Astronic No Break

Uninterruptible Power Supply System UPS

Battery-free

v. ENG.100208.NPL
Contents

3 Typical Utility Power Line

Problems and Failures

5 Introduction to the Astronic No Break

Uninterruptible Power Supply System

7 Beneficial Features of the

Astronic No Break System

9 Advantages of the Astronic No Break

Over Static Battery UPS Systems

10 Applications for the Astronic No Break

11 Some Clients and Users

12 Description of Components

14 The Astronic No Break Operation

16 Electrical Specifications

17 Available Models

18 Potencia Industrial

2
Typical Utility Power Line
Problems and Failures

All electricity distribution networks are susceptible to

failures and distortions in their power lines. Although
many power line disruptions aren!t perceptible to the
human eye, these do occur and affect the operation of
electrical and electronic equipment. The most common
power line problems are:

! Power interruptions, seconds to hours long

! High voltage spikes and low voltages
! Long periods of high or low voltage
! Wave harmonics and deformations

These problems have several different causes:

a. Connections and disconnections in the network,

blown fuses, limited capacity at the substations, power
factor corrections, incorrect circuit switching, etc. These
type of problems may occur up to 500 times a year.

b. Low voltage periods result when the energy demand

at a certain network reaches the maximum network
distribution capacity or the generation station capacity.
Usually when this happens, there is no warning from the
power company to consumers.

c. Blackouts are caused by programmed equipment

replacement in the network, overloads or by
inadequate power reserves. Blackouts are also caused
by atmospheric discharges or by short circuits.
Depending on the scale of the damage, power is
restored within a few seconds up to several days.

d. Other types of power line malfunction are caused by

sudden increases in the network demand for power, for
instance at startup of large electric motors. The power
line is also affected by the type and consumption rate of
the electrical equipment connected.

3
Typical Utility Power Line
Problems and Failures

Some natural causes are: Some unnatural causes are:

! Electrical Storm ! Service Suspension

! Rainstorm ! Phase Loss
! Windstorm ! Overload
! Sandstorm ! Short Circuit
! Hailstorm ! Electrical Noise
! Flood ! Network Switching
! Earthquake ! Power Factor Correction
! Tornado ! Tripped Circuit Breaker
! Hurricane ! Transformer Failure
! Freeze & Icing ! Broken or Fallen Lines
! Humidity ! Blown Fuse
! Salinity ! Maintenance
! Generation Equipment Failure
! Accidents and Sabotages

4
Introduction to the Astronic No Break
Uninterruptible Power Supply System

The Astronic No Break is an uninterruptible power supply (UPS) system patented in the
U.S. and Mexico. The system prevents costly damages to equipment and downtime
losses caused by disruptions in commercial power lines. It supplies uninterrupted,
dynamically generated energy of unlimited continuity, true sinusoidal power, completely
isolated from the problems of the commercial power line.

The Astronic No Break is a rugged, heavy duty electric machine system designed to
offer lifelong continuous service, free from batteries. The superiority of the Astronic No-
Break design in comparison with battery-powered electronic static UPS systems has been
proven for over 25 years by clients in many areas, including commercial, industrial,
military and government operations, throughout several countries. This UPS system is the
only one that offers a 10 year warranty.

The Astronic No Break can be configured according to the needs of each client, with a
capacity of 10 to 1,000 kVA per unit, and with larger capacities on synchronized units.

The system is composed of 3 mayor elements:

A. Continuity Unit (Motor-Generator-Flywheel Set)

B. Automatic Control Board
C. Backup Diesel Power Plant

It!s operation integrates 3 different power sources:

1. Commercial Power Line

2. Kinetic Energy Stored in the Flywheel
3. Diesel Motor

None of these three power sources are directly connected to the system!s power output,
which is fed directly from the generator on the motor-generator-flywheel set. This
generator is electrically independent from the three sources.

