RELIABILITY OF UPS SYSTEMS
RELIABILITY OF UNITERRUPTIBLE POWER SUPPLIES
PMC
The primary objective in the implementation of a UPS system is to improve the reliability to the limits of technical
capability, the ultimate aim being to totally eliminate the possibility of any disturbance or downtime. In the 50s
when the first static UPS systems appeared they were composed of a rectifier, battery and inverter and where
used to stabilize the output power and to continue to supply the load for a short period of time (autonomy of
battery) in the event of a rectifier failure. The reliability of this simple UPS chain depends dominantly on the
inverter reliability. An inverter failure meant an immediate load crash. Furthermore, the downtime (no supply to
the load) would last as long as the inverter repair. In the early 60s the static bypass switch was introduced to
enable an interruption-free load transfer to the stand-by mains in the event of inverter failures or overloads. The
stand-by mains although far not as reliable as the UPS, serves as a reserve power supply in case of an inverter
failure to enable the continuation of the power supply to the load while the inverter is being repaired. This new
architecture had substantially improved the overall reliability which did not depend dominantly on the inverter
reliability anymore. The reliability of the new UPS with static bypass depended on the quality of the mains
(MTBFMAINS), the time to repair of the UPS (MTTRUPS)and on the reliability of the static switch. Further on in this
paper (page 4) the impact of both the (MTBFMAINS) and (MTTRUPS) on the overall UPS reliability are shown.
The everyday activities which are dependent upon computer controlled real time information systems have
grown exponentially in recent years and the requirements for highest reliability UPS configurations have
become every day practice. Very critical loads cannot rely on a power supply configuration of a single UPS with
static bypass system; the need for (n+1) redundant parallel UPS configurations is becoming a standard.
In this paper the reliability of the various UPS configurations is shown. The reliability figures of the
rectifier/booster, battery, inverter , static bypass and other parts are based on the reliability figures presented in
the MIL-HDBK-217 F (Not.2, 1995). The following calculations where implemented on the RITTAL PMC UPSSeries and they have been confirmed by field statistics which unfortunately due to RITTALS policy cannot be
disclosed.
1.
Single UPS without static bypass switch (SBS)
The reliability of a single UPS without bypass depends basically on the reliability of the rectifier, battery and
inverter (see electrical block-diagram in Fig.1).
Example: In the event of an inverter fault the load would crash.
Electrical Block Diagram
Reliability Block Diagram
(Series Diagram)
Mains
RECTIFIER
BATTERY
INVERTER
RECT.
BATT.
INV.
Load
Fig. 1 Single UPS without static bypass. Electrical block diagram and reliability diagram
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RELIABILITY OF UPS SYSTEMS
Description of the variables that are used in the equations:
MTBFSU: Mean Time Between Failures of Single Unit without static bypass
UPS: Failure Rate of Single Unit without static bypass switch
RECT:
BATT:
INV:
Failure Rate Rectifier
Failure Rate Battery
Failure Rate Inverter
Calculation of MTBF for UPS System WITHOUT bypass (MTBFSU):
MTBFUPS = 1 / UPS
UPS = RECT.+ BATT. + INV.
.. (E.1)
If the figures from RITTALS statistical failure-analysis
RECT
= 20 10
-6
-1
[h ],
BATT
= 10 10
-6
-1
[h ],
INV. = 20 10-6 [h-1] are applied in equation (E.1), the Mean Time Between Failure (MTBFUPS) for a
UPS system without static bypass switch will be:
MTBFUPS = 20'000 [h]
2.
Single UPS WITH static bypass switch (SBS)
The reliability of a single UPS can be increased significantly by introducing a redundant mains power source by
and linking it to main UPS supply source by means of a static bypass static transfer switch.
Example: In the event of an inverter fault the load WILL NOT crash. The load will be transferred to mains
interruption-free.
Electrical Block Diagram
Reliability Block Diagram
(Parallel Diagram)
Mains
RECTIFIER
RECT.
BATT.
BATTERY
INVERTER
INV.
STATIC
BYPASS
SBS
Load
Fig. 2 Single UPS WITH static bypass. Electrical block diagram and reliability diagram
Description of the variables that are used in the equations:
MTBFUPS+SBS: Mean Time Between Failures of Single Unit WITH static bypass switch (SBS)
MTBFM :
Mean Time Between Failures of MAINS
UPS+SBS :
Failure Rate of Single Unit WITH static bypass switch
SBS :
Failure Rate of Static Bypass Switch with control circuit
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RELIABILITY OF UPS SYSTEMS
PBUS :
M:
SU:
M:
Failure Rate of Parallel Bus (only for parallel systems)
Failure Rate of MAINS
Repair Rate of Static Bypass Switch (SU = 1 / MTTRUPS)
Repair Rate of MAINS (M = 1 / MTTRM)
Mean Time To Repair of Static Bypass Switch
Mean Time To Repair of MAINS
MTTRSBS:
MTTRM:
Please note that all calculations are performed by using the following constants:
MTBFM = 50 [h] , this figure represents a good quality mains.
