UNIBLOCK UBTD+ ™

Diesel Rotary UPS

Nothing protects quite like Piller

piller.com
 UNIBLOCK UBTD+ ™

About Piller Manufacturing in a state-of-the art facility where Whatever the situation, facility designers have an
Piller headquarters, Osterode, Germany.
Founded in Hamburg, Germany over 100 years all products can be seen in the making, from raw obligation to end users to develop a technical
ago by Anton Piller, the company has a long history material through to finished goods. In 2016 Piller solution which minimises risk whilst optimising
in the manufacturing of exceptionally high quality Power Systems Inc., the US subsidiary of Piller whole life costs. At the same time, the final
electrical machines and power quality equipment. Group GmbH, acquired the business and assets of solution must be practical for maintenance and
Active Power Inc., a US kinetic energy storage versatile enough to be future proofed.
Today, Piller is a world leader and innovator in a
specialist. Piller Group GmbH is a division of the
number of power protection technologies, The new Piller UNIBLOCK™ UBTD+ family is exactly
UK based engineering and industrial group,
specialising in UPS systems for ‘mission critical’ that kind of UPS, combining state of the art machine
Langley Holdings PLC. (www.langleyholdings.com).
applications and Frequency Converters for Aircraft technology and electronics to deliver outstanding
Ground Power amongst other uses. For the past Power around the clock, around the world reliability, efficiency, flexibility and performance.
30 years, the company has designed and Power quality varies dramatically around the world.
Introducing the UNIBLOCK™ UBTD+
manufactured static technology products along- In some regions, adverse weather leads to regular
The UBTD+ is unlike any other UPS. Consisting
side its rotary counterparts, giving it a unique power supply disturbances and total failures. In
others, poor infrastructure causes voltage drops, of a special combination of proprietary motor-
position with widespread specialist capabilities
frequency instability and outages. In addition, the generator and choke, this UPS provides a very
for today’s power protection clients.
electrical characteristics of loads place a variety simple and highly reliable uninterruptible power
Piller UPS systems are found in colocation data solution with exceptionally high efficiencies.
of demands on the power source.
UBTD+ has the highest design flexibility: centres, financial institutions, broadcasting, tele-
n Low and medium voltage systems For industrial applications, there will often be The technology employed provides an extremely
communication networks, airports, healthcare
n Ride-through energy from batteries or extremely high power requirements spread across robust, small footprint, high power solution designed
facilities, continuous process production sites and
kinetic storage large sites, rapidly changing high current loads or to give over 20 years of dependable operation.
applications where high quality power is paramount.
n Cooling by air or chilled water the need for long term outage support. Not only that, The UBTD+ is available in single module sizes
Piller Frequency Converters and related products ownership and running costs of any solution from 500kW to 2700kW with options available in
n Containerised solutions
are prevalent in both military and civil applications, have to be factored in to the manufacturing or terms of energy storage and diesel engine
n Delayed or instant diesel starting
providing 400Hz ground power at airports, processing costs. thereby offering versatility to meet the specific
n Sophisticated load-dependent
50/60Hz ship-to-shore supplies in ports and on-
management options IT applications like data centres, on the other hand, conditions and load requirements. With the
board power systems for both submarine and
often have a different focus, with loads that are UNIBLOCK™ UBTD+ multiple system configurations
surface vessels.
less dynamic but where performance specifications are readily possible. Paralleling is simple, modular
Since 1919, Osterode in Germany has been the are more precise and high operational efficiency expansion is easy and there are solutions for
2 home of Piller Research, Development and combined with maximum uptime is paramount. every size of installation.
Mission Critical Power
Principle of Operation The UNIBLOCK™ machine’s motor and generator System Reliability Power Quality Improvement
The UNIBLOCK ™
UBTD+ Diesel Rotary UPS windings share a common stator and a single A design free of power capacitors eliminates the The UBTD+ will compensate for the supply of very
combines all the benefits of a rotary UPS with a brushless rotor to provide a highly compact common failure component generally found in static low input voltages, including voltage sags to 50% of
diesel engine in one integrated unit. double winding machine with unique electrical UPS. The durable rotary machine technology is nominal voltage, without disconnection. It can
characteristics. The combination of special electric far less sensitive to damage from overload and protect against brownouts to -30% without even
The system consists of the UNIBLOCK™ motor-
steel and combined stator windings gives rise to other electrical disturbances and uses no brushes, having to use the ride-through stored energy.
generator (MG) connected via a free wheel clutch
a machine with exceptionally high efficiency whilst slip rings or complex bearing arrangements.
to a diesel engine, all mounted on a single short The unit easily handles 100% non-linear loads as
exhibiting the sub-transient reactance required
base frame. The load is normally fed via an The power electronics employ rugged semi- well as 100% step loads while maintaining a stable
for low harmonic distortion and high fault clearing
isolating and coupling choke connected to the conductor technology with no need for internal output. Acting as a bi-directional filter inside the
capacity. An incorporated damper cage reduces
utility supply. The choke has a second tapped device paralleling or multiple power capacitors. UPS, the choke eliminates the passage of nearly all
harmonics and the standard bearing design
connection to the motor-generator. In the event Bypass operation is not required for any aspect harmonics between load and source.
ensures long operational performance with minimal
of short interruptions or complete outages, the of the UPS function and in most cases, electric
maintenance. The machine is manufactured and
load is supported initially by a ride-through source cooling fans are eliminated by using the impeller
balanced by hand at the Piller factory to ensure
which can be either a conventional battery system of the UNIBLOCK ™ machine for the system
extremely long service life.
or a Piller POWERBRIDGE™ electrically-coupled cooling. All of these factors combine to provide a
UPS which exhibits a level of reliability that cannot Bypass
kinetic energy store – alternatives unique to the
be matched by other technologies.
Piller design and providing the longest ride-through Coupling Choke
times available in the market. With the load safely
supported, the diesel engine is then given a Bypass
command to start. Once up to speed, the system Diesel
Coupling Choke Battery Engine
hands over the long-term support of the load to
the engine by seamlessly engaging the clutch. M/G

