Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410

Contents lists available at ScienceDirect

Renewable and Sustainable Energy Reviews

journal homepage: www.elsevier.com/locate/rser

Review: Uninterruptible Power Supply (UPS) system

Muhammad Aamir, Kafeel Ahmed Kalwar, Saad Mekhilefn
Power Electronics and Renewable Energy Research Laboratory (PEARL), Department of Electrical Engineering, University of Malaya, Kuala Lumpur 50603,
Malaysia

art ic l e i nf o a b s t r a c t

Article history: Uninterruptible Power Supplies (UPS) have reached a mature level by providing clean and unin-
Received 2 August 2014 terruptible power to the sensitive loads in all grid conditions. Generally UPS system provides regulated
Received in revised form sinusoidal output voltage, with low total harmonics distortion (THD), and high input power factor
7 September 2015
irrespective of the changes in the grid voltage. This paper provides comprehensive review of UPS
Accepted 18 December 2015
topologies, circuit configurations, and different control techniques used in the UPS system. A comparison
Available online 18 January 2016
based on the performance, size, cost, and efficiency of the system is presented. Different hybrid energy
Keywords: source UPS system and new generation UPS system for smart grid and micro-grid has been explained.
Uninterruptible Power Supply (UPS) Finally the paper describes performance evaluation of UPS system and explains different aspects that are
Energy Storage
to be considered for choosing a suitable UPS system by the user.
Control Methods
& 2016 Elsevier Ltd. All rights reserved.
Topologies

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1396
2. Classification of UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1396
2.1. Offline UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1396
2.2. Line Interactive UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1397
2.3. Online UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1397
2.4. Power problems and UPS solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1397
3. Topology-Based Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1397
3.1. Conventional Transformer based UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1397
3.1.1. Single stage UPS system with trapezoidal AC supply [16] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1398
3.1.2. Three leg type converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1398
3.2. High Frequency Transformer Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1398
3.2.1. A UPS with 110-V/220-V Input Voltage and High-frequency Transformer Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1398
3.2.2. UPS System with BIFRED Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1398
3.2.3. Two stage UPS with high power factor correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1399
3.3. Transformer-less UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1399
3.3.1. Four Leg Type Transformer-Less UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1399
3.3.2. Non-isolated UPS topology with 110/220 V input–output voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1399
3.3.3. Z-Source Inverter Based UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1399
3.3.4. Offline Transformer-less UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1399
3.4. Comparison of transformer based and Transformer Less UPS system [38–42]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400
4. Control Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400
4.1. Single Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400
4.2. Multi-loop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1401
4.2.1. Predictive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1401
4.2.2. Repetitive control scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1401
4.2.3. Iterative Learning Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1402

n
Corresponding author. Tel.: þ 60 379676851.
E-mail address: saad@um.edu.my (S. Mekhilef).

http://dx.doi.org/10.1016/j.rser.2015.12.335
1364-0321/& 2016 Elsevier Ltd. All rights reserved.
1396 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410

4.3.Non-linear Control Schemes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1402

4.3.1. Slide Mode control: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1402
4.3.2. Adaptive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
4.4. Modern Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
5. Uninterruptible Power Supplies with hybrid storage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1403
5.1. Fuel Cell/Batteries powered UPS system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1404
5.2. Supercapacitor/Batteries powered UPS system [85–87]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1404
5.3. Renewable energy Integrated UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1404
6. Next Generation Uninterruptible Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1405
7. Selection Considerations of UPS system for specific application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1405
7.1. Determining the need of UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1406
7.2. Calculating the Power requirement of UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1406
7.3. Selecting type of UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1406
7.4. Select configuration of UPS system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1406
7.5. Safety of UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1406
7.6. Availability of UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1406
7.7. Is selected UPS system affordable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1407
8. Performance Evaluation of UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1407
9. Future Trends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1407
10. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1408
Acknowledgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1409
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1409

1. Introduction This paper describes the classification of UPS system, different

line faults, and the recommended UPS system for these faults.
Uninterruptible power supply (UPS) system provides clean, Also the state of the art high efficiency, low cost, and small size
conditioned, and uninterruptible power to the sensitive loads such systems are covered and classified based on the circuit structure.
as airlines computers, data centres, communication systems, and Furthermore a comparison of a transformer based and
medicals support systems in hospitals etc. Generally the output of transformer-less is described based on which a recommendation
the UPS system must be regulated sinusoidal with low total har- of a particular topology has been given depending upon the
required power ratings.
monic distortion (THD), irrespective of the changes in the input
voltage and abrupt changes in the load connected to the system
[1]. Besides, low transients response time from online mode to
2. Classification of UPS
battery powered mode and vice versa, unity power factor, high
reliability, high efficiency, low cost, low weight, and small size, etc. Depending on the topological configuration, the UPS system is
are other essential considerations in the UPS system. classified as Offline UPS, Line interactive UPS, and Online UPS
Broadly the UPS can be classified as the Static UPS system and system [8–12].
Rotary UPS system. The static UPS system uses power electronics
converters and inverters to process, store, and deliver power in 2.1. Offline UPS
grid failure, while Rotary UPS uses motors and generators for the
same function. Sometime the combination of both static and The offline UPS consists of a battery charger, a static switch, and
rotary UPS system is used usually called hybrid UPS System [2,3]. an inverter as shown in Fig. 1. A filter and a surge suppressor are
Wide range of UPS systems is available in the market depending sometimes used at the output of the UPS to avoid line noise and
disturbance before being supplied at the output of the UPS. During
upon their ratings. The smaller units of only 300VA are used to
normal mode operation, a battery charger will charge the battery
provide back up to single computer, but the bigger unit of UPS may
bank, and at the same time the load is being fed by the power from
provide backup to entire building of several megawatts.
main AC line. The inverter is at the standby during this mode.
To cope with the recent issues of global warming and green-
When there is a power failure, the static switch connects the load
house gas emission, the use of renewable energy resources is to the inverter and the power is fed by the battery through the
tremendously increasing. UPS system with photovoltaic power has
also been introduced in [4,5] to utilize the solar energy for longer
period of time.
Commercially all the UPS system must fulfil the following
requirements in order to maintain the output voltage [6,7].

1. Constant steady state RMS voltage for 2% variation in any

parameter like temperature, load current, or battery voltage.
2. Maximum of 10% transient peak voltage deviation is allowed
during both loading and unloading of the UPS system.
3. Voltage drop of not more than 5% of the rated voltage cannot be
tolerated for more than 2 AC cycles.
4. Inverter output voltage with total Harmonic distortion (THD) of
only 4% is allowed for all the load conditions.
Fig. 1. Block Diagram of Offline UPS System.
 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410 1397

inverter. The switching time of the static switch is normally less
than 10ms, which does not affect the normal computer load. The
advantages of the offline UPS are low cost, simple design, and
smaller size of the system. But the lack of real isolation from the
load and the lack of voltage regulation are the main drawbacks of
the offline UPS system. Also the performance of this system during
non-linear load is also very poor. Offline UPS are suitable for
smaller loads with rating of about 600 VA.
2.2. Line Interactive UPS system
Line Interactive UPS consists of a static switch, bidirectional
converter/inverter, and a battery bank as shown in Fig. 2. The
bidirectional converter/inverter connects the battery bank to the
load. During normal mode of operation, the main AC line supplies
the power to the load and the bidirectional converter/inverter
charges the battery. During the grid failure, the static switch dis-
connects the load from the main supply and the bidirectional
converter/inverter supplies the power to the load. The line inter-
active UPS has the advantages of low cost, small size, and high
efficiency. The only limitation is that it does not provide any vol-
tage regulation during normal mode of operation. Generally the
Line interactive UPS system is rated between 0.5 kVA and 5 kVA,
and the efficiency of the system is normally greater than 97%,
provided the main AC line is clean from any transients and spikes.
2.3. Online UPS System
load irrespective of the harmonics and variations in the grid vol-
tage. The advantages of the online UPS include isolation of the load
from the main line and almost negligible switching time. The
major drawbacks of the online UPS are low efficiency, low power
factor, and high total harmonic distortion (THD). All the com-
mercial units of 5 KVA and above are commonly online UPS
system.
2.4. Power problems and UPS solutions
The power supplied by the grid is not always very clean and
continuous. There may be some major faults in the system which
leads to long interruptions and complete black out of the grid.
Besides voltage swells and dropouts, voltage sag, harmonic dis-
tortion, etc. are other faults which are commonly encountered in
the grid. Different UPS system provides protection against the
specific faults as shown in the Table 1.
3. Topology-Based Classification
UPS system can be classified on the basis of the topologies and
circuit configuration. The UPS system may be transformer-based,
transformer-less, or high frequency transformer based. These UPS
system are developed in the variety of configurations in order to
fulfil the exact requirement of the application.

Online UPS consist of a rectifier, an inverter, and a static switch
as shown in the Fig. 3. During normal mode of operation, the
rectifier charges the batteries as well as maintains the constant DC
link voltage. While the inverter converts the DC link voltage to the
required AC in order to feed the load. During power failure, the
Magnetic Contactor (MC) disconnects the AC line, but the inverter
keeps supplying power to the load from the battery bank without
any interruption. Thus the inverter keeps on operation in both the
modes. The inverter supplies clean, and conditioned power to the
3.1. Conventional Transformer based UPS system
Fig. 4 shows the circuit diagram of conventional UPS system
[13,14]. It consists of a rectifier, an inverter, line frequency trans-
formers, and a bypass circuit. The rectifier converts the AC line
voltage into DC link voltage in order to charge the battery bank
and maintain a constant DC link voltage. The inverter converts the
DC link voltage into the AC line voltage and provides the regulated
sinusoidal voltage to the connected load. Two power frequency
transformers are employed, one at the input side to step down the
line voltage into low voltage of battery bank and the other at the
output to step up the battery bank voltage as well as the operation

Table 1
Grid Disturbance and UPS Classification.

Sr. No UPS System Time Common line Faults

1 Off-line UPS 410 ms Line failure or long interrup-

tion, Voltage sags or dips,
dynamic overvoltage
2 Line Interactive Continuous Under voltage, Over voltage
UPS and voltage swell
3 Online UPS o 4 ms, Con- Transients, Harmonic distor-
Fig. 2. Block Diagram of Line Interactive UPS system. System tinuous and tion, Noise, frequency varia-
periodic tions, Impulses

Fig. 3. Block Diagram of Online UPS system. Fig. 4. Conventional UPS System.
1398 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410
of bypass switch [15]. Such system has an advantage of providing
galvanic isolation from the transients and spikes generated inside
the line grid. Also they are more robust in operation and can be
designed for high power applications. But since both the trans-
formers are operated at line frequency, so the size and weight of
the system is enormously increased and so is the cost of the sys-
tem. Also most of the switches are connected to the low voltage
battery bank. So high current is flowing through these switches;
causing extra current stress in these switches. Hence the efficiency
of such systems is very low.
3.1.1. Single stage UPS system with trapezoidal AC supply [16]
Fig. 5 shows a single stage UPS system which generates a tra-
pezoidal shape output voltage is specifically design for the optical
fiber/coax cable hybrid networks. The circuit design of this UPS is
almost similar to the conventional UPS system with the only dif-
ference of not using the power factor correction (PFC) circuit and
smaller DC link capacitor used in the circuit. The trapezoidal
shaped output voltage is synchronized with the input AC supply;
hence smaller DC link capacitor is used to remove the current
harmonics generated by the inverter. Since the line frequency
transformer used in the system are more costly, and have high size
and weight. Also the power factor of the system is considerable
low because of the absence of the power factor correction circuit,
thus this UPS system is not suitable for high power applications.
3.1.2. Three leg type converter
UPS systems using three leg type converter also gain much
popularity due to reduced number of active switches [17–19]. Fig.6
shows the circuit diagram of the UPS system proposed in [17]. In
three leg type converter, the first leg and the common leg act as
rectifier which also charges the battery bank. The third leg and the
common leg act as an inverter. The switches of the common leg
are controlled at the line frequency. By using this common leg, the
number of switches is reduced, which increases the overall effi-
ciency of the system. Two leakage frequency transformers are used
both at the input and output of the converter to reduce the cost of
the system. Though the number of switches are reduces but two
low frequency transformer increase the size and weight of the
Fig. 5. Circuit diagram of Single Phase UPS system with trapezoidal AC Supply.
Fig. 6. Three Leg type converter proposed in [14].
system. Also the batteries connected to the DC bus are high in
number; charging and discharging at the same time. Thus con-
tinuous overcharging may reduce the battery life.
3.2. High Frequency Transformer Isolation
With the development in the semiconductor industry, fast
switches and diodes are now available in the market with nearly
ideal characteristics. Now the transformer can be used at high
frequency with the advantages of reduced volume, inherent
property of galvanic isolation, and improved efficiency of the
system. Several UPS topologies with high frequency transformer
have been introduced in [20–27]. Such UPS system has smaller size
and weight as compare to the conventional UPS systems. But since
high number of active switches is employed in such systems to
operate the transformer at high frequency, it reduces the overall
efficiency and increase the cost of the system.
3.2.1. A UPS with 110-V/220-V Input Voltage and High-frequency
Transformer Isolation
Fig. 7 shows a flexible UPS topology which can operate over a
wide range of input voltage [20]. During normal mode of opera-
tion, the chopper converts the grid voltage into DC and delivers
high frequency pulses to the primary of the high frequency
transformer. The transformer steps down the rectified voltage in
order to charge the batteries. During the power failure mode, the
battery bank voltage is stepped up using boost converter and is
applied to the inverter which can supply regulated output voltage.
Although this topology has the advantages of small size and
weight because of the high frequency transformer and can also
provide galvanic isolation. But high number of active switches and
extra power processing stage decrease the efficiency of the system
and add complexity to the circuit.
3.2.2. UPS System with BIFRED Converter
An improved UPS system using High frequency transformer is
proposed in [21] as shown in the Fig. 8. In this topology, boost
integrated flyback rectifier/energy storage DC–DC converter
(BIFRED) has been used, which maintains the constant DC link
voltage in order to feed it to the inverter and conventional
Fig. 7. UPS system proposed in [18].
Fig. 8. UPS system with BIFRED Converter.
 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410
bidirectional converter is used to charge and discharge the battery.
The circuit provides excellent power factor correction, and with
high frequency transformer the size of the system is reduced
considerable. But the battery bank voltage of the circuit will be
increased significantly if the system is design for 220 V grid
voltage.
3.2.3. Two stage UPS with high power factor correction
A two stage UPS as shown in the Fig. 9 is proposed in [23]. The
first stage consists of an integrated battery charger which utilizes
the flyback converter for charging the batteries, maintaining high
power factor, and providing high frequency isolation. The second
stage consists of boost inverter which supplies the regulated
output voltage. Since the flyback converter may operate in dis-
continuous conduction mode, so the proposed topology is not
suitable for high power applications.
3.3. Transformer-less UPS System
Nowadays with the development of advanced microcontrollers,
and advancement in the power electronics, transformer-less UPS
are getting popularity in the market. These UPS are less costly,
highly efficient, and most importantly smaller in size than the
transformer-based UPS. But the transformer-less UPS still has also
some major limitation which needs to be addressed. This type of
UPS is more likely to be effected by the transients and spikes
caused by miscellaneous devices connected to the main utility grid
[28]. The battery bank in transformer-less UPS is very high to
achieve high DC link voltage, which increases the battery cost and
lower the reliability of the system [29,30].
3.3.1. Four Leg Type Transformer-Less UPS
Four leg type transformer-less online UPS system has been
proposed in [29]. The four leg type converter act as a rectifier,
battery charger/discharger, and an inverter as shown in the Fig.10.
Fig. 9. UPS system proposed in [23].
Fig. 10. Circuit Diagram of Four Leg type converter.
1399
The common leg is switched at a line frequency while the rectifier,
the battery charger/discharger, and the inverter are switched at
their respective PWM signals. Since a bidirectional converter has
been used, that charges the battery during normal mode and
discharges the battery during the power failure mode. So the
system has been operated without transformer, and the battery
bank is reduced to 192 V.
3.3.2. Non-isolated UPS topology with 110/220 V input–output
voltage
Another non-isolated online topology is proposed in [31] as
shown in the Fig.11. This UPS system can be operated at two dif-
ferent voltage levels and can also provide two output of 110 V.The
proposed UPS topology consist of a battery charger, three level
boost rectifier, and a double half bridge inverter. The double half
bridge inverter generates two independent 110 V AC output vol-
tages. An autotransformer is used at the input of the system to
enable the operation at 110 V. The DC link voltage in this topology
is about 450 V and nine batteries connected in series form the
battery bank, which is still very high.
3.3.3. Z-Source Inverter Based UPS System
Another transformer-less UPS topology has been proposed in
[32–36] which utilizes a Z-source inverter. No dedicated boost
converter has been used to step up the battery bank voltage as the
Z source inverter combines the two stages of power conversions
(DC–DC Step up converter and DC–AC inverter) into a single power
conversion stage. Also a dual loop control scheme has been used to
increase the transient response time of the system. No dead time
in the PWM signal is required to prevent the switches of the same
leg turning ON at the same time. Thus the distortion in the AC
output voltage is reduced considerable. Thirty batteries connected
in series provide the 360 V DC voltage at the input of the DC
voltage. So the battery bank is very high, and is only feasible for
high power applications.(Fig. 12)
3.3.4. Offline Transformer-less UPS System
Transformer-less topologies has been proposed in Offline UPS
system as well. The system studied in [37] has been designed with
reduced number of components which reduces the cost of the
system. During charging mode, the uncontrolled rectifier converts
Fig. 11. Non-isolated UPS system.
Fig. 12. Z-Source inverter UPS System.
1400 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410