5
 Figure I. Astronic No Break.

B A C
MOTOR

GENERATOR
AUTOMATIC FLYWHEEL
CONTROL
DIESEL MOTOR
Automatic
Control Board GENERATOR
Backup Diesel
Power Plant
Continuity
Unit

6
Beneficial Features of the
Astronic No Break System

" Unexpected power shortages are eliminated trough the use of the Astronic No Break.
Critical applications that benefit include:

! Data processing centers and servers

! Telecommunication and transmissions
! Industrial automatization
! Security systems
! Emergency systems
! Special equipment and machinery
! Lighting and illumination
! Special production activities

" The power provided by the Astronic No Break is:

! Uninterrupted
! Unlimited
! Protected from high voltage spikes and low voltages
! Protected from wave harmonics and deformations
! Protected from lightning strikes on the power lines

" The continuity of power provided by the Astronic No Break is very reliable because:

! It uses kinetic energy stored in a forged steel flywheel, spinning at 1,800 rpm
! Uses no batteries, therefore eliminating the risks involved with battery reliability
! It!s robust construction and simple design replaces delicate electronics and complicated
circuits
! A fast diesel engine startup is ensured by kinetic energy
! Uses no transfer switches on the critical load
! It!s diesel power plant unlimited continuity depends only on fuel availability

7
" The Astronic No Break supplies adequate loads for demanding applications such as
large electric motor startups:

! Up to 200% overload
! No DC to AC inverter required since power is delivered from an electric generator
! Appropriate for resistive, inductive and capacitive loads

" Protects electronic equipment and increases it!s life expectancy:

! No wave deformation caused by direct current to alternating current inverters

! Voltage regulation of 1%

" Easy installation, operation and maintenance:

! No complex installations required

! No air conditioning required
! Does not require specially trained personnel for operation and maintenance
! Small maintenance requirements: lubrication and electrical connections
! Technical support during installation included, with an optional ongoing service plan
! Suitable for remote locations
! Remote monitoring available

" The Astronic No Break provides several commercial advantages such as:

! Useful life over 25 years

! 10 year warranty 1
! No need for battery replacements or charging equipment
! No battery contamination
! Low maintenance cost
! Low operation cost

1 When a service and maintenance plan is provided by authorized distributors.

8
Advantages of the Astronic No Break
Over Static Battery UPS Systems

Operation Astronic Static

Characteristics No Break Systems

Continuous power without time limitation. ! #

Eliminates need for periodic battery replacement.* ! #

Supplies power to resistive, inductive and capacitive loads. ! #

Supplies isolated power, free from disturbances on the

commercial power lines, including lightning strikes on ! #
distribution lines.

Eliminates the need for complicated and delicate circuits and

! #
electronics subject to fast degradation.

Integrates a diesel power plant in a way that startup is

assured without the need of batteries or transfer switches on ! #
the load.

Small maintenance that can be performed without the need

! #
of highly specialized personnel.

10 year warranty. ! #

* By eliminating batteries, problems and costs associated with charging, replacing,

maintenance and pollution are also avoided.

9
Some Applications
of the Astronic No Break

" Computer, Administration and Statistical Centers

" Telecommunications Centers
" TV and Radio Production Stations
" TV and Radio Relay Stations
" Microwave Relay Stations
" Cellular Phone Relay Stations
" Phone Service Center
" Radar Facilities
" Air Traffic Control
" Airports
" Banks
" Sales Centers
" Corporate Offices
" Intelligent Buildings
" Critical Building Services
" Industrial Automation
" C.N.C. Machinery
" Robotics
" Military and Police Stations
" Hospitals and Clinics
" Universities and Colleges
" Commercial Malls
" Highway Pay Tolls
" Tunnel Lighting
" Scientific Laboratories
" Security Systems
" Emergency Systems

10
Some Clients and Users
of the Astronic No Break

Motorola, Kellogg's, Pepsico, Cadbury Adams, Good Year Oxo, Dowell Schlumberg,
Cynamid, Mead Johnson, Fuller, Ferro Mexican, Shering Plough, Moore Business Forms,
Sidney Ross, Crouse Hinds, Fester, Kendall, Pilgrims Pride, Ford Motor Company,
Qumica Fluor, Dupont, Merck,

USA UPS Systems, Inc., Marathon Electric, Basler Electric, Computer Power Products,
Instituto Costarricence de Electricidad, YF Internacional de Taiwan, Mitsubishi Heavy
Industries Japan

Centro Nacional de Meteorologa (CENAM), Institutos de Fsica, Qumica y Astronoma de

la Universidad Nacional Autnoma de Mxico (UNAM), Universidad Autnoma
Metropolitana (UAM), Instituto Mexicano del Petrleo (IMP), CINVESTAV del Instituto
Politcnico Nacional (IPN), Universidad Tecnolgica de Mxico (UNITEC),

