Powering Homeland Security Technologies
By Michael A. Stout, Vice President of Engineering, Falcon Electric

As military and government are faced with the difficulties of fighting the war on terrorism, an emphasis is placed on the rapid implementation of newly developed technology-based solutions. Due to the international nature of the war, these solutions must be deployed quickly, operate from any domestic, international or military power source, and operate with near absolute reliability. Incorporating COTS on-line uninterruptible power supply (UPS) and frequency converter products can offer the fastest solution to these requirements through their unique design topology.

Power quality issues such as line noise, high voltage transients, harmonic distortion and and frequency shifts can wreak havoc with sensitive communications and computer systems. On-line UPSs and frequency converters are the ideal choice to mitigate these problems as they take the incoming alternating current (AC) utility voltage and direct it through a surge protected rectifier where it is converted to direct current (DC), and filtered by large electrolytic capacitors. These systems also provide “ride-through” in the event of momentary power interruptions. If an on-line UPS is used, batteries are typically connected to this part of the circuit, providing battery backup in the event of utility loss. The filtered DC is now directed to a DC-DC converter or chopper, which steps up the voltage and provides DC voltage regulation. Next, the regulated DC voltage powers a 100% duty cycle Pulse Width Modulated (PWM) Inverter, where a new 50, 60 or 400Hz output is re-created. This facilitates a typical output voltage regulation of ±2%, while the utility voltage may vary up to ±20%.

Powering technologies from differing utility voltages is a simple matter of installing a transformer to adjust the voltage as required. Changing the frequency is not a simple matter however, and requires the use of a frequency converter. Additionally, not all international utility power sources are as regulated or reliable as those found in first-world countries. There is a good chance that sensitive computer-based systems will operate unreliably or possibly be damaged when connected to third-world utility power. Even if the equipment is connected to a reliable utility source, blackouts or localized power pollution created by other equipment operating within the same location may render the equipment inoperable. As new technologies are being developed by companies located throughout the world, the equipment may only operate on the voltage and frequency of a specific region; this includes 50, 60 and 400Hz.

One such company, CIS Secure Computing, is the fastest growing TEMPEST manufacturing company in the United States specializing in rugged and secure communications solutions for the United States Federal Government. EMI/TEMPEST, or simply TEMPEST, is a term the U.S. Army’s Blacktail Canyon Testing facility coined in 1981. TEMPEST addresses counter-espionage tactics and countermeasures that lead to secure computing, communications techniques, and hardware customization. Specifically, TEMPEST focuses on electromagnetic interference (EMI) signals that emanate from computers and other communications devices.

TEMPEST mandates a number of shielding methodologies and techniques for these signals to ensure classified information is not compromised. Without proper shielding, classified data or conversations can be compromised by surveillance equipment that is designed to intercept the EMI signals. This can be done from a distance of several hundred feet; for example, from a parked van outside an office building, or even greater distances using advanced technologies. As electronics evolve in sophistication, the need for security assurances provided by companies like CIS becomes even more critical.

CIS has one of the largest portfolios of products in the market, including numerous DO-160E qualified solutions. Their newest plant, a 23,000 square foot facility, is the first TEMPEST-certified manufacturing facility since the early 1990s, making CIS the most contemporary TEMPEST product manufacturer in the industry. Located in Dulles, Va., this plant is home to their computer and communications specialists, who have a combined industry experience of over 90 years and includes certified TEMPEST professionals, electrical, and mechanical engineers.

The DO-160E military specification, developed by the Radio Technical Commission for Aeronautics, focuses on the performance characteristics and environmental testing for airborne equipment, computers and communications gear. In particular, the DO-160E governs how well the equipment handles vibration, shock and the ability to remain intact should it be subjected to a high number of G-Forces in a crash. This is an area that CIS has a great deal of expertise.
“A recent project for the Air Force required a rugged rackmount uninterruptible power system (UPS) to protect sophisticated TEMPEST electronics housed inside an aircraft,” said John Turner, vice president and general manager of CIS Secure Computing. After reviewing several COTS products, Turner adds, “The Falcon ED Series™ 2400VA rackmount unit met the project’s UPS specifications. The ED Series’ on-line design allows the UPS to perform power conditioning and regulation as well as frequency conversion. Working together with Falcon, we were able to modify their product to meet the exact physical and environmental requirements of the customer. This included very demanding shock, vibration, and EMI requirements for aircraft deployment.

“In our line of business, we often collaborate with our suppliers to customize their hardware to meet exacting standards, such as DO-160E,” Turner explains. “This can lead to disappointing results when the supplier cannot provide the appropriate engineering support needed to complete the project. In this context, however, Falcon Electric is one of the best suppliers we have worked with in some time. Their engineering support has been superb throughout the entire project and we are already working with Falcon Electric on other projects. With Falcon, we have found a solid technology partner with a similar customer-focused quality standard that makes our business better and our customers happy.”

Not all products on the market utilize a true double-conversion on-line design, and will not provide the discussed capabilities. Always discuss your particular application in detail with the manufacturer’s applications engineer prior to incorporation of any on-line UPS or frequency converter product.

.COTS on-line UPS and frequency converters are readily available and exceptionally cost-effective, making them a viable solution to these difficult problems.

Falcon Electric
www.falconups.com
TXTLINX.COM130
Email this article to a friend!