From single computer to large data

For High power applications,

Design for hybrid fiber/coax
centres with load in MVA

Medium And High Power

Considerable high Power
Low power Applications
Low power applications

High Power Application

Used for smaller loads
Applications

Application

Application
networks
Fig. 13. Offline Transformer-less UPS system.

the line AC into DC link voltage, while the boost converter per-
forms the PFC (Power Factor Correction) and the buck converter

Very High

Medium

Medium
Weight

Smaller

Smaller
Smaller
smaller
step down the voltage in order to charge the battery. During

Size &

High

High
power failure, the boost converter steps up the battery bank vol-
tage and the inverter converts it into the AC voltage to provide it to
the load terminals.(Fig. 13)

Battery

12 V "
360 V

360 V
192 V

108 V
192 V
bank
3.4. Comparison of transformer based and Transformer Less UPS

48 V

48 V
80 V

96 V
system [38–42]

System Specification
Nowadays the transformer-based UPS system has been sub-

110 Vac as well as

jugated by the transformer-less UPS system because of its small

Both 110 Vac &

110 V/220 Vac
size, light weight, and high efficiency. These UPS system offers
highly compact and cost effective design for low power applica-

220 Vac

220 Vac

220 Vac
220 Vac
110 Vac

110 Vac

110 Vac

220Vac
tions without using any bulky power transformer. Table 2 shows
the comparison of different UPS configurations.
But which one is the most suitable UPS system according to the

0.8 " 0.9

required circumstances? The answer is very complex. It requires
Power
Factor
understanding of the basic topologies and the particular require-

high
0.99

0.99

0.99
0.9

0.7

0.9
ment for the specific application. In selecting a UPS system, there

-
is always a trade-off among certain features of the system, and the Less than 90% Available with ratings
selectors always have to go for the features which are important greater than 750KVA
for that specific application. Transformer based UPS system iso-
Power Ratings

lates the load from the faults generated in the main supply. In fact
the transformer itself acts like a barrier and avert all the transients

o500 VA
o1 KVA
and spikes propagating to the DC bus from the main supply and

2.6 KVA
1 KVA

3 KVA

3 KVA

3KVA
2 KV
vice versa. Also the transformer based UPS are more reliable and
robust in operation with high Mean Time Before Failure (MTBF). Less than 90%
However the transformer based UPS are more expensive than
Efficiency

transformer-less UPS system. Without input and output transfor-

mer, the cost of the transformer-less UPS system can be reduced to

4 90%
85%

87%

86%

84%

96%

86%
30% or even more. Also the size and weight can be reduced to 50%
in transformer-less UPS system as shown in the Table 2. Moreover
Single Stage UPS system with trapezoidal AC Three & a Power Frequency

Three & a High Frequency

An on-line UPS system with electric isolation Three & a High Frequency
Number of Power stages

the efficiency of the transformer-less UPS is about 10% greater than

two & Power Frequency

Two & High Frequency

the transformer-based UPS system of the same specification due to

the absence of the power frequency transformer.
Auto-transformer
three & leakage
Transformers

Transformers

Three Stages
Transformer

High-Frequency Transformer Isolation [20] Transformer

Transformer

Transformer

Two Stages
Properties

4. Control Techniques
Comparison of different UPS system Configurations.

The control strategy is the most important part of all UPS

systems. Parameters like THD of the output voltage, dynamic
Two stage UPS with high power factor cor-
Three Leg Type Converter UPS system [17]

response to the transients and spikes; power factor correction,

Non-isolated UPS with 110/220 V input –
Transformer-less Online UPS System [29]

Z Source Inverter Based UPS System [32]

A UPS with 110/220-V Input Voltage and

voltage and current regulation etc. are all dependent on the con-
Conventional Transformer Based UPS

trol strategy applied in the UPS system. Nowadays many modern

control techniques have been proposed to provide regulated out-
using BIFRED converter [21]

put voltage in all the circumstances. Broadly the control techni-

ques can be classified as single control and multi loop control
output voltage [31]

schemes

4.1. Single Loop Control

UPS topology

rection [23]
supply [16]

In single loop control scheme, the output voltage feedback loop

Table 2

is used to provide the well regulated output voltage [43]. The

output voltage is compared with the reference signal to generate
 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410
an error that is compensated by suitable controller. Though this
system is simple to design and quiet inexpensive but its perfor-
mance is poor in complex loading condition such as unbalanced
and nonlinear loads.
4.2. Multi-loop System
Multi-loop control schemes are more suitable in order to get
better performance. They are more robust and flexible in control,
even in non-linear and unbalanced system [44,45]. A conventional
multi-loop control scheme has been shown in the Fig. 14. In this
control scheme, different parameters are used as a feedback to the
controllers like filter inductor/capacitor current or output current
and voltage. The outer loop uses output voltage as feedback signal;
while the inner loop uses inductor or capacitor output filter cur-
rent as the feedback signal. The feedback signal is compared with
the reference signal to generate an error, which is compensated by
the suitable compensator to achieve stable output. Similarly the
output of the voltage loop is the reference for the current loop.
Hence both the voltage and current stability is achieved using
multi-loop system. Different high performance controllers have
been developed by employing multi-loop feedback control scheme
which provide excellent performance [46–51]. Such as dead beat
control[47,52–54], Model Predictive control [48,55,56], Iterative
learning control [49] etc.
4.2.1. Predictive Control
Predictive control technique has emerged as promising control
technique for power inverters. Predictive control uses the system
model to predict the future behaviour of the controller variables
and respond according to predefined optimization criteria. Pre-
dictive control concepts are easy to understand and can handle the
system with many constraints and non-linearity’s. The predictive
control can be classified in Deadbeat control and Model Predictive
control. The detail of each controller is as follows.
4.2.1.1. Deadbeat Control. Deadbeat control scheme is one of the
most popular schemes for UPS system [47]. In deadbeat control,
the reference voltage is calculated during each sampling period
using system model parameters, and is applied to follow the
reference value in the next sampling instant. It offers fastest
transient response because all the closed loop poles are placed
near zero. This results in minimum settling time as few sampling
steps are required. However the dead beat control is very complex
and is highly sensitive to parameter variations, loading uncer-
tainties, and steady state error. Moreover, performance of the
deadbeat control also reduces due to unpredicted sources of dis-
turbance, such as dead-times, dc-link voltage fluctuations, and so
Fig. 14. Multi-loop control Scheme.
Fig. 15. Deadbeat Control for UPS system.
1401
on, since there is no inherent integral action in the control struc-
ture. Fig. 15 shows a deadbeat control scheme for UPS system. A
state observer is used to compute the delay while the load current
is estimated using the disturbance observer. Any disturbance in
the system is compensated by the state observer. In Deadbeat
control the load current at time k is different to the reference
current iref. This error is used for calculation the reference voltage
Voref, which is applied to the load at time k. Ideally at time k þ 1,
the load current will be equal to the reference current. This
method gives better performance by reducing control sensitivity
to model uncertainties, parameter mismatches, and noise on
sensed variables
4.2.1.2. Model Predictive Control [55,57]:. Model Predictive Control
(MPC) is considered as one of the important advancement in the
process control engineering. Model Predictive control also knows
as receding horizon control, provides high performance and sta-
bility in the control of UPS system. MPC is very flexible control in
which different system constrains e.g current and voltage limita-
tion, switching states, and non-linearity can be included in the
optimization of the controller. A cost function is usually for-
mulated considering different variables and weighting factor. A
Switching state is selected in order to minimize the cost function
and applied in the next switching state.
Fig. 16 shows the common model predictive control for the
inverter of UPS system. The load current measured at instant K is
used as input to the predictive model which derives the value of
the current for the next sampling time, for each switching state of
the inverter. At each instant K, cost function over a finite horizon of
length N is minimized. The cost function can be derived by
equation
Kþ
X N&1
iðxðkÞ; uðkÞÞ ¼ F ðxðK þN ÞÞ þ LðxðlÞ; uðlÞÞ ð1Þ
l¼K
where F and L are the weighting functions which predicts the
system behaviour e.g difference between the current reference
and predicted value. The optimization of the moving horizon is
performed at each sampling step i.e. at time K þ 1, the system
state x(K þ1) is measured and the horizon is shifted to next step,
where another optimization has been performed.
4.2.2. Repetitive control scheme
Repetitive control scheme has widely been used for the rejec-
tion of periodic disturbance in a dynamic system [46,58,59]. This
scheme is based on the multiple feedback loops, with time delay
unit which results in eliminating the periodic errors efficiently. But
the limitations of this system include slow dynamic response,
large memory requirements, and poor performance in non-
periodic disturbance. Repetitive control has been introduced for
the control of inverter with non-linear load. The steady state
performance of the repetitive control is quite good but the
dynamic response is not satisfactory because of long delay time
between input and output. Therefore, repetitive control is nor-
mally incorporated with other feedback controller with fast
dynamic response. ! "
In repetitive controller, a periodic signal generator zN 1& 1 has
been added in the closed loop system for exact tracking a
Fig. 16. Model Predictive control for UPS system.
1402 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410

reference signal. The repetitive controller eliminates all the har- If (4) is satisfied for all ω, then monotonic decay of the tracking
monics below the Nyquist frequency by introducing infinite gain error to zero will take place over successive cycles, and stable
at the harmonic frequency [60]. operation will be achieved. Table 3 shows the comparison between
A repetitive control system is shown in Fig. 17 The feedback different multi-loop control schemes.
control and repetitive control are complementary. The transfer
function of repetitive control is given as
4.3. Non-linear Control Schemes
kg Z & N1 kg Z N 3
Gg ð z Þ ¼ Gf ð Z Þ ¼ N Gf ð Z Þ ð2Þ Non-linear controllers are more robust in operation, show good
1&z & N
Z &1
performance result as compared to linear controllers. However the
where kg is the control gain and Gf ðZ Þ is a low-pass filter. implementation of this system is very complex. The most common
The conventional feedback controller offers fast response and
non-linear control system is slide mode control and adaptive
robustness. However the feedback controller has no memory.
control for the UPS inverter control.
Hence if there is any imperfection, it will keep repeating in all
subsequent cycles. Similarly the repetitive controller stored per-
4.3.1. Slide Mode control:
vious information in memory, and ensures steady-state zero error
For non-linear load, Slide Mode Control (SMC) [62,63] strategy
tracking by repetitive learning. But the zero error tracking took
has gained special interest. SMC has been widely implemented in
longer time. Hence the repetitive control scheme together with
the power inverters because of its effective performance against
feedback controller ensures fast dynamic response of feedback
non-linear system with uncertainties. A major feature of the SMC
controller and the high precision tracking ability of repetitive
is its robustness, good dynamic response, stability against non-
controller [61].
linear loading conditions, and easy implementation. But the SMC
has the disadvantages of inheriting the chattering phenomena i.e
4.2.3. Iterative Learning Scheme
the undesirable oscillation with finite frequency and amplitude
In Iterative Learning Control (ILS), the control command is
which leads to low control accuracy and high heat losses in the
adjusted at each iteration, thus converging to zero tracking error.
system [64].
The ILS aims to accomplish this result without the knowledge of
A SMC has been presented in Fig. 18. SMC changes the
the system. The system is examined at each cycle and is adjusted
dynamics of the system by employing the discontinuous control
for the next repetition. But the design procedure of the ILS is very
signal that forces the system to slide along the system normal
complex.
ILS can be used to eliminate tracking error caused by the per- behaviour [65]. The linear sliding surface function for the UPS
iodic disturbance. The updated rule for ILC is given by inverter can be expressed as (6)

ui þ 1 ðzÞ ¼ ui ðzÞ þ k∅ðzÞei ðzÞ ð3Þ S ¼ λx1 þ x2 λ 4 0 ð6Þ

Where ui ðzÞ is the Z transform of the command that is given to the
system at repetition I, k is the learning gain and ∅ is the designed
controller transfer function. While ei is the z-transform of the
racking error at repletion i.
ei þ 1 ðzÞ ¼ ðð1 & k∅ðzÞPðzÞÞei ðzÞ ¼ T f ðzÞei ðzÞ
where Tf is the transfer function between the two consecutive
repetitions. The error component at a particular frequency will
decay over successive repetition if
! "
j1 & k∅ ejwT PðejwT Þj o 1 ð5Þ
where λ is a real constant and x1 is the voltage error, and its
derivative is given by x2 ¼ x_ 1 . For the dynamic behaviour the
(6) will be
S ¼ λx1 þ x_ 1 ¼ 0 ð7Þ
ð4Þ
The objective of the control in (6) is to drive the trajectory of
the system from any initial condition x(0) to the sliding surface S
(x)¼0. This trajectory is maintained at the sliding surface, and
consequently directs the system towards the steady state condi-
tion. The slide mode control law for the inverter is given by

Fig. 17. Repetitive control for the UPS system. Fig. 18. Slide Mode Control scheme.

Table 3
Comparison of Different Multi-loop Control Schemes.

Control Scheme Features

Controller Used Response Time Performance Sensor Complexity

Dead Beat Control [47] ADMC401 0.5 ms Not good for Non-linear loads Output Voltage, Inductive current Complex
Model Predictive Control [55] TMS320C6713 Slow Good Output voltage, Filter current Simple
Repetitive Control [46] TMS320FS40 Slow Excellent Output Voltage Complex
Iterative Learning Controller [49] TMS320F240/MPC8240 Slow Excellent Output voltage Complex
Neural Network Control [50] Analog Circuit Fast, 7.55 us Good Output Voltage Complex
B-spline Network (BSN) Control [51] DS1104 Fast, 7.78 us Excellent Output Voltage Simple
 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410 1403

equation
1
S ¼ λðVout & Vref Þ þ ðiC & iref Þ ð8Þ
C
The control law need to be tuned very precisely in order to
achieve a trade-off between the tracking precision and robustness
to the uncontrolled dynamics. The chattering phenomenon in the
SMC is eliminated by using smoothed control law in narrow
boundary layer. The smoothed control law applied to the pulse
width modulator results in the fixed switching frequency of the
inverter. The control scheme shows excellent performance with
THD less than 1.7% for non-linear loads.