Servicios a la Navegacin en el Espacio Areo Mexicano (SENEAM) de la SCT, Autopista

Mxico-Veracruz de la SCT,

Aeropuerto Militar de Zapopan, Secretara de la Defensa Nacional (SEDENA), Secretara

de Comunicaciones y Transportes (SCT), Sindicato Nacional de Trabajadores de la
Educacin (SNTE), Tribunal Superior de Justicia del Distrito Federal, Secretara de
Desarrollo Social (SEDESOL),

Ferrocarriles Nacionales, Temic AEG Mexicana, TV Azteca, Telecables Mas, ALCOMEX,

Qualitas Compaa de Seguros, Cementos Anahuac, Despacho Gonzlez Luna y Prez
de Acha, Guerra Gonzlez y Asociados.

Casa de Bolsa del Valle de Mxico, Multivalores, Factoraje Bancomer, Casa de Bolsa
AVKA, Inversora Burstil, Ruiz Urqiza & Co., Seguros Monterrey Aetna, Afianzadora
Insurgentes, Caf Orin.

El Palacio de Hierro, Calzado Sandak, Tereftalatos Mexicanos, Abrasivos Especiales,

Consorcio Zimapan Protexa, Productos de Maiz, Tremec, Azucar, H. Steel, Hylsa LAs
Encinas, Grupo Fuerza.

11
Description of Components
of the Astronic No Break

As described above, the Astronic No Break UPS system integrates a Continuity Unit (A),
an Automatic Control Board (B), and a Backup Diesel Power Plant (C). The Continuity
Unit (A) is composed of an induction motor, a synchronous generator and a flywheel, with
all rotors mounted on a common shaft. The Automatic Control Board (B) is composed of
transfer switches automatically operated by a Programable Logic Control. The Backup
Diesel Power Plant (C) is composed of a diesel engine and a synchronous generator.

A. Continuity Unit

Heavy duty, continuous operation, vertical axis construction, self-ventilated ODP, long life
bearings with oil level indicators, grounding terminals, and temperature protection on both
bearings. Cobalt blue industrial grade finish paint.
High efficiency AC induction motor, squirrel cage, high torque, 4 pole, 3 phase, voltage
according to customer specification from 208 to 440 volts and 50, 60 or 400 Hz. Reinforced
Class F insulation system, embedded winding temperature detectors.
High efficiency AC synchronous generator, 3 phase, voltage according to customer specification
from 208 to 440 volts and 50, 60 or 400 Hz. Reinforced Class F insulation system, embedded
winding temperature detectors.
Inertial flywheel made from special steel, precision machined and dynamically balanced.

B. Automatic Control Board

Programable Logic Control (PLC).

Measures and monitors incoming current and voltage from the utility line, output current and
voltage on the Continuity Unit (A), frequency, current and voltage on the diesel motor output (C).
Power transfer to Continuity Unit (A) from the utility line or the Backup Power Plant; indicating
input source and stage (utility input, diesel test startup, diesel startup, and diesel input).
Alarm indication (high motor temperature, high motor voltage, low motor voltage, high upper
bearing temperature, high lower bearing temperature, low oil pressure on the diesel motor, high
diesel coolant temperature).
Event system counter, internal memory records and remote monitoring.
Manual operation controls are concealed behind key-locked door.

12
 UTILITY
POWER LINE
AUTOMATIC
CONTROL B

MOTOR

GENERATOR

FLYWHEEL

DIESEL MOTOR

A GENERATOR STARTER
C

UPS
LOAD

Figure II. Diagram of the uninterruptible power supply system Astronic No Break.

C. Backup Power Plant

1,800 rpm. diesel engine with high speed governor, battery-free automatic electric starter. Liquid
cooled with radiator and fan, electric heater for liquid. Temperature detectors on oil, coolant and
starter. Directly coupled to generator, engine exhaust silencer.
AC synchronous generator, 4 pole, 3 phase, 0.8 P.F., high frequency brushless exciter, 4 pole,
voltage according to customer specification from 208 to 440 volts and 50, 60 or 400 Hz.
Reinforced Class F insulation. Grease lubricated low friction bearings.

13
Astronic No Break Operation

Operation under normal conditions

During normal operation of the utility power lines, the electric motor on the Continuity Unit
(A) is fed by the utility line. The A motor keeps the Continuity Unit spinning as the flywheel
ensures a constant turning speed for the A generator.

