FINDING THE BEST AC UPS SYSTEM SOLUTION FOR AN INDUSTRIAL

ENVIRONMENT
M. Dreier
GUTOR Electronic Ltd
Hardstrasse 72-74
5430 Wettingen

G. Andersen
Member, IEEE
GUTOR Electronic Ltd
Hardstrasse 72-74
5430 Wettingen

Switzerland

Switzerland
Abstract - Continuous availability of secured power supplies
is a key factor for a smooth plant operation.
This paper evaluates the different AC-UPS system
(Uninterruptible Power Supply) topologies applied in an
industrial environment (Petrochemical- and Power Generation
Plants) by firstly analysing typical load types and power
distribution networks.
Advantages and disadvantages of typical UPS set-ups will
be explained. A good understanding about layouts, operating
modes, downstream distribution and load supply feeder
connection schemes is given based on single line diagrams.
In consideration of functionality, reliability, maintainability,
operability and cost the most suitable UPS solution for a given
load- and distribution architecture is recommended. This by
rating each topic in regards to major UPS system set-ups.

of 0,4 inductive to 0.9 capacitive. Lighting equipment, motors,

valves, heaters and power supplies with power factor correction
(PFC) are typical linear loads. Loads of this group have only
one power incomer connection.
B.

Linear Loads with Dual Inputs

This group of loads provides two independent power inputs,

which are normally galvanically isolated. One available source
is enough to power the load while the second one serves as
stand-by supply. However the internal architecture allows to
select the available source by means of a high-speed transfer
switch or by coupling the two sources after galvanic isolation
and power factor corrected rectification (AC/DC converter). Fig.
1 shows a typical single line diagram of a dual input load with
coupled sources on DC side.

Index Terms UPS, Secured Power Supply, Double

Conversion, PWM Inverter, UPS Configurations, On line
I.

A UPS system is a vital part in a complex power conversionand distribution scheme for process control and monitoring.
Evaluating the best suitable configuration for the given
requirements and topologies is a key issue during the
engineering stage for a new application or for refurbishment of
an existing set-up. However, the decisive / determining factors
are multifaceted and linked together. In any case there is no
one and only solution. Closer investigations often reveal that
simple and cost effective configurations fulfil the specifications
much better than the complicated high-end choice. The UPS
technology elaborated in this paper is based on double
conversion concept with thyristorised rectifiers and pulse width
modulated inverters, which is a state of the art UPS solution for
heavy industrial applications.
II.

UPS LOAD TYPES

UPS AC-loads are characterised by the number of feeding

inputs and their linearity considering the input current.
A.

PFC

INTRODUCTION

Linear Loads with Single Input

Linear AC-loads are specified by their sinusoidal input

current. Therefore they do not inject current harmonics into the
feeding network. Their power factor may vary in a typical range

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AC Input 1
PFC
AC Input 2

Fig. 1 Linear Load with Dual Inputs

C.

Non-linear Loads with Single Inputs

A majority of critical loads connected to UPS systems are

non-linear. Their input current wave shape is not sinusoidal and
shows high peak values (high crest factor). The resulting
distortion is mainly caused by the embedded Switched Mode
Power Supplies (SMPS). These consist of a rectifier bridge with
a filter capacitance to condition the unregulated DC followed by
a high frequency DC/DC converter. Such a set-up causes the
heavily distorted current shape. Fig. 2 illustrates the simplified
diagram and the corresponding input voltage- and current
snapshots. The AC power is connected to one connection
point.

Fig. 3 Non-linear Load with Dual Inputs

III. UPS POWER NETWORKS
+

HF Converter

A key factor to determine the best UPS solution is the

upstream- and downstream feeder set-up.

