5 Must-Have Features in a Industrial UPS Systems

While UPSs in data centers are critical for business continuity and protecting the bottom line, in other instances loss of power can be even more catastrophic. Consider a petrochemical station or a ship at sea, where power loss could well be a matter of personal safety, and even loss of life. Or an assembly plant, where a power failure could result in the waste of inventory and many man-hours of labor. The list goes on and on.

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So when it comes to applying UPS technology to industrial applications, customers have numerous issues to consider in order to select the right solution, one that will ensure not only effective disaster recovery and business continuity but safety, efficiency and the proper functioning of the facility and the equipment in it. With that in mind, the following are my top five issues to consider when selecting a UPS for critical industrial applications.

1. Environment
The environment in which the UPS will live often dictates the type of UPS you’ll need. A UPS intended for a typical data center is intended to function well in a room with temperatures of 32° to 104° F (0°-40°C) and a relatively humidity range of 0 to 95, with ingress protection sufficient to prevent disruption from fingers, tools, large falling debris and stray cables. That may seem like sufficient environmental protection, but not if you’re putting the UPS on a ship at sea, where it’s subject to exposure to salt water spray and salt air. Or consider an oil exploration field in the southwest, where a UPS could be subject to temperatures well over 100° for long stretches, not to mention plenty of dust and sand. In other situations, such as a factory floor, a ship or areas subject to earthquakes, vibration and stability could be an issue.

These sorts of extreme environments call for specialized, often ruggedized UPSs that are built to withstand such conditions. Various certifications and design approaches exist from the likes of NEMA, OSHPD and others for all sorts of such conditions, such as outdoor corrosion resistance, heat, residual or spraying water and excessive humidity. The key is to work with an engineer or UPS vendor to determine what special requirements you have and select or custom-build a UPS that will perform in that specific environment.

2. Load profile
Your UPS should also be sized to appropriately fit the electrical properties, or load profile, of the equipment the UPS is intended to protect. Consider factors such as the maximum load the UPS will protect, and whether that max load typically happens in short bursts or for long periods of time. Some equipment, such as industrial or 3D printers, laser cutters and scanning devices, also present non-sinusoidal current requirements or harmonic complications, which may boost the load requirements of the UPS that protects them or the sorts of filtering accessories it needs. Similarly, a typical commercial UPS can’t absorb power generated from the load, such as regenerative feedback from synchronous motors. If a variable frequency drive or soft-start kit is being used with a motor-based load, that will likewise affect the UPS size you need.

Here again, it takes a careful conversation with your engineer or a trusted UPS vendor to thoroughly assess the loads that need protecting and to select the most appropriate UPS.

A UPS protecting industrial loads should also have sound metering and reporting capabilities, so it can send an alert if any load issues arise and show reports on load over time, to help you assess the impact of any changes that have occurred.

3. Efficiency
Another selection criterion for a business-critical UPS (or any UPS, really) is energy efficiency. While a more efficient model may cost a bit more up front, if it provides a savings of even 5% or so over its lifetime compared to other models, in a large environment you could be talking six-figure savings – more than enough to pay for itself. (Read this previous post to learn more about various approaches to UPS efficiency.)

4. Network integration
These days, just about anything can be monitored – but not if you can’t connect to it. So be sure to consider whatever network you have in your environment and to get a UPS that can connect to it. Any UPS deemed suitable for critical applications should support management, whether via a network management card or simple web interface, and protocols such as SNMP. So long as you can connect it to the surrounding network, whether it’s Ethernet, Modbus or a serial network, you should be able to feed UPS management data into whatever tool you use to monitor the rest of the operation.

Keep in mind, of course, that anything that connects to your network should be secure. So be sure your chosen UPS has a track record of security, with features such as strong authentication and encryption. (Check out this Frost and Sullivan report to learn more.)

5. Industry experience and service
Critical applications should only be trusted to UPS vendors that have a track record to stand behind. Ask about industry experience and the extent to which they stand behind the product. How fast can they respond in case of an emergency – and to the exact location that you require? Ask, too, about the range of options available in terms of accessories, including those from third party partners. Extensive safety features are another sign of an experienced UPS vendor, including back feed protection and dead front panels. Multiple energy storage options are also a plus, including not just traditional valve-regulated lead-acid batteries (VRLA) but newer lithium ion batteries, which promise longer life and the same power in a smaller footprint compared to VRLA. Another option is kinetic flywheels, which also reduce footprint and eliminate electrolyte and hydrogen concerns from the site.

For more background on UPSs and their characteristics, download the free APC by Schneider Electric white paper, “The Different Types of UPS Systems.”

In the fast-paced world of industrial operations, power is the lifeblood of productivity. A sudden loss of power can bring production lines to a halt, damage critical equipment, or cause data loss, leading to costly downtimes. That’s where Uninterruptible Power Supply (UPS) systems step in. They act as a safety net, ensuring that your industrial operations remain unaffected by power disruptions, surges, or outages. However, industrial UPS systems are more than just backup power solutions—they’re essential in ensuring long-term operational efficiency and safety.