4.3.2. Adaptive Control

Adaptive control is another robust control scheme which
automatically adjusts to the structural and environmental uncer-
tainties. It does not need a priori information about the uncertain
parameters rather the system characteristics are obtained on-line,
while the system is operating. The adaptive control provides high
performance with excellent voltage regulation for both unbalance
and non-linear loads. Also it provides fast transient behaviour,
small steady-state error, and low THD under sudden load change.
However the computation complexity of adaptive control is
very high.
Fig. 19 shows the block diagram of adaptive control law
implemented in the inverter of the UPS system. A linear optimal
load current observer is designed to accurately estimate load
current. The load current observer is asymptotically stable in
operation. The load current information is forwarded to adaptive
control law. For deriving the adaptive control law, the control
input are derived using both the compensated control terms and
the feedback control term.
vi ¼ uf f þ ufb
Applying the adaptive control law leads to equation
4
X unmeasured disturbance. The prediction gain is calculated using
U ff ¼ mi p i þ v L
i Kalman filter and robust stat predictor. The proposed controller
where ‘m’ is the adaptive gain incorporate in the compensated
control term vi given in Eq. (9).
4.4. Modern Control System
Recently many state of the art control scheme has been pro-
posed in [30,66–70]. Any advance control scheme should have the
features of less execution time, low cost, high flexibility, and
excellent performance with all the loading conditions. According
to [67], selecting of a suitable control scheme depends on the
optimum trade-off between cost, complexity, and waveform
quality required for a particular application. A multi loop SPWM
control scheme has been proposed in [66] as shown in the Fig. 20.
The outer voltage loop controls the fundamental frequency com-
ponents and the steady state RMS value of the output voltage
using PI compensator. The first inner loop acts as voltage feed
forward loop and provide fast transient response. The second
inner loop compares the AC output to a reference created by the
Fig. 19. Adaptive control for the UPS Inverter.
Fig. 20. Modern Control Scheme for UPS system.
main loop, and an error signal is generated. This will correct the
phase shift and improve the quality of the waveform. In the last, a
current loop is added which provides overload protection and
current limiting.
Thus the outer voltage loop provides voltage regulation while
the inner loop maintains THD, with excellent stability of the sys-
tem. For linear loads, the controller achieve 0.3% THD while for
non-linear loads, it achieve 3% THD. This control scheme can easily
be implemented with less complexity and high response time of
10ms for any load.
Another robust tracking control of UPS Inverter has been pro-
posed in [71]. The proposed controller utilizes state feedback and
integral controller of the tracking error. The gain of the controller
is designed keeping in view the parameters of uncertainties. Thus
the controller shows fast tracking performance in uncertain con-
ditions of the load. Also a one step ahead predictor has been
ð9Þ introduced to reduce the time delay caused by computation and
space vector modulation. Luenberger type observer is used to
make the prediction of the inductor current, capacitor voltage and
ð10Þ
shows good performance under linear and non-linear loads with
very low total harmonics distortion.
In [70] a multiple resonant control scheme has been proposed
which provides very robust control framework to the UPS systems.
In this scheme, output feedback controller has been designed
using Linear Matrix Inequality (LMI) constraints. Thus efficient
control parameters are derives to achieve a good compromised
between transient performance, sinusoidal reference tracking and
harmonics rejection. Multiple resonant controller attenuates the
periodic disturbance efficiently resulting in low THD of the UPS
output voltage. Table 4 shows the comparison of the modern
control schemes used in the UPS systems.
5. Uninterruptible Power Supplies with hybrid storage system
Uninterruptible power supplies with batteries as storage source
provides good performance during grid interruption and blackout
by suppling instant backup energy. However batteries cannot
provide backup for a very long period of time and have limited
charge/discharge cycles. Also batteries contain toxic heavy metals
such as cadmium, mercury, and lead which may cause serious
environmental problems. Recently other methods of energy sto-
rage such as fuel cells, super-capacitor, and their combinations
have gained popularity. The power sharing between these energy
storage devices is a promising solution for improving system
performance due to their dynamic behaviour and long life. Fig. 21
shows options of back-up power and their energy capacity. Many
1404 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410

Table 4
Comparison of Modern Control Schemes.

Ref [66] [70] [72] [65] [71]

Controller SPWM Controller Multiple Resonant Synchronous Ref. Frame Voltage Fix Switch Frequency Slide Mode Robust Tracking
Controller Control Control Controller

THD(L) 1.1% - 0.2% 1.1% 1.3%

THD(NL) 3.8% 2.7% 1.68% 1.7% 5.5%
Transient (ms) 60 16 1.0 0.5 -
Complexity Medium Complex Complex medium Medium

Fig. 21. Options of Backup power system.

reviews have focused on the composition, features, and perfor-

mance of different energy storage systems [73–77]. In this portion
brief review has been presented to highlight the performance of
different energy systems in UPS applications.

5.1. Fuel Cell/Batteries powered UPS system

A UPS system with hybrid energy source has been presented in

the [78–82]. In this system, fuel cell and battery bank is combined
as such to ensure that there is sufficient energy available to pro-
vide backup to the external load. When there is interruption in the
utility grid, the hydrogen gas will be supplied to the pack of fuel
cell. Since fuel cell required some time to develop the required
voltage hence cannot provide instant backup energy. To overcome
this problem rechargeable battery or super-capacitor can be
employed to respond quickly to the external load. A block diagram
of the hybrid UPS system is illustrated in Fig. 22 [24].
The Fuel cell is the main source of energy. Batteries and super-
capacitor act as secondary source of energy. Fuel cell is linked to
DC-Bus through the DC–DC converter while all other sources are
linked to the common DC-Bus through bidirectional converter. The
bidirectional converter acts as battery charger during grid mode
and discharger during backup mode of operation. The DC-Bus
supply energy to the connect load through inverter.
The circuit diagram of the hybrid energy storage UPS system is
shown in Fig. 23. A conventional boost converter is used to step up
the fuel cell voltage to DC-link voltage. Bidirectional converter
charges the battery/supercapacitor during grid mode (buck
operation) and discharges the battery/supercapacitor during
backup mode (boost mode), in order to provide stable supply to
the DC-Bus. Different bidirectional converters have been presented
in literature with both isolated and non-isolated topologies
[83,84]. Bidirectional converter is selected depending on the con-
version ratio, efficiency, and reliability of the system. H-bridge
inverter is used to deliver regulated output AC voltage to the load.
A fuel cell powered UPS system provides stable operation during
utility interruption. Fuel cell is excellent replacement to the con-
ventional UPS energy sources in near future. Supercapacitor
module is incorporated to overcome transients such as instanta-
neous power fluctuations, slow dynamics of the fuel pre-processor
and overload conditions. However the fuel cell technology still
faces drawbacks such as high cost, slow response time, and sen-
sitivity to low frequency ripples.
Fig. 22. Block Diagram of hybrid energy storage UPS system.
5.2. Supercapacitor/Batteries powered UPS system [85–87]
Normally batteries of UPS system provide backup power for 5–
15 min until the generator starts and provides backup to the load.
Supercapacitor provides backup for 5–15 s. Hence in application
where the long backup is not required, supercapacitor can replace
the battery storage system. Nowadays hybrid system of battery for
higher energy and supercapacitor for higher power are combined
to provide more reliable and high power. Table 5 shows the
comparison of supercapacitor with lead-acid battery.
Introducing supercapacitor in parallel reduces the stress on the
battery. Supercapacitor supply power during transient demand of
power while batteries supplies during smooth demand of power.
However the cost of supercapacitor are still very high and further
research and investigation is required to balance the cost and
performance of the supercapacitor based UPS system.
5.3. Renewable energy Integrated UPS system
Since global warming and greenhouse effect has reached to its
threatening level, renewable energy is the only option for future
energy requirement. Photovoltaic (PV) and wind energy are the
most promising solution to supply energy in isolated areas.
Uninterruptible power supplies with renewable energy resources
connected with the utility grid provide more reliable and quality
power to the connected load [88–90]. UPS with PV system is
shown in the Fig. 24. The PV module is connected to the system
through the DC–DC converter while the batteries and super-
capacitor are connected to the DC-Bus using bidirectional
 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410 1405

Fig. 23. Circuit Diagram of Hybrid Storage UPS system.

Table 5
Comparison of Lead-Acid Battery and Supercapacitor.

Properties Lead acid battery Supercapacitor

Specific energy density 10–100 Wh/kg 1–10 Wh/kg

Specific power density o1000 W/Kg o 10,000 W/Kg
Cycle life 1000 85–98%
Charger/discharger efficiency 70–85% 0.3–30 s
Fast Charge time 1–5 H 0.3–30 s
Discharge time 0.3–3 h 0.3–30 s

Fig. 25. Block Diagram of Intelligent UPS system.

accommodation of DG sources. Fig. 25 shows the block diagram of

Fig. 24. UPS system with PV energy Source.
converter. The inverter supply AC voltage to the connected load.
When there is a surplus energy available, it is stored in the con-
nected battery bank and supercapacitor. Under the conditions,
when load demand exceeds the generation or during night time,
the stored energy is utilized to fulfil the requirements of the load.
Supercapacitor is added in the system to provide fast dynamic
regulation of the power. UPS with PV system helps in peak
shearing, smoothing out load fluctuations, and making up for
intermittent variation in renewable energy sources so as to make
an efficient energy management in integrated systems [91].
the next generation UPS system. The UPS system has high fre-
quency converter which allows the parallel connection of the
batteries with other Distributive generation (DG) system to the
smart grid. Hence the proposed UPS system in addition to tradi-
tional operation can also realize the cyclic use of electrical power
between the power grid and storage system. Due to its modular
structure, it can be applied to motor drive, auxiliary power sup-
plies for hybrid electrical vehicles and DG system.
Line interactive UPS systems proposed in [98,99] are designed
for microgrid. The proposed system helped in improving the
reliability, economy, and efficiency of the microgrid. Power can be
exported to the grid when the tariffs are advantageous. Hence the
UPS system can share power with in the microgrids in parallel
with other DG Units. Multiple energy sources, multiple storages,
and a highly reliable power conversion system work together to
guarantee the uninterruptible power supply. But the idea of
intelligent UPS system still needs extensive research in order to
realize the concept in smart grid and micro grid.

6. Next Generation Uninterruptible Power Supply

In recent years, the concept of smart grid is getting famous and
is considered as the next generation power grid [92–95]. Elec-
tricity generation using sustainable energy is environmental
friendly and can be added to the smart grid. The distributive
generating system provides standby power during grid interrup-
tion and load sharing during peak hours, thus it helps in cost
reduction and reliable power delivery. In fact the concept of dis-
tributive generation system falls into the category of the UPS
system.
An intelligent UPS system has been presented in [96,97] for the
smart grid which is energy saving, reliable and flexile for
7. Selection Considerations of UPS system for specific
application
With so many choices of the UPS system available to choose
from, which is the most suitable for your circumstances? Selecting
a particular type and configuration of UPS depends upon the fol-
lowing factors. (1) Power requirement, (2) Power factor, (3) Cost,
(4) Size and Weight, (5) Grid environment, (6) Reliability, (7) Pro-
tection, (8) Required level of Power quality, and (9) Size of the
battery bank.
The Process of selecting a UPS system consists of seven steps.
(1) Determining the need of UPS system, (2) Calculating the Power
1406 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410
requirement of UPS system, (3) Selecting type of UPS system,
(4) Select configuration of UPS system, (5) Safety of UPS system,
(6) Availability of UPS system, (7) Is selected UPS system afford-
able. Fig. 26 shows the flow chart for selection of a UPS system for
particular application.
7.1. Determining the need of UPS system
The selection of UPS system is strongly dependent on the
application for which the system is chosen. Applications such as
hospital life support and medical equipment, military equipment’s,
and communication devices cannot tolerate any power interrup-
tion even for very short period of time. UPS system required for
such application should provide backup until the utility grid
power is restored. For data centres, the backup may require for
only few moments until the devices are shutdown. Surveying the
history of commercial outages by power companies can better
provide statistics about selection of UPS system.
7.2. Calculating the Power requirement of UPS system
Specification such as load kVA, power factor, inrush current,
load voltage, number of phases and frequency, and backup time is
required to determine the size of the UPS system. Load kVA can be
calculated as (V ' I)/1000 for single phase and (1.73 ' V ' I)/1000
for three phase system. The load power factor should be in the
range of 0.7–1 depending upon the load. Battery sizing depends on
the size of the load and duration of backup requirement until the
critical load is safely shutdown. Ampere-hour (AH) capacities
decrease as the rate of discharge increases. For varying load, the
summation of the ampere-hour of each load gives the approx-
imate size of the battery.
7.3. Selecting type of UPS system
Selection of UPS system depends upon the power quality,
protection, efficiency, volumetric size, and weight of the system.
The details discussion of different type of UPS system has been
done in Section 2. Table 6 summarizes the features of different
type of UPS system.
Fig. 26. Flow diagram for selecting the UPS system.
Table 6
Comparison of Different Type UPS system.
Practical Power Range
Offline UPS System 0–0.5
Line Interactive UPS system 0.5–5
Online UPS system 5–5000
7.4. Select configuration of UPS system
The level of protection and the power requirement of the load
determine the type and configuration of the UPS system.
Transformer-based UPS are more suitable for high power appli-
cation. They are more suitable to provide protection even in the
polluted grid environment to more sensitive equipment like
medical equipment’s and data centres because of the galvanic
isolation.
While the transformer-less UPS systems are cheaper, with
smaller size, and are suitable for low power applications. They are
more suitable for circumstances, where the grid supply is less
polluted. Similarly the complex control system also escalates the
cost of the UPS system. So the choice of the UPS system is deter-
mined by the balance between the performance and cost, taking
into consideration the acceptable level of other factors which best
suits the circumstances. Table 7 correlates the properties of UPS
system with the different topologies of UPS system.
7.5. Safety of UPS system
Safety should be given up most importance before selecting
any UPS system. For safety it is preferred to follow the codes and
standards adopted by government and commercial agencies. Bat-
tery bank needs special care and safety for its sound operation
[100].
7.6. Availability of UPS system
Since UPS system provides back up to critical load without any
interruption [101]. The availability and reliability of the system is
very crucial. The availability of the UPS system is defined by
equation
MTBF
AUPS ¼ ð11Þ
MTBF þMTTR
where AUPS is the availability of the UPS system, MTBF is the Mean
Time Before Failure, and MTTR is the Mean Time To Repair.
Reliability of the UPS system can be improved by introducing the
redundant units in parallel where each one is capable of sharing
the connected load [102,103].
Voltage Conditioning Cost per VA Efficiency Inverter always operating
Low low Very High No
Design implementation Medium Very high Design Dependent
High Medium Medium Yes
 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410 1407

Table 7
Selection of UPS System.

Recommended Type of UPS Topology Power Level (KVA) Grid Condition Load Condition Capital Cost Weight& Volume Power Quality Efficiency

Transformer Based 1–10 Polluted Variable High High Average Low

High Frequency Less Polluted Medium Medium Good High
Transformer-less Clean Almost Fix Low Small Excellent High
Transformer Based 10–50 Polluted Variable High High Average Medium
High Frequency Less Polluted Variable Medium Medium Good High
Transformer-less Clean Fix Low Small Excellent High
Transformer Based 50–200 Polluted Variable Very high High Average Low
High Frequency Clean Fix High Medium Average Medium

Table 8
Typical 3-Ø UPS System Specification by ANSI/IEEE 446–1987 [105].

Input (Rectifier/charger)

Voltage 208 V or 480 V,7 l0%, 3-phase

Power factor Minimum 0.8 at rated load
Frequency 50 or 60 Hz, t5%
Harmonic Contents in 10% (5% preferred)
Current
Start-up current Limiting Maximum 25% of full-load current (energizing
rectifier transformer with inverter at no load)
Steady State Current limit Adjustable, with two standard settings:1) For uti-
lity power, 125% rated load, 2) For emergency
power, 100% rated load plus 5 kVA
Output (Inverter)
Voltage 208 V or 480 V, 3-phase, 3- or 4-wire
Regulation 1) 72% for balanced load, 2) 7 3% for 20% unba-
lanced load (100% or 80%) Fig. 27. Input Voltage and Current waveform.
Line Drop Compensation 0 to 5%, adjustable
Transient Response 1) 75% for loss or return of ac input power, 2)
7 8% for 50% load step, 3) 7 10% for bypass or system is shown in the Fig. 27. The power factor of the input
return from bypass current is close to unity with minimum THD. According to the IEEE
Harmonic content of 4% total, 3% any single harmonic standard ANSI/IEEE 446–1987, minimum power factor is 0.8 at the
voltage
rated load and harmonics content less than 5% is preferred for the
Frequency 50 or 60 Hz
Current capability 1) Overload 125% for 10 m and 150% for 10 s input rectifier of the UPS system.
The output voltage and current of the inverter of UPS system
Fault clearing 150% to 300% for 10 cycles, maximum should be well regulated, with THD less than 5% for both non-
limited for self-protection linear and unbalanced load. In addition, the inverter should exhibit
DC Link (Battery)
Battery type Lead-acid or nickel-cadmium (NICAD)
excellent response against sudden change in the load. Fig. 28
Recharge time 10 times discharge time shows output voltage and current of the inverter of UPS system
Energy storage capacity Sized to requirement (normally 15 min) where the THD is less than 3% for both the linear and non-linear
load well below according to the standard (IEEE standard 4% total
& 3% for each harmonic). Fig. 29 shows the step response of the
7.7. Is selected UPS system affordable inverter for change of load from 0 to 100% and vice versa. Fig. 30
shows the dynamic deviation of the output voltage for the addi-
The cost of UPS system varies depending upon the type, con- tion and removal of the step linear load. The dynamic behaviour of
figuration, protection, backup time, and extra additional features the controller should not exceed the classification 1 of IEC62040-3
of the system. Mostly sophisticated system having automatic standard
monitoring, fast switching, and control functions require addi- The transfer time from grid mode to backup powered mode is
tional components, adding to the complexity and cost of the sys- very important to evaluate the performance of UPS system. Online
tem. Cost analysis can only be done when the first six steps are UPS system has negligible transfer time, while line-interactive and
completed. offline UPS system inherits some transfer time during transition
switching of UPS operating modes. Fig. 31 and Fig. 32 show the
experimental waveform of the step change from grid mode to
8. Performance Evaluation of UPS System backup mode and vice versa.

