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Dawn Kluchenek

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When is it time to replace your UPS?

Have you experienced an outage, and your UPS failed to protect critical equipment? Is your UPS showing an error or alarm? Is your UPS approaching or past its end-of-useful-life (EOL) recommendation from the manufacturer? Any of these may have you thinking about replacing your system. When you can no longer trust a device, you must consider replacing it.

Understanding the life of your UPS

A single-phase UPS can have a useful life of up to 10 years. While its possible to keep a UPS running up to or past its useful life, critical UPS components will require attention well before the unit reaches its EOL.

UPS components have individual lifespans which attribute to the overall lifespan of the UPS. Batteries are generally the first component to require attention. It is generally recommended to schedule battery replacements between the third and fifth year of normal operation. UPS capacitors and fans are typically rated between 7 and 10 years. Unless a PM states otherwise, schedule your first battery replacement at no later than 5 years and capacitor and fan replacement between 7 and 10 years.

If the component replacement conflicts with the EOL of your specific unit, consider replacing the system instead of the component.

Maintaining your UPS throughout its life

Maintaining your UPS and its components, through regular PM visits, can serve to avoid headaches and costly downtime. Knowledge of critical components within your UPS and some proactive planning can go a long way in extending the life of your UPS.

PM visits result in valuable information about the health of your UPS. Thanks to information stored in “Field Service Reports,” it becomes possible to make proactive decisions to ensure the longevity of your unit.

When it’s time to replace

Once your UPS has reached its EOL or if it has reached critical failure, partner with a firm you can trust to provide the best guidance on choosing a replacement system. At SEPS, with over 35 years of field experience and leadership in power protection, we are well equipped to provide you with any advice you need, and we can provide all preventive maintenance and replacement services to keep your UPSs healthy for the long haul. For more information, please contact us, or speak with one of our Power Protection experts at 630-283-2399 or dmayo@seps-inc.com.

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4 Main Components of a UPS System

As we have discussed in a previous blog, there are several popular UPS topologies (designs) to choose from when seeking power protection for your facility. Each UPS design has its benefits and drawbacks. The standby UPS design is low cost, but it can result in disruption of operation of sensitive loads. The line-interactive UPS provides a more comprehensive level of protection from power anomalies (thanks to power conditioning), but it still has a transfer time to batteries in the case of an outage or disruption.  Finally, the double-conversion (online) UPS design provides top level protection and efficiency, but it comes with a high price tag.

While an understanding of each UPS topology is important, it is equally important to have some understanding of components which make up the UPS. This blog will cover the main functional components found in UPSs: batteries, inverter, rectifier and static bypass.

Batteries

Batteries are the heart of every UPS. Additionally, batteries are the main source of UPS failure because they are the most likely component to fail. Batteries die for a variety of reasons – high or uneven temperatures, lack of maintenance, aging – and each battery type has its own recommendations for proper care.

The most common types of UPS battery are: Valve Regulated Lead Acid (VRLA), Flooded Wet Cell (also known as VLA) and Lithium-Ion. VRLA has long been the most popular UPS battery type, because it is readily available and therefore relatively inexpensive. VRLA UPS batteries generally last 3-7 years in the proper environment. VLA batteries can provide a longer lifespan – as much as 20 years – but they require more maintenance when compared to their VRLA counterparts. Lithium UPS batteries are the “new kid on the block,” and are just gaining popularity in the UPS battery market. UPSs built specifically to use lithium ion battery technology are in the market today. 

No matter what battery type is used in your UPS, it is important to keep your UPS and its batteries in a viable environment to ensure longevity. UPS batteries should be maintained along with other components, and they should be replaced on a strict schedule to ensure that battery failure does not result in down time for your facility.

Inverter

The inverter, found in all UPS designs, converts DC power from batteries (or from the rectifier) back into AC power for load use. In double conversion UPS designs, during normal operation, the rectifier and inverter are used in tandem to convert AC to DC and DC to AC (i.e. double conversion) which protects IT loads from any power anomalies. In standby and line interactive UPS designs, the inverter is switched on immediately after utility power goes down, to deliver battery power to the load. The downside to these designs is the “transfer time” to batteries – meaning it takes time (milliseconds) for the UPS to switch from normal operation over to the inverter/batteries.