In this guide, we will examine industrial UPS systems, how they work, and why they are indispensable for industries that rely on uninterrupted power. Understanding their capabilities enables you to make informed decisions to protect your infrastructure from power-related mishaps.

Understanding Industrial UPS Systems

An Uninterruptible Power Supply (UPS) system is designed to provide backup power when the main electrical source fails. In industrial settings, UPS systems play a critical role, as these environments often use heavy machinery, sensitive electronics, and critical data systems that cannot afford power disruptions. Unlike typical UPS systems used in residential or office settings, industrial UPS units are built to handle larger loads, offer longer battery life, and provide more robust protection.

Industrial UPS systems ensure that power remains uninterrupted during blackouts and serve other purposes. They condition the power supply, filtering out voltage spikes, dips, and electrical noise that could damage equipment over time. The result? Enhanced equipment longevity, increased operational uptime, and reduced maintenance costs.

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However, not all UPS systems are the same. The type and capacity of the UPS system you need will depend on the specific requirements of your industrial operations, from power demand to environmental factors.

Types of Industrial UPS Systems

Selecting the right UPS system for an industrial setting requires a thorough understanding of the types available. Broadly, industrial UPS systems can be classified into three main types:

1. Offline/Standby UPS

This is the most basic form of UPS. It monitors the incoming power supply and switches to battery power when it detects a problem. Offline UPS systems are commonly used for smaller, less critical equipment. However, there may be better options for industrial environments with more sensitive operations due to the slight delay in switching from main power to battery.

2. Line-Interactive UPS

More advanced than offline systems, line-interactive UPS units feature an automatic voltage regulation (AVR) system, which allows them to handle minor power fluctuations without switching to battery power. This makes them ideal for environments where power quality could be more consistent, but outright power outages are rare.

3. Online/Double-Conversion UPS

This is the most robust type of industrial UPS system. It converts incoming AC power to DC and back to AC, providing a constant, clean power supply. Because of this double conversion, there is zero transfer time when switching to battery mode, making it the ideal choice for industries where power reliability is non-negotiable. Double-conversion systems are perfect for environments with critical equipment like medical devices, data centers, or heavy industrial machinery.

Choosing the right UPS system depends on the complexity of your industrial setup and the critical nature of your equipment.

How UPS Systems Ensure Power Quality

A key function of industrial UPS systems, beyond simply providing backup power, is their ability to maintain and improve power quality. In many industrial settings, power from the grid can be unstable, with frequent fluctuations in voltage, electrical noise, and other disturbances. These irregularities can damage sensitive equipment, leading to costly repairs, downtime, or even irreversible failure.

UPS systems help by providing a stable and clean power supply. They do this through features like surge protection, filtering out electrical noise, and regulating voltage levels. For instance, if the power supply from the grid suddenly spikes or dips, the UPS will step in to ensure that the output remains steady. Many UPS systems also incorporate voltage correction, automatically adjusting the power supply to safe levels if irregularities occur. This feature is especially critical for industries that rely on precision machinery or sensitive electronics, as even minor voltage fluctuations can cause serious disruptions.

By ensuring consistent power quality, industrial UPS systems help prevent damage to equipment, reduce maintenance costs, and ensure smooth operation, even in environments where power fluctuations are common.

Factors to Consider When Choosing an Industrial UPS System

Selecting the right UPS system for your industrial needs is not a one-size-fits-all process. Several key factors should be considered to ensure that the system you choose will meet your operational requirements:

Power Capacity

Determine the total power load your equipment requires during a blackout or power fluctuation. Industrial operations often have higher demands than standard commercial or residential setups, so choosing a UPS that can handle the load without becoming overloaded is essential.

Battery Runtime

Battery runtime is the time the UPS can supply power during an outage. Consider how long your operations can afford to run on battery power alone. While some operations may only need a few minutes to shut down safely, others may require longer runtimes to maintain critical processes.

Environmental Factors

The physical environment where the UPS system will be installed plays a significant role in the selection process. Factors like temperature, humidity, and air quality can affect a UPS’s performance. Rugged UPS systems designed to withstand extreme conditions are recommended in harsh environments, such as manufacturing plants or outdoor installations.

Maintenance and Monitoring

Look for UPS systems with real-time monitoring and remote management capabilities. Industrial environments can be complex, and it’s crucial to have a system that allows you to monitor power conditions, battery health, and performance metrics without requiring manual checks.

Redundancy and Scalability

In many industrial settings, redundancy is crucial for ensuring uninterrupted power. This involves using multiple UPS units or additional power sources to back up the primary system. Also, consider whether the UPS system you choose can be scaled to accommodate future growth in your operations.

Ensuring Operational Stability: The Importance of Industrial UPS Systems in Power Management