AC Input

A.
400

Voltage [V]

200
0
-200
-400
60
150

70

80

90

Current [A]

100

Time [ms]

Upstream Supply Set-up

A single UPS system set-up typically requires to be

connected with two AC sources: Rectifier input- and bypass
mains (also called alternative- or emergency mains). Those
inputs are normally galvanically isolated. This offers the
possibility to connect two independent power feeders even
from different sources in order to improve availability. However,
it is also feasible to connect the inputs to the same supply to
reduce wiring work and installation costs. Fig. 4 shows a typical
upstream feeder set-up.
Source 2

Source 1

100
50
0

Tie-up

-50

Bus 1

-100
-150
60

70

80

90

Bus 2

100

Time [ms]

Rectifier
Mains

Bypass
Mains

Fig. 2 Non-linear Load with Single Input

UPS

D.

Non-linear Loads with Dual Inputs

The internal topology of this load type is typically based on

two SMPS power supplies, which are coupled on the output
side. Each supply entity has its own AC input, again
galvanically separated from other. They can be equipped with
load sharing facility to ensure that the total power is equally
distributed to both AC feeders. Powering one input only is
enough to operate such loads. However, it is normally preferred
to energise both inputs simultaneously in order to enhance the
availability of the load. Fig. 3 illustrates the typical internal setup.

HF Converter

HF Converter

AC Input 1

AC Input 2

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Fig. 4 UPS Upstream Supply Scheme

B.

Downstream Distribution Set-up

Each UPS system is typically feeding a dedicated securely

powered distribution board (safe bus). Individual feeders to the
loads are fused and pulled from there, or via another subdistribution. Dual input loads are preferably supplied by two
independent distribution boards. Fig. 5 illustrates a typical
scheme. Interconnection (tie-up) to another distribution board is
very much restricted and therefore only allowed for special
UPS configurations and topologies (same UPS size and active
load sharing control mandatory) in order to avoid circulating
currents with possible consequential damage.
Special attention shall be given to the earthing concept. It is
recommended to go for galvanic isolation in the bypass- and
inverter branch within the UPS modules to achieve most
effective immunity to mains conducted disturbance. This allows
a floating (IT) UPS distribution network, or earthed (TN, TT)
scheme by bonding the neutral conductor to protection earth.

UPS A

UPS B

Tie-up
Safe Bus A

Safe Bus B

Single Input
Load

Dual Input
Load

Single Input
Load

Fig. 5 Typical UPS Power Distribution Network

IV. UPS CONFIGURATIONS
There are many different UPS configurations available to
fulfil the load- and electrical network requirements. This part of
the paper describes the set-up and the basic functionality of
major topologies in conjunction with the application of double
conversion UPS systems.
A.

Single Unit Configuration

This is a basic UPS set-up fulfilling the minimum requirement

for a secured power source. It is also used as a module to build
up more complex architectures described in this chapter.
1) Functional Description: Fig. 6 illustrates the main
functional blocks of a single UPS system with mains bypass
(emergency- or alternative line).
Single UPS Module
Bypass
Input

Bypass
Transformer

Manual
Bypass Switch

Rectifier
Rectifier
Input

Inverter SSW Inv.

Battery Bank

Secured Load Bus

SSW Byp.

Fig. 6 Single UPS System Block Diagram

The rectifier block converts mains AC (normally three phase)
to DC power. Galvanic isolation transformers at the input are
often used to reduce distortion fed back to the mains and to
allow a floating DC circuit for best immunity. 6- or 12 pulse
rectifiers equipped with thyristors are typically applied for this
conversion stage followed by a LC filter to smoothen the DC.
The intermediate DC circuit comprises the battery bank,

