Emerson

Product Presentation
DC UPS System

The Modular Flagship

industrial rectifier
from Emerson

Krishnendu Chakrabarti
Director- Global Business Development
 Users Demand
• Highest Reliability
• Long Life
• Should Boost and Float Charge the battery
• Load should not be interrupted in any condition
• Should not exceed maximum allowable voltage limit at load
terminal.
• Should meet the maximum load demand as and when
required during emergency.
• Should monitor all voltages and currents.
• Should annunciate in case of abnormalities in the system.
•
 Out of Focus
• MTBF of the system
• MTTR
• Up time calculation
• Complete monitoring of the system including battery, DCDB
and the rectifiers.
• Efficiency
• Power Factor
• Total current harmonics distortion
• Remote interface
• Foot print
 The Emerson Flagship Industrial DC UPS
for Heavy Duty Industries

Emerson FP-40RM:
The Industrial DC UPS from Emerson Network Power to protect:
•Transmission substations motorized switchgears
•Power Generation plants processes
•Highly critical processes and control systems
 SCR Control System
Benefits

 Very Simple
Architecture and easy
to Design.
 Widely accepted
technology for last
more than 50 years
 Large number of
Manufacturers due
simple technology.

Limitations

 Not much scope to improve MTBF due to large number of connections over a long distance
 NO scope to improve MTTR due to high volume components and discreet components.
 Limited Up time reliability even with 2 x 100% redundancy.
 Very difficult proposition to improve Power factor without large capacitor bank and number
of contactors.
 Input current harmonics distortions can be controlled with complex 12, 18, 24 pulse design
 Not possible for much improvement of Output AC ripple content.
 Impossible to improve dynamic response and DC Voltage over shoot
 Switch-Mode Technology

Input EMC AC HF AC Output

PFC EMC
AC DC

PWM 50-100kHz

Advantage Difficulties

 Very high energy density means smallest footprint  Very complex design
 Very low volume of magnetic components ensures high needs special
dynamic response, high efficiency. machineries for high
 High frequency switching make design simple for improved reliability.
power factor and THDI  Only high volume
 Sophisticated manufacturing process ensures very high production can control
reliability. cost.

 What we get
 Modular Design & Light Weight
 Addition of Rectifier Allows For Easy Expansion (Parallel option for redundancy)
 On-site Spare Rectifier Modules & Simple Repair Easy Serviceability
 Hot Pluggable Rectifier Modules
 DC ripple ≤0.1%, regulation ≤0.5%
 Dynamic Response < 200 μs
 THD < 5% and Input Power Factor ≥ 0.99
 Efficiency ≥ 90% on rated Load
 MTBF > 2,50,000 Hours
 Smaller in size & less in weight.
 Global Certification
 Utmost Input Performances
for Project Savings
SMPS modules Impact Benefits
performances
 Wide input voltage range ► Battery kept fully charged  Compliant with the worst Utility
conditions
 Possibility to have more load
 Integrated Input Power On upstream transformer:
connected to the supply transformer
Factor Corrector (PFC): ► Input current through supply  No need to replace the transformer
 From 0.92 to 0.99 transformer is reduced by a larger unit
On upstream losses:  Reduction of losses in cables
► Line current is reduced  Reduction of cable size (-20% from
► Reduced I²R heating in the resistance of PF0.8 to PF0.99)
generators, transformers and cables  Reduction of the upstream transformer
 Reduction of upstream switchgear
 Integrated Power Factor Corrector
 Low rejected THDi ► Reduced disturbances for  Upstream generator do not need to
 <5% (in nominal the other loads connected nearby be oversized
conditions) ► Avoided interferences reflected to the  Reduced stress on neutral cables
Mains (GenSet)
 Reduced inrush current:  Switchgear of smaller ratings can
 <1.5 In for FP-60Z w input transformer be selected to pass the inrush
Hot-Swappable Power Modules
for High Availability of Power
Benefits

