Technical project references detailing customized DC UPS, battery chargers, and power conversion systems across global critical infrastructure.
For over three decades, international EPC contractors, utility authorities, and industrial system integrators have trusted Helios Power Solutions to engineer reliable power conversion and backup architectures. The case studies below demonstrate our capacity to fulfill strict technical specifications, environmental compliance, and SCADA integration requirements.
Helios Power Solutions engineered a fully monitored DC UPS system designed for 11kV switchgear protection duty. Delivering 5.5kW output at 110VDC from a 400VAC 3-phase input, the system was supplied to Ravensdown Fertiliser in partnership with ABB New Zealand to maintain uninterruptible protection relay and tripping power.
A specialized dual-output 21U power system integrating 5.5kW 110VDC and 1.2kW 24VDC modular battery chargers with high-temperature battery banks. Designed for transmission grid substations in New Zealand, featuring complete N+1 modular redundancy, active temperature compensation, and SNMP/DNP3 Ethernet interface.
Airfield Approach Lighting Systems (ALS) demand continuous power availability during low-visibility landings. Helios custom-engineered a redundant industrial battery charging setup with instant switchover and fault isolation, ensuring zero operational disruption for airport air traffic control and landing aids.
Engaged during the initial engineering design phase alongside ABB, Helios manufactured and factory-tested industrial DC backup power systems for the bark handling and heavy processing machinery at OKI Pulp & Paper, preventing costly un-planned mill shutdowns.
Following severe cyclone damage, two heavy-duty 6.2kW float chargers were deployed to restore micro-hydro power station operations. Standardized for high ambient humidity and marine atmospheres, these systems power hydraulic control valves and turbine lubrication systems.
Factory-tested 1+1 redundant 48V 50A convection-cooled modular charger plants supplied across six transmission substations for the Power Grid Company of Bangladesh (PGCB). Designed to protect vital SCADA/EMS systems and telecom NMS nodes.
Custom design and manufacture of high-capacity 750V boost charging stations used to rapid-charge specialized electric maintenance vehicles operating on the Auckland Harbour Bridge infrastructure, built to withstand continuous vibration and heavy daily duty cycles.
A summary of technical parameters and compliance capabilities implemented across our engineered DC and AC system references.
| Application Sector | Nominal DC Voltages | Redundancy & Architecture | SCADA Protocols & Standards |
|---|---|---|---|
| High Voltage Substations | 110VDC / 125VDC / 220VDC | N+1 Modular / Dual Bus 1+1 Redundant | DNP3 TCP/Serial, Modbus RTU, IEC 61850 Alarm Mapping |
| Rail & Transit Systems | 24VDC / 48VDC / 750V Charging | Hot-Swappable Shelves, Shock-Mounted Enclosures | EN 50155, Conformal Coating, Temperature Compensated |
| Critical Infrastructure & Airfields | 24VDC / 48VDC / 110VDC | Active Redundant Chargers + Battery Bank Monitoring | SNMP Traps, Volt-Free Dry Alarm Contacts, IP54/IP65 |
| Process & Paper Mills | 110VDC / 220VDC High Current | Thyristor / Switch-Mode Heavy Industrial Chargers | IEC 60146, IEEE 485 Autonomy Sizing, Boost/Float Profile |
We assist consulting engineers, OEM designers, and EPC contractors from single-unit custom modifications to complete utility-grade system packages.
Submit your electrical single-line diagram, ambient parameters, and load profiles. Our engineers will verify system sizing and protocol mapping.
Every custom system undergoes full factory testing, insulation resistance checking, and functional verification prior to export dispatch.
Regional hubs across Australia, New Zealand, Asia, and the Middle East provide long-term spare parts, documentation, and technical support.
Download our complete engineering technical product catalog or speak directly with our engineering team.