Industrial UPS (Uninterruptible Power Supply) systems are designed to provide reliable backup power and protection for industrial environments such as manufacturing plants, oil & gas facilities, data centres, and process automation systems.
They are classified mainly based on topology, power capacity, and application.
Here’s a breakdown:
⚙️ 1. Based on Topology (Design Principle)
a. Offline / Standby UPS
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Operation: Switches to battery only when utility power fails.
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Typical Use: Rare in industrial settings (more for small offices or control panels).
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Advantages: low cost, simple design.
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Limitations: Small capacity; switching time (2–10 ms) may affect sensitive equipment.
b. Line-Interactive UPS
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Operation: Has an autotransformer that regulates minor voltage fluctuations without switching to battery.
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Typical Use: Medium-critical loads, small automation systems.
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Advantages: Better voltage regulation than the offline type.
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Limitations: Still not ideal for highly sensitive or mission-critical industrial systems.
c. Double Conversion / Online UPS
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Operation: Converts AC → DC → AC continuously. The output is fully isolated from the input.
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Typical Use: Critical industrial loads, data centres, control systems, and PLCs.
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Advantages:
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No transfer time during outage.
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Perfect voltage and frequency regulation.
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Isolation from harmonics and electrical noise.
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Limitations: Higher cost, lower efficiency (~90–95%).
d. Delta Conversion Online UPS
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Operation: Similar to double conversion but with delta conversion for improved efficiency.
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Typical Use: Large industrial systems requiring high efficiency and reliability.
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Advantages: High efficiency (>96%), continuous power conditioning.
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Limitations: More complex design, higher initial cost.
⚡ 2. Based on Power Rating / Capacity
| Type | Power Range | Typical Applications |
|---|---|---|
| Small Industrial UPS | <10 kVA | Local control panels, small machinery, sensors |
| Medium Industrial UPS | 10–200 kVA | Process control, substations, automation |
| Large/Central UPS | >200 kVA | Refineries, steel plants, data centers, utilities |
🏭 3. Based on Application/Environment
| Type | Features | Typical Industry |
|---|---|---|
| Industrial-grade (ruggedized) | High IP rating, vibration resistance, wide temp range | Oil & gas, mining, marine |
| Modular UPS | Scalable, hot-swappable modules | Data centers, critical process industries |
| DC UPS | Provides DC output (24V, 48V, etc.) | Control systems, telecom, SCADA |
| Rotary UPS (Diesel Rotary / Flywheel) | Uses kinetic energy for backup | Power plants, large industrial sites |
🔋 4. Common Brands / Manufacturers
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ABB
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Eaton
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Schneider Electric
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Vertiv (Emerson)
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Siemens
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Socomec
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Riello
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AEG Power Solutions