 Very low MTTR

(Mean Time To Repair)
 High MTBF of power modules
(Mean Time Between Failures)
250 000 hours

 In case of module failure, a new

module can immediately replace the
faulty one
 The new rectifier is immediately
operational via CAN bus
Characteristics of Rectifiers
 Very low MTTR
(Mean Time To Repair)
 High MTBF of power
modules
(Mean Time Between
Failures) 250 000 hours
 Wide Selection of Power Modules
Single-Phase Modules
ER 2475/S ER 4850/S ER 11010/S ER 22005/S
Height: 132.3mm Height: 132.3mm Height: 176mm Height: 145mm
Width: 85.3mm Width: 85.3mm Width: 88mm Width: 72mm
Weight: ~3.5kg Weight: ~3.5kg Weight: ~6kg Weight: ~3kg

Rated Voltage: 24V Rated Voltage: 48V Rated Voltage: 110V Rated Voltage: 220V
Rated Current: 75A Rated Current: 50A Rated Current: 10A Rated Current: 5A
Max output power: 2175W Max output power: 2900W Max output power: 1170W Max output power: 1175W
Efficiency: ≥90% Efficiency: ≥91% Efficiency: ≥91% Efficiency: ≥91%
Input Power factor: 0.99 Input Power factor: 0.99 Input Power factor: 0.99 Input Power factor: 0.98

Three-Phase Modules
ER 11020/T ER 11040/T ER 22010/T ER 22020/T
Height: 132.3mm Height: 132.3mm Height: 176mm Height: 145mm
Width: 85.3mm Width: 85.3mm Width: 88mm Width: 72mm
Weight: ~3.5kg Weight: ~3.5kg Weight: ~6kg Weight: ~3kg

Rated Voltage: 110V Rated Voltage: 110V Rated Voltage: 220V Rated Voltage: 220V
Rated Current: 20A Rated Current: 40A Rated Current: 10A Rated Current: 20A
Max output power: 2860W Max output power: 5800W Max output power: 2860W Max output power: 5800W
Efficiency: ≥91% Efficiency: ≥93% Efficiency: ≥91% Efficiency: ≥93%
Input Power factor: 0.92 Input Power factor: 0.99 Input Power factor: 0.92 Input Power factor: 0.99
 Output Performances
for Advanced DC Load Protection
Efficiency Benefits
 24V/75A: >88%
 Savings on the Air conditioning
 48V/50A: >91%

 Savings during system operation on

 110V/10A: >91% the electricity bill
 220V/5A: >91%

 110V/20A: >91%
 220V/10A: >91%

 110V/40A: >93%
 220V/20A: >93%

Output Regulation
 Static regulation: +/- 0.5%
 Low ripple voltage: <0.5%
 Fast and efficient output regulation to
permanently keep the load safe and
within accepted limits
 Improved battery lifetime
EMU10: The FP-40RM Control and Displaying Unit
Features: Benefits
 Size 7’’
 User-friendly navigation
 Touch Pad
 Quick access to all the information
 Push buttons
 Coloured graphical display
 3 LEDs: Normal, Warning, Alarm
 USB port Quick Access
LEDs
 Access to System parameters via 2 level buttons
password (User, Maintenance)
 Front page drawing configured according to the
system design*

System drawing

Message area

*NOTA: inverters can not be represented

EMU10: Automatic Configuration of Front Page
Features:
 Automatic Detection of the system configuration
 Front page drawing configured according to the
system design*

 2 Rectifier modules  5 Rectifier modules  5 Rectifier modules

 1 Battery  1 Battery  1 Battery
 Load  Load  Load
 Dropping Diodes
 DC Earth Fault
EMU10: Access to Measures
 Rectifiers Measures  Input Measures (with EAU option)