The UNIBLOCK™ Motor-Generator UNIBLOCK™

At the heart of every Piller Rotary UPS lies the
pre-eminent UNIBLOCK™ synchronous motor- M/G
generator with its unique low-distortion, high
UBTD+ with external battery ride-through.
fault-clearing characteristics. POWERBRIDGE™ UNIBLOCK™
3
UBTD+ with POWERBRIDGE™ kinetic energy store.
 UNIBLOCK UBTD+ ™

Power Factor Correction supply transformer impedances, ensuring fault-

Power factor correction is automatic with the clearing current can be generated internally by
UNIBLOCK™ UBTD+ features
UBTD + . The MG and choke combination the UPS. This capability represents a step n Single machines sized 500kW
up to 2700kW
compensates for poor power factor loads so that improvement in fault tolerance of the power system
n Paralleling up to 40MW
the utility sees near unity across all load levels. when compared for example, to a conventional
This means no electricity tariff penalties need static UPS solution. n Higher reliability than other technologies
apply and additional power factor correction units n Highest partial and full load efficiencies
Simple Maintenance with energy store connected
are not required.
Nothing in the standard UBTD+ design requires n Total design flexibility
Fault Handling off-site refurbishment and the maintenance
n Medium and low voltage options
The UBTD+ is inherently capable of clearing short requirements are less than most alternative
n Battery or kinetic energy store versions
circuit faults by virtue of extremely low sub-transient topologies, with no power capacitors or fans to
n Typically 3 times longer bridging time
reactance, that approximates towards normal be periodically changed. Life expectancy of the from the POWERBRIDGE™ compared with
UNIBLOCK™ easily exceeds 20 years. other UPS
n Fastest recharge time with
POWERBRIDGE™
Motor and Generator Windings n Wide leading and lagging load power
in a common Stator factor without de-rating
n Inherent fault clearing ability for
Common Rotor downstream short circuits
with Damper winding System Fan n Virtual unity input power factor
n 99% input/output harmonic isolation
n Small footprint and high power density
Brushless Bearing n Simple maintenance requirements
Excitation

Bearing

4
Energy storage solutions
POWERBRIDGE™ Option reduces forces on the main bearings, resulting in
Piller’s electrically-connected kinetic energy storage extremely high efficiency. This also serves to
option offers designers the chance to save space extend the bearing life ensuring many years of
and maximise power density per unit. continuous operation.