Several features are essential to analyse the performance of the

UPS system. These features include input power factor, THD of the
output voltage, transient response time and transfer time from
utility grid mode to backup mode and vice versa. Hence the per-
formance indicator of the UPS system is proposed to be according
to the specified standards. Table 8 shows the specifications of a 3-
Ø UPS system define by IEEE standard ANSI/IEEE 446–1987.
Experimental results of a 2 kVA laboratory prototype of online UPS
system have been presented to demonstrate clearly the perfor-
mance of UPS system. The input voltage and current of the UPS
9. Future Trends
With the development in the advanced microcontrollers and
fast switching devices, ever most capable UPS systems have been
proposed with high performance, greater efficiency, and more
importantly at lower costs. Transformer-based UPS systems have
been developed to a mature level and are now available even in
megawatt range, utilized for varying applications. Besides, a con-
siderable development has been made in transformer-less UPS
1408 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410
Fig. 28. Output Voltage and Current for linear load and non-linear load.
Fig. 29. Experimental waveform of step change from 0% to 100% and 100% to 0.
Fig. 30. Output Dynamic performance of the UPS Inverter.
Fig. 31. Transition from Normal to Battery Powered Mode. Input Voltage Vin and
Current Iin, Output Voltage Vout and Current Iout.
systems. New trends are heading towards the development of
efficient control techniques to ensure fast transient and dynamic
response, low THD, good voltage regulation, and stability against
load variations.
Further improvement in the UPS technology in terms of
replacing the conventional storage with fuel cells will be a real
boost for UPS in low power applications [5,104]. Fuel cells have
high specific energy, high reliability, and are environment friendly
as compared to conventional storage systems. UPS systems that
use the fuel cell in combination with the super-capacitor are also
not that extensively investigated. Recognizing the advantages of
the hybrid system, we can expect more advanced UPS system,
with added functionality and better performance.
10. Conclusion
In this paper, a review of UPS systems has been presented to
explain the various configurations, control strategies, and com-
parisons of important UPS topologies. A topological classification
of the UPS system has been discussed with their performance,
efficiency, advantages, and disadvantages. Comparative analysis of
different systems and their control schemes have been presented
to provide useful information, which helps in easy selection of
control scheme for a particular application. Model predictive
control shows excellent performance for the control of the inver-
ter. Non-linear control schemes can also be adopted for non-linear
loads though their implementation is complex. Hybrid energy
sources UPS systems and their application in smart grid bring new
direction for research and development in this field. Power sharing
between different energy storage devices adds dynamic stability
and reliability to the performance of UPS system. Depending upon
the grid environment, power rating, volumetric size, and backup
time a suitable topology can be selected. Performance evaluation
 M. Aamir et al. / Renewable and Sustainable Energy Reviews 58 (2016) 1395–1410
Fig. 32. Transition from Battery power mode to Normal mode, Input Voltage Vin
and Current Iin, Output Voltage Vout and Current Iout.
of the UPS system has been presented and important features for
selection of UPS system have been explained such as input power
factor, output voltage, step response, and transient time for change
of modes (Grid and Backup). This review will be very useful
reference for the researchers, designers, users, and manufacturers
working on the UPS system.
Acknowledgment
The authors would like to acknowledge the financial support
from University of Malaya. This research was carried under the
High Impact Research Grant (UM.C/HIR/MOHE/ENG/24)scheme
and Bright Spark Unit, University of Malaya.
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The Benefits of a Preventive
Maintenance Service Plan
for Your UPS
Ed Spears Art Mulligan
Eaton Corporation

I
mplementing a preventive maintenance service plan for your UPS is much What are the root causes
like completing routine repairs and inspections on your vehicle. Not only is of downtime?
completing scheduled maintenance recommended by every auto manufac- It may come as a surprise that more
than two-thirds of downtime events stem
turer, but the findings can help detect a wide range of ailments under the hood
from preventable causes, according to
before they become serious issues. In the same way that analyzing pressure and the 2007 Study of Root Causes of Load
fluid levels, checking the alignment, and inspecting the brake pads at specified Losses compiled by Eaton Corporation.
Studies have also shown that approxi-
mileage intervals can maintain performance and factory specifications for your mately four percent of UPS failures are
vehicle, preventive maintenance helps ensure the ongoing integrity of your UPS. the result of components wearing out due
After all, it is much more palatable to tweak the alignment at the first sign of to age, while up to 20 percent fail due to
bad batteries. Studies into the causes of
needed adjustment as opposed to finding out down the road that you now need downtime reveal that:
four new tires—not to mention the original alignment that likely would have
preserved the tires in the first place. Preventable downtime (67%) is caused
by:
A variety of different UPS service options are available including routine scheduled • Human error
maintenance, emergency parts and labor service, and other value-added offerings such • Lack of process
as remote monitoring capabilities. Regardless of the exact course of action you choose, • Incorrect procedures
an effective preventive maintenance plan will save time and money by minimizing busi- • Poor design
ness interruption and the costs of downtime as well as enhancing your overall return • Inadequate redundancy
on investment by extending the lifespan of your critical power equipment. Preventive • Insufficient maintenance
maintenance is also crucial to achieving maximum performance from your equipment
by affording the opportunity to detect and repair potential problems before they become Nonpreventable downtime (33%) is
significant and costly issues, thereby minimizing the risk of unplanned downtime. caused by:
• Equipment failure (despite proper
Downtime is disastrous maintenance and testing)
No matter how you assess it, downtime carries an enormous price tag. Electric Power • Supply chain/service chain failure
Research Institute (EPRI) estimates the national cost of power interruptions at approxi- • Cyber terrorism
mately $80 billion per year to U.S. electrical customers, with momentary interruptions
accounting for two-thirds of the total cost at $52 billion. The U.S. economy loses between The positive news is that routine
$104 billion and $164 billion to outages each year, and another $15 billion to $24 billion preventive maintenance appreciably
to power quality issues. Furthermore, the annual downtime average for the utility grid reduces the likelihood that a UPS
in the U.S. is currently eight hours and 45 minutes. However, with on-site generation will succumb to downtime. In fact,
equipment and UPS solutions, this downtime can be reduced to the equivalent of five the same load loss report revealed that
minutes and 15 seconds per year. customers without preventive mainte-

www.netaworld.org Winter 2008-2009 NETA WORLD

nance visits were almost four times more likely to experience
a UPS failure than those who complete the recommended
two preventive maintenance visits per year. These findings
validate the significance of regular UPS service as a highly
effective means to reduce the potentially devastating effects
of downtime.
What is your risk of UPS failure?
Because all manufacturers’ UPSs are complex devices
that perform several critical power conditioning and backup
supply functions, they are all subject to failure. However, by
implementing a comprehensive preventive maintenance
service plan that is delivered by trained and certified tech-
nicians, you can significantly reduce your vulnerability to a
load loss and extend the life span of your UPS.
As Chart 1 illustrates, routine preventive maintenance
significantly reduces the probability of a load loss event.
Through the completion of systematic inspections, a preven-
tive maintenance plan ensures that the various electronic and
mechanical components of a UPS are thoroughly evaluated,
cleaned, tested, and calibrated on a regular basis. Without
proper maintenance, many UPSs will fail prematurely since
critical components such as batteries and capacitors wear
out from normal use. However, a solid maintenance plan
identifies issues and greatly reduces this risk of failure.
Chart 1 — Powerware UPS load losses by preventive maintenance
visits delivered in prior year.
Minimize interruption to your business
Lost or corrupted files, hardware malfunctions, the in-
ability to access the critical systems you need - all of these
unpleasant consequences (just a small sampling of the pos-
sible outcomes of unexpected downtime) can significantly
impact your ability to conduct business, not to mention the
potential for lost revenue and damaged reputation in the
event that customer service mechanisms such as on-line
ordering, phone systems, or other sales tools are unavailable
to potential customers. In many instances, there is very little
lag time between system downtime and financial disaster.
However, with an effective preventive maintenance plan,
your business will have access to more reliable, higher quality
and more cost-effective power, all of which minimize the
risks of downtime and disruption to your business.
NETA WORLD Winter 2008-2009
Outlining an effective preventive
maintenance plan
There are a number of measures that are recommended to
ensure the ongoing integrity of your UPS, including:
• Annual scheduled preventive maintenance for both the
electronics and battery
• Access to rapid emergency response from trained techni-
cians on the specific UPS models
• On-site parts inventory or local field technicians with
van-stocked required parts
• Access to technical support and design engineering re-
sources during escalation
• Remote monitoring with monthly trended reporting,
7x24 alarm notification and rapid response linkage to
field technician
• Adherence to recommended parts replacement cycles,
especially items that wear out more quickly such as bat-
teries and capacitors
• Understanding of the UPS life cycle, expansion features,
and total cost of ownership
• Access to 7x24 call center specialists and local
technicians
• Maintaining accurate records
Furthermore, since most VLRA batteries wear out every
three to five years, it is critical that they are regularly in-
spected. And, considering the fact that the failure of a single
battery jar can cause an entire UPS to fail, battery testing
and replacement as needed are a fundamental component
of a proper UPS maintenance plan, with most customers
opting for semiannual VRLA or quarterly wet cell battery
preventive maintenance. A new trend in battery and UPS
maintenance plans is to deploy a battery monitoring system
to constantly measure and report if any individual battery is
out of factory specification. By allowing a qualified service
provider to remotely monitor battery systems, businesses
gain peace of mind knowing that expert eyes are watching
and interpreting data round-the-clock.
Typical maintenance replacement cycles
The following guidelines will help you determine the
optimal replacement period for various UPS components:
Battery Life
Standby use: Three to five years for VRLA batteries, wet
cell battery; life is variable.
Cycle use: 1200 cycles at 30% of discharge, 550 cycles at
50% of discharge, 250 cycles at 100% of discharge.
Capacitors: Inspect annually. Replace every seven years or
as needed.
Hot-Swappable
Fans: Replaceable with unit online if redundant or on bypass.
Verify annually; replace every seven years.
Lug terminals: Crimp any mechanical power lugs, annual
visual and thermal inspection.
Air Filters: Replace annually or as needed.
www.netaworld.org
Common UPS tests to optimize availability
The most successful UPS installations, which are mea-
sured by system availability or uptime, include prescriptive
maintenance programs that are rigorously enforced. Within
an effective maintenance strategy are a number of func-
tional tests and component checks that should be conducted
regularly. Specifically, an operational test or major preven-
tive maintenance event, which cycles the UPS through its
various change-of-state modes, should be conducted while
monitoring key operating parameters such as voltage, fre-
quency, current, and temperature. The following operational
tests are typical:
1. Transfer to bypass and return to UPS: This test checks
the static switch and bypass breaker motor operator or
contactor. The test interval should be at least annually
and can be performed with the load on maintenance
bypass.
2. Battery operation and return: Sometimes coupled with
a transfer-to-generator support and return to normal,
this test is typically performed monthly and tests the
UPS, generator, and automatic transfer switch (ATS)
functions.
Photo 1 — UPS failure due to the ingress of conductive, foreign material
Photo 2 — Random component failure
www.netaworld.org
3. Load balancing evaluation: This test checks for loads
on any phase that may be approaching 100 percent. To
limit potential overloads, loads may be redistributed as
necessary. It is important to note that any one phase may
be overloaded and trigger an unexpected alarm or transfer
even if the other two phases are only lightly loaded.
4. Phase rotation/site wiring checks: This test inspects for
out-of-limit bypass alarms or site wiring faults that may
have occurred as a result of normal site wiring changes
or maintenance. These problems can go undetected until
a transfer to bypass is attempted.
5. Listening tests: An experienced technician should listen
for abnormal operational sounds, particularly arcing, fan-
bearing noise, or synchronization problems, including
hunting sounds or beat frequencies. These subtle hints
can easily go unnoticed by users unfamiliar with the
warning sounds.
6. Operator refresher training: Since most power inter-
ruptions are a result of human error, constant attention
should be paid to ensuring and documenting that all per-
sonnel with access to the UPS and associated switchgear
have a solid understanding of the operation of the system
and the consequences of any incorrect actions.
Conclusion
Every UPS contains life-limited components that must
be replaced according to the manufacturer’s specifications.
To ensure these parts are properly cared for and replaced
when needed, regular maintenance is critical.
An effective preventive maintenance strategy can be one
of the most cost-effective measures you can take to ensure
the ongoing health of both your critical equipment and your
overall business. Because regular maintenance practices so
dramatically improve the UPS reliability and performance,
while notably deterring downtime, preventive maintenance
is an essential component of an end-to-end solution to keep
your critical networks operating at peak performance in the
face of multiple threats.
Ed Spears is a product marketing manager in Eaton’s Critical Power
Solutions Division in Raleigh, North Carolina. A 28-year veteran in the
power systems industry, Spears has experience in UPS systems testing,
sales, applications engineering and training—as well as working in power
quality engineering and marketing for telecommunications, data centers,
cable television, and broadband public networks. He may be reached at
EdSpears@Eaton.com.
Art Mulligan is a services marketing manager in Eaton’s Critical
Power Solutions Division in Raleigh, North Carolina. With 20 years
of high-technology marketing background, Mulligan has experience in
UPS service product line management, sales, promotions and pricing—as
well as marketing leadership roles in advertising, telecommunications,
and applications software. He may be reached at ArthurRMulligan@
Eaton.com
Winter 2008-2009 NETA WORLD
—
U P S B AT T E RY H A N D B O O K

The Main Characteristics of UPS

Battery Systems
Power protection for critical
infrastructure
2 A B B U P S S Y S T E M S B AT T E R I E S

—
Understanding UPS batteries helps to
ensure a continuous flow of clean power.

—
01 The lifeblood of A secure supply of energy is the foundation for This handbook describes the main characteristics
financial institutions
the success and continuity of many enterprises – of UPS battery systems, with particular emphasis
is a reliable source
of quality electrical be they industrial plants, offices, healthcare fa- on the lead–acid battery type, as these are in
power. This is why
cilities, utilities or data centers. For some of widespread use.
businesses install a UPS.
The battery in a UPS these concerns, power outages can be very ex-
is the most vulnerable
pensive indeed, with costs sometimes running Further information can be found in national and
part of the system.
into the tens of millions of dollars. This is why international standards, such as “BS EN 50272-
many businesses install an uninterruptible 2:2001– Safety requirements for secondary bat-
power supply (UPS). tery and battery installations – Stationary batter-
ies,” released by the European Committee for
A critical part of the UPS is the battery bank that Electrotechnical Standardization.
provides the energy needed to ensure that a con-
tinuous flow of clean power is available to the
critical process that the UPS is powering. Param-
eters that have to be taken into consideration in
properly selecting battery systems are the de-
sired power and autonomy, inverter efficiency, fi-
nal discharge, and available charging voltage.
These and many other factors must be carefully
considered when choosing and configuring a UPS
battery system.

—
01

—
Batteries in UPS systems
—
01 Internal and external UPS applications make use of a wide variety of
components of a valve-
battery types; however, lead–acid (LA) batteries
regulated lead-acid
(VRLA) battery are currently the most common technology. In
specific instances with special requirements,
nickel–cadmium or lithium-ion batteries are
sometimes used. Lithium-ion is a rapidly grow-
ing battery technology, used where high-energy
density and low weight are the primary require-
ments.
Lead–acid batteries
The LA battery represents the most economical
choice for larger power applications where
weight is of little or no concern. Most UPS sys-
tems use LA batteries as they provide excellent
performance, high power efficiency with low in-
ternal impedance, high tolerance to improper
treatment, and attractive purchasing costs.
LA batteries use an electrolyte that consists of
water and sulfuric acid, and plates made up of
sponge lead (negative electrode) and lead oxide
(positive). The two main LA battery types are:
• VRLA (valve-regulated lead–acid), also known as
“sealed” or “maintenance-free”
• Flooded, also called “vented” or “open”
—
01
Positive terminal
ABS lid
Negative strap connector
Positive strap connector
ABS battery case
Negative plate
3
VRLA batteries
VRLA batteries are sealed and can be mounted in
any orientation. The battery case is equipped
with a valve that vents any buildup of gas exter-
nally. Gas buildup is usually an exceptional event,
which may occur, for example, when the battery is
subject to a high charging rate or rapid discharge.
VRLA batteries normally require no direct mainte-
nance – they do not need to be topped up with
water, as any hydrogen released during charging
is recombined internally with oxygen to form wa-
ter. There are two main VRLA types, distinguished
by their electrolyte composition:
• Absorbed glass material (AGM), where the elec-
trolyte is held within a highly porous microfiber
glass separator.
• Gel, which has an electrolyte gel made from a
mixture of sulfuric acid and silica.
UPS applications normally work with the VRLA
AGM type because of its lower internal resistance,
high specific power and efficiency, low self-dis-
charge, and lower purchasing costs. AGM batter-
ies also charge faster and can deliver high current
of short duration.
Lifting handle
Vent strip for valves
Negative terminal
Positive plate
Separator
4 A B B U P S S Y S T E M S B AT T E R I E S

—
01 These graphs Flooded batteries Nickel–cadmium batteries
compare NiCd with
Flooded LA batteries, as the name suggests, have Nickel–cadmium (NiCd) battery electrodes are
different LA battery
types. Active material plates that are immersed in an acid electrolyte. made of nickel hydroxide (positive plate) and cad-
composition varies
Since they are not sealed, the hydrogen generated mium hydroxide (negative plate). The electrolyte
by manufacturer, so
performance may vary during operation escapes directly into the envi- is an aqueous solution of alkaline potassium hy-
from case to case.
ronment, meaning that ventilation systems must droxide. NiCd batteries provide a very long calen-
be more powerful than those for VRLA and, so, dar life (up to 20 years) and can cope with tem-
sized adequately. In most cases, the battery perature extremes (-20 °C to +40 °C). They also
banks are accommodated in a dedicated room. offer a high cycle life and have good tolerance to
DIN VDE 0510 Part 2, for example, sets out the deep discharges. However, NiCd batteries cost
provisions for equipping such a battery room. much more than traditional VRLA equivalents.
Flooded batteries must be kept and operated up-
right, and their water levels must be manually
topped up. They provide a longer lifespan and
higher reliability than sealed LA batteries.

