Are all Rotary UPS the same ?

Contents

1 Introduction...................................................................................................................... 3

2 Rotary UPS architectures............................................................................................. 4

Rotary UPS with flywheel as energy storage unit ....................................................... 4

Rotary UPS with battery as energy storage unit ......................................................... 7
Rotary UPS with Diesel backup ..................................................................................... 8
Rotary UPS with separate generator........................................................................... 12

3 Diesel start ..................................................................................................................... 14

4 Efficiency - Maintenance – Total costs of ownership......................................... 16

Efficiency calculation......................................................................................................... 16
Maintenance ....................................................................................................................... 17
Total cost of ownership (TCO) ........................................................................................ 18

5 Summary......................................................................................................................... 19

6 References ..................................................................................................................... 19

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1 Introduction
Uninterruptible power supplies (UPS) are typically realized in two fundamentally different
technologies – static UPS and rotary UPS. The rotary UPS offers a less complex and hence
more reliable UPS solution and is better suited for higher power applications. Even within
this category there are significant differences between one rotary UPS solution and another.
The name Rotary UPS results from the fact that the load is supplied by a rotary machine.
The Parallel Online Architecture, widely used in high-power Rotary UPS systems, is shown
as a block diagram in Figure 1-1. In this case the load is fed directly from the input supply
system via an inductor (choke). In this arrangement deviating input voltages are
compensated by the regulation of the rotary machine, so that the load is always supplied with
a constant voltage. In the event of mains failure or serious disturbance of the supply system,
the rotary machine takes over the complete supply to the load, fed from the connected
energy storage unit.

Figure 1-1 General mimic diagram of a Rotary UPS in Parallel Online Topology

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2 Rotary UPS architectures

Rotary UPS with flywheel as energy storage unit

In the Rotary UPS with a flywheel as the energy storage unit, in the event of a mains failure
the energy needed to supply the electrical machine is stored in the form of kinetic energy.
This happens because a sufficiently large mass (flywheel) is made to rotate during normal
mains operation. When this power failure occurs, this rotational energy is then retrieved and
is again converted into electrical energy via the generator of the UPS. This electrical energy
is then fed to the load in the form of a constant, regulated voltage.

There are two basic methods for connecting the flywheel storage device to the UPS and for
transferring the flywheel energy to the load, i.e. the induction coupling and the electric
coupling.

In the case of the induction coupling (see Fig. 2-1 and 2-2), kinetic energy is stored via the
difference in rotational speed of two rotors. One of the two rotors is free-running and forms
the actual flywheel or, if an external flywheel is used, it is rigidly attached to this one. The
second rotor is permanently attached to the generator rotor. In the mains mode the flywheel
is run up to the base speed by an external motor (pony motor) and then accelerated up to the
rated speed via an additional AC winding in the generator rotor. This speed is above that of
the actual generator. This speed difference, along with the flywheel, represents the amount
of energy available during a power outage. In the event of a mains failure, a further winding
in the generator rotor, which is realised as a DC winding, is now excited. This has a braking
effect on the flywheel with respect to the rotor to which the generator is coupled. As a result,
energy is transferred by the induction principle to the generator rotor which continues to be
driven. The transferred power is determined by the level of excitation in the DC winding. If
the flywheel is decelerated to the speed of the generator, the available amount of energy is
used up. On restoration of the mains the flywheel is powered up again. The recharging time
is performance-based on pony motor and AC winding of the generator. Depending on the
design, the flywheel can be realised as an external rotor or as an inner rotor.

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 Figure 2-1 Block diagram of a rotary UPS with flywheel storage device and induction coupling

Due to the permanent mechanical connection between the external pony motor, the flywheel,
the induction coupling and the generator, it is absolutely imperative to achieve very precise
alignment of the individual components. For this reason all components are usually built onto
a sturdy frame which, fitted with vibration dampers, is then set up at its installation site. This
horizontal arrangement demands a relatively large installation area. This does not include the
necessary switchgear with incoming disconnector, outgoing disconnector and bypass. In
addition, the space required for the choke between the mains supply and the load must also
be taken into account. The design of the base frame with its large number of rotary elements
requires an appropriate number of bearings. Depending on the design, up to six bearings are
required just for the induction coupling with the two "nested" rotating rotors which, due to the
nested rotor arrangement, allows on-site maintenance only in exceptional circumstances.
The large number of mechanical components used together with the two rotors running on
different speed results in a high mechanical noise level.