The POWERBRIDGE™ comprises a vertically- A vertically mounted flywheel and generator utilising
mounted synchronous generator whose rotor is magnetic bearing technology, the POWERBRIDGE™
connected to a flywheel to provide the energy is available in a number of sizes for different power
storage. Whenever stored energy is needed, it is ratings and ride-through autonomy.
discharged though the generator into a converter
Battery Option
stage that ensures a stable frequency into the
The Piller UNIBLOCK™ UBTD+ is also available
UNIBLOCK™ motor-generator. Recharge works
with an option where batteries are used to
similarly in the opposite direction.
provide the ride-through energy. While the
With a POWERBRIDGE™, stored energy levels electrical efficiency of a battery solution is superior
are guaranteed, air-conditioned battery rooms to any equivalent kinetic energy solution, there is
can be avoided and there is no environmental a trade off against space and other key factors.
disposal issue to manage in the future. However, the longer and customised autonomy
of batteries offers the advantage of further limiting
Significantly, a POWERBRIDGE™ can absorb
diesel engine starts which may be required in
energy at the same rate as it can dissipate and
certain applications.
can do so on an indefinite basis. No other electrical Top bearing
storage solution can equal this. This capability The UNIBLOCK™ system is extremely battery- Brushless excitation
acts as a cushion for the engine so as to provide friendly, helping to maximise battery service
Main machine
unequalled frequency stability under dynamic load life and reduce costs as the batteries are not
conditions. Magnetic-lift technology significantly subject to constant harmful DC ripple currents Flywheel
from rectifier-inverter operation. Bottom bearing

5
 Other design solutions
UNIBLOCK™ UBTD+ Water-Cooled Option In this configuration, each UBTD+ unit has a closed UNIBLOCK™ UBTD+ Containerised
The UBTD + can be naturally cooled with the air cooling circuit that passes via a heat exchanger The Piller UNIBLOCK™ UBTD+ can be installed in
UNIBLOCK™ impeller ducting the warm air straight cabinet integrated at the end of the UPS. With the a plant room or supplied complete from the factory
to the outside world. When site restrictions make cooling unit providing the UPS with its own climate as a containerised unit. All components necessary
this impossible, the plant room can either be the UPS can be operated in small rooms, in harsh for operation are integrated into the container,
force-cooled or alternatively, the UBTD+ can be environments or in areas where quiet operation is making the Piller UNIBLOCK™ UBTD+ a transportable
Water-cooled benefits: provided with its own heat exchanger directly required. Without the need for external forced UPS system ready to be set to work wherever a
n Higher efficiency in the plant room connected to the building’s chilled water supply. cooling, complex plant room airflow studies can be project programme better suits off-site construction
n Capable of operation in harsh eliminated, space can be saved and maintenance or wherever utilisation of the building space needs
environments routines simplified. to be maximised.
n Reduced investment costs
n Lower operating costs
n Smaller space requirement
n Quieter operation

A Air flow

Cross section of water-cooled unit

A: The enclosed air circuit is operated by an
internal fan impeller incorporated in the
rotor of the electrical machine
B: The UNIBLOCK™ with built in water
cooling is connected to the chilled water
circuit of the building.

6 B
 Optimised protection
Enhanced Diesel Engine Starting Thanks to the POWERBRIDGE™, the unique design within its POWERBRIDGE™. Where other diesel
Containerised benefits: Research shows that in most utility supplies, mains of the Piller UNIBLOCK™ UBTD+ gives an extended UPS solutions need virtually all of their stored
n Operating readiness immediately on disturbances lasting more than 10ms occur almost ride-through capability with no need to start up energy just to run the generator up to speed and
connecting to the mains
daily, jeopardising or substantially disrupting the the diesel generator for the majority of mains take over the load, the stored energy of the Piller
n No structural measures for noise
operation of electrical equipment. disturbances. This can reduce the number of UNIBLOCK™ UBTD+ removes the need to start
attenuation, ventilation or cabling
false generator starts to practically none, compared the engine except for the longest of outages, which
n Minimal expenditure for on-site testing In a typical overhead network system, over 60%
and commissioning with around 5 starts per week with other diesel could be seconds, or even minutes.
of all mains failures last more than 100ms and
n No outlay on complex installation or plant UPS solutions.
yet only some 2% continue for more than a few
room construction
seconds. In countries where the power supply The Piller Diesel UPS system’s ability to ride through
n Temporary use in different locations or
system is still developing, the statistics show nuisance disturbances without a generator start
use in modular expansion
more outages, which also tend to be longer. comes from the large storage capacity available
n Reduced on site programmes
208

