Chapter 12

Uninterruptable
Power Supply
 Chapter 12 [UPS]

12.1. Introduction:
In the electrical system environment, power disturbances will occur. These can be
caused by faults on the distribution system, the operation of nearby equipment,
lightning strikes, normal utility operations, or any number of other causes. The
resulting disturbances such as electrical noise, voltage spikes, sags, swells, and
complete outages can exceed the electrical tolerances designed for the electrical
equipment in use.

There is a simple way to protect your electronic equipment from the damage and
downtime due to standard power problems that can result from power outages. It is
called an uninterruptible power supply, or UPS.

These devices are designed to provide continuous power to a load, even with an
interruption or loss of utility supply power.

Some manufacturers categorize their UPS's according to the power problems they
can handle. The degrees of protection vary from one manufacturer to the other.
It is generally considered, especially in larger installations, that the incoming and
commercial power should never be directly connected to the load (computer)
equipment. Several types of UPS systems are available to ensure this does not
happen.
To determine the requirements for a UPS generally involves a balance of cost vs.
need.

12.2. What is the UPS?

An uninterruptible power supply, or UPS, (sometimes called an 'uninterruptible
power source ') is a device or system that maintains a continuous supply of electric
power to certain essential equipment that must not be shut down unexpectedly.
The equipment is inserted between a primary power source, such as a commercial
utility, and the primary power input of equipment to be protected, to eliminate the
effects of a temporary power outage and transient anomalies. Historically, a UPS

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was likely to be used in areas where the power supply is interrupted frequently (such
as developing countries and some rural areas in developed countries).

However, that view has been changing in recent years as the number of instances of
blackouts continues to increase. In order to prevent blackouts, electrical utilities will,
from time to time, use a process called load shedding. This reduces the amount of
power sent to the consumers but sometimes it does eliminate it entirely for an hour
or so. This drop in voltage is called voltage sag or a brownout. A UPS will also
protect equipment upon the occurrence of a brownout by using its internal batteries
to correct the drop in voltage.

Main mission of UPS

1) Provide battery back up from a few minutes to several hours in the event of a
power cut .

2) Protect telecoms, computer & other equipment from power disruptions .

3) Provide clean and conditioned AC power to computer/equipment and networks.

12.3. Where the UPS should be used?

They are generally associated with electronic equipment that is critical to your home
or business should be protected. This includes personal computers, cash registers,
phone equipment, programmable logic Controllers, telecommunications equipment
and other facilities such as airport landing systems and other locations where even
brief commercial power interruptions could cause injuries or fatalities, serious
business disruption or data loss.

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12.4.The difference between standby generator and a (UPS)?

This is often not clearly understood, because the term Uninterruptible Power Supply
is often used to refer to a wide range of power protection products. It is often
deceptively used to describe the Standby Generator, which only solves a minimal
number of power quality problems.
It is appropriately used to define the true On-line Uninterruptible Power Supply
(UPS), capable of removing or eliminating the greatest number of power quality
problems.
A UPS is not to be confused with a standby generator, which does not provide
protection from a momentary power interruption, or which may result in a
momentary power interruption.
When it is switched into service, whether manually or automatically. However, such
a generator may be placed before the UPS to provide cover for lengthy outages.

UPS stands for uninterruptible power supply, this means that load can't accept any
shutdown in service.

12.5. Components of UPS

A complete UPS (Uninterruptible Power Supply) System includes a

Ø Rectifier/Charger
Ø Static Inverter
Ø Static Bypass Switch
Ø Manual Bypass Switch
Ø The battery bank

1- Rectifier Charger:
It is the component assembly that rectifies the incoming AC power, regulates this DC
to a precise voltage level to properly "Float Charge" the battery during normal
operation, and provides DC power to the inverter.

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2- The inverter:
It converts the DC from
the Rectifier/Charger and/or battery to
the proper regulated AC voltage for the load.

3- The static switch:

It's a solid state assembly which is capable of transferring the load from the Inverter
to the Bypass source without interruption.
It continuously senses the Inverter output voltage and the UPS load current,
checking for an Inverter failure or system overload.

4- The manual bypass switch:

It's provided to bypass the Inverter and Static Switch for maintenance purposes. In
the "Bypass" position the Bypass source is connected to the load.

