What are all the components of UPS?

The following are the main sections of the online UPS:

1. Rectifier

2. Inverter

3. Battery

4. Static Switch

5. Mains Distribution Unit

6. Output Distribution Module

Rectifier

Here are some key points about the rectifier in a process industry UPS system:

• In process industries, the rectifier is a crucial component within a UPS (Uninterrupted Power Supply) system.
•  Its primary function is to convert alternating current (AC) power from the utility or generator into direct current (DC) power, which is used to charge the UPS batteries and supply power to the inverter.

AC to DC Conversion

• The primary role of the rectifier is to convert the incoming AC power into a stable DC power source.
• This DC power is used to charge the batteries and provide a steady supply for the UPS system.

Semiconductor Devices

• Rectifiers are typically composed of semiconductor devices such as Silicon Controlled Rectifiers (SCRs), Insulated Gate Bipolar Transistors (IGBTs), and diodes.
• These devices are chosen for their ability to efficiently control and convert electrical power.

SCR and IGBT-based Rectifiers

•  In process industries, UPS systems are often equipped with SCR and IGBT-based rectifiers at the input.

Each of these devices has its advantages:

SCR (Silicon Controlled Rectifier)

• SCR-based rectifiers are known for their robustness and reliability. They are well-suited for applications where a high degree of power control is required. SCR rectifiers can handle heavy loads and provide precise voltage regulation.

IGBT (Insulated Gate Bipolar Transistor)

• IGBT-based rectifiers offer a good balance between efficiency and controllability. They are often used when the load varies and needs to be adjusted dynamically. IGBT rectifiers are also known for their ability to handle high-frequency switching, making them suitable for UPS systems with rapid response requirements.

Efficiency and Power Quality

• The choice between SCR and IGBT-based rectifiers depends on the specific requirements of the process industry. Both types aim to maximize efficiency and maintain high power quality to ensure that the load receives stable and clean power.

Redundancy

• In critical applications, redundancy in the rectifier system is common. UPS systems may feature multiple rectifier modules to ensure uninterrupted operation even if one module fails. This redundancy is essential for maintaining the continuous supply of DC power to the UPS.

Inverter

• The inverter is a critical component within a UPS (Uninterrupted Power Supply) system.
• Its primary function is to convert direct current (DC) power from the UPS batteries into high-quality alternating current (AC) power that can be used to supply continuous electricity to the connected equipment.

Here are key points about the inverter in a process industry UPS system:

DC to AC Conversion

• The primary role of the inverter is to convert the stored DC power from the UPS batteries into a clean and stable AC power source.
• This conversion is essential to ensure that critical equipment receives a reliable power supply during AC power interruptions.

Semiconductor Device

• Inverters are typically constructed using semiconductor devices known as IGBTs (Insulated Gate Bipolar Transistors).
• IGBTs are chosen for their ability to handle high voltages and currents while providing precise control over the AC output.

What is IGBT in UPS system?

IGBT-based Inverters

• In process industries, UPS systems are often equipped with IGBT-based inverters at the output.
• IGBTs are favored for their ability to switch rapidly between conducting and non-conducting states, allowing for precise control over the AC waveform and output voltage.

Pure AC Power

• Process industries demand high-quality AC power to ensure the reliable and uninterrupted operation of sensitive equipment.
• IGBT-based inverters are known for their ability to produce “pure” AC power with minimal distortion, making them suitable for applications where power quality is critical.

Redundancy

• To enhance reliability, many UPS systems in process industries incorporate redundancy in the inverter section.
• Redundant inverters ensure that even if one module fails, the UPS can continue to provide clean AC power, minimizing the risk of downtime.

Output Voltage and Frequency Regulation

• Inverters are equipped with sophisticated control systems to maintain precise control over the output voltage and frequency.
• This is crucial for ensuring that connected equipment receives power within specified tolerances.

Transfer Time

• The transfer time from battery power to inverter power is typically very short, often measured in milliseconds.
• This rapid response time ensures that connected equipment does not experience any interruption during power outages.

Static Switch

• In process industries, a Static Switch is an important component within a UPS (Uninterrupted Power Supply) system that plays a crucial role in ensuring seamless and reliable power transfer between the primary AC power source (typically the utility power or a generator) and the UPS inverter (which provides backup power from batteries or an alternate source).

Here are key points about the Static Switch in a process industry UPS system:

Automatic Switchover

• The primary function of a Static Switch is to automatically and rapidly switch the load from the primary AC power source to the UPS inverter’s output when it detects anomalies or disruptions in the primary power.
• This transition must be seamless to ensure that connected equipment doesn’t experience any interruption in power supply.

Fault Detection

• Static Switches are equipped with sophisticated monitoring and fault detection mechanisms.
• They continuously monitor the quality of the incoming AC power, looking for issues such as voltage sags, surges, frequency variations, or complete power failures.
• When a problem is detected within the UPS system, the Static Switch ensures that the load is safely transferred back to the primary AC power source to prevent further issues and to maintain power continuity.
• The Static Switch acts as a backup mechanism to protect critical equipment and processes during UPS system faults or maintenance.