Rectifier

The rectifier, in double conversion UPS designs, coverts utility AC power in to DC power. The rectifier, coupled with the inverter, allows for protection from power anomalies and delivers clean power to the load. Standby and line-interactive UPSs will not contain a rectifier. This is because these designs deliver utility power to the load during normal operation. These designs will have a battery charger which allows the batteries to remain ready in case of power disruption.  

Static Bypass

The static bypass switch allows utility AC power to flow directly through the UPS to the load, bypassing UPS components. Static bypass is a feature of double conversion UPS systems. When major preventive maintenance is needed on a UPS, normal operation will be halted, and a technician will switch the UPS into bypass (maintenance) mode. In this state, the load is vulnerable to a utility outage.

With more than 35 years of field experience and leadership in power protection, SEPS is well qualified to perform UPS preventive maintenance. SEPS offers a full suite of UPS services and all technicians are trained and certified to manufacturer standards, assuring a thorough job.  For more information, please contact us, or speak with one of our Power Protection experts at 630-283-2399 or dmayo@seps-inc.com.

Blog

3 benefits of a proactive UPS maintenance plan

Why are PM’s important?

While there are many factors affecting the life of your UPS, there’s also a very simple way you can ensure optimal UPS performance: regular preventive maintenance (PM). A UPS is an incredibly complex system, which has several components vulnerable to wear and tear. A PM visit provides the opportunity to detect and repair problems before they become costly issues. Critical environments, such as data centers, rely on the resilient power that the UPS helps provide. So it makes sense in terms of profitability and efficiency to ensure that your system runs at peak performance.  Here are 3 reasons to consider adding PM visits to your calendar:

Identify component issues. A UPS system has several components vulnerable to deterioration, and eventual failure. The component most likely to result in UPS failure are the batteries. Regular inspection can almost always predict a failing battery or string of batteries, and an assessment can be given on when batteries should be replaced.

In addition, there are other internal UPS components that a trained technician performing a PM visit would check. This includes: Capacitors, fans, power supplies, contactors, relays, air filters and internal connections.

Reduced Cost and Improved Efficiency. Regular preventive maintenance visits keep a UPS running at optimal performance. Regular check-ups allow for failing components to be identified, and replaced. Well-maintained UPS’s require less power to run, and therefore save money.

Minimize Downtime. While downtime cannot be eliminated completely, keeping a close eye on your UPS can reduce the risk of critical system failure. In the result of an emergency, the importance of having an experienced UPS service provider on speed dial – who can not only react quickly, but who is also familiar with your equipment and facility – cannot be overstated. A relationship such as this can be crucial to minimizing disruption and maintaining regular business operation.

With more than 35 years of field experience and leadership in power protection, SEPS is well qualified to perform UPS preventive maintenance. SEPS offers a full suite of UPS services and all technicians are trained and certified to manufacturer standards, assuring a thorough job.  For more information, please contact us, or speak with one of our Power Protection experts at 630-283-2399 or dmayo@sepsinc.local.

Blog

208V Single Phase Power, MBB Bypass Switches, and Isolation Transformers: What You Need to Know

If you are designing a site that will have 208V single phase power to feed the UPS, you should be aware of the nature of 208V power and how it works with different UPS models. This is one of the subjects that raise the most questions because it is different for the different UPS types, it is something you may not encounter on every project, and it has the potential to be a costly error if ignored.

As I said, this situation is not an issue in every case. SEPS has configured the standard part numbers to avoid potential issues, but some questions often remain.

The Nature of the Issue

Simply put, on some combinations of UPS model, bypass switch type, and input voltage, there exists the potential for an incompatibility. This all stems from the nature of 208V power and how it is affected by transformers.

 

120/208V Single Phase Power

120/208V single phase is derived from 208V three phase power. If viewed on an oscilloscope, the three voltage waveforms on the three “hot” conductors all peak at different times: each one is 120 degrees behind the next. When using 120/208V single phase, you will use any two of those same three hot conductors, with the two waveforms peaking 120 degrees apart from each other.