—
01

Nickel–Cadmium Lead–Acid AGM

Design life Design life

Price per Cycle life Price per Cycle life

system system

Storage Maintenance Storage Maintenance

Energy density Energy density

Lead–Acid Gel Lead–Acid Flooded

Design life Design life

Price per Cycle life Price per Cycle life

system system

Storage Maintenance Storage Maintenance

Energy density Energy density

 5

—
01 Internal and external Other benefits relate to the low internal resis- rents. Further, as both nickel and cadmium are
components of a
tance, which offers high power density combined toxic, battery disposal/recycling processes are
flooded battery
— with fast-charging capability. The storage time of costly. NiCd batteries also require maintenance in
02 Internal and external
NiCd batteries is very long, especially if fully dis- the form of topping up with water – especially in
components of nickel-
cadmium battery charged, and they provide high protection high-cycle applications, or under heavy charging
against improper treatment – e.g., overcharging, rates with some charging methodologies.
over-discharging, and high-ripple charging cur-

Negative plate group Plate group

Separator Positive plate group

Negative plate Positive plate

Negative flat grid Gauntlet

Positive tubular grid

—
01

Flame arresting vents

Battery terminal

Negative plate tab

Positive plate tab

Plate frame

Separating grids

Cell case

Plate

—
02
6 A B B U P S S Y S T E M S B AT T E R I E S

—
01 Different types of
lithium-ion batteries
Lithium-ion batteries
In a lithium-ion battery (LIB), the "cathode" is usu-
ally made of a metal oxide, while the anode is usu-
ally porous carbon graphite. Both are immersed
in a liquid electrolyte made of lithium salt and or-
ganic solvent. During discharge, the ions flow
from the anode to the cathode through the elec-
trolyte and separator; charging reverses the di-
rection, and the ions flow from the cathode to the
anode.
A common way to distinguish the main different
types of lithium-ion batteries is to consider the
cathode composition. The choice of battery de-
pends on various factors, including cell voltage,
capacity, energy and power capabilities, cycle life,
and temperature of operation.
Various LIB chemistries exist, which can be sim-
plified into six main types based on the composi-
tion of the cathode material (items 1 to 5) or an-
ode material (item 6):
1. Lithium cobalt oxide (LCO)
2. Lithium manganese oxide (LMO)
3. Lithium-nickel manganese cobalt oxide (NMC)
4. Lithium iron phosphate (LFP)
5. Nickel cobalt alumina (NCA)
6. Lithium titanium oxide (LTO)
It is not possible to compare these different fami-
lies precisely, since many aspects other than
technology play an important role in perfor-
mance, such as mechanical form, cell size and ac-
tive material mix. Different battery manufactur-
ers also combine technologies to improve
performance for a specific application.

—
01

LCO NCA NMC

Energy Energy Energy

Cost Power Cost Power Cost Power

Safety Life Safety Life Safety Life

LMO LFP LTO

Energy Energy Energy

Cost Power Cost Power Cost Power

Safety Life Safety Life Safety Life


—
Battery capacity and C-rate
The nominal capacity (KN) of a battery is the
guaranteed capacity when discharging over a
specified discharge current (IN) for a certain du-
ration (nominal discharge duration, tN), at nomi-
nal temperature, nominal density and nominal
electrolyte level, without failing to achieve the fi-
nal discharge voltage (UsN). The nominal battery
capacity can, therefore, be expressed as KN = IN ×
tN.
7
The chemistries mostly used for UPS applications
are LMO-NMC and LFP because of their long cal-
endar life, high safety and high power density.
ABB’s first choice for battery technology is an LIB
cabinet solution with a special combination of
lithium manganese oxide and nickel manganese
cobalt capable of providing over 200 kilowatts of
continuous power for several minutes.
The next part of this handbook mainly focuses on
traditional VRLA batteries, since they are most
common in UPS applications.
The nominal capacity values (in ampere-hours)
set by battery manufacturers typically refer to a
ten-hour discharge (C/10) of a lead battery and a
five-hour discharge (C/5) of a NiCd battery. In
UPS system applications, the real usable, extract-
able capacity is significantly lower than the nomi-
nal capacity due to the shorter discharge dura-
tion. The amount of power requested within the
specific autonomy time are major factors that im-
pact battery sizing.
8 A B B U P S S Y S T E M S B AT T E R I E S

—
Battery sizing

—
01 Impact of operating Sizing the batteries normally starts with two Major aspects of battery selection to be carefully
temperature on
major requirements: power and autonomy. The considered are:
battery life
power value to consider is the one coming out • Battery life
from the batteries, so the calculation should • Performance at beginning or end of life (BOL or
start with the load power and consider the EOL)
power factor and inverter efficiency. • Operating temperature
• Depth of discharge
Pbat_out_ = (Pload × cosPhi ) / Upsefficiency • Cutoff voltage
• Charging time
There are two main methodologies for proper
battery sizing. One option is to refer to battery Operating temperature
performance sheets that give details on auton- Operating temperature has a strong impact on
omy values under different constant power/cur- battery life and performance. All major manufac-
rent discharge characteristics versus tempera- turers recommend operating their batteries at
ture and cutoff voltage limits. 20–25 °C.
The other option is to use the ABB battery config-
urator tool or the online battery configurators Higher temperature values increase battery per-
available on suppliers’ websites. formance but decrease battery lifespan. Accord-
It is important to make sure that each system ing to the Arrhenius law, battery life is halved for
uses only one battery model, and that there are each 10 °C increase above the
never more than four to five strings in parallel per 20–25 °C range.
system. (This is the best practice, but it may vary
depending on the recommendations given by bat- Battery manufacturers provide battery perfor-
tery manufacturers.) mance sheets for the specific operating tempera-
ture.

— 12 A
01 A
Very long life: over 12 years

10 B
B Long life: 10–12 years

C
8 General purpose: 6–9
C
Lifespan (years)

D
6 Standard commercial: 3–5 years

0
20 25 30 35 40 45 50 55 60

Temperature (C°)
 9

—
01 Cycle service Battery life
life diagram
A battery type consistent with the lifespan re-
quired by the project specifications should be
chosen. All major battery manufacturers’ prod-
ucts are categorized by lifespan. Eurobat pro-
vides a clear picture of the four main categories:
• Standard commercial: 3–5 years
• General purpose: 6–9 years
• Long life: 10–12 years
• Very long life: over 12 years
Battery lifespan depends on various factors, and
real service life may differ significantly from the
original design life specified by manufacturers -–
in most cases (e.g. where temperature is higher
than nominal), it is 50 to 70 percent less.
Beginning- and end-of-life performance
Customer specifications may require a specific
level of performance (e.g., power and autonomy)
from batteries at their beginning of life (BOL) or
end of life (EOL). Battery sizing must include an
oversizing factor (typically 125 percent as for
IEEE485) to account for aging in the case of an
EOL requirement.
Depth of discharge (DOD)
Batteries can be discharged completely or par-
tially. The less (state of charge) a battery dis-
charges per cycle, the lower the number of cycles
that the battery will provide during its entire life.
The number of cycles is normally not so pertinent
for UPS systems, since they normally utilize the
batteries just a few times a year. However, in
some cases, and for specific countries, this as-
pect may be more relevant. The following graph
shows typical discharge/lifetime behavior for
VRLA batteries used in UPS applications.

— 140 A
01
Discharge depth 100%

120 B
Discharge depth 50%

C
100 Discharge depth 30%

Ambient temperature 25°C (77°F)

Capacity (%)

80

60
A B C

40

20

0 200 400 600 800 1000 1200 1400

Number of cycles (times)

10 A B B U P S S Y S T E M S B AT T E R I E S

—
01 Floating charge at Cutoff voltage
constant voltage
The lower the cutoff voltage is, the more power a
battery can deliver. All battery manufacturers de-
clare battery performance relating to cutoff volt-
age limit.
When sizing a battery system, it is important to
consider the minimum cutoff voltage per cell
(e.g., 1.65 V per cell, 1.7 V per cell, etc.). Normally,
the project specifications indicate the require-
ment for this value. It is also very important to
verify that the DC battery voltage range of the se-
lected UPS is compatible with the calculated
number of battery blocks.
If batteries ever discharge below their minimum
cutoff voltage, they are considered to be over-dis-
charged. In such a case, internal resistance in-
creases due to plate sulfation, and both capacity
and life decrease dramatically.
Charging time
Charging time depends on the maximum power
that a battery can accept without jeopardizing its
lifespan.
For LA batteries, charging power and voltage are
normally sized to provide a maximum current of
C/10 (a charge rate in amperes of one-tenth the
overall battery capacity in ampere-hours), with a
constant current and constant voltage charging
methodology. In some cases where long autono-
mies are required, it is also very important to ver-
ify that the UPS charging power is sufficient to
ensure proper battery charging within the re-
quired time.
The DC charging voltage must be ripple-free,
since this may strongly affect battery life. This
voltage must also stay within the range specified
for the particular battery: with a higher charging
voltage, the internal pressure in the battery will
increase and force open the valve to allow gas to
escape. Overcharging like this will corrode the
positive plate, shortening the battery life.

— A B C
01 Charge Charging Charging
Volume Current Voltage
(%) (A) (V/cell) 0.1CA-2.25V/cell temparature 25°C

B
120 0.10C 2.4
A

100 0.08C 2.3

Charging parameter

80 0.06C 2.2

60 0.04C 2.1

40 0.02C 2.0

C
A
B
20 0C 0
0 4 8 12 16 20 24 28 32 36

Charging time (hours)


—
Main causes of failure
Battery failure is the cause of 50 to 70 percent
of UPS outages. Other than short circuits, there
are three main mechanisms (excluding external
and internal short circuits) that reduce VRLA
battery life and performance:
Plate corrosion
Plate corrosion is usually the result of oxygen-
ation of the positive plate. It reduces the amount
of active material that can participate in chemical
reactions, reducing battery performance and life.
This factor is unavoidable. A battery that reaches
end of life through this failure mode has met or
exceeded its anticipated lifetime. Limiting the
depth of discharge, reducing the cycle count, op-
erating at moderate temperatures and controlling
overcharge are preventive measures that keep
plate corrosion under control.
Dry-out
“Dry-out” means a decrease in electrolyte quan-
tity, which strongly impacts battery life and per-
formance. The main reasons for battery dry-out
are excessive temperatures and overcharging.
With a higher charging voltage or current, the in-
11
ternal rate of gas recombination is not enough to
compensate for the large amount of hydrogen
and oxygen generated. This leads to an internal
overpressure, which causes the relief valve to
open. In a VRLA, the electrolyte lost to the envi-
ronment cannot be recovered, strongly affecting
battery performance and life. In the worst case, it
may result in thermal runaway, or even in a fire or
explosion.
Sulfation
In normal chemical reactions when a VRLA dis-
charges, lead sulfate crystals are deposited on
the plates. In charge mode, they are converted
back to active materials. If batteries remain
empty or only partially charged for a certain pe-
riod, these lead sulfate crystals harden, and it is
not possible to convert them back to lead or lead
oxide during charging. This strongly impacts bat-
tery performance, life and capacity, so it is im-
portant to fully charge batteries after each dis-
charge and to follow the battery manufacturer’s
instructions on proper charging voltage settings,
since a charging voltage that is only slightly lower
than specified may still cause this issue.
12 A B B U P S S Y S T E M S B AT T E R I E S

—
Storage

—
01 Capacity retention VRLA batteries discharge themselves, so their
characteristic diagram
available capacity decreases even when they are
not operating. VRLA batteries must be stored
fully charged, in their original packaging, and in
a dry, clean and well-ventilated environment.
There should be no visible traces of acid on their
cases. Do not stack different pallets or batteries
on top of each other unless instructed to so by
the manufacturer.
As a rule, inside buildings, flooded batteries
should be stored on liquid-proof ground with acid
collection trays. For VRLA cells/blocks, an acid
collection tray is not necessary. Batteries must be
well protected from metallic parts that may cause
short circuits, and be guarded against accidental
damage and falling objects.
During storage, batteries must be correctly man-
aged. After a certain period has elapsed since a
battery’s production date or most recent
charging, the battery needs to be recharged ac-
cording to the manufacturer’s instructions. This
period depends on aspects like storage tempera-
ture, battery model, etc. Higher ambient tem-
peratures decrease the time allowed between
charges. For this reason, the supplier’s recom-
mendations for the specific battery model should
always be followed. It is also common to measure
the battery’s open-circuit voltage and postpone
the charging process in cases where measure-
ment results are higher than the limits.

— 100 No supplementary charge required

01 (carry out supplementary charge before
use if 100% capacity is required)
90

80
Capacity retention ratio %

5°C Supplementary charge required before

(41°F) use. This supplementary charge will
70 help to recover the capacity and should
be made as early as possible.