MTTRUPS = 6 [h]
MTTRM = 0.1 [h]
Furthermore from RITTALS statistical failure-analysis we have the following figures for the failure rates of the
static bypass switch for the power part and the control electronic part:
SBS
-6
-1
= 2 10 [h ]
Calculation of MTBF for UPS System WITH static bypass switch (MTBFSU+SBS):
MTBFUPS+SBS = 1 / UPS+SBS
UPS+SBS = UPS//M+SBS
UPS // M
... (E.2)
UPS M (UPS + M +UPS+M)____
UPS M +UPS M +(UPS+M) (UPS+M)+2UPS+2M
UPS+SBS = UPS // M + SBS
-6
-1
-6
-1
UPS M (UPS+M)_ = 6 10-6 [h-1]
UPS M
-6
-1
= 6 10 [h ] + 2 10 [h ] = 8 10 [h ]
MTBFUPS+SBS = 125'000h
NOTE:
In the above formula it can be seen that the reliability of the UPS with static bypass switch
( MTBFUPS+SBS ) depends largely on three parameters: reliability of the mains, the MTTR of
the UPS and the reliability of the static bypass switch. This dependence is illustrated in Fig 3.
MTBFups = f (MTBFmains, MTTRups)
600000
12
0,5
500000
MTTR:
MTTR=6h
MTBFM=50h
400000
300000
200000
MTBFups [h]
24
100000
0
10
24
50
80
100
250
500
1000
10000
MTBFmains [h]
Fig. 3 This graph shows the dependence of the MTBFUPS+SBS on MTBFMAINS and MTTR UPS.
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RELIABILITY OF UPS SYSTEMS
3.
Parallel Redundant UPSS WITH Static Bypass Switch (SBS)
The reliability of a single UPS can be increased significantly by introducing a redundant
parallel configurations.
UPS 1
UPS 2
RECTIFIER
UPS (n+1)
RECTIFIER
BATTER
RECTIFIER
BATTER
INVERTER
BATTER
INVERTER
STATIC
BYPASS
INVERTER
STATIC
BYPASS
PARALLEL BUS
STATIC
BYPASS
PARALLEL BUS
RECT.
RECT.
RECT.
BATT.
BATT.
BATT.
INV.
INV.
INV.
PBUS
PBUS
PBUS
SBS
SBS
SBS
Fig. 4 Electrical and Reliability Block Diagram of (n+1) Parallel Redundant UPS Configuration.
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RELIABILITY OF UPS SYSTEMS
Calculation of MTBF for a (n+1) REDUNDANT PARALLEL UPS System (MTBF(n+1)UPS+SBS):
We will start by the equations used for the calculation of the failure rate:
(n+1)UPS+SBS = (UPS1//UPS2..//UPS(n+1)) + (n+1) PBUS + (SBS1//SBS2..//SBS(n+1))
Failure Rate:
(n+1)UPS+SBS ~
Reliability:
MTBF(n+1)UPS+SBS = 1 / (n+1)UPS+SBS (E.5)
Availability:
A (n+1)UPS+SBS = MTBF(n+1)UPS+SBS
.. (E.3)
(n+1) PBUS (E.4)
/ MTBF(n+1)UPS+SBS + MTTR UPS
(E.6)
The reliability of a (n+1) parallel redundant system depends largely on the reliability of the failure rate
of the PARALLEL BUS which is the only single point failure.
The UPS parallel redundant chains, the static bypass switches and their control electronics as well as
the mains power lines are all redundant and have therefore minor or even neglecting impact on the
overall reliability.
We will perform some calculations for parallel redundant systems, by using the following constants:
MTBFM = 50 [h] , this figure represents a good quality mains.
PBUS
= 0.4 10 -6 [h-1]
Reliability (MTBF)
Failure Rate ()
(1+1) redundant configuration
1250000 [h]
~ 0.8 10-6 [h-1]
(2+1) redundant configuration
830000 [h]
~ 1.2 10-6 [h-1]
(3+1) redundant configuration
625000 [h]
~ 1.6 10-6 [h-1]
(4+1) redundant configuration
500000 [h]
~ 2.0 10-6 [h-1]
(5+1) redundant configuration
420000 [h]
~ 2.4 10-6 [h-1]
Redundant Parallel Configuration
Table 1
MTBF and Failure Rate of (n+1)-Redundant Configurations, N=1,2,3,4 and 5
Conclusion:
In the single UPS chain (rectifier, battery and inverter) the reliability of the UPS largely depends on
the reliability of the inverter.
By introducing the static bypass switch i.e. a reserve mains power supply, the reliability will increase
by a factor of 6 if the mains MTBF is 50h (good quality) and the MTTR of UPS is 6h. This reliability
level is unfortunately not sufficient, because it still depends substantially on the reliability of the raw
mains and on the quality of the after sales organization (reaction time, traveling time, repair time etc.)