5- The battery bank:

It consists of an assembly of high quality energy storage cells which are charged
continuously during normal operation. It serves as the power source to the Inverter
during incoming AC power outages.
The batteries fall into two general types: Stationary and sealed.
Stationary batteries are those which require ventilation due to the fact that they are
designed to release gases into the atmosphere including hydrogen when they are
charging. Consequently, these batteries also require routine maintenance such as
periodic watering, specific gravity, and voltage checks. In general, these batteries
are longer-lived than sealed batteries. Sealed batteries are those which are
essentially sealed and release only small amounts of gas under high internal
pressure as a safety precaution.

A- Lead Calcuim-Stationary batteries :

This type offers the best cost versus service reliability for stationary batteries
available for UPS installa ons. These ba eries typically carry a 20-year warranty
and have a 20-25 year life expectancy when used under float conditions. Hydrogen
generation is low compared to lead antimony batteries and when maintained at a
float voltage of 2.25 volts/cell, do not require rou ne equaliza on. Maintenance
consists of watering, terminal cleaning, and checking electrolyte specific gravity at
six-month intervals. Equalization is necessary only upon initial energization.

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B- Lead Antimony-stationary batteries :

These batteries generally are equal in size and capacity to the lead calcium batteries.
Usually they are warranted for 15-20 years, with a life expectancy of 15-22 years.
These batteries are normally better suited for applications where they are cycled
rather than in full float application. Hydrogen generation is considerably greater
than lead calcium batteries and maintenance is required more frequently, including
periodic (monthly) equalization, and weekly watering checks with additions as
necessary.

C- Nickel cadmium-stationary batteries :

NICAD batteries are the most expensive of the stationary types discussed, costing
approximately two to three mes calcium ba eries. Although it requires 92 cells of
nickel cadmium to equal 60 cells of lead calcium, they s ll have an advantage in
being smaller in size and weight for a given capacity. They also have excellent low
temperature and high temperature properties and have an exceptionally long
service life even at high temperatures. Service life expectancy under normal
condi ons is approximately 25 years or more.

D- Sealed (Maintenance Free) batteries :

As previously discussed, sealed batteries are those which, due to special

construction, do not normally vent gas into the atmosphere, and because they are
sealed, require no routine water additions. Because they do not gas, they are well
suited for installation into an office area or computer room environment where
special ventilation would be difficult or impractical to provide. These two
advantages present cost savings which should be considered when evaluating your
battery requirements. Sealed batteries lend themselves well to cabinet mountings,
and as a result can be attractively packaged for installation in an office or computer
room along with the UPS system. One can also recognize sealed batteries by the use
of names such as Gel Cell, Absorbed Electrolyte, Starved Electrolyte, or Suspended
Electrolyte.
Caution :
Sealed batteries are maintenance free only in the sense they require no electrolyte
checks or water addition. It is important that the battery terminal connections be
inspected and re-torqued periodically to maintain a sound connection.

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Life expectancy and manufacturer’s warran es vary from 1 year to 20 years with a
corresponding varia on in price. As an average, a 10-year sealed battery on an open
rack will be priced approximately equal to the lead calcium 20 year wet ba ery.

12.6 Modes of Operation

1-Normal operation: The Rectifier/Charger shall receive power from the primary AC
power Source converting the AC to DC to provide DC input power to the Inverter and
to float charges the battery. The load shall be continuously supplied by the Inverter
through the Static Switch.

2- Emergency operation: When the primary AC power source fails, the Inverter
shall begin to use Energy from the Battery rather than the Rectifier/Charger. There
shall be no load switching required.

3- Recharge: When the primary AC power source returns after an outage, the
Rectifier/Charger shall provide power to the Inverter while simultaneously
recharging the depleted battery. This shall occur automatically with no Interruption
to the critical load.

4- Static bypass: In the event of a UPS malfunction, a Static Bypass Switch shall
ensure the continuity of power to the critical load by automatically transferring the
load to an alternate AC source within 4 ms.
The following conditions shall cause a Static Switch transfer to the alternate source:
A. Battery depleted to its discharged point.
B. UPS overload
C. Inverter output voltage varies beyond specified limits.
D. Manual initiation by a control push button.
E. Inverter off line manually or because of component failure.