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acting as energy storage tank, which is continuously kept in a

fully charged condition by the rectifier as long as mains is
available. This circuitry is feeding power to the inverter, the next
conversion stage. Its duty is to convert DC back to pure AC.
The common technology used for this is PWM (Pulse Width
Modulation) obtained by IGBT (Insulated Gate Bipolar
Transistor) power stacks. An inverter output isolation
transformer provides galvanic separation from the DC- to the
AC part and allows high flexibility for the desired output voltage
range. Moreover it is a part of the PWM filter to warrant for a
high quality sinusoidal output voltage. An optional silicon static
switch (SSW) connects or disconnects the inverter stage to the
UPS output. Single- or three phase outputs are individually
configurable.
The bypass mains input is linked via an optional matching
transformer to a second static switch, which is normally open
and leading to the UPS output. The inverter is constantly
synchronised to the bypass voltage as long as the voltage
quality is sufficient. This allows uninterrupted changeover from
inverter to bypass source in case of heavy overload, inverter
malfunction or if requested by operating personnel. An
additional manual make-before-break switch allows a smooth
transfer of the critical load to the bypass supply and vice versa.
This mainly during maintenance and repair activities were a deenergised rectifier- and inverter part is mandatory for safety
reasons. Finally the secured UPS power distribution board is
supplied from there.
2) Operation Modes: There are three major operation
modes:
a) Normal operation: Rectifier and inverter are in
operation and feeding the load through the closed static switch
and manual bypass selector switch. The batteries are
maintained in fully charged condition. The bypass branch is
typically energised with its static switch open. This mode is also
called online operation and is maintained as long as possible
st
(1 priority).
b) Battery operation: Rectifier is shutdown due to input
power failure. The batteries now supplying the inverter are
being discharged. The load is still fed by the inverter with
continuous high power quality and the bypass circuitry can
either be available or not. The latter would prevent an
uninterruptible changeover to the alternative mains.
c) Bypass operation: The load is directly fed by the
alternative (bypass) supply through the static- and manual
bypass switch. Rectifier and inverter may still be operational but
are no longer supplying the load. Bypass operation should be
considered as emergency operation mode only (drained
batteries, inverter breakdown, short circuit) since the load is no
longer properly backed-up and power quality very much
depends on the mains. Unless the system is forced to switch to
bypass by manual intervention this mode has the lowest priority
and should therefore be avoided if possible.
3) System Topology Summary: Single UPS systems with
the described architecture are well established in the industrial
environment. They are suitable for linear- and non-linear loads.
However, todays highly sophisticated DCS (Distributed Control
Systems) and other process control gear call for a very high
power availability and as such require sophisticated UPS
concepts that are based on multiple module set-ups to achieve
higher redundancy.
B.

Cascade or Hot-standby Configuration

Cascade systems are a combination of two single UPS units

in order to enhance the systems availability without paralleling
them. The main improvement compared to the single unit is the
secured bypass supply of the main unit (master) which is
backed-up by the stand-by system (slave).
1) Functional Description: Fig. 7 shows the typical single
line diagram.

Bypass
Input

Slave UPS Module

Rectifier
Input
Slave

Secured Load Bus

Master UPS Module

Rectifier
Input
Master

c) Power failure on slave: The slave module changes to

battery operation. This does not affect the integrity of the
master unit as this still receives bypass power, at least for as
long as the slaves batteries last.
d) Power failure on master and slave: Both modules
change to battery operation whereby the battery bank of the
master unit is drained first followed by a changeover to static
bypass to load the slaves inverter and finally discharging its
battery, provided that an individual battery concept is in place.
e) Inverter fault on master: The total load is immediately
transferred to the slave module. However, an uninterrupted
transfer is only possible if the slaves output is available and
masters inverter was synchronised before the incident.
3) System Topology Summary: Cascade Systems are
easy to build up with two single UPS modules. They do not
require complex electronics to control the overall behaviour and
are easy to understand and maintain. The weak point is the
static bypass switch of the master module, which is ultimately
required to connect the safe bus to the slave module in case of
the master module breaking. Ageing of the two modules is
unequal due to different loading schemes. It is not possible to
parallel the modules for higher output peak currents. Moreover,
the short circuit current performance is even lower compared to
a single system due to the long power path with two static
switches in series.
Today cascade systems are outdated yet still obtainable.
They are suitable mainly for linear- and non-linear loads with
single inputs where a higher power availability is desired
compared to the classical single systems.
C.