Zero-Transition Time

• One of the key advantages of Static Switches is their ability to transfer power with virtually no transition time.
• This is critical in process industries where even a momentary interruption in power can have significant consequences, such as production line disruptions or data loss.

Redundancy

• To enhance reliability, some process industry UPS systems incorporate redundant Static Switches. Redundancy ensures that if one Static Switch fails, there is a backup switch to take over the load transfer process, minimizing the risk of downtime.

Bypass Capability

• Static Switches often have a bypass capability, allowing them to temporarily route power directly from the primary AC source to the load in case of UPS system maintenance or a fault in the UPS inverter.
• This feature helps ensure continuous power supply during UPS maintenance or repair.

Voltage and Frequency Matching

• Static Switches ensure that the output voltage and frequency from the UPS inverter closely match those of the primary power source.
• This matching is essential to avoid compatibility issues with sensitive equipment.

Integration with Monitoring Systems

• Static Switches are typically integrated with comprehensive monitoring and control systems.
• They provide real-time status information, fault alerts, and performance data, allowing operators to proactively manage power transfer and UPS system health.

Isolation

• Some Static Switches provide electrical isolation between the primary power source and the UPS inverter, adding an extra layer of protection against electrical disturbances and ensuring the safety of connected equipment.

Battery Bank Unit

• The Battery Bank Unit in process industries’ UPS systems is a critical module responsible for providing backup power to the UPS in case of a mains power failure.
• This module comprises a battery pack designed to store electrical energy and ensure uninterrupted operation of essential equipment and processes.
• Several types of batteries are commonly used in these battery modules, including Sealed Maintenance-Free Batteries (SMFB), Lead-Acid Tubular Batteries (LATB), Nickel-Cadmium (Ni-Cad) batteries, and more.
• The choice of battery type depends on factors like required capacity, runtime, and environmental considerations.
• Battery modules can be provided in different forms, including enclosed units or as racks, depending on the specific needs and space constraints of the industrial setting.
• It’s important to note that some battery types, like LATB, are vented batteries that emit acidic fumes during operation.
• To ensure safety and proper functioning, these batteries may require a dedicated and well-ventilated room to prevent the buildup of harmful fumes and protect personnel.
• Adequate safety measures and maintenance are essential to manage these vented batteries safely.
• Battery Bank Unit in process industries’ UPS systems is a vital component, storing electrical energy using various battery types.
• The choice of battery and its form factor depends on capacity and environmental considerations, with vented batteries requiring special safety precautions.
• This module ensures uninterrupted power supply during mains power failures, safeguarding critical industrial processes and equipment.

Mains Distribution Unit (Main input and Bypass input)

• The Mains Distribution Unit is an integral component of an installation, responsible for distributing utility or generator power throughout the facility.
• It serves as the primary source of input power for the UPS system, ensuring seamless operation during power disruptions.
• Additionally, it plays a critical role in establishing the safety “earth” connection for the UPS system, ensuring proper grounding for electrical safety measures.
• Essentially, the Mains Distribution Unit serves as the gateway for power supply, managing the flow of electricity and ensuring a reliable and safe electrical infrastructure within the facility.

Output Distribution Module

• The Output Distribution Module is a critical component within an Uninterruptible Power Supply (UPS) system, responsible for efficiently and safely distributing the UPS’s output power to various loads or devices.
• This module ensures that power is delivered to connected equipment in a controlled and organized manner.

Here are key points about the Output Distribution Module:

Load Distribution

• The Output Distribution Module plays a pivotal role in distributing the UPS system’s output power to multiple loads or devices within a facility.
• These loads can include servers, control system, data storage, industrial machinery, or any critical equipment that requires uninterrupted power.

Switches and Fuses

• Typically, the module includes switches and fuses for each load or group of loads.
• Switches allow for individual control and isolation of specific loads, while fuses protect against overcurrent conditions.
• The use of switches and fuses ensures that a fault in one load does not affect the operation of other loads.

Coordination of Fuses

• Coordination of fuses is crucial to prevent cascading faults.
• If a fault occurs in one load, properly coordinated fuses will ensure that only the affected load is isolated, allowing the rest of the connected loads to continue operating without disruption.
• This is particularly important in critical applications where downtime is costly or unacceptable.

Isolation and Redundancy

• The module may also provide isolation capabilities between different loads, enhancing safety and preventing issues from spreading.
• Redundancy options can be incorporated to ensure that backup loads are available if a load or module fails.

Load Prioritization

• In some cases, the Output Distribution Module can be configured to prioritize certain loads over others.
• This is essential in scenarios where specific equipment must remain operational at all times, even during extended power outages.

Monitoring and Control

• Advanced Output Distribution Modules may offer monitoring and control features, allowing operators to remotely manage and monitor the status of individual loads.
• This enables proactive maintenance and swift responses to issues.

Customization

•  The module’s design can be customized to suit the unique requirements of the facility, accommodating different loads, voltage levels, and control schemes.