordownstream short circuitsn Virtual unity input power factorn 99% input/output harmonic isolationn Small footprint and high power densityn Simple maintenance requirements
Energy storage solutionsPOWERBRIDGE Optionreduces forces on the main bearings, resulting inPiller’s electrically-connected kinetic energy storageextremely high efficiency. This also serves tooption offers designers the chance to save spaceextend the bearing life ensuring many years ofand maximise power density per unit.continuous operation.The POWERBRIDGE comprises a vertically-A vertically mounted flywheel and generator utilisingmounted synchronous generator whose rotor ismagnetic bearing technology, the POWERBRIDGE connected to a flywheel to provide the energyis available in a number of sizes for different powerstorage. Whenever stored energy is needed, it isratings and ride-through autonomy.discharged though the generator into a converterstage that ensures a stable frequency into theUNIBLOCK motor-generator. Recharge workssimilarly in the opposite direction.With a POWERBRIDGE , stored energy levelsBattery OptionThe Piller UNIBLOCK UBTD is also availablewith an option where batteries are used toprovide the ride-through energy. While theelectrical efficiency of a battery solution is superiorare guaranteed, air-conditioned battery roomsto any equivalent kinetic energy solution, there iscan be avoided and there is no environmentala trade off against space and other key factors.disposal issue to manage in the future.Significantly, a POWERBRIDGE can absorbenergy at the same rate as it can dissipate andHowever, the longer and customised autonomyof batteries offers the advantage of further limitingdiesel engine starts which may be required incertain applications.Top bearingstorage solution can equal this. This capabilityThe UNIBLOCK system is extremely battery-Brushless excitationacts as a cushion for the engine so as to providefriendly, helping to maximise battery serviceunequalled frequency stability under dynamic loadlife and reduce costs as the batteries are notconditions. Magnetic-lift technology significantlysubject to constant harmful DC ripple currentsFlywheelfrom rectifier-inverter operation.Bottom bearingcan do so on an indefinite basis. No other electricalMain machine5
Other design solutionsWater-cooled benefits:n Higher efficiency in the plant roomn Capable of operation in harshenvironmentsn Reduced investment costsn Lower operating costsn Smaller space requirementn Quieter operationUNIBLOCK UBTD Water-Cooled OptionThe UBTD can be naturally cooled with theair cooling circuit that passes via a heat exchangerUNIBLOCK UBTD ContainerisedThe Piller UNIBLOCK UBTD can be installed inUNIBLOCK impeller ducting the warm air straightcabinet integrated at the end of the UPS. With thea plant room or supplied complete from the factoryto the outside world. When site restrictions makecooling unit providing the UPS with its own climateas a containerised unit. All components necessarythis impossible, the plant room can either beforce-cooled or alternatively, the UBTD can bethe UPS can be operated in small rooms, in harshenvironments or in areas where quiet operation isfor operation are integrated into the container,making the Piller UNIBLOCK UBTD a transportableprovided with its own heat exchanger directlyrequired. Without the need for external forcedUPS system ready to be set to work wherever aconnected to the building’s chilled water supply.cooling, complex plant room airflow studies can beproject programme better suits off-site constructioneliminated, space can be saved and maintenanceor wherever utilisation of the building space needsroutines simplified.to be maximised.In this configuration, each UBTD unit has a closedAAir flowCross section of water-cooled unitA: The enclosed air circuit is operated by aninternal fan impeller incorporated in therotor of the electrical machineB: The UNIBLOCK with built in watercooling is connected to the chilled watercircuit of the building.6B
Optimised protectionEnhanced Diesel Engine StartingResearch shows that in most utility supplies, mainsThanks to the POWERBRIDGE , the unique designof the Piller UNIBLOCK UBTD gives an extendedwithin its POWERBRIDGE . Where other dieselUPS solutions need virtually all of their storeddisturbances lasting more than 10ms occur almostride-through capability with no need to start upenergy just to run the generator up to speed anddaily, jeopardising or substantially disrupting thethe diesel generator for the majority of mainstake over the load, the stored energy of the Pilleroperation of electrical equipment.disturbances. This can reduce the number ofUNIBLOCK UBTD removes the need to startIn a typical overhead network system, over 60%of all mains failures last more than 100ms andyet only some 2% continue for more than a fewfalse generator starts to practically none, comparedthe engine except for the longest of outages, whichwith around 5 starts per week with other dieselcould be seconds, or even minutes.UPS solutions.seconds. In countries where the power