Figure 2-2 Flywheel with electrical coupling Flywheel with induction coupling

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In the electric coupling (see Fig. 2-2 and 2-3), there is no mechanical connection between
the flywheel energy storage unit and the generator of the UPS. In this case, the energy is
stored in a vertically rotating flywheel. The flywheel is equipped with an upright synchronous
machine. In the mains mode this drives the flywheel and keeps it charged up. In the event of
a power failure the kinetic energy of the charged-up flywheel is converted into electrical
energy and transmitted to the UPS, which then supplies the load. Since the flywheel storage
device is discharged the speed of the integrated synchronous machine changes and
therefore also its electrical output frequency. The power is transferred via a very simple
heavy-duty converter to the generator of the UPS. The generator is likewise an upright
synchronous machine which supplies the load via a choke. If the supply system is again
within specification, the synchronous machine of the flywheel storage device is supplied via
the choke, UPS and converter to drive the flywheel and recharge the energy storage unit.

Figure 2-3 Block diagram of a rotary UPS with flywheel storage device and electric coupling

In contrast to the mechanical connection of the storage device, the electric coupling enables
a bi-directional power handling. Energy can be taken up or supplied very quickly and flexibly.
Since both machines are mounted vertically, each manages with two bearings. In addition,
the bearings of the flywheel storage device are magnetically supported so as to compensate
a large part of the rotor weight. During operation, all bearings are automatically re-lubricated
by a regular grease supply. These measures extend the maintenance intervals and the
service life. All bearings can be serviced on site and are also replaceable in the event of
failure. A further advantage of this system is its compactness. The individual components are
housed in sturdy sheet-steel cabinets which are transported and installed separately. The
cabinets also contain the individual switchgear elements such as incoming and outgoing
disconnectors, bypass and connectivity options. The advantage of this compactness is also
reflected in the small footprint. The electric coupling allows a modular system design with

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paralleled flywheels up to an energy content of 42 Mega Joule which represents the ride
through time with respect to a certain load. With the induction coupling and due to the stiff
mechanical connection to the generator parallel flywheels are unfeasible and the energy
content therefore limited to around 15 Mega Joule. This borders the single none Diesel UPS
system size to about 1000 kW.

Rotary UPS with battery as energy storage unit

The electric coupling makes it easy to connect other energy storage units such as batteries,
for example. In this case a battery system is employed instead of the flywheel storage device
(see Fig. 2-4). During a mains failure, the battery feeds the machine of the UPS via a simple
inverter, and the UPS supplies this power to the load. When the mains becomes available
again, the battery is charged up and charging is maintained via the UPS.

Figure 2-4 Block diagram of a rotary UPS with battery as storage device, and electric coupling

Power output and run time can be matched to the load conditions by varying the number of
battery cells. If required, redundancy within the energy storage unit can be easily achieved
by connecting battery strings in parallel. With this flexible design systems can be planned
exactly to the requirements of certain markets (eg. banking) that need ride through times of
ten minutes which cannot be realized with a flywheel system. Specific manufacturers are
able to combine battery and flywheel in the same system to cope with operational
requirements like supporting important loads with longer ride through time of the battery
while secondary loads get the bridging energy from the flywheel.

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Rotary UPS with Diesel backup

If only a poor-quality supply is available from the utility and there is a risk that it could lead to
prolonged mains failures, then a long run time must be provided for. In this case the use of a
UPS with a short-term energy storage unit and an additional Diesel engine for bridging long
mains failures is recommended. The purpose of the short-term energy storage unit is to
supply power to the load until the Diesel engine is started and is able to take over the supply.
During a power outage the primary energy storage unit initially takes over the supply to the
load via the UPS. The Diesel engine can now be started and run up to speed until the
overrunning clutch or the electrically-operated clutch closes and the engine directly drives the
generator of the UPS. Once the Diesel has fully accepted the load, the primary energy
storage unit is again charged up within a short time with the superfluous energy of the Diesel
engine. In theory, power which is independent of the mains can be supplied by means of the
Diesel engine for an infinitely long period.
In the Rotary Diesel UPS with electric coupling a battery can also be considered as the
primary energy storage unit (see Fig. 2-5 and 2-7). With the additional ride through time
powered by a battery the energy content can be adapted to the mains supply quality, where
mains perturbations are particularly onerous. A further positive effect is the cutback of Diesel
engine start counts which reduces stress on the engine and cuts down false starting. This all
together comes with reducing noise and saving fuel.

Figure 2-5 Block diagram of a Diesel UPS with a battery as the energy storage unit

Where a flywheel energy storage unit is used, (see Fig. 2-6 and 2-7), ideally this is designed
so that transient mains failures of a few seconds can be bridged even without starting the
Diesel engine. The Diesel is only started when the energy level during discharging of the
flywheel falls below the level specified as adequate for starting the Diesel.