60
Supplementary charge may often
fail to recover the capacity. The
50 battery should never be left standing
40°C 30°C 25°C until this state is reached.
(104°F) (86°F) (77°F)

40

0 2 4 6 8 10 12 14 16 18 20

Storage period (Months)


—
Maintenance and battery monitoring
VRLA batteries do not need to be topped up
with water like the flooded type does, but the
following steps are important in order to ensure
longer battery life and stable performance:
• Check battery voltage and temperature and ver-
ify that all connections are free of dust (never
use solvents to clean batteries; a damp cloth is
enough), corrosion or leakage. Check that the
ventilation is working and that all connections
are tight and fastened. This last check may be
also done with a thermal scan while the batter-
ies are operating, as bad connections are usu-
ally the site of hotspots.
• Perform a battery discharge test at least once a
year to evaluate the battery’s internal resistance
and available capacity on all connected blocks.
This specific test must be agreed to, and con-
firmed by, the customer, since the load may not
be fully covered while this test is being run. To
simplify this test, ABB has developed the AKKA
diagnostic tool, which provides connections as
well as acquisition systems to measure the
most relevant battery parameters and detect
weak batteries that may need replacing.
13
Any damaged batteries must be replaced with
one with a similar internal resistance. Normally,
this is possible in the first two to three years of
operation, depending on battery type. After that,
the replacement should be a used battery of a
similar age. If such “aged” spare parts are unavail-
able and the UPS cannot operate with a reduced
number of batteries per string, the entire string
of batteries must be replaced.
To reduce the required maintenance work, a bat-
tery monitoring system can be used. Many sys-
tems are already available and used in the field in
ABB UPS applications. These tools continuously
monitor battery parameters such as voltage, cur-
rent, temperature and internal resistance, provid-
ing real-time alerts and warnings. They also offer
full data acquisition packages and tools for
proper analysis and metrics. These systems usu-
ally also offer thermal runaway control and re-
mote monitoring features, and in some cases
even active balancing between batteries.
The capex costs for such systems are quite high,
but – more notably than all the functionalities de-
scribed below – they provide the very important
benefit of advance warning of which battery is
going to fail so it can be promptly replaced, avoid-
ing unexpected outages.
14 A B B U P S S Y S T E M S B AT T E R I E S
—
Ventilation and safety
Irrespective of whether they are sealed or not,
all lead–acid batteries can emit explosive gases
– especially while charging – so adequate venti-
lation is mandatory (hydrogen gas emitted
during charging is explosive at concentrations
above 4 percent). Hydrogen and oxygen gases
may also be released if, for example, if the bat-
tery is moved or shaken.
In order to dilute gases (hydrogen and oxygen)
generated during charging and discharging - and
thus eliminate the risk of explosion - battery
rooms must be ventilated in accordance with the
EN 50272-2 standard. Such ventilation obviates
the need for EX-proof electrical equipment. The
ventilation system must be designed to cope with
wet-room conditions.
Do not install batteries in airtight enclosures!
Spark-generating parts must be installed with a
safety distance to cell or battery block.
Ventilation requirements
EN 50272-2 states, the minimum air flow rate for
ventilation of a battery location or compartment
shall be calculated by the following formula:
Q = 0.05 x n x Igas x Crt x 10 -3 [m3/h]
With
N = number of cells
Igas = Ifloat or boost [mA/Ah} relevant for calculation
(see table below)
Crt = capacity C10 for lead acid cells (Ah),
Uf = 1.80 V/cell at 20°C”
The following table states the values for Igas to be
used:
Operation Vented cells (Sb < 3%) VRLA cells
Float charging 5 1
Igas according to EN 50272-2 for IU and U-charging
depending on operation and lead-acid battery
type (up to 40°C operating temperature). The
gas-producing current, Igas can be reduced to 50
percent of the values for vented cells where re-
combination vent plugs (catalyst) are used.
With natural ventilation (air convection), the mini-
mum inlet and outlet areas are given by:
A ≥ 28 x Q [cm2]
(Air convection speed ≥ 0.1 m/s)
For more details on how to size the ventilation
system for a battery room properly, refer to spe-
cific international and national standards (e.g., BS
EN 502720-2:2001).
 15

—
Recycling and disposal

—
01 At the recycling Nearly 100 percent of lead–acid batteries are re- The lead–acid recycling system is ecologically al-
facility, used batteries
cycled. There are two main reasons for this: Re- most a closed loop, and it is highly regulated at
are broken apart
and separated into cycling lead is cheaper than obtaining new raw the local, state, national, and international levels.
components to begin
material, and all the parts of the battery can be Battery owners can safely dispose of their spent
the recycling process.
completely recycled. batteries at retailers and recycling drop off cen-
ters – or even return them directly to the manu-
Polypropylene is recycled into more battery plas- facturer, some of whom provide this service for
tic to produce new battery cases, sulfuric acid is free.
collected and resold as commodity acid, and lead
is smelted and reused in batteries or other prod- For proper battery disposal, refer to national/in-
ucts. ternational legislation and local waste disposal
rules and regulations.

—
01

PLASTIC LEAD ELECTROLYTE 1 ELECTROLYTE 2

Plastic pellets recycled
from battery cases and
covers are used to
manufacture new cases
and covers.
Lead ingots recycled from battery
grids, other battery parts and
lead-oxide are used to
manufacture new grids, parts,
and lead oxide.
Used electrolyte is reclaimed and
reused in manufacturing new
batteries.
Sodium sulfate crystals
separated from used
electrolyte are recycled and
sold for use in i.e. textiles
and glass.
—
www.abb.com/ups
ups.sales@ch.abb.com

© Copyright ABB. All rights reserved.

04-2782_PO_EN | Printed in Switzerland, 2012

Specifications subject to change

without notice.
4NWP101121R0001 EN

© Copyright 2017 ABB. All rights reserved.

Specifications subject to change without notice.
 Infrastructure and Mobility, Traffic Solutions
Sopers Lane, Poole, Dorset
BH17 7ER

UPS Solution General Handbook

Part no.
667/HB/47750/000

THIS DOCUMENT IS ELECTRONICALLY APPROVED

AND HELD IN THE STC DOCUMENT CONTROL TOOL

Prepared By Checked and Released

Company/Dept. Siemens Traffic Solutions/Engineering Siemens Traffic Solutions/ Engineering
Name Ore Oluwatudimu / Ashley Thorpe Antonio Rhodes
Function Product Development Engineer Hardware Engineering Manager
Signature

Date
COPYRIGHT STATEMENT
The information contained herein is the property of Siemens plc. and is supplied without liability for errors
or omissions. No part may be reproduced or used except as authorised by contract or other written
permission. The copyright and the foregoing restriction on reproduction and use extend to all media in
which the information may be embodied
Copyright Siemens plc 2016 All Rights Reserved

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Document UPS Solution General Handbook Doc. No. 667/HB/47750/000
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Copyright Siemens plc 2016 All Rights Reserved
 Infrastructure and Mobility, Traffic Solutions
Sopers Lane, Poole, Dorset
BH17 7ER

Preface

SAFETY INFORMATION
Safety of Installation and Maintenance Personnel

In the interests of health and safety, when installing, using or servicing this
equipment the following instructions must be noted and adhered to:
(1) Only skilled or instructed personnel, with relevant technical knowledge
and experience, who are familiar with the safety procedures required
when dealing with modern electrical/electronic equipment, are to be
allowed to use and/or work on this equipment. All work shall be
performed in accordance with the Electricity at Work Regulations 1989.
(2) Such personnel must take heed of all relevant notes, cautions and
warnings in this Handbook and any other Document or Handbooks
associated with this equipment.
(3) The equipment must be correctly connected to the specified incoming
power supply.
(4) Mains voltages may be present within traffic system. Before any
maintenance work within the system is carried out, any mains supply to it
must be isolated or switched off.
(5) Mains voltages may still be present within traffic equipment even when
the site mains supply has been isolated or switched off. The UPS
Solution must be completely off to ensure no mains power is supplied to
connected traffic equipment.
(6) Only trained / competent persons should work on this equipment.
(7) Surfaces within the associated traffic equipment get hot, e.g. lamp, lens
and reflector. Therefore care should be taken when working in such
areas.
(8) Any power tools must be regularly inspected and tested.
(9) Any ladders used must be inspected before use to ensure they are
sound and not damaged.
(10) When using a ladder, before climbing it, ensure that it is erected properly
and is not liable to collapse or movement. If using a ladder near a
carriageway, ensure that the work area is properly signed and coned.
(11) Any personnel working on site must wear the appropriate protective
clothing with high visibility jackets and safety boots as a minimum.

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 Infrastructure and Mobility, Traffic Solutions
Sopers Lane, Poole, Dorset
BH17 7ER

Safety of Road Users

It is important that all personnel are aware of the dangers to road users that
could arise during repair and maintenance of traffic control equipment.
Ensure that the junction area is coned and signed as necessary to warn
motorists and pedestrians of any dangers and to help protect the personnel
working on the site.

Precautions for Safe Battery Handling and Storage

Keep battery containers tightly closed when not in use.
If the battery case is broken, avoid contact with any internal components or
materials.
Do not handle near heat, sparks or open flames.
Protect battery containers from physical damage to avoid leaks or spills.
Place cardboard or other insulating material between layers of stacked
batteries to avoid damage and short circuits.
Do not allow conductive material to touch the battery terminals. A dangerous
short-circuit may occur and cause battery failure, fire, arcing, flash burns, etc.
Keep away from combustible materials, organic chemicals, reducing
substances, metals, strong oxidizers and water.
Batteries must be charged in a ventilated area. General ventilation is
acceptable.
Insulated tools must be used at all times and cases involving batteries.
For further information on proper battery handling see the Lead Crystal
Battery User Manual – 667/HB/47764/000.

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 Infrastructure and Mobility, Traffic Solutions
Sopers Lane, Poole, Dorset
BH17 7ER

MAINTENANCE PROVISION (MP)

Product Reference

UPS Solution – 667/1/44750/ETC.

Installation and Commissioning

Methods of installation, configuration and commissioning are described in this
handbook. In addition, there are a series of documents which have more
specific detail but are supplied by the OEM (Original Equipment
Manufacturer). These documents are listed in section 1.2 below.

Spares and Maintenance

The UPS system elements are designed for ‘return to base’ repair with the
exception of battery replacement.

Modifications
There are no approved modifications for this product.

Warning
Use of components other than those indicated within this document or
modifications or enhancements that have not been authorised by Siemens
will invalidate Type Approval of this product.

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 Infrastructure and Mobility, Traffic Solutions
Sopers Lane, Poole, Dorset
BH17 7ER

CONTENTS
1 Introduction ........................................................................................................................ 9
1.1 Scope .................................................................................................................... 9
1.2 Related Documents................................................................................................ 9
1.3 Definitions .............................................................................................................. 9
2 System Overview .............................................................................................................. 10
2.1 Description ........................................................................................................... 10
2.2 Cabinet Variants .................................................................................................. 10
2.3 Supported Loads .................................................................................................. 10
2.4 Generator Connectivity......................................................................................... 11
2.5 Electrical Information............................................................................................ 11
3 Modular Overview............................................................................................................. 12
3.1 UPS Cabinet Modules .......................................................................................... 12
3.2 Battery Expansion Cabinet Modules ..................................................................... 13
3.3 Modular Elements ................................................................................................ 14
3.3.1 Reinforced Cabinet Stool .................................................................................. 14
3.3.2 Vented Cabinet Outer Case.............................................................................. 14
3.3.3 Battery Housing Module ................................................................................... 14
3.3.4 UPS Housing Module ....................................................................................... 15
3.3.5 DC Housing Module ......................................................................................... 16
4 Hardware Overview .......................................................................................................... 17
4.1 Alpha FXM UPS unit ............................................................................................ 17
4.2 Universal Automatic Transfer Switch .................................................................... 18
4.3 Lead Crystal Batteries .......................................................................................... 19
5 Sizing the UPS Solution ................................................................................................... 20
5.1 Key Considerations .............................................................................................. 20
5.2 Sizing Example .................................................................................................... 21
5.2.1 Which UPS Unit Should be Installed? ............................................................... 21
5.2.2 How Many Battery Packs are Required?........................................................... 21
6 Internal Cabling Scheme .................................................................................................. 22
6.1 UPS Cabinet Internal Wiring................................................................................. 22
6.2 Battery Expansion Cabinet Internal Wiring............................................................ 23
7 External Cabling Scheme ................................................................................................. 24
7.1 Mains Power Supply ............................................................................................ 24
7.2 UPS Fault / Alarm Relay Contacts ........................................................................ 25
7.3 Ethernet Cable ..................................................................................................... 25
7.4 Battery Expansion ................................................................................................ 25
8 Further UPS Connectivity ................................................................................................ 26
8.1 Battery Temperature Sensor ................................................................................ 26
8.2 RS232 Interface ................................................................................................... 26
8.3 LAN Interface ....................................................................................................... 26
9 Installation ........................................................................................................................ 27
9.1 Required Tools and Consumables........................................................................ 27
9.2 Preparing and Installing the Reinforced Stool ....................................................... 28
9.3 Pulling and Gland Ducted Cables ......................................................................... 29
9.4 Fitting the Vented Cabinet Outer Case and Sealing the Base ............................... 30

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Sopers Lane, Poole, Dorset
BH17 7ER

9.5 Fitting and Connecting the Battery Housing Module.............................................. 31

9.6 Mounting and Connecting the UPS Housing Module............................................. 33
9.7 Mounting and connecting the DC Housing Module................................................ 34
9.8 Terminating External Cables into the UPS Connection Panel ............................... 35
9.9 Terminating External Cables into the DC Connection Panel .................................. 36
9.10 Terminating and Connecting the Ethernet Cable................................................... 36
9.11 Fitting and Connecting the Batteries ..................................................................... 37
9.12 Fitting the Battery Temperature Sensor ................................................................ 38
10 Isolation Switches ............................................................................................................ 39
10.1 Housing Module MCBs......................................................................................... 39
10.2 Universal Automatic Transfer Switch (UATS)........................................................ 39
10.3 FXM UPS Unit...................................................................................................... 40
11 Commissioning ................................................................................................................ 41
11.1 Electrical Safety Testing ....................................................................................... 41
11.2 Putting the UPS Solution in BYPASS ................................................................... 41
11.3 Powering and Commissioning the Controller ........................................................ 42
11.4 Starting Up the UPS Solution ............................................................................... 42
11.5 Testing the UPS Battery Support Function ........................................................... 43
12 UPS System Operation..................................................................................................... 44
12.1 Operating Modes ................................................................................................. 44
12.2 Active Fault Monitoring ......................................................................................... 44
12.2.1 Fault / Alarm Relay Contacts ........................................................................ 44
12.2.2 Fault Monitoring using Siemens RMS and UTMC Systems ........................... 46
12.3 Communicating with the UPS Solution ................................................................. 47
12.3.1 Three-Button Interface.................................................................................. 47
12.3.2 RS232 Interface ........................................................................................... 47
12.3.3 LAN Interface ............................................................................................... 49
12.4 Battery Charging .................................................................................................. 51
12.5 Temperature De-Rating........................................................................................ 52
12.5.1 Power output ................................................................................................ 52
12.5.2 Battery Charging .......................................................................................... 53
12.5.3 Battery Support Hold Up Times .................................................................... 53
12.6 Generators ........................................................................................................... 53
12.6.1 The Generator Connect Feeder Pillar ........................................................... 53
12.6.2 Generator Selection...................................................................................... 54
12.6.3 Protection and Reference Earthing ............................................................... 54
12.6.4 Connecting and Removing a Generator ........................................................ 54
13 Maintenance ..................................................................................................................... 56
13.1 Periodic inspection ............................................................................................... 56
13.2 Maintenance Bypass Switching ............................................................................ 57
13.3 Switching Off the UPS Solution ............................................................................ 58
13.4 First Line Maintenance ......................................................................................... 59
13.4.1 Replacing the Alpha FXM UPS unit .............................................................. 59
13.4.2 Replacing a Battery Pack ............................................................................. 60
13.4.3 Replacing an Alpha UATS unit...................................................................... 62
13.5 Second Line Maintenance .................................................................................... 62
14 Disposal ............................................................................................................................ 63
14.1 Under Maintenance Contract................................................................................ 63
14.2 End of Life and Scrapping .................................................................................... 63
15 Part Numbers / Spares List .............................................................................................. 64

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 Infrastructure and Mobility, Traffic Solutions
Sopers Lane, Poole, Dorset
BH17 7ER

15.1 Hardware Spares ................................................................................................. 64

15.2 Housing Modules ................................................................................................. 64
15.3 Outer Case and Stool ........................................................................................... 64
15.4 Connection Panel and MCB Spares ..................................................................... 64
15.5 Connection Accessories ....................................................................................... 64
15.6 Generator Connect Feeder Pillar .......................................................................... 64
APPENDIX A – Estimated Hold Up Times .............................................................................. 65
APPENDIX B – FXM UPS Faults and Alarms .......................................................................... 68
APPENDIX C – Hardware Datasheets ..................................................................................... 69
Alpha FXM Series UPS Unit............................................................................................. 69
Alpha Universal Automatic Transfer Switch (UATS).......................................................... 71
Betta Batteries 6CNFT-55 12V 55Ah Front Terminal Lead Crystal Battery ........................ 73
APPENDIX D – UPS Commissioning Certificate .................................................................... 75

Figure 3-1: UPS Cabinet Modules ....................................................................................... 12

Figure 3-2: Battery Expansion Cabinet Modules (Cabinet removed)..................................... 13
Figure 3-3: Reinforced Stool – FRONT VIEW (CET plate attached) ..................................... 14
Figure 3-4: Battery Housing Module..................................................................................... 15
Figure 3-5: UPS Housing Module ........................................................................................ 15
Figure 3-6: DC Housing Module (shown fitted on top of a battery housing module) .............. 16
Figure 4-1: Alpha FXM Series UPS Unit .............................................................................. 17
Figure 4-2: Universal Automatic Transfer Switch.................................................................. 18
Figure 4-3: 6CNFT-55 Lead Crystal Battery with Key Electrical Information.......................... 19
Figure 5-1: Battery Hold up times at 20°C and 0°C .............................................................. 20
Figure 5-2: Sizing Example – Battery Pack Selection ........................................................... 21
Figure 6-1: UPS Cabinet Internal Wiring Diagram ................................................................ 22
Figure 6-2: Battery Expansion Cabinet Internal Wiring Diagram ........................................... 23
Figure 7-1: Mains Power Supply Chain ................................................................................ 24
Figure 9-1: Reinforced Stool and CET plate ......................................................................... 28
Figure 9-2: Stool Installation Diagram .................................................................................. 29
Figure 9-3: Reinforced Stool – LEFT HAND SIDE VIEW ...................................................... 30
Figure 9-4: Two Battery Housing Modules stacked on the Reinforced Stool (Cabinet removed)
........................................................................................................................................... 31
Figure 9-5: Battery Housing module mount .......................................................................... 32
Figure 9-6: Earth Connection between Battery Housing modules ......................................... 32
Figure 9-7: UPS Housing mounted on Battery Housing within Cabinet ................................. 33
Figure 9-8: Battery Cable Loom Connectors ........................................................................ 34
Figure 9-9: UPS Connection Panel ...................................................................................... 35
Figure 9-10: Battery Terminals Connected with the Terminal Linking Bar ............................. 37
Figure 9-11: Battery Temperature Sensor ............................................................................ 38
Figure 10-1: UATS Switches................................................................................................ 39
Figure 10-2: Alpha FXM UPS Circuit Breakers ..................................................................... 40
Figure 12-1: Fault Monitoring Connectivity Example ............................................................ 46
Figure 12-2: Alpha FXM Series UPS RS232 Interface Screenshot ....................................... 48
Figure 12-3: LAN Interface Screenshot – Relay Contact Configuration................................. 50
Figure 12-4: Battery Charging Cycle .................................................................................... 52
Figure 5: Generator Connect Feeder Pillar........................................................................... 53
Figure 6: Three-position Changeover Switch ....................................................................... 55
Figure 13-1: Battery Terminals Connected with the Terminal Linking Bar ............................. 61
Figure A-1: Estimates of UPS Solution Performance at +20°C ............................................. 65
Figure A-2: Estimates of UPS Solution Performance at 0°C ................................................. 66
Figure A-3: Estimates of UPS Solution Performance at -25°C .............................................. 67