Number of Mains Failures per year

182

62
18
9 8
10ms - 100ms - 0.5s - 1s - 3s 3s - 20s 20s - 60s
100ms 0.5s 1s
Duration of Mains Failure

Others Piller

Engine Speed
0 t
4s x - variable from seconds to minutes

Containerised UNIBLOCK™ UBTD+. No Diesel start

7
 Unit configurations
The UNIBLOCK™ UBTD+ UPS the Short-Break Bus. The two circuits are isolated backup. This backup unit normally operates in a
In its basic form, the Piller UBTD+ provides 100% by virtue of the transformer action between the no-load condition. In the event that one unit fails
of its available output as continuous uninterruptible windings and so the two outputs are electrically or is taken off-line, the critical loads are
power. In alternative forms, the power is split isolated. In other circumstances, use of the automatically transferred to the redundant unit
between UPS (Critical Bus) power and Short- same alternator for both supplies may be a via seamless change-over instead of going
Break power (similar to a standby generator). preferred option, particularly in MV solutions. to bypass.
This is known as Dual Output Bus.
Isolated Redundant Configuration Additionally, some non-critical load can be
Depending upon the particular design requirements, Traditionally, where redundancy was required a connected to the redundant unit utilising the
it is sometimes necessary or desirable to isolate parallel redundant configuration would be used. available diesel UPS power. Compared to the
the short-break loads from the Critical Bus – this With an isolated redundant configuration, parallel redundant configurations at low voltages,
is known as Dual Output Isolated Bus. In this redundancy is created on the basis of standard this configuration can be used for much higher
configuration, the generator winding provides the single units. All individual units support their system power ratings without the need to adopt
Critical Bus source and the motor winding of the individual critical loads. In an ‘N+1’ configuration, medium voltages.
UNIBLOCK™ machine becomes a generator for these systems have one redundant unit as a

Bypass Bypass

Coupling Choke Coupling Choke

POWERBRIDGE™ POWERBRIDGE™

MAINS MAINS
LOAD LOAD
ALTERNATIVE ALTERNATIVE
M/G Diesel M/G Diesel Dual
Engine Engine Output Bus

UNIBLOCK™ UNIBLOCK™

BATTERY BATTERY Dual Output

Isolated Bus UNIBLOCK™ UBTD+ with
alternative Dual Output
UNIBLOCK™ UBTD+ in standard output configuration. Bus configurations.
8
MAINS SB

LOAD SB
System configurations
Distributed Redundant Configuration The UBTD+ in High Power Applications Isolated Parallel (IP) Configuration
In the isolated redundant configuration, the The UNIBLOCK ™ UBTD + is available for high The isolated-parallel system uniquely enables the
Other UNIBLOCK™ Configurations:
redundant unit normally supplements a non- power applications with unit sizes ranging from advantages of combining isolated-redundant and n System + System
critical load, or runs with no load; this arrangement 500kW up to 2700kW. In medium voltage parallel-redundant UPS configurations. This means n Hot-Stand-by
can be enhanced with the distributed redundant systems, the units can be paralleled to 40MW, that very large ‘N+1’ redundant electrical systems n Parallel Redundant
concept. Distributed redundant systems are either with individual or common coupling chokes. can be created at low voltage without excessive
normally designed for ‘N+1’ redundancy. No single At low voltages, simple paralleling is limited to about fault currents and that at any voltage, the
module is assigned as a redundant unit. Instead, 5MW but there are configurations using fault configuration can be concurrently maintainable.
this role is shared equally among all modules. In isolated parallel techniques that allow this to be By reducing the redundant UPS units to a minimum
the event of a single unit failure, its load will be increased reliably and safely to 20MW. and avoiding systems which run in the standby
shared proportionately over the remaining units. mode the IP system is an excellent choice for
optimising the combination of redundancy, resilience,
The load transfers are accomplished through
maintainability and cost.
automatic transfer switches and/or via dual corded
equipment. The advantages are the elimination of
single point failures and equal load sharing among
all units.
NO-BREAK LOAD

