Industrial UPS
For use in situations / industrial manufacturing , such as plant facilities and factories.

Home UPS

For use in Home, Fans, Lights.

Different types of UPS design

There are three general categories of modern UPS systems are on-line, line interactive or standby/offline.

An standby/offline UPS system the load is powered directly by the input power and the backup power circuitry is only invoked when the utility power fails. Most UPS below 1 kVA are of the line-interactive or standby variety which are usually less expensive.

An line interactive UPS maintains the inverter in line and redirects the battery’s DC current path from the normal charging mode to supplying current when power is lost.

An on-line UPS uses a “double conversion” method of accepting AC input, rectifying to DC for passing through the rechargeable battery (or battery strings), then inverting back to 120V/240V AC for powering the protected equipment.

For large power units, dynamic uninterruptible power supplies are sometimes used. A synchronous motor/alternator is connected on the mains via a choke.  When the mains power fails, an Eddy-current regulation maintains the power on the load. UPS are sometimes combined or integrated with a diesel-generator, forming a diesel rotary uninterruptible power supply, or UPS.

Standby/Offline UPS design

The Standby/Offline UPS system (SPS) offers only the most basic features, providing surge protection and battery backup. With this type of UPS, a user’s equipment is normally connected directly to incoming utility power with the same voltage transient clamping devices used in a common surge protected plug strip connected across the power line. When the incoming utility voltage falls below a predetermined level the SPS turns on its internal DC-AC inverter circuitry, which is powered from an internal storage battery. The SPS then mechanically switches the connected equipment on to its DC-AC inverter output. The switchover time can be as long as 25 milliseconds depending on the amount of time it takes the Standby UPS to detect the lost utility voltage. Generally speaking, dependent on the size of UPS connected load and the sensitivity of the connected equipment to voltage variation, the UPS will be designed and/or offered (specification wise) to cover certain ranges of equipment, i.e. Personal Computer, without any obvious dip or brownout to that device.

Line-interactive UPS design

This type of UPS is able to tolerate continuous under voltage brownouts and overvoltage surges without consuming the limited reserve battery power. It instead compensates by auto-selecting different power taps on the autotransformer. Changing the autotransformer tap can cause a very brief output power disruption,[citation needed] so the UPS may chirp for a moment, as it briefly switches to the battery before changing the selected power tap.

This has become popular even in the cheapest UPS because it takes advantage of components already included. The main 50/60 Hz transformer used to convert between line voltage and battery voltage needs to provide two slightly different turns ratios: one to convert the battery output voltage (typically a multiple of 12 V) to line voltage, and a second one to convert the line voltage to a slightly higher battery charging voltage (such as a multiple of 14 V). Further, it is easier to do the switching on the line-voltage side of the transformer because of the lower currents on that side.

To gain the buck/boost feature, all that is required is two separate switches so that the AC input can be connected to one of the two primary taps, while the load is connected to the other, thus using the main transformer’s primary windings as an autotransformer. Note that the battery can still be charged while “bucking” an overvoltage, but while “boosting” an under voltage, the transformer output is too low to charge the batteries.

Autotransformers can be engineered to cover a wide range of varying input voltages, but this requires more taps and increases complexity, and expense of the UPS. It is common for the autotransformer to only cover a range from about 90 V to 140 V for 120 V power, and then switch to battery if the voltage goes much higher or lower than that range.

In low-voltage conditions, the UPS will use more current than normal so it may need a higher current circuit than a normal device. For example to power a 1000 watt device at 120 volts, the UPS will draw 8.32 amps. If a brownout occurs and the voltage drops to 100 volts, the UPS will draw 10 amps to compensate. This also works in reverse, so that in an overvoltage condition, the UPS will need fewer amps of current.

On-Line UPS Design

The online UPS is ideal for environments where electrical isolation is necessary or for equipment that is very sensitive to power fluctuations. Although once previously reserved for very large installations of 10 kW or more, advances in technology have permitted it to now be available as a common consumer device, supplying 500 watts or less. The online UPS is generally more expensive but may be necessary when the power environment is “noisy” such as in industrial settings, for larger equipment loads like data centres, or when operation from an extended-run backup generator is necessary.

The basic technology of the online UPS is the same as in a standby or Line-Interactive UPS. However, it typically costs much more, due to it having a much greater current AC-to-DC battery-charger/rectifier, and with the rectifier and inverter designed to run continuously with improved cooling systems. It is called a Double-Conversion UPS due to the rectifier directly driving the inverter, even when powered from normal AC current.

In an online UPS, the batteries are always connected to the inverter, so that no power transfer switches are necessary. When power loss occurs, the rectifier simply drops out of the circuit and the batteries keep the power steady and unchanged. When power is restored, the rectifier resumes carrying most of the load and begins charging the batteries, though the charging current may be limited to prevent the high-power rectifier from overheating the batteries and boiling off the electrolyte.

The main advantage to the on-line UPS is its ability to provide an electrical firewall between the incoming utility power and sensitive electronic equipment. While the standby and Line-Interactive UPS merely filter the input utility power, the Double-Conversion UPS provides a layer of insulation from power quality problems. It allows control of output voltage and frequency regardless of input voltage and frequency.

A second major advantage is the inbuilt bypass circuit in on-line UPS which ensures should any problems occur with the UPS or batteries as long as there is mains power the load will be powered. The bypass is either automatic or a combination of manual and automatic depending on the model/manufacturer.