supplyThe Piller Diesel UPS system’s ability to ride throughsystem is still developing, the statistics shownuisance disturbances without a generator startmore outages, which also tend to be longer.comes from the large storage capacity availableNumber of Mains Failures per year208182621810ms 100ms100ms 0.5s0.5s 1s1s - 3s983s - 20s20s - 60sDuration of Mains FailureSOthersPillerEngine SpeedContainerised benefits:n Operating readiness immediately onconnecting to the mainsn No structural measures for noiseattenuation, ventilation or cablingn Minimal expenditure for on-site testingand commissioningn No outlay on complex installation or plantroom constructionn Temporary use in different locations oruse in modular expansionn Reduced on site programmest04sContainerised UNIBLOCK UBTD .No Diesel startx - variable from seconds to minutes7
Unit configurationsThe UNIBLOCK UBTD UPSIn its basic form, the Piller UBTD provides 100%the Short-Break Bus. The two circuits are isolatedby virtue of the transformer action between theno-load condition. In the event that one unit failsof its available output as continuous uninterruptiblewindings and so the two outputs are electricallyor is taken off-line, the critical loads arepower. In alternative forms, the power is splitisolated. In other circumstances, use of theautomatically transferred to the redundant unitbetween UPS (Critical Bus) power and Short-same alternator for both supplies may be avia seamless change-over instead of goingBreak power (similar to a standby generator).preferred option, particularly in MV solutions.to bypass.This is known as Dual Output Bus.Isolated Redundant ConfigurationAdditionally, some non-critical load can beTraditionally, where redundancy was required aconnected to the redundant unit utilising theit is sometimes necessary or desirable to isolateparallel redundant configuration would be used.available diesel UPS power. Compared to thethe short-break loads from the Critical Bus – thisWith an isolated redundant configuration,parallel redundant configurations at low voltages,Depending upon the particular design requirements,is known as Dual Output Isolated Bus. In thisredundancy is created on the basis of standardthis configuration can be used for much higherconfiguration, the generator winding provides thesingle units. All individual units support theirsystem power ratings without the need to adoptCritical Bus source and the motor winding of theindividual critical loads. In an ‘N 1’ configuration,medium voltages.UNIBLOCK machine becomes a generator forthese systems have one redundant unit as aBypassBypassCoupling ChokeCoupling ChokePOWERBRIDGE POWERBRIDGE eUNIBLOCK LOADM/GDieselEngineDualOutput BusUNIBLOCK BATTERY8backup. This backup unit normally operates in aBATTERYDual OutputIsolated BusUNIBLOCK UBTD withalternative Dual OutputBus configurations.UNIBLOCK UBTD in standard output configuration.MAINS SBLOAD SB
System configurationsIn the isolated redundant configuration, theThe UBTD in High Power ApplicationsThe UNIBLOCK UBTD is available for highThe isolated-parallel system uniquely enables theredundant unit normally supplements a non-power applications with unit sizes ranging fromadvantages of combining isolated-redundant andcritical load, or runs with no load; this arrangement500kW up to 2700kW. In medium voltageparallel-redundant UPS configurations. This meanscan be enhanced with the distributed redundantsystems, the units can be paralleled to 40MW,that very large ‘N 1’ redundant electrical systemsconcept. Distributed redundant systems areeither with individual or common coupling chokes.can be created at low voltage without excessivenormally designed for ‘N 1’ redundancy. No singleAt low voltages, simple paralleling is limited to aboutfault currents and that at any voltage, theDistributed Redundant ConfigurationIsolated Parallel (IP) Configurationmodule is assigned as a redundant unit. Instead,5MW but there are configurations using faultconfiguration can be concurrently maintainable.this role is shared equally among all modules. Inisolated parallel techniques that allow this to beBy reducing the redundant UPS units to a minimumthe event of a single unit failure, its load will beincreased reliably and safely to 20MW.and avoiding systems which run in the standbyOther UNIBLOCK Configurations:n System Systemn Hot-Stand-byn Parallel Redundantmode the IP system is an excellent choice forshared proportionately over the remaining units.optimising the combination of redundancy, resilience,The load transfers are accomplished throughmaintainability and cost.automatic transfer switches and/or via dual cordedequipment. The advantages are the elimination ofsingle point failures and equal load sharing amongall units.NO-BREAK LOADIP- BUSSHORT-BREAK LOADThe UNIBLOCK UBTD can be paralleledup to 40MW in an IP-Bus System.9MAINS