Parallel Redundant Configuration

A parallel redundant system comprises at least of two UPS

modules which are paralleled at the output. This allows a
significant increase of the systems availability and improves
the total power capability in regard to overloads and short
circuits.

Fig. 7 Cascade System Architecture

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1) Functional Description: Fig.

understanding of the single line level.

Bypass
Input

allows

better

Common Bypass
UPS Module A

Rectifier
Input
Module A

UPS Module B

Rectifier
Input
Module B

Secured Load Bus

The main UPS module is normally maintaining the full load

while the stand-by module is idle and just energising the
bypass input of the master unit. Typically there is no particular
communication or control logic between the two units in order
to avoid a common failure point. Although a common battery
bank configuration is possible an individual one is highly
recommended. This maintains the integrity of each unit and
prevents any unwanted DC circulating currents.
2) Operation Modes: Operation modes of a cascade
system are grouped as follows.
a) Normal operation: All parts of the overall system are
available with all power sources in tolerance. The master
module is feeding the load like a single system. Its alternative
mains input (bypass) is powered by the slave module which is
running in normal operation but at no load since the static
bypass switch is open.
b) Power failure on master: The master module changes
to bypass operation to connect the fully operational slave
module with the critical load. The changeover takes place
without interruption. Depending on the master module set-up it
is also possible that it first changes to battery operation and
after this to bypass operation when the individual battery bank
is discharged.

1) Functional Description: Fig. 9 shows the overall system

topology.
Fig. 8 Parallel Redundant Configuration

D.

Dual UPS Configuration

The dual UPS configuration is a combination of two single

modules. It is preferred for dual feed distribution schemes with
associated double input loads. Each UPS module is related to
its own distribution board. There are no common components
for both UPS blocks.

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UPS Module A
Secured Load Bus A

Bypass
Input
Module A

Rectifier
Input
Module A

Bypass
Input
Module B

UPS Module B
Secured Load Bus B

Both UPS modules have the same priority and are equally
sharing the total load while the nominal power rating of either
unit must not be exceeded. A common bypass source is
distributed to the two static bypass switches and can be routed
directly to the load by means of the manual make-before-break
switch. The communication bus together with the associated
control gear obtain proper load sharing and synchronisation to
the bypass source. All operation modes are duly co-ordinated.
Even though a common battery bank is possible individual
battery banks are recommended. Some manufacturers allow to
parallel more than two modules to further increase the
redundancy factor.
2) Operation Modes: The following operation modes
comprise the most important ones:
a) Normal operation: Each part of the overall system is
available with any power sources in tolerance. Both, rectifiers and inverters units are sharing the total output power. Bypass
source is stand-by and acting as synchronisation source.
b) Power failure on one module: This particular UPS
module switches to stand-by operation while the other one will
carry the full load. No power re-routing by means of switches is
required. This also preserves the precious battery power for as
long as possible.
c) Power failure on both modules: Both modules call up
battery operation simultaneously and discharge the battery
banks equally yet still delivering 50% of the total output power.
Co-ordinated changeover to bypass takes place if the battery
capacity is completely used up.
d) System fault on one module: The concerned module
is immediately set to stand-by mode while the remaining one
takes the full load without disturbing it.
e) Overload condition: Both modules are capable to
supply 100% of their nominal rating which equals to 200%
overall power performance. An uninterrupted transfer to bypass
mains would occur by closing both static bypass switches
simultaneously in case this value is exceeded.
3) System Topology Summary: Parallel redundant
systems offer highest power availability and optimal overall
function co-ordination. Although the required parallel control
electronics can be considered as common failure point, the
redundant communication links and a well-proven circuitry
reduce this risk to an absolute minimum. Unique ageing of both
modules, high overload and peak current capability are strong
factors to consider this solution for very critical linear- and nonlinear loads with single inputs.
Todays state of the art PWM technology allows this kind of setup without restrictions, and this is also why many
manufacturers are promoting it.

