Astronic No Break®

Uninterruptible Power Supply System UPSBattery-free

v. ENG.100208.NPL

Contents

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Typical Utility Power Line

Problems and Failures

Introduction to the Astronic No Break

Uninterruptible Power Supply System

Beneficial Features of the

Astronic No Break System

Advantages of the Astronic No Break

Over Static Battery UPS Systems

Applications for the Astronic No Break

Some Clients and Users

Description of Components

The Astronic No Break Operation

Electrical Specifications

Available Models

Potencia Industrial

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.

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Typical Utility Power Line

Problems and Failures

Some natural causes are:

! Electrical Storm

! Rainstorm

! Windstorm

! Sandstorm

! Hailstorm

! Flood

! Earthquake

! Tornado

! Hurricane

! Freeze & Icing

! Humidity

! Salinity

Some unnatural causes are:

! Service Suspension

! Phase Loss

! Overload

! Short Circuit

! Electrical Noise

! Network Switching

! Power Factor Correction

! Tripped Circuit Breaker

! Transformer Failure

! Broken or Fallen Lines

! Blown Fuse

! Maintenance

! Generation Equipment Failure

! Accidents and Sabotages

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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.

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Figure I. Astronic No Break.

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A

FLYWHEEL

GENERATOR

MOTOR

AUTOMATICCONTROL

B C

GENERATOR

DIESEL MOTOR

Continuity

Unit

Backup Diesel

Power Plant

Automatic

Control Board

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

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" 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 warranty1

! No need for battery replacements or charging equipment

! No battery contamination

! Low maintenance cost

! Low operation cost

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

Advantages of the Astronic No Break

Over Static Battery UPS Systems

OperationCharacteristics

Astronic No Break

Static 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.

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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

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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, Química 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 Meteorología (CENAM), Institutos de Física, Química y Astronomía de la Universidad Nacional Autónoma de México (UNAM), Universidad Autónoma Metropolitana (UAM), Instituto Mexicano del Petróleo (IMP), CINVESTAV del Instituto Politécnico Nacional (IPN), Universidad Tecnológica de México (UNITEC),

Servicios a la Navegación en el Espacio Aéreo Mexicano (SENEAM) de la SCT, Autopista México-Veracruz de la SCT,

Aeropuerto Militar de Zapopan, Secretaría de la Defensa Nacional (SEDENA), Secretaría de Comunicaciones y Transportes (SCT), Sindicato Nacional de Trabajadores de la Educación (SNTE), Tribunal Superior de Justicia del Distrito Federal, Secretaría de Desarrollo Social (SEDESOL),

Ferrocarriles Nacionales, Temic AEG Mexicana, TV Azteca, Telecables Mas, ALCOMEX, Qualitas Compañía de Seguros, Cementos Anahuac, Despacho González Luna y Pérez de Acha, Guerra González y Asociados.

Casa de Bolsa del Valle de México, Multivalores, Factoraje Bancomer, Casa de Bolsa AVKA, Inversora Bursátil, Ruiz Urqiza & Co., Seguros Monterrey Aetna, Afianzadora Insurgentes, Café Orión.

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.

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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.

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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.

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FLYWHEEL

GENERATOR

MOTOR

DIESEL MOTOR

STARTER

GENERATOR

UTILITYPOWER LINE

AUTOMATICCONTROL

UPSLOAD

A C

B

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.

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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.

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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 Temperaturefor Ventilation

40° C. (1000 AMSL)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 BoardC. Backup Power Plant (Diesel)

Astronic No Break Model 2

A. Continuity Unit (Motor-Generator-Flywheel Set)B. Automatic Control BoardC. 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

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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 industry´s 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 industry´s 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.

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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.

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www.astronicnobreak.com

Potencia Industrial, S.A.Av. Año de Juárez no. 205Col. Granjas San AntonioDel. Iztapalapa, Ciudad de MéxicoC.P. 09700, D.F., México

T. +52 (55) 5686.7277T. +52 (55) 5686.9699

sales@potenciaindustrial.com.mxwww.potenciaindustrial.com.mx

20Copyright © 2009 Potencia Industrial, S.A. All rights reserved.

Hummingbird illustration on page 2 courtesy of Moyo Films, S.A de C.V.

v. ENG.100208.NPL