The A generator, spinning at a very constant speed, converts the kinetic energy on the
flywheel into healthy electric power, with excellent waveform and voltage regulation.

The A generator is electrically independent from the A motor and from the utility power
line, separating the critical load from any problems on commercial power line.

During operation in normal conditionsm, constant amount of kinetic energy is stored as

the inertia of the flywheel.

a) Voltage variations. " b) Power interruptions.

Figure III. Graphics illustrate beneficial operation of the Astronic No Break.

Red lines show (a) voltage variations and (b) interruptions in the utility power line input. Blue lines show the
uninterrupted and regulated power at the Astronic No Break output.

14
Operation during utility line interruptions

When a power interruption occurs in the commercial utility line, the energy stored in the
flywheel maintains the Continuity Unit (A) spinning, and therefore the A generator
continues to supply electric power to the critical load. At this moment, the Automatic
Control Board (B) detects the failure and commands the Backup Power Plant (C) to start.

A successful Backup Power Plant (C) startup is crucial to the operation of the Astronic
No Break system. The most common cause for diesel power plant startup failure are
faulty batteries on the starter. Because of this, the system has the most reliable startup for
its diesel motor (C), accomplished by two design features unique to this system: the
elimination of batteries from the diesel starter and the startup aid provided by the
Continuity Unit to the diesel motor.

To further aid the Backup Power Plant startup, at the same moment that the diesel starter
is activated, a transfer switch is closed between the induction motor on the Continuity Unit
(A) and the synchronous generator on the Backup Power Plant (C). Because the motor A
is spinning faster than the generator C, these two will inherently switch places. The faster
spinning motor A will become a generator and supply energy to the slower moving
generator C that in turn acts as a motor and therefore drives the diesel engine to nominal
speed. As the diesel motor (C) reaches its nominal speed, the synchronous generator C
will transition from receiving power to supplying it, and thus the induction motor on the
Continuity Unit (A) will transition back to its operation as a motor.

The Backup Power Plant running on diesel will continue providing uninterrupted power
until the the Automatic Control Board (B) detects nominal levels on the utility line. The
Control will then transfer the utility line feed back to the motor A and will order the Backup
Power Plant (C) to shut down.

During utility line failure, transfer and Backup Power Plant startup, the A generator on the
Continuity Unit will never stop generating energy at constant speed and power rate.

15
Astronic No Break
Electrical Specifications

Capacity (Stand Alone Unit) From 10 to 1,000 kVA.

Nominal Input Voltage From 208 to 480 volts AC

Nominal Output Voltage From 208 to 480 volts AC

Nominal Input Frequency 50, 60 or 400 Hz.

Nominal Output Frequency 50, 60 or 400 Hz.

Phases 3

Wires 3 or 4

Output Power Factor 0.8, 80%

Harmonic Deviation (Line to Line) ! 2%

Deviation Factor < 5%

Waveform Factor 1.05 to 1.18

Telephonic Influence Factor (TIF) ! 50

Output Voltage Manual Adjustment 10%

Output Voltage Regulation 1%

Diesel Motor Response Time ! 300 ms.

Admissible Overload 200%

Electrical Isolation Class F

Thermal Insulation Class B

Max. Ambient Air Temperature 40 C. (1000 AMSL)

for Ventilation 30 C. (2300 AMSL)

Complies with NEMA, MG 1, NOM, IEC and IEEE standards.

For other voltages and frequencies, special characteristics and capacities over 1,000
kVA, please consult our sales department at sales@potenciaindustrial.com.mx

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Astronic No Break
Available Models

Astronic No Break Model 1

A. Continuity Unit (Motor-Generator-Flywheel Set)

B. Automatic Control Board
C. Backup Power Plant (Diesel)

Astronic No Break Model 2

A. Continuity Unit (Motor-Generator-Flywheel Set)

B. Automatic Control Board
C. Backup Power Plant (Diesel)
D. Structural Steel Base (Mounting A, B and C, with Diesel Storage Tank)

Astronic No Break Model 3

A. Continuity Unit (Motor-Generator-Flywheel Set)

B. Automatic Control Board (For Critical and Non-Critical Loads)
C. Oversized Backup Power Plant (Diesel)

Astronic No Break Model 4

A. Continuity Unit (Motor-Generator-Flywheel Set)

B. Automatic Control Board

FOR MORE INFORMATION AND QUOTES PLEASE CONTACT OUR SALES DEPARTMENT AT
sales@potenciaindustrial.com.mx