Rectifier
Input
Module B

Fig. 9 Dual UPS Configuration

Each individual UPS module operates similarly to a
standalone single system. It is recommended to connect
different power sources per UPS module in order to extend the
availability in case of a failure on one supply. The distribution
boards must not be connected together (tie-up) as there is no
load sharing or synchronisation control gear available.
However, a tie-up is possible provided both systems are
operating in bypass mode with exactly the same bypass
supply.
2) Operation Modes: The operation modes are given as
follows:
a) Normal operation: Both UPS modules are available,
operating in normal operation mode and supplying the loads
connected to their distribution boards. Load sharing depends
on a well-balanced load schedule only.
b) Power failure on one module: This particular module
will first change to battery- and finally to bypass operation mode
if latter is available. The other module continues to supply their
loads in normal operation mode.
c) Power failure on both modules: Both modules will call
up battery operation. The individual batteries are discharged
according to the actual loading, which is not co-ordinated
between the two units.
d) System fault on one unit: The captioned module tries
to maintain the load by changing to another operation mode if

possible. However, the risk to loose the output is quite high in

this case.
3) System Topology Summary: The Dual UPS
configuration does not improve power availability for any single
feed load (linear or non-linear) connected to one distribution
bus only. The main purpose and advantage show in connection
with dual feed loads where the inputs are split to the two
distribution boards. In this case it is the best choice as there
are no common failure points within this configuration.
However, it is difficult to establish a UPS load set-up with dual
feed loads only. Wiring costs and required space demand are
much higher compared to the other solutions expanded in this
paper.
V.

UPS CONFIGURATION COMPARISON

Comparison of the different UPS set-ups in regards to main

decisive topics is the content of this section. It shall serve as a
planning guide for new UPS installations or as a tool to review
existing ones.
Key factors for UPS configurations covered in section IV are
rated in tables. A score from 1 to 5 is applied whereby a 1
indicates the lowest respectively a 5 excellent suitability or
fulfilment.
A.

Functionality:

The functionality rating reflects the ability of a UPS

configuration to supply the critical load with secured power from
the inverter(s) regardless of external voltage disturbances or
faults for as long as possible. Transfer to the alternative source
to maintain the load constitutes a risk and a possible
degradation of the power quality. It has therefore a negative
impact on the score rate if this is a part of the UPS functionality.
The load types depending on number of inputs are also
considered.
UPS Configuration
Single Unit
Cascade
Parallel Redundant
Dual Units

Score Rates
Single feed loads Dual feed loads
3
3
3
3
4
4
3
5

UPS Configuration
Single Unit
Cascade
Parallel Redundant
Dual Units

TABLE II UPS CONFIGURATION RELIABILITY

SCOREBOARD
Conclusion: A dual unit configuration with a full dual load
scheme is scoring best, followed by the parallel redundant
configuration.
C.

B.

Reliability

The reliability of a UPS configuration is mainly expressed by

the continuous up-time duration between two critical system
faults leading to a shutdown condition of the connected loads.
The longer, the better the reliability, which is often also
specified as MTBF (Mean Time Between Failure) figure in
hours. Supply disturbances or faults in the up- or downstream
installation are not taken in consideration in Table II. Power
failure on one input of a dual feed load is still considered as a
healthy condition.

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Maintainability

Every UPS system has to be properly maintained to warrant

for a high system availability over a long period of time. The
scope of a typical maintenance programme is similar for all of
the configurations covered in this paper. The comparison is
emphasising on the ability to perform a safe maintenance and
service work without disturbing the load and without adhering
complex switching procedures. High scores are given to
configurations where the load (at least one input for dual feed
loads) is continuously supplied by an inverter while a part of, or
even an entire UPS module, is completely isolated for
servicing. It is presumed that all configurations are equipped
with manual bypass changeover switches.
UPS Configuration
Single Unit
Cascade
Parallel Redundant
Dual Units

TABLE I UPS CONFIGURATION FUNCTIONALITY

SCOREBOARD
Conclusion: A parallel redundant configuration offers the best
functionality for single feed loads whereas the dual set-up is
most suitable for loads with two inputs.