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5- Automatic/Manual re transfer: There shall be an Automatic/Manual Re

transfer select switch In "Automatic", the event of a UPS overload shall cause the
load to transfer to the alternate source. The Static Switch shall latch to the alternate
source and will not attempt to re transfer back to the Inverter while the overload
exists .When the fault condition ceases to exist, a time delay shall elapse, then the
Inverter shall again assume the load and the alternate source shall be disconnected
from the load without an interruption in power to the load.
The length of the time delay shall be user selectable. The selections available shall be
approximately 10, 30, 60, and 80 seconds .When the Automa c/Manual Re transfer
Select Switch is in the "Manual" position, a fault condition shall cause the Static
Switch to latch to the alternate source. Manual initiation of a control push button
shall be required to shift the load back to the Inverter .Regardless of the position of
the Automatic/ Manual Re transfer Switch, should Bypass power fail, the Static
Switch will re transfer the load to the Inverter.

6- Manual maintenance bypass switch: A Manual Bypass Switch shall be

provided on the front of the UPS Cabinet. It shall be a "make before break" type to
allow the critical load to be transferred to the alternate source while simultaneously
isolating the Inverter and Static Switch.

12.7. UPS types:

A variety of design approaches are used to implement UPS systems, each

with distinct performance characteristics. The most common design
approaches are as follows:
Ø Standby
Ø Line Interactive
Ø Standby-Ferro
Ø Double Conversion On-Line
Ø Delta Conversion On-Line

The standby UPS: The Standby UPS is the most common type used for Personal
Computers. In the block diagram illustrated in Figure 1, the transfer switch is set to
choose the filtered AC input as the primary power source (solid line path), and
switches to the battery / inverter as the backup source should the primary source
fail. When that happens, the transfer switch must operate to switch the load over to

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the battery / inverter backup power source (dashed path). The inverter only starts
when the power fails, hence the name "Standby." High efficiency, small size, and low
cost are the main benefits of this design. With proper filter and surge circuitry, these
systems can also provide adequate noise filtration and surge suppression.

The line interactive UPS: The Line Interac ve UPS, illustrated in Figure 2, is the
most common design used for small business, Web, and departmental servers. In this
design, the battery-to-AC power converter (inverter) is always connected to the
output of the UPS. Operating the inverter in reverse during times when the input AC
power is normal provides battery charging. When the input power fails, the transfer
switch opens and the power flows from the battery to the UPS output. With the
inverter always on and connected to the output, this design provides additional
filtering and yields reduced switching transients when compared with the Standby
UPS topology. In addition, the Line Interactive design usually incorporates a tap-
changing transformer. This adds voltage regulation by adjusting transformer taps as
the input voltage varies. Voltage regulation is an important feature when low
voltage conditions exist, otherwise the UPS would transfer to battery and then
eventually down the load. This more frequent battery usage can cause premature
battery failure. However, the inverter can also be designed such that its failure will
still permit power flow from the AC input to the output, which
eliminates the potential of single point failure and effectively provides for two
independent power paths. High efficiency, small size, low cost and high reliability
coupled with the ability to correct low or high line voltage conditions make this the
dominant type of UPS in the 0.5-5kVA power range.

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The standby-ferro UPS: The Standby-Ferro UPS was once the dominant form of UPS in
the 3-15kVA range. This design depends on a special saturating transformer that has
three windings (power connections). The primary power path is from AC input,
through a transfer switch, through the transformer, and to the output. In the case of
a power failure, the transfer switch is opened, and the inverter picks up the output
load.
In the Standby-Ferro design, the inverter is in the standby mode, and is energized
when the input power fails and the transfer switch is opened. The transformer has
a special "Ferro-resonant" capability, which provides limited voltage regulation
and output waveform "shaping". The isolation from AC power transients provide
by the Ferro transformer is as good as or better than any filter available. But the
Ferro transformer itself creates severe output voltage distortion and transients,
which can be worse than a poor AC connection. Even though it is a standby UPS
by design, the Standby-Ferro generates a great deal of heat because the Ferro-
resonant transformer is inherently inefficient. These transformers are also large
relative to regular isolation transformers; so standby-Ferro UPS are generally
quite large and heavy.

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Standby-Ferro UPS systems are frequently represented as On-Line units, even

though they have a transfer switch, the inverter operates in the standby mode,
and they exhibit a transfer characteris c during an AC power failure. Figure 3
illustrates this Standby-Ferro topology.