17
Potencia Industrial

Potencia Industrial designs and manufactures special application,

high efficiency electrical motors and generators. Specializing in
creative solutions and applications, our company meets the highest
technical requirements in power security and energy efficiency. Our
state of the art machines meet and exceed the most stringent
customer specifications and maintain IEEE, NEMA and IEC
standards. Potencia Industrial has set several industry
benchmarks in permanent magnet generator, kinetic energy
storage, and high efficiency patented technologies.

Structured under vertical integration, Potencia Industrial meets

engineering and manufacturing challenges with the experience of a
solid 50 year background. Our vertical integration of our
manufacturing processes include lamination stamping, core
assembly, welding and fabrication, high-precision machining, coil
manufacturing, winding, assembly and laboratory testing. Tools,
dies, jigs, fixtures, casting patterns and molds are also designed
and made in-house.

History

In 1958 our company initiated manufacturing of the NEMA-size

electric motors as Reliance de Mexico (REMSA) under license
from Reliance Electric Company of Cleveland, Ohio. REMSA
became the first company in Mexico to meet industrys demands to
locally manufacture motors for special applications including UL
approved explosion proof, high torque, and multi-speed
requirements.

In 1968 our company initiated manufacturing electric salient pole

synchronous generators as Potencia Industrial under license
from Kato Engineering Company of Mankato, Minnesota.
POTENCIA became the first company in Mexico to meet industrys
demands to manufacture generators for special applications
including 50, 60 and 400 Hz., motor generator sets, load isolators,
frequency converters, dynamic flywheel systems, and volume
production of standard generators for the emerging Engine Gen-
Set market for backup and emergency power.

18
In 1975 Potencia Industrial initiated the development of cage
induction and permanent magnet generators for wind applications,
and in 1976 obtained a patent for the world's first direct drive
permanent-magnet wind generator.

In 1976 our company initiated manufacturing large electric motors

and generators up to 10,000 horsepower in 1976 under license
from Parsons Peebles Electric LTD, of Edinburgh, Scotland,
including Induction Squirrel Cage, Wound Rotor, and Synchronous
Salient Pole machines.

In 1985 our company acquired the tooling and engineering of the

Electric Products Company of Cleveland, Ohio, to manufacture
special electric motors and generators up to 10,000 HP.

In 1995 our company entered into a manufacturing and

engineering agreement with the Louis Allis Company, Milwaukee
Wisconsin, to manufacture special electric motors and generators
up to 10,000 HP.

We have dedicated over 30 years to the advanced design of high-

efficiency special application technology, primarily for renewable
energy sources, and have a long and proven track record servicing
industrial, wind and hydro markets. Potencia Industrial is today a
world leader in permanent magnet generator technology and its
applications for renewable energy.

Potencia continues as Mexico's sole designer and manufacturer of

custom made electric rotating machinery using USA materials. We
became the first company in Mexico to meet demand for motors in
sizes up to 10,000 HP. Some of our customers include:

Clipper Windpower, Edisson Electric Company, Florida Power &

Light, Power Systems & Controls, ENXCO, EMS, Ford Motor
Company, Pepsico, Kellogg's, Merck, Canadian Hydro, Shering
Plough, Dupont, Mitsubishi, Goodyear, Georator Power Systems,
INET Airport Services, Yoeman's Chicago Corp, Visicom Industries,
Motorola, Mead Johnson, Procter & Gamble, York, Schlumberger,
FESTER, Japan Gas Corp., Byron Jackson, SUMITOMO.

19
www.astronicnobreak.com

Potencia Industrial, S.A.

Av. Ao de Jurez no. 205
Col. Granjas San Antonio
Del. Iztapalapa, Ciudad de Mxico
C.P. 09700, D.F., Mxico

T. +52 (55) 5686.7277

T. +52 (55) 5686.9699

sales@potenciaindustrial.com.mx
www.potenciaindustrial.com.mx
v. ENG.100208.NPL

20
Copyright 2009 Potencia Industrial, S.A. All rights reserved.
Hummingbird illustration on page 2 courtesy of Moyo Films, S.A de C.V.