Guidelines for High Reliability Remote Power System Design
Kevin Conlin, Vice President, Solarcraft, Inc.
Part one of a two part series! Remote’s June/July 2008 issue will feature part 2.

When designing high reliability power systems for critical loads at remote sites, a variety of considerations must come into play during the design process.
The purpose of this two part article is to familiarize the reader with the key issues affecting reliability. This first article will start with the simple, but often overlooked gathering of accurate load information, information, then onto how to accurately size a solar system and select the proper solar array and battery bank, how to select reliable components.

Cummins Power Generation is First-to-Market with IBC-Certified Generator Sets Under 230 kW

Cummins Power Generation has become the first manufacturer to publicly release International Building Code (IBC) certification on all its production generator sets under 230 kW. The IBC code, in various editions (IBC-2000, 2003 and 2006), is currently used at the state or local level in 47 states plus Washington, D.C. It addresses both the design and installation of building systems with an emphasis on performance in emergency situations.  The certification process is continuing on larger units and the company’s goal is to have all generator sets certified by the end of 2008. 

“The IBC code certifies that Cummins Power Generation generator sets can withstand specific seismic forces and remain ‘online and functional’ after an emergency has occurred,” says Gary LaFine, product director, commercial genset business, Cummins Power Generation.  “The code recognizes that a standby power system is a critical component of a building and needs to continue to operate during and after disasters such as hurricanes, earthquakes or even terrorist attacks.”

The IBC certificate of compliance qualifies the company’s generator sets rated at 230 kW and under for use in emergency power systems wherever the IBC code requires that seismically rated equipment must be considered.  Emergency standby power systems serve a critical need by providing electrical power to life-safety systems after the primary (utility) source has failed.

The primary applications for IBC-certified emergency power systems will be in earthquake and hurricane prone areas of North America. However, because the design parameters recommended by IBC affect a significant number of facilities in both public and private sectors, many types of facilities must now consider IBC-certified generator sets. They include healthcare facilities, telecommunications centers, power plants, military and government buildings and water treatment facilities, among others.

In accordance with section 1708.5 of the IBC, to be certified compliant with the code, a generator set must survive an actual test on a shake table or be proven to withstand specified seismic design forces through modeling and analysis in accordance with the American Society of Civil Engineers document 7 (ASCE 7).

DC-AC Inverter Provides Uninterruptable AC Power

Wilmore’s low-profile 1,000-VA dc-to-ac inverters are now available with optional built-in automatic load switchover features enabling them to operate in UPS or standby-power modes in conjunction with another AC source, commercial ac power or a second inverter, for example. Model 1725 inverters occupy only 1.75 inches (1U) of vertical space in 19 or 23 inches equipment racks with or without the optional switchover features.

Available in 24, 48 and 130-Vdc input versions, these inverters are designed for telecommunications, SCADA and security applications where a stable and reliable source of AC power needs to be derived from a DC-power (battery) system. The efficient, approximately 90 percent, Model 1725 inverters provide an isolated, regulated 120-Vac, frequency-stable 60-Hz, quasi-sine-wave output that is well suited for powering a variety of loads.

New SolarPulse Charges Batteries While Removing Sulfate Deposits

Pulse Technology has released its new SolarPulse module. Available in three models, SolarPulse efficiently charges 12-volt batteries it also cleans the battery plates by removing the sulfate deposits from the plates and converts them to active electrolytes.
 
When installed permanently, SolarPulse not only provides clean, quiet energy but also help keep sulfates from building up again so batteries will stay strong all the time. With clean plates, batteries recharge faster, accepting a full charge and release all stored energy providing maximum power.

SolarPulse is currently available in 2-Watt (735X302 SP-2), 5-Watt (735X305 SP-5) and 6-Watt (735X613 12V ERV Unit), configurations. The 5-Watt solar panel is nearly half the size of other 5-Watt panels and offers more installation options. The 6-Watt model is ideal for emergency rescue and law enforcement vehicles due to its unique rectangular size, easily mounted on many light bars. The 2-Watt and 5-Watt models include 17 feet of wire between circuit box and solar panel, and the 6-Watt unit includes 14 feet of wire.

In addition to the clean, quiet energy charge and maintenance systems, SolarPulse helps offset energy-robbing key-off parasitic loads. The system works with all 12 V lead-acid batteries (flooded cell, AGM and gel) and is well suited for generators in areas without access to electrical power.

The low profile industrial-strength solar panel mounts flat, with no frame required, so it’s virtually indestructible. The system also typically extends battery life up to three to five times longer, and carried a five year warranty.

Tripp Lite’s New Switched and Metered PDUs Feature Centralized Configuration and Monitoring Software

Tripp Lite has expanded its line of power distribution units (PDUs) to provide new options in power capacity, form factor and management. Most new models feature Tripp Lite's built-in network interface that allows users to remotely monitor and control individual outlets and connected devices via SNMP, Web or Telnet.

"The new PDUs demonstrate our commitment to provide customers with the highest level of network functionality," said Rich Feldhaus, Tripp Lite product specialist. "The switched PDUs allows network managers to remotely control individual outlets and connected devices by remotely rebooting locked devices. Users can also extend runtime of critical devices by remotely turning off non-essential devices during a power interruption. These features will no doubt greatly reduce the number of costly service calls."

