A consistent, reliable power supply is crucial in industrial engineering. Downtime can cause significant financial losses and operational disruptions, so having a robust power backup system is non-negotiable. This is where industrial uninterruptible power supplies (UPS) come into play, providing a crucial safety net against power grid failures, voltage fluctuations, and unforeseen outages.

In this comprehensive guide, explore industrial UPS systems and their significance, functionalities, lifespan, best practices for setup, and essential factors to consider when selecting the best UPS systems for your engineering applications.

What is an Industrial UPS?

An industrial UPS, or uninterruptible power supply, is a sophisticated electrical apparatus designed to provide instantaneous backup power to critical equipment during power disturbances or failure. Unlike standard commercial UPS systems, the industrial-grade units are engineered to withstand the harsh operating conditions commonly found in industrial settings. This type of UPS system offers enhanced reliability, robustness, and scalability to cater to the demanding power requirements of large-scale industrial operations.

Industrial UPS systems serve as vital defense, safeguarding sensitive electronic equipment, processes, and data from the detrimental effects of power disruptions. Having a reliable industrial UPS battery backup maintains operational continuity, prevents production downtime, and averts potential financial loss.

The Role of an Industrial UPS in Engineering Applications

In any business, the loss of power can be detrimental, but it can be incredibly significant in industrial environments, and even become dangerous, making an uninterruptible power supply system a piece of critical equipment. UPS systems act as a backbone, providing uninterrupted power to critical machinery, control systems, and infrastructure for seamless functionality.

Industrial UPS systems are specifically designed and tested to perform at a more demanding level than other commercial systems. If AC power is cut in industrial environments, it could lead to dangerous situations, like chemical process instability, or result in expensive processing system damage. Industrial environments will also usually have higher ambient temperatures and more air contamination, so the industrial UPS is capable of tolerating extreme temperatures and moderate levels of non-conductive dust.

Even if the industrial application is considered "light," such as in pharmaceutical or food and beverage manufacturing, losing AC power won't necessarily be dangerous, but it can be costly, resulting in product loss and interrupted production time.

What is the Average Lifespan of an Industrial UPS?

Understanding the expected lifespan of an industrial UPS is crucial for effective maintenance planning and budget allocation. On average, industrial UPS systems have a lifespan of 10 to 15 years, but this lifespan is contingent on various factors, including usage patterns, environmental conditions, and maintenance practices.

Routine maintenance can help extend the life and efficiency of an industrial UPS system. Over time, UPS systems will experience decreased efficiency, and if left running with such inefficiencies, businesses will see significant costs related to wasted electricity.

As a general rule of thumb, here are the typical life expectancies of various UPS systems:

• Small, low-voltage uninterruptible power supply: Maximum 5 years
• Large, floor-standing uninterruptible power supply: 10 to 15 years max
• Mission-critical uninterruptible power supply systems: 10 to 12 years max

Maintenance practices will help uninterruptible power supply systems reach their maximum expected lifespan.

Best Practices for Setting Up an Industrial UPS

For optimal performance and durability, it's important to follow some best practices when setting up an industrial UPS system. Proper installation, positioning, and maintenance help to mitigate potential risks, enhance system reliability, and prolong the unit's lifespan. Here are some best practices for setup as recommended by trusted manufacturer, Eaton:

• Work with an Electrician: A hardwired UPS system should be installed by a licensed electrician or an experienced technical or electrical engineer. In either case, the installer should be familiar with the particular industrial UPS system model. Even if you select an easy-to-install UPS system, having the setup reviewed by an electrician or engineer will offer peace of mind it was done correctly.
• Check All Connections: UPS systems that have been shipped may have internal connections that have shifted. Loose connections may cause equipment to spark after installation, which could result in charring or fires. An electrician should be able to quickly identify and fix these loose connections. After installation, properly monitor the unit and follow routine preventive care to detect and resolve any potentially problematic electrical connections.
• Consider the Environment: Where you are installing the UPS system is important to ensure you're avoiding potential triggers like heat, humidity, and dust. The installation environment should offer proper airflow, an optimal temperature of 77˚F (25˚C) with no direct sunlight, and offer the ability to receive notifications of any pending problems.
• Limit Access to the UPS System: Installing UPS systems out of the way doesn't mean they are secure. Your uninterruptible power supply system should be installed in a secure area to prevent unauthorized access.
• Invest in a Warranty and/or Service Plan: Most UPS systems will include a standard two- to five-year warranty, but purchasing an extended warranty can save time and money in the long run. Extended warranties can provide you with expedited replacement parts and batteries, as well as minimize business interruption and costs due to downtime.
• Don't Ignore the Battery: The battery is the heart of a UPS system, but it's incredibly vulnerable. Batteries are the leading cause of UPS failure and load loss. On average, valve-regulate lead acid (VRLA) batteries require replacement every three to five years, and participating in preventive maintenance can ensure you get the most life out of the battery while avoiding catastrophic issues.
• Integrate a Maintenance Bypass: A maintenance bypass offers a simple, effective means to bypass the UPS while maintaining power to the load. This allows you to service or replace the unit without shutting down any connected equipment, preventing downtime.