Score Rates
Single feed loads Dual feed loads
2
2
3
3
4
4
2
5

Score Rates
Single feed loads Dual feed loads
2
2
3
3
4
4
2
5

TABLE III UPS CONFIGURATION MAINTAINABILITY

SCOREBOARD
Conclusion: The most suitable configurations allows an
uncritical manual shutdown and isolation of one UPS module
without involving critical switching procedures yet maintaining a
secured power source for the load.
D.

Operability

Another important factor is the operation of a UPS system.

User friendly operation and a good integrated overall control
and monitoring scheme allow fast and correct interventions in
case of system troubles or during routine checks. Co-ordinated
changes of operation modes between two or more UPS
modules avoid unwanted shutdowns caused by circulating
currents. The goal is to keeping the operation simple and safe.

Score Rates
Single feed loads Dual feed loads
4
4
3
3
4
4
3
3

UPS Configuration
Single Unit
Cascade
Parallel Redundant
Dual Units

TABLE IV UPS CONFIGURATION OPERABILITY

SCOREBOARD
Conclusion: Single- and parallel redundant configurations are
integrated systems with an overall control and monitoring
scheme that guide users and provide built-in interlocking
functions for critical changes in operation modes. They
therefore offer best operability.
E.

System- and Installation Costs

Commercial perspective considerations are becoming more

and more important. Both, UPS equipment and associated
installation costs, including wiring and distribution boards, must
be considered in getting an accurate picture of the solution
cost. Needless to say that a multi UPS module set-up is in any
case more expensive than a single one but meets more
stringent specifications. The single UPS unit with a single feed
load scheme is scaled to 100% cost, allowing a relative
comparison with the other set-ups.
Relative Solution Cost
Single feed loads Dual feed loads
100%
120%
180%
200%
180%
200%
200%
220%

UPS Configuration
Single Unit
Cascade
Parallel Redundant
Dual Units

TABLE V SYSTEM- AND INSTALLATION COST

COMPARISON
Conclusion: Single- and parallel redundant configurations
with single feed loads are most cost effective while meeting the
key factors to a very high degree.
F.

Overall Ranking

It is almost impossible to give an accurate final judgement

considering all expanded criterias due to the complexity of all
interactions. The authors have therefore decided not to publish
an overall ranking.
VI. CONCLUSION

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Evaluating the most suitable UPS solution is based on many

influencing factors and given circumstances. This paper has
covered the most important areas based on long-term
engineering-, field- and application experience. Profound
understanding on the operation modes and the overall
behaviour of the different configurations is a key issue to judge.
Other UPS technologies than PWM double conversion
systems are not within the scope of this evaluation. The whole
battery area, though being a very important part of a UPS
system, is likewise not included in this publication.
A UPS system solution must always be considered and
scrutinised in its entirety with the associated installation- and
loading schedule. An expensive UPS solution in a poor
installation environment and operability does not serve better
than a cost effective single module in a well embedded entity
with a good operation and maintenance concept applied.
VII. VITAE
Matthias Dreier has started with GUTOR Electronics Ltd in
1995 as UPS commissioning engineer and trainer. He was
entrusted the responsibility for the worldwide After Sales
Organisation, including Service and Spare Parts in 1997. Four
years later he was promoted to Manager Engineering
Competence Centre. He and his team are responsible for the
entire GUTOR UPS Solutions product management and
provide support to the worldwide engineering and sales crew.
Gert Andersen received a bachelor degree in electronic
science from the University of Odense in Denmark. Prior to his
employment with GUTOR Electronic Mr. Gert Andersen
worked as R&D Manager in the Laboratory of Energy Research
University of Odense and during 1984 and 1988 in SILCON
A/S, Kolding. He joined GUTOR in 1988 and currently is the
Technology Director. Gert Andersen is a member of IEEE.