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 Figure 2-6 Block diagram of a Diesel UPS with flywheel energy storage

A Diesel UPS is designed so that the synchronous machine of the UPS is arranged
horizontally in order to realise the mechanical coupling to the Diesel engine by means of an
overrunning clutch or an electrically-operated clutch. In this case the Diesel engine and the
synchronous machine are permanently mounted on a common frame. The other components
like those in a UPS without a Diesel engine are housed in steel cabinets.

Figure 2-7 Rotary UPS with Diesel engine as long-term energy storage unit

In the Rotary UPS with induction coupling, only the flywheel can be considered as the
primary energy storage unit. The coupling to the Diesel engine is likewise realised by a
mechanical coupling (overrunning clutch or electrically-operated coupling). The Diesel engine
is either coupled to the rotor of the induction coupling (Fig. 2-8), which is permanently
connected to the generator, or the Diesel engine drives the generator directly (see Fig. 2-7).

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 Figure 2-8 Block diagram of a rotary Diesel UPS with induction coupling

The operating principle is basically that of the UPS without a Diesel engine already
described. Following a mains failure, the flywheel storage unit takes over the supply of
energy until the Diesel engine has reached the speed of the second rotor or of the generator.
The overrunning clutch then engages and takes up the drive of the rotor of the induction
coupling and of the generator in order to supply energy to the load. In systems where the
Diesel engine directly drives this induction coupling's rotor, the total energy of the flywheel is
contained in the induction coupling since no additional flywheel can be connected. This
energy level is usually lower than in systems with additional flywheel. However, this means
that the ride-through time is often measured quite short and the Diesel engine has to be
started extremely quickly in order to take over the secure power supply. Furthermore, it
means that the energy level is not adequate to bridge additional short power outages without
starting the Diesel engine, which basically means that the Diesel needs to be started at every
mains failure. On the other hand for such systems with prolonged recharge time the Diesel
engine must run longer than necessary to make sure the flywheel is fully charged before
another mains failure occurs.

Figure 2-9 Rotary Diesel UPS with induction coupling

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Another point to be noted is the handling of large, rapid changes in load in the Diesel mode.
The permanent mechanical coupling of generator and Diesel engine via the rotor of the
induction coupling allows energy to flow from the Diesel via induction coupling and generator
to the load (see Fig. 2-10). If a large load change now occurs at the load, for example due to
load disconnection, the superfluous energy of the Diesel engine cannot initially be taken up
anywhere. This causes an increase in the engine speed and an increase in frequency in the
load voltage. In an extreme case such a load shedding can result in emergency shut-down of
the Diesel engine. The system is only normalised again by readjusting the Diesel engine.

Figure 2-10 Energy flow in the Diesel UPS with induction coupling

The electrically coupled system provides for a bidirectional energy flow (see Fig. 2-11). Here,
with load changes in both directions, the energy balance can be corrected up to 100% by the
flywheel storage unit. Consequently, there is negligible increase in frequency of the output
voltage or overloading of the Diesel engine. This system therefore offers advantages for
varying loads such as occur in large industrial plants for example.

Figure 2-11 Energy flow in the Diesel UPS with electric coupling

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Rotary UPS with separate generator (1)

The use of Diesel engines is frequently associated with operational restrictions (storage of
fuel, removal of exhaust gas, etc.) which require these to be installed and operated away
from loads or UPS. In systems with electrical coupling to the energy storage unit and the
associated longer ride-through times, it is possible to meet these requirements with an
external Diesel-generator combination (Genset). In principle in this case the Genset can be
connected to the mains or to the load side of the UPS. An upstream Genset (see Fig. 2-12)
operates as a quasi-standby power system which, in the event of a mains failure, takes over
the supply to the entire system. On restoration of the mains, the Genset is synchronised to
the mains and the load is transferred back to the incoming mains supply.

Figure 2-12 Rotary UPS with upstream Genset

In the case of a downstream Genset (see Fig. 2-13), the flywheel storage unit accepts the
supply to the load following a mains failure. After the Genset has been started the load is
transferred from the UPS to the Genset. On restoration of utility the internal synchronisation
unit of the UPS takes care about the synchronization and switches the entire system back to
mains.