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 Infrastructure and Mobility, Traffic Solutions
Sopers Lane, Poole, Dorset
BH17 7ER

Table 2-1: UPS Load Suitability ........................................................................................... 10

Table 2-2: UPS Solution Electrical Information ..................................................................... 11
Table 3-1: UPS Cabinet Module Quantities .......................................................................... 12
Table 3-2: Battery Expansion Cabinet Module Quantities ..................................................... 13
Table 4-1: FXM Series UPS – Key Electrical Information ..................................................... 17
Table 4-2: UATS – Key Electrical Information ...................................................................... 18
Table 7-1: Alarm Contact Cable Specification ...................................................................... 25
Table 7-2: Ethernet Cable Specification ............................................................................... 25
Table 7-3: Battery Expansion Cable Specification ................................................................ 25
Table 9-1: Installation Steps for the UPS and Battery Expansion Cabinets ........................... 27
Table 9-2: RJ45 Interface Cable Connection........................................................................ 36
Table 12-1: Key UPS Solution Operating Modes.................................................................. 44
Table 12-2: Default Fault Contact Settings........................................................................... 45
Table 12-3: RMS Bit Labelling and Description .................................................................... 46
Table 12-4: RS232 Interface Connection Information ........................................................... 47
Table 12-5: LAN Interface Connection Information ............................................................... 49
Table 12-6: Maximum Output Power against Ambient Temperature ..................................... 52
Table B-1: FXM UPS Unit Fault and Alarms......................................................................... 68

CHANGE HISTORY
Version Date Author Change
Jan Ore
1-4 Produce Document
2014 Oluwatudimu
Nov
5 Ashley Thorpe Section 15 - added black outer case variant to parts list
2014
Nov Ore Section 11 – Updated
5A
2015 Oluwatudimu Appendix D – added commissioning certificate
Feb Ore
6 Section 12 – added generator information (12.6)
2016 Oluwatudimu

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Document UPS Solution General Handbook Doc. No. 667/HB/47750/000
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 Infrastructure and Mobility, Traffic Solutions
Sopers Lane, Poole, Dorset
BH17 7ER

1 Introduction
1.1 Scope
This handbook provides a general description of the Siemens UPS Solution and its key
elements, outlining the detailed procedures for installation, commissioning and
maintenance.

1.2 Related Documents

Reference Title Author/Contact
Alpha FXM Series UPS Installation and Operation Alpha Technologies
667/HB/47760/000
Manual Europe Ltd.
Alpha Universal Automatic Transfer Switch Alpha Technologies
667/HB/47761/000
Installation Manual Europe Ltd.
667/HB/47764/000 Lead Crystal Battery User Manual Betta Batteries
667/US/47764/000 Lead Crystal Battery Material Safety Data Sheet Betta Batteries
ST950 ELV Installation, Commissioning and
667/HE/45950/000 Dave Martin
Maintenance Handbook
ST950 LV Installation, Commissioning and
667/HE/46950/000 Dave Martin
Maintenance Handbook
667/HB/45040/000 Isolators and Feeder Pillars General Handbook Peter Lings

1.3 Definitions
Abbreviation Explanation
UPS Uninterruptable Power Supply
UATS Universal Automatic Transfer Switch
LC Lead Crystal (refers to battery technology)
VRLA Valve Regulated Lead Acid (refers to battery technology)
SOC State of Charge
SNMP Simple Network Management Protocol
LAN Local Area Network
MCB Miniature Circuit Breaker
LCD Liquid Crystal Display
GUI Graphical User Interface
OTU Outstation Transmission Unit
OMU Outstation Monitoring Unit
OEM Original Equipment Manufacturer

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2 System Overview
2.1 Description
The UPS Solution has been designed to provide seamless battery support to a Siemens
type traffic controller in the event of a loss of mains supply. The solution offers a line-
interactive uninterruptable power supply unit to constantly monitor the status of the mains
supply, maintaining a battery bank when power is present and switching to battery back
up when it is not. The switch from mains power to battery back up, and back again, is
almost instantaneous, ensuring that the traffic intersection controller sees no significant
break in power and remains operational.
The UPS Solution can be scaled to suit a range of power and battery hold up time
requirements. Hold up times can be extended further still with the connection of an
external generator as described in section 2.4.

2.2 Cabinet Variants

The UPS solution has been designed to be housed within a standard Siemens traffic
controller cabinet outer case to reduce its visual impact. When installed, the controller
and UPS solution cabinets appear identical. Two cabinet variants are available, as
described below.

UPS Cabinet - Houses the UPS system equipment and up to two

48V 55Ah battery banks.

Battery Expansion Cabinet -
Houses up to three 48V 55Ah battery banks only.
The Battery Expansion cabinet can be installed
alongside the UPS cabinet, providing additional
battery support in cases when an extended period of
support time is required.

WARNING: No more than one Battery Expansion Cabinet can be connected to

any one UPS Cabinet.

2.3 Supported Loads

The UPS solution is ideally suited to support ELV/LV LED traffic controllers only. It
caters for intersection loads up to 2000W in two optimised steps via a choice of UPS unit:

UPS Unit Max Power Output Suitable for

Alpha FXM1100 1100W / VA Loads up to and including 1000W
Alpha FXM2000 2000W / VA Loads from 1000W to 2000W
Table 2-1: UPS Load Suitability

WARNING: Both units are subject to de-rating at high temperature. This must
be considered when specifying each solution. See sections 4.1 and 12.5.1 for
details. See section 5.2 for a solution sizing example.

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2.4 Generator Connectivity

The UPS solution offers the possibility of connecting up an external diesel generator
through a specially design support product, the Generator Connect Feeder Pillar. This
adaptation of the normal large feeder pillar allows a portable generator to be used as a
substitute for the mains supply in cases of extended power outages.

See section 12.6 for more information on the Generator Connect Feeder Pillar.

2.5 Electrical Information

Parameter Value
Input:
Voltage 230Vac (150Vac – 328Vac without switching to battery support)
Frequency 50Hz / 60Hz Auto-detect (±5%)
Current (at max battery FXM1100: 8A at 230Vac
charging current) FXM2000: 15A at 230Vac
Mains Input Circuit Breaker 20A at 230Vac
Rating
Output:
Voltage 230Vac
Frequency 50Hz / 60Hz Auto-detect (±5%)
Maximum Power1 FXM1100: 1100 W/VA
FXM2000: 2000 W/VA
Waveform Pure Sine Wave
Switching Time <5ms
Voltage Distortion <3% THD
Efficiency Normal mode (LINE): >98%
Battery support mode (INVERTER): >82%
Battery Charging:
Charge Current 10A
Temperature Compensation -5mV/°C/Cell
Battery Type 12V 55Ah Valve Regulated Lead Crystal
Environment:
Operating Temperature -25°C to +74°C
Operating Altitude 12000ft
Operating Humidity Up to 95%
Table 2-2: UPS Solution Electrical Information

1
Power output de-rates in high ambient temperatures. See sections 4.1 and 12.5 for details.
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3 Modular Overview
This section details the five key building blocks of the UPS Solution; the stool, cabinet
outer case and three equipment housing modules.

3.1 UPS Cabinet Modules

Table 3-1 and Figure 3-1 show the modules involved in making up the UPS cabinet.

UPS Solution Modules Quantity Refer to

Reinforced Stool 1 Section 3.3.1
Vented Cabinet Outer Case 1 Section 3.3.2
Battery Housing 2 (maximum)2 Section 3.3.3
UPS Housing 1 Section 3.3.4
DC Housing 0 N/A
Table 3-1: UPS Cabinet Module Quantities

Figure 3-1: UPS Cabinet Modules

2
The UPS Cabinet can be fitted with only 1 Battery Housing module in cases where
reduced battery support is required.

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3.2 Battery Expansion Cabinet Modules

Table 3-2 and Figure 3-2 show the modules involved in making up the Battery Expansion
Cabinet.

UPS Solution Modules Quantity Refer to

Reinforced Stool 1 Section 3.3.1
Vented Cabinet Outer Case 1 Section 3.3.2
3
Battery Housing 3 (maximum) Section 3.3.3
UPS Housing 0 N/A
DC Housing 1 Section 3.3.5
Table 3-2: Battery Expansion Cabinet Module Quantities

Figure 3-2: Battery Expansion Cabinet Modules (Cabinet removed)

3
The Battery Expansion Cabinet can be fitted with one, two or three Battery Housing modules
allowing each solution to be tailored to the customer performance requirements.
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3.3 Modular Elements

3.3.1 Reinforced Cabinet Stool

UPS Cabinet and Battery Expansion Cabinet
The Reinforced Cabinet Stool is a load bearing replacement to the normal ST950 cabinet
stool. It provides mounting points for the cabinet outer case and internal housing modules
as well as a CET plate for cables entering and exiting the cabinet via underground
ducting.

Figure 3-3: Reinforced Stool – FRONT VIEW (CET plate attached)

3.3.2 Vented Cabinet Outer Case

UPS Cabinet and Battery Expansion Cabinet
Plastic ventilation devices have been added to the ST950 outer case to provide the
additional airflow required by UPS system equipment. The vents are fitted behind the
cabinet’s front door and are invisible when the door is closed.

3.3.3 Battery Housing Module

UPS Cabinet and Battery Expansion Cabinet
The Battery Housing module is the main building block of the internal mounting frame. It
provides mounting and connectivity for one 48V 55Ah battery bank, made up of four
individual batteries. A 63A double-pole MCB on the right hand side provides isolation,
allowing the batteries to be removed and replaced whilst the UPS Solution is still
powering the intersection, and a simple battery connector gives easy plug-and-play
connectivity to the rest of the system.

Battery Housings are stackable and are designed to slide into place on top of each other
for ease of installation. A bar, fitted to the front of each module, can be raised to form a
lip for battery retention.

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Figure 3-4: Battery Housing Module

NOTE: The Battery Housing Module does not come with batteries fitted.
Batteries are shipped separately and should only be mounted at the end of
installation.

3.3.4 UPS Housing Module

UPS Cabinet ONLY
The UPS Housing contains the key system hardware and is the main control and
connectivity hub for the entire UPS solution. It contains the UPS unit and UATS (as
described in sections 4.1 and 4.2) as well as a UPS Connection Panel that provides
termination for internal and external cabling related to the entire UPS Solution, including
mains input and output, Battery Expansion Cabinet connection and fault-monitoring relay
contacts. A 20A double-pole MCB provides mains input isolation. Wiring of the UPS
Connection Panel is detailed in sections 6.1 and 9.8.

Figure 3-5: UPS Housing Module

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3.3.5 DC Housing Module

Battery Expansion Cabinet ONLY
The purpose of the DC Housing provides a Connection Panel similar to that found within
the UPS Housing. This DC Connection Panel allows for the termination of internal and
external cabling related to the Battery Expansion Cabinet only. A 63A double-pole MCB
can be used to isolate the Battery Expansion Cabinet from the rest of the UPS Solution.

Figure 3-6: DC Housing Module (shown fitted on top of a battery housing

module)

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4 Hardware Overview
4.1 Alpha FXM UPS unit
The Alpha FXM series from Alpha Technologies are outdoor, military grade, line-
interactive Uninterruptable Power Supply units that have been selected for use within the
Siemens UPS solution. The unit offers an extended operating temperature range and is
well suited for use with ELV/LV LED type traffic controller equipment.

Figure 4-1: Alpha FXM Series UPS Unit

Each Siemens UPS solution uses one of two FXM series UPS units, depending on the
power requirements of the traffic intersection to be supported.

FXM1100 – Intersections up to 1kW

FXM2000 – Intersections up to 2kW

Key information for each type of unit is listed here. For more detailed information, please see
APPENDIX C – Hardware Datasheets or consult the FXM Series UPS Operating Manual –
667/HB/47760/000.

Parameter FXM1100 FXM2000

Nominal Voltage 230VAC
Nominal Frequency 50Hz / 60Hz
Typical Efficiency >98% (normal mode)
Typical Transfer time <5ms
Operating Temperature -40°C to +74°C
Power output:
At -40° to +50° (Nominal) 1100W/VA 20000W/VA
At 65° (UK Worst case) 962.5W/VA 1700W/VA
At 74° (Operating worst case) 838.75W/VA 1520W/VA
De-rating 1.25% per degree above 55°C 1.0% per degree above 50°C
Table 4-1: FXM Series UPS – Key Electrical Information
NOTE: Care must be taken when selecting a UPS unit if high temperatures are
expected. See section 5 for a solution sizing information and 12.5.1 for further
information on temperature de-rating.

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4.2 Universal Automatic Transfer Switch

The Universal Automatic Transfer Switch (UATS), also from Alpha Technologies,
provides a manual bypass switch for maintenance purposes. It has been designed to
work alongside the Alpha FXM UPS series and includes an automatic transfer facility that
constantly monitors the output of the UPS unit and will switch the system to bypass if a
fault is detected.

Figure 4-2: Universal Automatic Transfer Switch

Key information on the UATS is listed below. For further information on the unit, please
see APPENDIX C – Hardware Datasheets or consult the UATS Installation Manual –
667/HB/47761/000.

Parameter Value
Nominal Voltage 230Vac
Nominal Frequency 50Hz / 60Hz
Rated Input Current 16A
Rated Output Current 16A
Max. Output Power 3600W/VA (at +40°C)
Operating Temperature -40°C to +74°C
Table 4-2: UATS – Key Electrical Information

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4.3 Lead Crystal Batteries

Battery back up within the Siemens UPS solution is provided by banks of 55Ah 12V front
terminal Lead Crystal batteries. Each bank consists of 4 of these batteries, creating a
48V 55Ah pack. Lead Crystal batteries have a greatly extended operating temperature
range and a longer life expectancy when compared to their Lead Acid equivalents.

For more detailed information, please see APPENDIX C – Hardware Datasheets or

consult the Lead Crystal Battery User Manual – 667/HB/47764/000.

Figure 4-3: 6CNFT-55 Lead Crystal Battery with Key Electrical Information

WARNING: Great care must be taken when handling batteries. Ensure all
relevant safety information has been has been read and understood before
commencing any process involving the Lead Crystal batteries. See the safety
information at the beginning of this document.

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5 Sizing the UPS Solution

5.1 Key Considerations
There are two key factors to consider when sizing a UPS Solution for any one traffic
intersection. These are the junction power requirements and the desired battery hold
up time.

A traffic intersection’s power requirements determine which of two Alpha FXM UPS units
is to be installed. The required battery support hold up time determines the number of
battery packs that will need to be installed within the UPS Solution. Extended hold up
periods will require the installation of a Battery Expansion Cabinet alongside the UPS
Cabinet.

Where cost or space is critical, a compromise between the junction power requirements
and required hold up time must be reached. Reducing the required hold up time
potentially decreases the number of battery packs to be installed. Reducing the junction
power requirements, and therefore the UPS system output, will allow each battery pack
to go further in terms of hold up time. Both options should be considered to meet
installation requirements.

Figure 5-1: Battery Hold up times at 20°C and 0°C

Figure 5-1 displays a basic estimated battery hold up time chart for all options of the UPS
Solution at nominal ambient temperature of 20°C. Dashed lines indicate the estimated
hold up at 0°C. See APPENDIX A – Estimated Hold Up Times for a clearer view battery
hold up against temperature.

WARNING: The chart shown in Figure 5-1 is a performance estimate based on

manufacturer information to be used as a sizing guideline only.