SHORT-BREAK LOAD
IP- BUS

The UNIBLOCK™ UBTD+ can be paralleled

up to 40MW in an IP-Bus System.
9
MAINS
 Total Cost of Ownership
Owning and operating a data centre or large The TCO for a UPS is a combination of the capital
scale industrial process plant is an expensive expense, the electrical operating costs, the routine
A TCO analysis incorporating the
UNIBLOCK™ UBTD+ system compares
business; the cost of real estate and energy may maintenance and the periodic overhaul or
favourably with other solutions
heavily influence the final design and the location replacement. It is also dependent upon the requisite because of the combination of its
of the facility. Add to that the pressures of surrounding infrastructure (building space, running characteristics:
designing an environmentally friendly solution and costs, capital costs for switchgear, transformers, n High electrical efficiency
the restrictions become even greater. First and cabling, power factor correction and cooling). In n Very simple, economic maintenance
foremost, a UPS must be reliable. Secondly, it most TCO calculations, the dominant factor is and overhaul
should deliver an optimised total cost of ownership the electrical running cost of the entire system n Elimination or reduction of air
(or TCO) over its useful life. rather than capital costs or maintenance. conditioning requirements
n Reduced space requirement
n Cyclic maintenance and care work is
all undertaken on site
$ n Reduced engine wear by
minimised starting
18,000 n Natural cooling capability
17,000
16,000
15,000
14,000
13,000
12,000
11,000
10,000
9,000
UNIBLOCK™ UBTD+ Other Diesel Rotary UPS

Day 1 Investment $ Cost of Electrical Losses $ Cost of Maintenance/Overhaul $

10 TCO comparison by Expense Category (DCF)

Taking care of your investment
After Sales Service Emergency Response Service Consultation and Other Services
Piller believes it is simply not enough to manufacture Sometimes, support and expertise is needed Ever changing demands in business can lead to
a first class product with inherent high reliability. A when you least expect it. For those times, you the need for alteration, expansion or redeployment
UPS system must protect the client’s interests can be assured that help will be available in the of a UPS system. In such cases, Piller‘s technical
just as well on its last day as it does on its first, shortest possible time. Piller Service Centres are support teams will evaluate the requirements
which is why Piller offers a worldwide network for strategically positioned to provide local knowledge and advise on necessary changes. They can
the professional care of its clients’ investments in of the client’s installation and the best possible also manage the delivery of these changes,
Piller UPS technology, deploying a team of highly response time. Piller offers 24 hour emergency consulting with clients and their partners to
trained and internationally co-ordinated technicians. response with technicians on standby for immediate ensure minimal disruption.
dispatch at each of its service centre locations.
The team takes care of over 9000 units of high
power UPS equipment in over 40 countries, Preventative Maintenance Service n Replacement battery systems
supporting clients’ activities in data processing, Periodic preventative maintenance in accordance n Reconfiguration and redeployment
banking and finance, industry, communications, with well-defined Piller standards ensures security n Upgrades
aviation and defence, 24 hours a day, 365 days of supply to critical equipment as well as minimising n Remote monitoring systems
a year. malfunctions and extending the life of the UPS n Site surveys
system to 20 years or more.

Parts Availability Operator Training

Piller preventative maintenance and emergency All newly installed systems will involve a degree of
response services are fully supported by a operator training conducted either on site or in
network of stocked parts held both at the service one of Piller’s training centres. Piller offers further
centres and elsewhere in strategic locations around refresher courses to ensure that client staff or
the world. their appointed operational representatives have
the skills necessary to operate the UPS system
with minimum risk.

11
HEADQUARTERS
Piller Group GmbH
Abgunst 24
37520 Osterode
Germany
Tel: +49 5522 311 0
E: [email protected]

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Piller 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.