Figure 2-13 Rotary UPS with downstream Genset

The electrical coupling to the energy storage allows the integration of a separate Diesel
Generator into the controls of the Rotary UPS to utilize the entire advantages and

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functionality of a Rotary Diesel UPS. This powerful and multifunctional system is named a
DeRUPSTM (Diesel electrically coupled Rotary UPS). This system combination with a
downstream Genset is able to have a load distribution between the energy storage of the
UPS and the Diesel Generator to shift the load to the Diesel Generator just after the mains
failure once it is started and connected to the load bus. This real DeRUPSTM allows the
charging of the energy store during Diesel operation and is capable to compensate even
rapid load changes via this storage unit so that the dynamic characteristic equals that of the
electrically coupled Diesel UPS. With this capability the DeRUPSTM controls all
synchronization processes like the return into mains operation once utility is available again.
In the downstream combination the Gensets can be operated independently of the UPS if
necessary. Thus maintenance of UPS and Diesel machine can be done separately. During
Genset overhaul the load still has short term protection by the UPS powered form the energy
store.
If Diesel-generator combinations are used in high-power systems, a standard solution is to
incorporate these as upstream Gensets and operate them as a stand-by generating solution.
Here the Gensets run in parallel and feed a common isolated bus (see Fig. 2-14).

Figure 2-14 Upstream Gensets in high-power systems

In the event of a mains failure, the DeRUPSTM controls the starting and the synchronization
of the Gensets and connect them to this bus. The UPS input bus is supplied via a central
circuit-breaker only if the system is completely supplied on the isolated bus. This procedure
prevents the UPS from returning to the mains mode before all necessary Gensets are
securely operating. In this arrangement the number of Gensets must not equal the number of
parallel UPS. But the number can be optimised to the required capacity and additional
redundancy built in. Loads where a short interruption is allowed can in this case be
connected to the UPS input bus, thereby isolating them from the critical loads at the UPS.
output.

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3 Diesel start
Operational safety and reliability of the Diesel engine is crucially important in Diesel UPS
systems. If the Diesel does not start in the event of a mains failure the load cannot longer be
supplied once the energy from the primary short-term storage unit has been used up. The
more frequently the Diesel engine is started, the greater the probability of an abortive start.
Unnecessary starts therefore increase the risk of not being able to supply the load when it is
really necessary to do so. Apart from higher costs of resources, the maintenance interval of
the engine is also shortened by frequent start-ups. Not least, this causes unnecessary
damage to the environment by air and noise pollution. An examination of the statistics of
power outages per annum reveals that 97% of them have duration of 10 ms – 3 s. A short-
term energy storage unit which is able to bridge this period and – in the event of a longer
mains failure – then still provide appropriate energy to reliably start the Diesel engine, can
drastically minimise the number of Diesel starts. In systems with an induction coupling alone,
the amount of energy is usually not sufficient for this. This means that the Diesel must be
started very shortly after the mains failure. In systems with an electric coupling, due to the
large amount of energy stored in the flywheel, there is sufficient time to delay this start. This
delay time can be set from seconds to minutes, depending on load, size and number of
flywheel storage units; Up to 99 % of all mains failures can be bridged without starting the
Diesel engine. Statistically, the number of Diesel starts for UPS with electrically coupled
flywheels is therefore 5-8 and for induction coupled systems is 100-260 starting procedures
per year.

Figure 3-1 Diesel start delay

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After the Diesel engine has been started, this must run until the flywheel storage system has
recharged so that following restoration of the mains a mains outage can again be
immediately bridged. Depending on design, an induction coupled system normally needs
more than 10 minutes for this process, whereas an electrically coupled flywheel requires only
60-120 seconds.

A weak point in the Diesel engine system is the starter battery. Despite regular maintenance
it can suddenly fail if a power outage requires the Diesel to start.
With an electrically coupled flywheel storage unit, a rectified 24V voltage can be provided via
the generator of the UPS to start the Diesel engine if the starter battery is faulty.

Figure 3-2 External Diesel starting with electrically coupled flywheel

This option is not available with an induction coupled system. In this case, under certain
circumstances it is possible to implement an emergency starting process by closing the
electrically-operated clutch when the Diesel engine is stopped. This does of course result in
undue loading of the clutch and engine, which can cause greatly increased wear. This
procedure is not normally covered by the manufacturers' guarantees in respect of the engine
or clutch. Also for the induction coupling there is a heavy mechanical strain which influences
the speed of the generator and therefore causes a frequency deviation at the load.

Figure 3-3 External Diesel starting with induction coupled flywheel

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4 Efficiency - Maintenance – Total costs of ownership
In order to record the total cost of ownership of installed systems, running costs arising from
system losses and maintenance should not be ignored. Efficiency measurements are used
when determining the energy costs of power losses.