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High reliability and excellent line filtering are this design’s strengths.
However, the design has very low efficiency combined with instability when
used with some generators and newer power-factor corrected computers,
causing the popularity of this design to decrease significantly.

The principal reason why Standby-Ferro UPS systems are no longer commonly
used is that they can be fundamentally unstable when operating a modern
computer power supply load. All large servers and routers use “Power Factor
Corrected” power supplies which draw only sinusoidal current from the utility,
much like an incandescent bulb. This smooth current draw is achieved using
capacitors, devices which ‘lead' the applied voltage, Ferro resonant UPS system
utilize heavy core transformers which have an inductive characteristic, meaning
that the current 'lags' the voltage. The combination of these two items form
what is referred to as a 'tank' circuit. Resonance or 'ringing' in a tank circuit can
cause high currents, which jeopardize the connected load.

The double conversion on-line UPS: This is the most common type of UPS above
10kVA. The block diagram of the Double Conversion On-Line UPS, illustrated in Figure
4, is the same as the Standby, except that the primary power path is the inverter
instead of the AC main.

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In the double conversion on-line design, failure of the input AC does not cause
activation of the transfer switch, because the input AC is charging the backup
battery source which provides power to the output inverter. Therefore, during an
input AC power failure, on-line operation results in no transfer time.

Both the battery charger and the inverter convert the entire load power
flow in this design, resulting in reduced efficiency with its associated
increased heat generation.

This UPS provides nearly ideal electrical output performance. But the constant
wear on the power components reduces reliability over other designs and the
energy consumed by the electrical power inefficiency is a significant part of the
life-cycle cost of the UPS. Also, the input power drawn by the large battery
charger is often non-linear and can interfere with building power wiring or cause
problems with standby generators.

The delta conversion on-line UPS: This UPS design, illustrated in Figure 5, is a newer,
10 year old technology introduced to eliminate the drawbacks of the Double
Conversion On-Line design and is available in sizes ranging from 5kVA to 1.6MW.
Similar to the Double Conversion On-Line design, the Delta Conversion On-Line UPS
always has the inverter supplying the load voltage. However, the additional Delta
Converter also contributes power to the inverter output. Under conditions of AC
failure or disturbances, this design exhibits behavior identical to the Double
Conversion On-Line.

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Asimple way to understand the energy efficiency of the delta conversion

topology is to consider the energy required to deliver a package from the 4th
floor to the 5th floor of a building as shown in Figure 6. Delta Conversion
technology saves energy by carrying the package only the difference (delta)
between the starting and ending points. The Double Conversion On-Line UPS
converts the power to the battery and back again whereas the Delta Converter
moves components of the power from input to the output.

In the delta conversion on-line design, the delta converter acts with dual
purposes. The first is to control the input power characteristics. This active front
end draws power in a sinusoidal manner, minimizing harmonics reflected onto
the utility. This ensures optimal utility and generator system compatibility,
reducing heating and system wear in the power distribution system. The second
function of the Delta Converter is to control input current in order to regulate
charging of the battery system.

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12.8. How to select the UPS for any application?
In choosing UPS equipment, selecting a model of the proper size is central. Selecting a
UPS that is too small to provide enough power for the equipment you need protected
should be avoided. It may result in having to return the unit for a larger model, or
cause the UPS to fail. As a good portion of the purchase price of an UPS is directly
related to its size or output capacity, selecting one that is too large for your needs will
be a waste of money.
More important, it may be the difference between buying an over-sized standby
generator providing limited protection or the correct size On-line UPS, which gives a
much greater level of power protection.

12.9. System data to be specified during design

1. Input to UPS nominal voltage VAC 1 Phase or 3 Phase.

2. Battery standby time for fully loaded UPS (minutes or hours).
3. Output of UPS nominal voltage VAC (1 Phase or 3 Phase).
4. Frequency 60 Hz or 50 Hz.
5. KVA rating and PF.
6. Alternate source input If other than the UPS output, a transformer is required to
convert to the proper voltage and/or three phase configuration.

12.10. Ups system design for our hotel

1. Input to UPS nominal voltage VAC, 3 Phase 4 wires.

2. Battery standby time for fully loaded UPS 0.5 hour.
3. Output of UPS nominal voltage VAC 220 V / 1 Ph 2 wires.
4. Frequency 50 Hz.
5. KVA rating 85 KVA.
6. Primary voltage VAC 380, 3 Phase 4 wires.