Total Cost of OwnershipOwning and operating a data centre or largeThe TCO for a UPS is a combination of the capitalscale industrial process plant is an expensiveexpense, the electrical operating costs, the routinebusiness; the cost of real estate and energy maymaintenance and the periodic overhaul orheavily influence the final design and the locationreplacement. It is also dependent upon the requisiteof the facility. Add to that the pressures ofsurrounding infrastructure (building space, runningdesigning an environmentally friendly solution andcosts, capital costs for switchgear, transformers,the restrictions become even greater. First andcabling, power factor correction and cooling). Inforemost, a UPS must be reliable. Secondly, itmost TCO calculations, the dominant factor isshould deliver an optimised total cost of ownershipthe electrical running cost of the entire system(or TCO) over its useful life.rather than capital costs or ,00011,00010,0009,000UNIBLOCK UBTD Day 1Investment k 10Other Diesel Rotary UPSCost of ElectricalLosses k TCO comparison by Expense Category (DCF)Cost of Maintenance/Overhaul k A TCO analysis incorporating theUNIBLOCK UBTD system comparesfavourably with other solutionsbecause of the combination of itscharacteristics:n High electrical efficiencyn Very simple, economic maintenanceand overhauln Elimination or reduction of airconditioning requirementsn Reduced space requirementn Cyclic maintenance and care work isall undertaken on siten Reduced engine wear byminimised startingn Natural cooling capability
Taking care of your investmentConsultation and Other ServicesAfter Sales ServiceEmergency Response ServicePiller believes it is simply not enough to manufactureSometimes, support and expertise is neededEver changing demands in business can lead toa first class product with inherent high reliability. Awhen you least expect it. For those times, youthe need for alteration, expansion or redeploymentUPS system must protect the client’s interestscan be assured that help will be available in theof a UPS system. In such cases, Piller‘s technicaljust as well on its last day as it does on its first,shortest possible time. Piller Service Centres aresupport teams will evaluate the requirementswhich is why Piller offers a worldwide network forstrategically positioned to provide local knowledgeand advise on necessary changes. They canthe professional care of its clients’ investments inof the client’s installation and the best possiblealso manage the delivery of these changes,Piller UPS technology, deploying a team of highlyresponse time. Piller offers 24 hour emergencyconsulting with clients and their partners totrained and internationally co-ordinated technicians.response with technicians on standby for immediateensure minimal disruption.The team takes care of over 9000 units of highdispatch at each of its service centre locations.power UPS equipment in over 40 countries,Preventative Maintenance Servicesupporting clients’ activities in data processing,Periodic preventative maintenance in accordancebanking and finance, industry, communications,with well-defined Piller standards ensures securityaviation and defence, 24 hours a day, 365 daysof supply to critical equipment as well as minimisinga year.malfunctions and extending the life of the UPSsystem to 20 years or more.nnnnnReplacement battery systemsReconfiguration and redeploymentUpgradesRemote monitoring systemsSite surveysParts AvailabilityOperator TrainingPiller preventative maintenance and emergencyAll newly installed systems will involve a degree ofresponse services are fully supported by aoperator training conducted either on site or innetwork of stocked parts held both at the serviceone of Piller’s training centres. Piller offers furthercentres and elsewhere in strategic locations aroundrefresher courses to ensure that client staff orthe world.their appointed operational representatives havethe skills necessary to operate the UPS systemwith minimum risk.11
HEADQUARTERSPiller Group GmbHAbgunst 2437520 OsterodeGermanyTel: 49 5522 311 0E: info@piller.comROTARY UPS SYSTEMSHYBRID ROTARY UPS SYSTEMSDIESEL ROTARY UPS SYSTEMSSTATIC UPS SYSTEMSCONTAINERISED UPSSTABILISERSSTATIC TRANSFER SWITCHESKINETIC ENERGY STORAGEAIRCRAFT GROUND POWER SYSTEMSFREQUENCY CONVERTERSNAVAL POWER SUPPLIESSYSTEM INTEGRATIONSubsidiaries:AUSTRALIA CHINA FRANCE GERMANY INDIA ITALY SINGAPORE SPAIN UK USASales & Service:AUSTRIA BRAZIL CANADA HONG KONG NETHERLANDS MEXICO RUSSIA SOUTH KOREA SWEDEN TAIWAN USAAgents & Distributors:ALGERIA BAHRAIN BELGIUM BRAZIL CHILE CHINA EGYPT HONG KONG INDONESIA IRAN JAPAN MALAYSIA NIGERIA NORWAY POLAND ROMANIA RUSSIA SLOVENIA SOUTH KOREA SUDAN TAIWAN THAILAND TURKEY UAE USA VIETNAMNothing protects quite like Pillerpiller.comPiller UBTD (GB) 01 2019/Issue 4. Due to a policy of continued improvement, we reserve the right to change any specification without prior notice.ERRORS & OMISSIONS EXCEPTED. Printed on a Manroland R700 press.
Piller UPS systems are found in colocation data centres, financial institutions, broadcasting, tele-communication networks, airports, healthcare facilities, continuous process production sites and applications where high quality power is paramount. Piller Frequency Converters and related products