The Tripp Lite PDUs come in some 13 different configurations, for of which are 120 V models that come in varying levels of amps, mounting styles and outlets. The remaining units come in either 208V or 208V-230V with the same level of customization in regards to mounting, outlets and amps. 

For greater functionality, Tripp Lite offers free PowerAlert network management software to centrally monitor and control power for up to 250 UPS systems or PDUs on their network. PowerAlert allows managers to mass-configure multiple remote device settings from a single location and can also be set to auto-discover UPS and PDU devices in specific network segments or IP address ranges.  This software-only solution saves network managers the installation costs normally associated with other solutions that require additional hardware or license purchases.
PowerAlert software extends PDU capability beyond central monitoring and power control. Using Tripp Lite's Environmental Sensor  and a SNMP Web card, managers can also monitor external temperature/humidity and contact closure inputs.

Solarcraft, Inc. Develops New Mobile Solar Generator  

Solarcraft, Inc. has developed a new state of the art mobile power generator.  This portable system can travel to any location and provides temporary power where grid power isn’t available. 

“This system was custom developed for one of our customers and it can be utilized by many markets,” said Kevin Conlin, vice president, Solarcraft. “This is a perfect solution where solar alone is insufficient.  Because the unit is portable and can travel to any location it provides maximum reliability at an optimum cost with very minimal maintenance. ”

This Mobil Solar Generator provides from 100 to 1,000 watts of continuous power at 12, 24, 48 volts DC or volts 120 AC.  Suitable applications for this system include communications, radio, repeaters, instrumentation, remote monitoring, security and access control and is definitely the answer to any emergency disaster relieve or any other application where power is unavailable.

U.S. Army CERDEC Conducts Field Tests with UltraCell XX25 Reformed Methanol Fuel
Cell for Portable Power

The Communications-Electronics Research, Development, and Engineering Center’s Army Power Division (CERDEC) has recently completed prototype field tests at the Joint Readiness Training Center with the Ultracell XX25 Reformed Methanol Fuel Cell. This is the first experiment and training mission of its kind and demonstrates a huge step forward for fuel cell technology.

The U.S. Army Power Division’s Fuel Cell Technology Team is critically examining fuel cells and other alternative power technologies to provide a power solution that supports the digitized battlefield and growing power demands. Fuel cells offer high efficiency, low acoustic and thermal signatures, and low emissions. These incentives call for the Army to explore these technologies as a potential solution to the current power problem.

CERDEC’s current efforts reach across the globe and through many areas of fuel cell technology.
Several new fuel cell technologies are currently being evaluated as potential candidates to fill the power and energy gap within the military. These technologies are being scrutinized on performance and compared with the current military power solutions.

To date, in CERDEC lab tests, Ultracell’s XX25 has provided an advanced and mature fuel cell system. The XX25 is smaller and lighter than traditional military power sources, weighing only a few pounds, and provides a sustainable power supply that would significantly reduce the number of batteries a soldier would need to carry to operate equipment over long missions.

CERDEC coordinated with the JRTC to have soldiers field test the XX25 reformed methanol fuel cell. The field tests involved training soldiers on the use of XX25 fuel cells, supporting the equipment integration for the training missions, and equipping soldiers with fuel cells for use during training missions. CERDEC also obtained feedback from Soldiers on the fuel cell’s effectiveness upon their return from the field training.

A technical fuel cell team made up of CERDEC and Ultracell personnel provided all the equipment needed to power laptops, single channel ground-to-air radios, Army standard intelligence plotter systems, multiband inter/intra team radios, and BB-2590 battery chargers. The fuel cell team conducted a brief training session in a classroom environment with the soldiers on the uses and benefits of the technology.

The XX25 units were then signed out by military personnel for use with radios and laptops on a six day mission. Some applications included power for soldiers in observation posts, sniper posts and dismounted squads. Laptop computers were also powered by the XX25 in office environments where the fuel cells were used 24 hours a day with cartridges being swapped out every 12 to 15 hours.

There were no recorded failures in any mission scenario and all nine XX25 units that were used came back in working order. Weather conditions were 91°F during the day and 50 to 60°F at night with some light rain.

ersol Thin Film and Schott Solar Forge Alliance for the Development of Micromorphous Thin-Film Technology

ersol Thin Film GmbH and Schott Solar GmbH have concluded a cooperative agreement under which they will jointly develop micromorphous technology for thin-film solar cells. The two companies will be combining their resources in the area of research and development with the aim of achieving faster product maturity in micromorphous solar modules.

Substantial advantages can be anticipated from the merging of development activities in a location-independent project, e.g. shorter time-to-market for new products with optimized use of development resources.

Both ersol Thin Film and Schott Solar have already begun with the market launch of amorphous thin-film technology in the 1.4 sqm Gen 5 format. Schott Solar has been marketing Schott ASI thin film modules for a number of years. ersol Thin Film markets its amorphous modules under the brand name Nova-T series. Parallel to this, the company will now be pushing ahead with the development of micromorphous technology as the next generation of silicon-based thin-film technology.