Since the two waveforms peak at different times, the combined power you get from them is less than the numerical sum of the two. When one waveform is at its peak, measuring 120V, the other is only part of way through its cycle, measuring only 88V. The sum of the two is 208V. As you would expect, if the two waveforms were coincidental (peaked at the same time), you would add both 120V peaks together to get 240V.

 

Make-Before-Break Maintenance Bypass Switches

The purpose of this device is to allow a path for the UPS protected equipment to be fed by utility power in the event of UPS service or replacement. It completely removes the UPS from the power path, enabling the service technician to work in the UPS without the worry of getting shocked. It also allows the UPS cabinet to be completely removed and replaced without shutting down the protected equipment, which is the reason Motorola requires this switch with every hardwired UPS.

When the switch handle is operated, the Make-Before-Break (MBB) switch overlaps the power on the “UPS” line with the utility power on the “Bypass” line. This momentary overlap does not cause a problem because it is so short, but it is necessary because it enables the switch to transfer sources with no interruption to the protected equipment.

 

Isolation Transformer

This device, whether internal to the UPS or a separate unit, recreates the utility power into clean, conditioned power. In cases where the utility power is “dirty” or “’harsh”, you should use a UPS that includes isolation to provide the maximum protection to your equipment. UPS systems that include isolation are considered separately derived power sources per Motorola’s R56 Standards. (For a more detailed explanation of isolation transformers, please see the article “Isolation Explained” in this section.)

Kirchoff’s Law states that the power into a circuit must equal the power out of a circuit. This includes transformers, where power on the primary (input) side must equal the secondary (output) side. Transformers cannot “create” power; they can only influence what’s already there. Therefore, if you put 120V in, you will get 120V out, 208V in gets you 208V out, 240V in gets you 240V out, etc.

 

Putting It All Together

When you run 120/208V single phase power into an isolation transformer, the two individual hot conductors of 120V are combined into one 208V waveform. Since most Motorola equipment requires 120V, we need to split the 208V back into two 120V conductors – but it can’t be done.

As stated earlier, the power that goes in must match that power that comes out without creating anything new. When the one 208V waveform coming out of the transformer is split into two conductors, only 208V of total voltage is available, with both conductors peaking at the same time. When one 120V conductor is created, the remaining voltage is only 88V, which cannot be used by any equipment.

The logical solution is to set the output of the UPS for 240V, because with 240V can be split evenly into two 120V conductors. This would work, if it weren’t for the Make- Before-Break maintenance bypass switch. When that switch is operated, it overlaps the power from utility (120/208V) with the power from the output of the UPS (120/240V).

Since the phase angles of the two voltages are different, a magnetic “crash” will result and the circuit breaker feeding the UPS will be tripped.

 

Solutions

In UPS systems with isolation, since the UPS output should be 120/240V to avoid the “88V leg” and the input cannot be 120/208V, then the input must be 120/240V. If this is already available at the site, then there really is no issue here. However, if the site voltage feeding the UPS is 120/208V, you will have to change it to 120/240V. This is accomplished in different ways with the FERRUPS and the 9170+ UPS systems.

 

FERRUPS

The FERRUPS has a ferroresonant transformer at the heart of its design, so all models automatically include internal isolation. This means that all FERRUPS models that would be fed with a 120/208V circuit will be affected by this. When you are looking for a FERRUPS model number, note that models 3,000W and larger are configured as both 208V source systems and 240V source systems, and you need to choose the appropriate one. The only difference between the two is that the 208V source systems include an external transformer to step the input voltage up to 120/240V.

As an alternative to the step-up transformer, you can opt to use the Break-Before-Make (BBM) maintenance bypass switch. The BBM switch does not overlap the utility and UPS output feeds when the switch is operated, so there is a break in power. Any equipment still operating during that break will lose power and crash, so all protected equipment must be shut down first. Motorola believes that the protected equipment should never be shut down, even for UPS maintenance, so the BBM is not offered in any standard model configurations. SEPS will quote you a special configuration if the external transformer is not a workable solution.