Choosing an Industrial UPS: Essential Factors to Consider

Selecting the most suitable UPS for engineering applications requires careful consideration of various factors. The following are some of the key aspects you should prioritize when selecting industrial uninterruptible power supply systems.

Power Capacity Requirements

Assessing the power demands of your industrial setup ensures the UPS system is able to adequately support critical loads during outages or fluctuations.

• Understand the power demands of your connected devices and equipment, calculating total power consumption to select an industrial UPS with sufficient capacity. Industrial UPS systems that are over- or under-sized can lead to inefficiencies and possible system failures.
• Additionally, consider the required runtime you'll need for critical systems during a power outage. The battery capacity can directly affect the duration of backup power, so it's crucial to select an industrial UPS system with a battery power capacity that falls in line with your expectations.

Reliability and Durability

Opt for industrial UPS systems with proven reliability and robust construction that can withstand harsh industrial environments.

• The UPS should be capable of protecting equipment from power surges and voltage fluctuations with features like surge suppression and automatic voltage regulation (AVR). Surge protection will protect against transient voltage spikes and AVR will ensure stable voltage output, even during fluctuations, extending the life of the uninterruptible power supply.
• Reliability should also include cost-savings, so evaluate the UPS system's energy rating. High ENERGY STAR ratings will ensure reduced electricity costs and prevent a waste of power.
• The industrial UPS should also come with an adequate warranty and manufacturer or supplier support. Both will offer peace of mind that you'll receive prompt assistance in the event of any issues.

Battery Backup Features

The battery backup capabilities, recharge times, and autonomy periods to sustain operations of the industrial UPS will offer insights into how the system will perform during prolonged outages.

• A UPS system that provides remote monitoring and management capabilities will offer real-time visibility into the status, battery health, and power consumption.
• Choose the right battery technology for your needs. VRLA batteries are maintenance-free and cost-effective, making them great for any industrial application, but they do have a somewhat limited lifespan. Lithium-ion batteries offer a longer lifespan and higher energy density for improved reliability and long-term value, but come with a higher up-front cost.

Scalability and Compatibility

Selecting an industrial UPS solution that offers scalability and expandability will be capable of accommodating future growth, expansion, and compatibility with existing infrastructure and equipment.

• Additional battery modules can increase the capacity as needs evolve to meet changing demands without performing a complete system overhaul.

The Reliability You Need: Explore Industrial UPS Products from Wistex

At Wistex, we offer a range of comprehensive industrial UPS solutions tailored to your engineering applications. Our products are designed to deliver unmatched reliability, performance, and efficiency in demanding industrial environments.

Our diverse lineup of UPS solutions ensures you can find the perfect fit for your requirements. Some of the industrial UPS systems to explore include:

• Sola SDU AC - B Series UPS: The Sola SDU maximizes machine availability and minimizes unplanned disruptions, delivering stable power and higher efficiency, network diagnostic communications, notable certifications, and higher operating temperatures without compromising battery performance. This unit is ideal for use in data centers, oil and gas industries, automotive manufacturing, and food and beverage industries.

• SDU AC - B Series Din Rail UPS: The SDU Din Rail UPS boasts a lightweight, compact industrial design with a wide operation temperature range and cold start capability. This uninterruptible power supply is well-suited for a range of industries where continuous power supply is critical for operations. The SDU AC - B Series Din Rail UPS is ideal for industries such as manufacturing, energy and utilities, healthcare, and data centers.

• SDP Low Power DIN Rail Series: The SDP Low Power Din Rail Series UPS systems are extra small, efficient units designed specifically for industrial environments. Each unit is rated from -10ºC to 70ºC and contains a DC indicator and front panel adjustment potentiometer. This industrial UPS is ideal for industrial, process, and machine control, building automation, and instrumentation.

For alternate UPS solutions, explore the offerings from Trystar, a reputable provider in the industry. Trystar's uninterruptible power systems are known for their reliability and effectiveness in safeguarding critical operations against power disruptions, and the Wistex team is proud to be a service provider and distributor of Trystar's line of USPs.

When you choose an industrial UPS from Wistex, you can rest assured your purchase is backed by expert customer support, with installation services and ongoing technical support for seamless integration and operation of the system.

Expertise and Dependable Power Management Solutions from Wistex

Selecting the right industrial UPS system for your engineering application is imperative as power reliability is non-negotiable. Precision and reliability are paramount, and choosing Wistex ensures you will receive unparalleled expertise and peace of mind with any power management solution.

By partnering with Wistex, you gain access to expertise, dependable solutions, and unwavering support to safeguard your business against power interruptions and downtime. Explore our full range of industrial UPS systems and products, or contact our team today for personalized assistance.