Efficiency calculation

When calculating efficiency it is necessary to precisely define which loads are being
considered. In the example of a Diesel UPS, which supplies critical loads but also loads in
which a transient interruption is not problematic (so-called Short Break Load) it can be
demonstrated just how big the difference can be in the overall result.

• Efficiency calculation with and without a Short Break Load (see Fig. 4-1)

o 2 MW / 2.05 MW ≈ 97.6%
o 1 MW / 1.05 MW ≈ 95.2%

Figure 4-1 Power distribution of a Diesel UPS with a Short Break Load

Considering the Short break loads power values are taken into account which do not
contribute to the power losses of the UPS. The question here is: which is the correct
calculation?

Another important point in this calculation is the consideration of the flywheel during mains
operation. The speed of the flywheel must be kept constant in order to allow for a defined
energy level in the event of a mains failure. This is why it is necessary to reload a certain
amount of energy which balances the losses of the flywheel.

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 • Efficiency calculation with and without allowance for the flywheel storage unit
(see Fig. 4-2)
o 1 MW / 1.05 MW ≈ 95.2%
o 1 MW / 1.04 MW ≈ 96.2%

Figure 4-2 Power distribution of a Diesel UPS with and without energy storage unit

If the flywheel storage unit is not taken into account in the efficiency calculation (permissible
according to UPS Standard EN 62040-3), the losses incurred in maintaining the charging of
the storage device are ignored. This does not represent true UPS operation.

Maintenance

In systems with a large proportion of machinery, as is the case of the Rotary UPS, regular
maintenance is essential. The machine bearings of the Diesel engine, flywheel storage unit
and generator in particular are continuously under load. There are important points which
should be considered with regard to the maintenance expenditure:

• Regular replacement of bearings or only when faults are indicated

• On-site maintenance of bearings is possible or only at the manufacturer's premises

• Number of bearings
• Automatic in-service lubrication or manual lubrication only during downtime.

Reflecting to the different rotary UPS systems, for the electrical coupled system the
inspection and overhaul of the bearings is advantageous due to the ease of entry and
number of bearings. No overhead lifting system is necessary to replace the heavy-duty
converter like for the induction coupling of the mechanical coupled systems.

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The UPS - Genset systems have the ability to power the load with UPS support whilst
maintaining the Diesel engine. That is not possible under safe conditions with the Diesel
UPS. Not just maintenance is to be taken into account in the cost calculation. The downtimes
of the system itself, which occur as a result of these operations, and the risks which can arise
due to unsafe operation of the loads during this period, must also be considered.

Total cost of ownership (TCO)

The total cost of ownership of a UPS system consists of the one-off investment in the
procurement of components, the electrical operating costs, and the costs of maintenance
and servicing. If, nevertheless, the same bases for calculation in the cost accounting are
assumed, there are manufacturer-specific differences in operating costs. The same also
applies to maintenance and servicing costs. The differences are system-related but are also
associated with quality aspects, in development and manufacture of the system. A diagram
which represents total cost of ownership of two UPS systems from different manufacturers,
calculated for a period of 10 years, is shown below. With the same initial investment there is
a considerable difference in the operating costs over 10 years, which far exceeds the initial
investment.

Figure 4-1 Bar chart of total cost of ownership of two competitors over 10 years

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5 Summary
For high-power UPS systems the Rotary UPS systems are the most widely used. Here the
systems with an electrical coupling to the energy storage unit are proving to be far and away
the most flexible, since flywheel storage units as well as batteries can be incorporated as the
storage medium. Paralleling flywheels the energy content is much larger with these systems
and thus the ride through time much higher at the same load size. Due to the possible
vertical arrangement of the individual machines they offer clear space-saving advantages.
Different to the induction coupling system the inspection and overhaul of bearings and
inverter is easier done.
In the field of Diesel-backed UPS systems, electrically coupled energy storage units absorb
rapid changes in load, without the risk of overloading the Diesel engine or of unduly large
frequency deviations. The Diesel engines can also be installed as Diesel-generator
combinations, physically isolated from the UPS system, if operational restrictions require it.
Here the modern DeRUPSTM (Diesel electrically coupled Rotary UPS) is advantageously with
the possibility to separate maintaining Diesel engine and UPS whilst safe power supply of the
connected load.

6 References
1. Herbener, Dipl.-Ing. Frank. Rotary UPS and Gensets. 2013. Piller Whitepaper. WP061-1.

Piller Group GmbH,

Joachim.Hose@piller.com, Germany
White Paper No. 0062-0 / May 2013

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