 

 9170+

The 9170+ includes an external isolation transformer for all models that end in “ISO”. This external transformer has multiple input taps to allow you to supply it with 120/208V or 120/240V power, with the output set at 120/240V. This transformer provides the isolation and provides 120/240V out to the bypass switch, so neither of the two issues described above are relevant.

If the 9170+ is not equipped with an isolation transformer, it can be supplied with either 120/208V or 120/240V power. The absence of the transformer eliminates all of the issues described above.

As an alternative to the external isolation transformer, if the site has 1220/240V power to supply the UPS, then you can opt for an internal isolation transformer (see the Powerware 9170+ part number lists for details). Again, this option is only available with a 240V feed because its use makes the 9170+ very similar to the FERRUPS – the issues with the 88V leg and the phase angle mismatch appear. If you are unsure of site voltage, SEPS recommends not opting for the internal transformer to err on the side of caution.

Download PDF: 208V-MBB-Xfmr

Blog

UPS Topologies

Choosing the optimal uninterruptible power supply (UPS) for your facility can be a complex task. There are many factors to consider when you are expanding or re-evaluating your current infrastructure, and planning to add a UPS. A few elements to examine when selecting a UPS are: availability, reliability, environment, and sensitivity of the load.

Once those parameters have been assessed, you can decide on your preferred UPS topology. All UPS’s deliver correct voltage to the load, but the differences in how they do it give us the different topologies. The three main UPS topologies available in the market today are: the Standby UPS; the Line-Interactive UPS; and the Online UPS. Here, we will break down the main configurations of each UPS topology.

Standby UPS

A standby UPS, also known as off-line or line-preferred UPS, provides a low cost solution for protection from power failures. They are generally small in size, efficient, and easy to use. The standby UPS is most commonly used in less sensitive IT applications, such as personal computing.

During normal operation, a standby UPS takes utility power and delivers it directly to the load. This means that any power anomalies from utility power do pass through to the load. When power fails, or voltage/frequency changes become too severe, the UPS transfers to battery to provide power to the load. Transfer time to battery on a standby UPS is relatively slow (longer than 4 milliseconds) and the delay can disrupt the operation of some sensitive loads.

standby ups technology

Line-interactive UPS

A line-interactive UPS provides basic power protection at a moderate price. Like the Standby UPS, a Line-interactive UPS delivers utility power directly to the load during normal operation, which can let power anomalies through. Additionally, the Line-Interactive UPS employs a buck-boost transformer, also known as an Automatic Voltage Regulator (AVR), to manipulate the voltage to a tighter tolerance if the voltage fluctuates. This is helpful for more sensitive loads, and also prevents the battery from being used as often. If voltage falls outside of operating range or if power completely fails, the UPS transfers to battery to provide power to the load. Transfer to battery is not instantaneous. However, the transfer time for a line-interactive UPS (a few milliseconds or less) is generally much faster than a Standby UPS.

Line-interactive UPSs provide power protection against power failures, power sags, and power surges. They are designed to also protect against other power disturbances such as electrical line noise and brownouts.

line-interactive ups technology

Online UPS

An online UPS is designed to provide comprehensive power protection for sensitive IT loads. The online UPS consistently conditions power from the input of the UPS to the output. Utility power flows into the UPS and is converted from AC power to DC power. Then the power is converted back to AC power and delivered to the load. This completely isolates the IT load from any power anomalies which might occur from utility power and is the best choice for sensitive IT equipment. When the utility power fails, the UPS instantaneously draws its DC power from the battery. Thus, there is zero transfer time to battery in an online UPS.

One of the principal factors to consider when making an investment in an Online UPS is battery utilization. The online UPS, because of its design, uses the battery less often than the standby UPS and line-interactive UPS. This increases the life expectancy of the battery and decreases the cost of maintaining the UPS over its lifetime.

online ups technology

Interested in finding a UPS solution?

SEPS is proud to offer the most popular and trusted brands of uninterruptible power supplies in the critical power industry. For more information, please contact us, or speak with one of our Power Protection experts at 630-986-8899 or dmayo@sepsinc.local.

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