 Active Alarms  Battery Record

EMU10: Export / Import Configuration
Benefits
 Easily duplicate the system configuration to
another new system
 Keep an external “COPY” of the INITIAL
configuration
 Keep an external “COPY” of your actual
configuration
 Easily manage the system configuration (e.g.
if the EMU10 module needs to be replaced)
 System Architecture
EDU01

RUN
EDU (standard):
DC measures module
CAN

485

HF ALARM

EAU01

1 to 6 RUN
NORMAL
EAU (optional):
EMERGENCY
ALARM
AC input measures module
HF
CAN
EGU01

POWER
CAN
EGU (optional):
EMU (standard) RS485
ALARM
Switching inputs

EBU01

POWER EBU (optional):

COM

ALARM Battery measures module

RUN

RS 485
REMU
REMU (standard):
K7

K6

Volt-free outputs contacts

K4
K2

K3

K5
K1
 Minimal Standard Configuration
1 MCB per
module
HF
It Uo

1 to 6 Output measures:
230 VAC 1ph •Output current
•Output voltage
EDU01

or
RUN

HF
CAN

485

ALARM
EDU
400 VAC 3ph

EMU Colored
TouchPad 7’’
 Pre-Configured Options
Output
Input Dropping Distribution:
protection: Diodes: MCB/ MCCB/
MCB 10kA HF
3 contactors Switch
MCCB 36kA 7 steps It Uo

Uin Iin
1 to 6
Ub
EAU01
Ib RUN
EDU01

RUN

NORMAL

EMERGENCY
EAU
EAU
HF
CAN

485

ALARM
EDU
ALARM

Low voltage
Disconnect
Input measures: contactor
Line current(s)
Ph-N voltage(s)
Battery
Frequency Protection
MCB 10kA EGU01

EBU01
θ
POWER

CAN
EGU
EGU
POWER

EBU RS485

ALARM

EBU
COM

ALARM

RUN

Individual
Battery room
feeder
temperature
Battery Earth fault
Monitoring detection
Lead Acid/ Ni-Cd
Up to 216 cells/
Remote modules
Communication:
Modbus
IEC 61850
 AC load Back-up

HF
It Uo

AC Mains
input DC output
1 to 6
Ub
Ib RUN
EDU01

HF
HF
CAN

485

ALARM
EDU

Inverters:
24Vdc in / 1.5 kVA out
48, 110, 220 Vdc in / 2.5kVA out
4 modules max

Inverter
+Static switch

AC output
Reserve

Manual bypass
 Scalability and Pre-Configured Options
for Industrial Flexibility
Compatibility with any battery Benefits
 Lead Acid
 Wide output DC voltage window
 Nickel Cadmium
 Capability to Commission Vented NiCad cells
 Vented
 Recombination

Scalability  Addition of modules allow

 Up to 6 modules in one compact cabinet
(6 max, due to thermal consideration)
 Vented
 Recombination
up to 30kW in a 0.36m² footprint
 Module adjunction can be achieved at a later
stage, without reconfiguring the system
 Easy Increase of output power to meet
process evolution

System Flexibility
 Wide choice of rectifying modules
 Wide range of optional extras:  System adaptation to meet most industrial
 DC/AC inverter requirements
 Dropping diodes
 Monitoring solutions
 …
 Various Redundancy Levels
for High Availability of Power

Benefits

 Several Redundancy
levels to Ensure High
Availability of the
 DC load

 Up to 30kW in  Up to 22kW in one  Up to 22kW per cabinet

one cabinet cabinet  N modules with Nmax = 5
 N modules with  N modules with Nmax  1 Redundant module per
Nmax = 6 =5 cabinet
 1 Redundant module
System Internal layout
Charger Charger + Dropping Charger+Battery Charger+Inverter
diodes

Dropping diodes: Integrated battery: Integrated inverters

-Max 3 contactors -24 or 48Vdc only
-Max 7 steps -Max 150Ah
 Product Key Benefits
The New Modular Switch-Mode Rectifier – Battery Charger

High Availability of Power

Industrial flexibility