Deposit plants already existing for amorphous production permit conversion to the manufacture of microcrystalline cells. In the event that the project is a success, the preliminary work already performed will enable the development alliance to become one of the first companies to market this new technology in Europe as a product.

In contrast to the simple amorphous version, the micromorphous thin-film module has a double-layer structure consisting of an amorphous and a microcrystalline silicon film. The arrangement results in improved exploitation of sunlight, because the two silicon layers convert the whole light spectrum into power.

Active Power Providing Green Power Protection to Two Blue Chip Manufacturers  

Power outages that last for hours or even momentary interruptions lasting for fractions of a second can prove costly to industrial facilities. These types of disruptions can potentially damage sensitive manufacturing equipment and shut down mission critical operations, forcing labor to idle as equipment is reset and brought back online. Electric Power Research Institute (EPRI) reports the “aggregate cost of power quality events is estimated at $300 million each year for continuous process manufacturers and represents a considerable opportunity for improved energy-management performance.”

To protect their critical manufacturing processes, two blue chip industrial manufacturers have deployed Active Power’s flywheel based uninterruptible power supply (UPS) systems at their facilities, both based in Norman, Okla. Honeywell Building Solutions purchased the systems from Active Power and delivered them to both customers. Honeywell engineers also designed the layout at both facilities, ensuring a smooth process from concept to equipment acquisition to deployment.

One of the end users is a manufacturing and design company specializing in the machining and assembly of engine components for automotive and diesel manufacturers. The operator deployed an Active Power CleanSource 600 UPS system at the facility. The other end user is a manufacturing company that provides electronic contract manufacturing services for mission and business critical solutions for a broad range of industries. Honeywell installed a CleanSource 1,200 UPS system for this end user.

“These manufacturing facilities now benefit from an extremely power dense and rugged critical backup power systems,” said Jim Clishem, president and CEO at Active Power. “Our CleanSource UPS systems are designed to operate in a wide ambient temperate range which is typical on a manufacturing floor with no degradation in service over its 20 year design life.”

Fat Spaniel Partners with OutBack to Monitor Off-Grid Solar Energy Systems

Fat Spaniel Technologies, Inc has announced a service for managing solar inverter and battery systems from OutBack Power Systems, Inc.. Fat Spaniel’s monitoring system now communicates directly with the OutBack hardware to deliver real-time and historical energy system data about charge status, output, faults and greenhouse gas avoidance. The integrated offering helps system installers and operators effectively monitor and maintain remote, off-grid solar installations as well as grid-tie battery backup systems.

“Support for OutBack’s energy systems expands Fat Spaniel’s battery backup and off-grid services to ensure that our installers and end-customers worldwide are able to effectively monitor and maintain even the most remote solar energy systems,” said Chris Beekhuis, president and CTO of Fat Spaniel Technologies. “The partnership also builds on Fat Spaniel’s strong service offering which already has made the company the leader in monitoring services in the North American solar electric market.”

Fat Spaniel is currently monitoring OutBack systems at remote sites throughout North America. A recent installation was an 8 kilowatt system on Guemes Island, one of approximately 450 small islands in the San Juan archipelago. The photovoltaic system provides primary and emergency power for the Guemes Island Fire Station. Only accessible by ferry, the system was installed and maintained by Solar Energy International which now uses Fat Spaniel’s service to reduce travel time and costs, optimize energy generation, and rapidly identify and respond to system faults.

Remote 2008 Conference Call for Papers Deadline is April 25th, 2008!

Professionals in the onsite, back-up, stand-by, co-generation, Gen-Set, renewables, UPS, Flywheel and power protection markets, we need you to speak the Remote 2008 Conference and Expo! The deadline for submitting speaking submissions is April 25th, 2008. Don’t miss out!

Onsite Power Topics Include: (But are not limited to)

• Back-up and Stand-by Power Solutions
• Gen-sets, Fuel Cell and Other Onsite Power Solutions
• Renewable Energy as a Remote Power Source
• Power Reliability for 24/7 operation
• Dual Redundancy of Power for Critical Operations
• Low Power Systems for Monitoring and Communications
• Power Protection Systems (UPS/Flywheel)

For more information please visit: http://www.remotemagazine.com/rem08_call.php

May
4-6, Niagara Summit, Chapel, Fla. Contact www.niagarasummit.com

4-7, UTC Telecom, Orlando, Fla. Contact - http://utctelecom2008.utc.org

5-7, Battcon 2008, Pompano Beach, Fla. Contact www.battcon.com

5-8, Offshore Technology 2008, Houston, Texas Contact www.otcnet.org/2008

14-15, West Coast EMC, Seattle, Wash. Contact - www.aeecenter.org/shows

18-19, ISA100 Solutions Summit, Cleveland, OH. Contact www.isa.org

20-22, Connectivity Week, Santa Clara, Calif. Contact: www.connectivityweek.com/about.asp

28-30, Utilities Field Service 2008, New Orleans, La.
Contact www.utilitiesfieldservice.com

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