Modern critical loads have far higher reliability requirements and cannot rely on the mains quality and
on longer repair times.
To overcome the dependability from the raw mains, (n+1)-redundant parallel UPS-configurations are
suggested. The disadvantage of traditional stand-alone (n+1)-redundant configuration is the relatively
long repair time of the UPS (typically 612h). By implementing modular, hot-swappable, (n+1)
redundant parallel systems the critical load will be completely mains-independent; a faulty UPSmodule may be replaced without the need to transfer the rest of the UPS modules to raw mains (hotNW/MTBF Calculus-VX-190903
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RELIABILITY OF UPS SYSTEMS
swap). Furthermore the replacement of the modules takes at most 0.5h, which dramatically decreases
the time to repair in comparison to traditional parallel systems.
Below you will find an example where various UPS configurations are compared and it is shown what
impact the choice of the right system/configuration might have on the reliability and availability:
Example:
Comparison of the Availability of a Traditional (1+1)-Redundant UPS Configuration
and a Modular (4+1)-Redundant UPS Configuration
Fig. 5 shows a block diagram of two redundant UPS configurations. The system on the left
represents a (1+1)-redundant configuration with traditional stand-alone UPSS, whereas the
system on the right side represents a (4+1)-redundant configuration with modular hot
swappable- modular UPSS.
(1+1)-Redundant Configuration
(traditional stand-alone)
UPS 1
120kVA
UPS 2
120kVA
(4+1)-Redundant Configuration
(modular, hot-swappable)
UPS 1
30kVA
UPS 2
30kVA
UPS 3
30kVA
Availability
LOAD
120kVA
Fig. 5
UPS 4
30kVA
UPS 5
30kVA
Availability
LOAD
120kVA
Block diagram of two redundant UPS configurations
AVAILABILITY (A) is an important parameter when evaluating the reliability of UPSconfigurations. A is defined as follows:
MTBFUPS
A = ---------------------------------
. (E.7)
MTBFUPS + MTTR UPS
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RELIABILITY OF UPS SYSTEMS
From equation (E.7) we see that the Availability of a UPS depends on the:
MTBF UPS = Mean Time Between Failures of a UPS configuration and
MTTR UPS = Mean Time To Repair of the UPS.
Table 2 shows the Availability Comparison of the UPS configurations in Fig.5. Note that the
MTBF UPS figures for the UPS configurations are taken from Table 1.
Two cases are considered:
Case 1:
both UPS-configurations have the same Meant Time To Repair : MTTRUPS = 6 [h]
Case 2:
The traditional stand-alone UPS configurations has: MTTRUPS = 6 [h], whereas
Modular UPS configuration with hot-swappable modules has: MTTRUPS = 0.5 [h]
Redundant-Configuration
(1+1)
Redundant-Configuration
(4+1)
MTBF
MTTR
Availability
1250000 [h]
6 [h]
0,9999952 (5 nines)
500000 [h]
6 [h]
0,9999888 (4 nines)
MTBF
MTTR
Availability
1250000 [h]
6 [h]
0,9999952 (5 nines)
500000 [h]
0.5 [h]
0,9999990 (6 nines)
Case 1
Case 2
Comments:
Case 1: The Availability of (1+1)-Redundant Configuration is higher than the Availability
(4+1)-Redundant Configuration if the MTTR is the same for both configurations.
This evident due to the fact that the MTBF of a (1+1)-Redundant Configuration is
higher than the MTBF of a (4+1)-Redundant-Configuration
Case 2: The Availability of a (1+1)-Redundant-Configuration with longer MTTR may be lower
than the Availability of a (4+1)-Redundant-Configuration with a shorter MTTR.
CONCLUSION
FROM THE ABOVE CASES IT IS SHOWN HOW IMPORTANT THE PARAMETER MTTR IS FOR
REACHING HIGH AVAILABILITIES. IF IN ONE OF THE ABOVE REDUNDANT CONFIGURATIONS
ONE OF THE UPS IS FAULTY, THERE WILL BE NO REDUNDNACY LEFT (LOW-AVAILABILITY
REGIME) AND WE NEED TO THEREFORE REPAIR/REPLACE THE FAULTY PART/MODULE AS
QUICKLY AS POSSIBLE, IN ORDER TO RESTORE THE REDUNDANCY (HIGH-AVAILABILITYREGIME).
WITH RITTAL PMC MODULAR UPS WE CAN REACH SHORTEST MTTRS AND
CONSEQUENTLY HIGHEST AVAILABILITIES EVEN IF WE PARALLEL BIGGER NUMBERS OF
MODULES.
[1] A. BIROLINI
Reliability Engineering, Theory and Practice
NW/MTBF Calculus-VX-190903
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