Temperature extremes in both the hot and cold regions have detrimental effects on the
performance of the UPS Solution. See section 12.5 for more information on temperature
de-rating.

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5.2 Sizing Example

The following subsections give an example of sizing a UPS solution for a traffic
intersection in the UK with the following requirements.

Required Junction Power: 900W

Desired Hold up Time: 3.5 hours

WARNING: For the majority of UK installations, it is reasonable to assume a

worst case cabinet temperature range of 0°C to 65°C.The UPS Solution must
be derated to at least these values to help ensure correct operation.

5.2.1 Which UPS Unit Should be Installed?

Derating the UPS units’ power output to the reasonable UK worst case of 65°C gives the
following maximum output figures:

FXM1100 max. output at 65°C: 962.5W/VA

FXM2000 max. output at 65°C: 1700W/VA

A junction requiring 900W of power falls within the FXM1100 range.

5.2.2 How Many Battery Packs are Required?

Derating the battery hold up performance to the reasonable UK worst case of 0°C, two
battery packs are not sufficient to support a 900W load for 3.5 hours. Three battery
packs are required.

Figure 5-2: Sizing Example – Battery Pack Selection

NOTE: Any solution requiring 3 or more battery packs to achieve its desired
hold up time will require the installation of a Battery Expansion Cabinet.

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6 Internal Cabling Scheme

The UPS Housing, DC Housing and Battery Housing modules all come fitted with pre-
wired cable looms for ease of installation. The following subsections detail the internal
wiring interconnecting key system elements in both the UPS and Battery Expansion
cabinets.

6.1 UPS Cabinet Internal Wiring

Mains Controller Controller I/O
Supply Supply Card

UPS HOUSING

Mains Mains C1 – C6
MCB
IN OUT Faults/Alarms
UPS Connection Panel

Switch or Circuit Breaker

DIN Rail Terminal Block

UPS / BYPASS
External Cabling
UATS
UPS
ON/OFF

Mains
Mains O/P Fault Contacts
I/P CB

Alpha FXM Series UPS Unit

Battery CB

54VDC BUS
Battery + / -

MCB MCB

BATTERY BATTERY Battery Expansion

HOUSING 1 HOUSING 2 Cabinet

Figure 6-1: UPS Cabinet Internal Wiring Diagram

As stated in section 3.3.4, the UPS Housing module comes fitted and prewired with key
system elements and all internal cabling. External cables are to be terminated within the
UPS Connection Panel as part of the Installation process. See section 9.8 for details.
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Also shown within Figure 6-1 are the switches and circuit breakers used to isolate key
parts of the solution. See section 10 for further information.

WARNING: The FXM Series UPS unit offers further connectivity not shown in
Figure 6-1, some of which must be fitted for proper system operation. See
section 8 for details.

6.2 Battery Expansion Cabinet Internal Wiring

Figure 6-2: Battery Expansion Cabinet Internal Wiring Diagram

As stated in section 3.3.3, the DC Housing comes prewired with all interconnecting wiring
looms and the DC connection panel provides a termination point for all of these, as well
as isolation from the UPS cabinet via a 63A double-pole MCB. Mains voltages are not
present within the Battery Expansion cabinet.

Also shown within Figure 6-2 are the switches and circuit breakers used to isolate key
parts of the solution. See section 10 for further information.

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7 External Cabling Scheme

7.1 Mains Power Supply
All site installations should be designed in such a way that the controller cabinet, UPS
cabinet, Battery Expansion cabinet (if required) and feeder pillar (generator connect or
otherwise) are kept within the immediate vicinity of each other. Cable lengths between all
pillars and cabinets should be minimized wherever possible.

3 core mains cable is to be used for the following connections:

Mains supply within Feeder Pillar UPS mains Input
UPS mains output ST950 Controller Mains input

Figure 7-1: Mains Power Supply Chain

Distances between all elements within the mains power supply chain should be kept to a
minimum to reduce the impact of cable losses.

Cable size and length between the feeder pillar and traffic controller depend on the
controller fusing and expected voltage drop, as dictated in the following document:

667/HB/45040/000 – Isolators and Feeder Pillars General Handbook

The UPS cabinet can be installed in any location between the feeder pillar and controller
cabinet as long as the total cable length does not exceed the values specified in the
above document.

WARNING: The same cable is to be used throughout the mains power supply
chain from feeder pillar to controller.

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7.2 UPS Fault / Alarm Relay Contacts

A total of 18 relay contact termination points are made available via the UPS Connection
Panel (Normally Closed, Normally Open and Common for six relay outputs). These can
be cabled via ducting into the traffic controller for status and fault monitoring of the UPS
Solution. See sections 9.8 and 12.2.1 for details.

Cable selection for this interconnection is dependant on the number of cores required to
terminate all necessary contacts. Refer to Table 7-1 below.

Part Number Description

998/4/70468/004 Armoured 1/1.13mm 8core PVC cable
998/4/70468/006 Armoured 1/1.13mm 12core PVC cable
998/4/70468/008 Armoured 1/1.13mm 16core PVC cable
998/4/70468/050 Armoured 1/1.13mm 20core PVC cable

Table 7-1: Alarm Contact Cable Specification

7.3 Ethernet Cable

When the FXM Series UPS unit’s LAN interface feature is to be used, CAT5e cable is to
be ducted into the controller cabinet and connected to an IP enable Ethernet connection.

Use the cable specified in Table 7-2 for this connection.

Part Number Description

998/4/88384/000 Armoured CAT5E cable for duct installation
Table 7-2: Ethernet Cable Specification
See section 8.3 and 12.3.3 for LAN connection details.

7.4 Battery Expansion

Additional battery support from the Battery Expansion Cabinet is to be cabled into the
UPS Cabinet using the following armoured cable.

Part Number Description

2
998/4/88346/100 Armoured 10mm 3core PVC Mains cable

Table 7-3: Battery Expansion Cable Specification

WARNING: This cable is to be clearly labelled to prevent confusion with Mains

supply chain cabling. Only two of the three cores available are to be used for
battery termination. The Green/Yellow core is to be used to link the main earth
studs of the UPS and Battery Expansion Cabinets.

See sections 9.8 and 9.9 for installation details.

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8 Further UPS Connectivity

8.1 Battery Temperature Sensor
Each Alpha FXM UPS unit is fitted with a sensor that is used to monitor battery
temperature. The sensor appears on a cable from the ‘Battery Temp’ port on the front of
the FXM Series UPS unit and, when correctly applied to the battery support bank,
enables temperature compensated battery charging.

WARNING: The Battery Temperature Sensor must be fitted for proper

operation of the UPS solution.

For details on the proper installation of the battery temperature sensor, see section 9.12.
See section 12.5.2 for more information on temperature compensated battery charging.

8.2 RS232 Interface

Alpha FXM UPS units are fitted with a female 9-way D-type connecter for RS232
connectivity to a computer or laptop. Status information and configuration settings are
made available via this interface and can be used to interrogate the UPS Solution when
on site. See section 12.3.2 for more information on the RS232 interface.

8.3 LAN Interface

Alpha FXM series UPS units provide internet and intranet connectivity via an
embedded SNMP (LAN) card and RJ45 connector. An IP based connection can be
utilized for remote system configuration using the UPS unit’s supporting software. See
section 9.10 and 12.3.3 for more information on the fitting and using the UPS Solution’s
LAN Interface.

NOTE: The SNMP (LAN) card is fitted to all Alpha FXM UPS units within
Siemens UPS Solutions as standard.

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9 Installation
WARNING: Ensure all power sources are switched off and safely isolated
before installation commences. All switches and MCBs should be in the OFF or
BYPASS position.

The UPS solution’s modular sections have been designed with ease of installation in
mind. Much of the solution comes prewired with simple plug and play interconnects
between modules. The table below lists the steps required for installation of both the UPS
cabinet and the Battery Expansion Cabinet.

Step No. UPS Cabinet Battery Expansion Cabinet Refer to

1 Prepare and install the Reinforced Stool Section 9.2
2 Pull and gland ducted cables Section 9.3
3 Fit the Vented Cabinet Outer Case and seal the base Section 9.4
4 Fit and connect the Battery Housing module(s) Section 9.5
5 Mount and connect the UPS N/A Section 9.6
housing module
6 N/A Mount and connect the DC Section 9.7
Housing module
7 Terminate External cables into N/A Section 9.8
the UPS Connection panel
8 N/A Terminate External Cables into Section 9.9
the DC Connection Panel
9 Terminate and connect the N/A Section 9.10
Ethernet Cable
10 Fit and connect the batteries Section 9.11
11 Connect the Batt. Temp. N/A Section 9.12
sensor
Table 9-1: Installation Steps for the UPS and Battery Expansion Cabinets

9.1 Required Tools and Consumables

14mm socket/spanner
10mm socket/spanner
10mm insulated spanner
5mm Alan key
Terminal Screwdriver
Cross-head screw driver
RJ45 Crimp Tool
Cable Ties
Gorilla Tape4

4
Or similarly industrial self-adhesive tape. Insulation or Electrical tape is not acceptable.
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9.2 Preparing and Installing the Reinforced Stool

Step No. UPS Cabinet Battery Expansion Cabinet Refer to
1 Prepare and install the Reinforced Stool Section 9.2

WARNING: Prior to installation of the Reinforced Stool, instruct the Civils

Contractor as to the correct orientation of all cabinet stools, ensuring all
cabinets on site will face the right way.

The reinforced stool is based on a normal controller cabinet stool and the installation
process is much the same.

WARNING: Although similar, the normal ST800, ST900 or ST950 cabinet stool
must not be used when installing the UPS Solution as it is not capable of
supporting the total weight of all cabinet elements.

1. Prepare the Reinforced stool by fitting the CET plate to the upward fold in the top
of the stool using the two bolts and fixings provided.

Figure 9-1: Reinforced Stool and CET plate

2. Have the stool concreted into place in site in accordance with 667/HE/45950/000.
See Figure 9-2.

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Figure 9-2: Stool Installation Diagram

9.3 Pulling and Gland Ducted Cables

Step No. UPS Cabinet Battery Expansion Cabinet Refer to
2 Pull and gland ducted cables Section 9.3

NOTE: It is recommended that the Ethernet cable, if fitted, is pulled through all
conduits prior to attaching the RJ45 termination jack. This ensures the
termination is not compromised in any way during the pulling procedure. See
section 9.10 for termination details

NOTE: Sharp bends in all cables are to be avoided. A minimum bend radius of
4x the cable diameter should be observed where possible.

1. Pull all external cables through underground ducting and up into the cabinet via
the aperture in the left of the stool by the CET plate. See section 7 for details on
external cabling.

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CABLE ENTR
Y OPENING

Figure 9-3: Reinforced Stool – LEFT HAND SIDE VIEW

2. Working from back to front, gland these SWA cables to the CET plate, using the
holes and notches provided, in the following order:
o UPS Fault / Alarm relay contact cable (if required)
o Battery Expansion 54Vdc cable (if required)
o Controller 230Vac feed cable
o DNO 230Vac supply cable
o Ethernet cable (if required)

NOTE: Leave enough slack on all cables for termination at the top of the
cabinet. Cables should extend a minimum of 1500mm from the glanding point.

NOTE: When fitting the Battery Expansion Cable, terminate the Green/Yellow
core to the main earth stud on the CET plate.

9.4 Fitting the Vented Cabinet Outer Case and Sealing the Base
Step No. UPS Cabinet Battery Expansion Cabinet Refer to
3 Fit the Vented Cabinet Outer Case and seal the base Section 9.4

The Vented Cabinet Outer Case is simply a modified ST900 style controller cabinet and
is fitted to the stool in exactly the same way.

NOTE: The Vented Cabinet is packaged with the fixings necessary for fitting
the solutions housing modules (Battery, DC and UPS). Retain fixings until
reaching the appropriate installation step.

1. Fit the Vented cabinet outer case to the reinforced stool using the appropriate
M10 fixings as with the ST900 cabinet outer cases. Refer to 667/HE/45950/000.

2. The cabinet base should now be sealed. See 667/HE/45950/000 for details.

NOTE: Further installation from this point may involve work above un-cured
base seal. It is therefore recommended to mask the openings stool top with
cardboard or similar to prevent the loss of dropped fixings.
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9.5 Fitting and Connecting the Battery Housing Module

Step No. UPS Cabinet Battery Expansion Cabinet Refer to
4 Fit and connect the Battery Housing module(s) Section 9.5

The Battery Housing Module design allows them to be stacked unto each other. A
varying number of battery housing modules can be fitted depending on specific site
requirements.

WARNING: Batteries MUST NOT be fitted within the Battery Housing module
during installation.

Figure 9-4: Two Battery Housing Modules stacked on the Reinforced Stool
(Cabinet removed)
NOTE: Secure external cables from the CET plate to the cable
management holes in the left hand side of the Battery Housing modules as
each module is installed

Fitting the first Battery Housing Module:

1. Pass the first battery housing through the front door aperture of the cabinet outer
case and place unto the raised box section ‘top hats’ of the reinforced stool.

2. Align the countersunk holes in the bottom of the battery housing with the
threaded holes in the ‘top hats’, then secure into place using the Alan key and
fixings provided.

3. Pass the loose earth wire from the right side of the battery housing through the
opening in the housing bottom and secure to the marked earth stud on the box
section ‘top hat’ below.
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Fitting further Battery Housing Modules:

1. Pass the Battery Housing module through the front door aperture in the cabinet
outer case and place on top of the previously installed battery housing.

2. Using the back and side stops slide the Battery Housing into place, aligning the
countersunk holes on the bottom surface with the threaded holes in the top of the
Battery Housing module below. Secure using the fixings provided.

Figure 9-5: Battery Housing module mount

3. Pass the loose earth wire from the right side of the Battery Housing through the
opening in the housing bottom and secure to the marked earth stud on the
Battery Housing module below.

Figure 9-6: Earth Connection between Battery Housing modules

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9.6 Mounting and Connecting the UPS Housing Module

Step No. UPS Cabinet Battery Expansion Cabinet Refer to
5 Mount and connect the UPS N/A Section 9.6
housing module

The UPS housing module contains the UPS Solution equipment and is pre-wired with
cable looms for connectivity with the Battery Housing Cable looms.

WARNING: The UPS Housing module weighs a total of 30.7kg. On a solo

install, disconnect and remove the FXM UPS unit. This can then be replaced
once the housing module is securely installed.

Figure 9-7: UPS Housing mounted on Battery Housing within Cabinet

1. Pass the UPS housing module through the front door aperture of the cabinet
outer case and place on top of the previously installed Battery Housing module.

2. Using the side stops, slide the UPS Housing module into place, aligning the
holes in the bottom flange with the threaded holes in the top of the Battery
Housing module below. Secure into place using the bolts provided.

3. Secure the loose earth cable to the marked earth stud on the side of the Battery
Housing module below.

4. Connect the loose battery connection cable looms to the red connector sockets
on the right side of each Battery Housing module, using the right hand opening in
the base of the Battery Housing module to reach the connector of the housing
below.

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Figure 9-8: Battery Cable Loom Connectors

NOTE: in cases where only one battery housing is installed within the UPS
cabinet, the longer of two battery cable looms can be removed and retained as
a maintenance spare.

9.7 Mounting and connecting the DC Housing Module

Step No. UPS Cabinet Battery Expansion Cabinet Refer to
6 N/A Mount and connect the DC Section 9.7
Housing module

The DC housing provides a termination point for all batteries fitted within a Battery
Expansion Cabinet.

1. Pass the DC Housing module through the front door aperture of the cabinet outer
case and place on top of the previously installed Battery Housing module.

2. Using the side stops, slide the DC Housing module into place, aligning the holes
in the bottom flange with the threaded holes in the top of the Battery Housing
module below. Secure into place using the bolts provided.

3. Secure the loose earth cable to the marked earth stud on the side of the Battery
Housing module below.

NOTE: The DC Housing module is sometimes fitted to a Battery Housing

Module before shipping. If this is the case, check that the DC housing is secure
and that the earth cable is properly connected, then follow the normal Battery
Housing module installation steps (section 9.5) ensuring the DC Housing
module is placed at the top of the stack.

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4. Connect the loose battery connection cable looms to the red connector sockets
on the right side of each Battery Housing module, using the right hand opening in
the base of the Battery Housing module to reach the connector of the housing
below.

NOTE: in cases where less than three battery housing modules are installed
within the Battery Expansion Cabinet, unused battery cable looms can be
removed and retained as maintenance spares.

9.8 Terminating External Cables into the UPS Connection Panel

Step No. UPS Cabinet Battery Expansion Cabinet Refer to
7 Terminate External cables into N/A Section 9.8
the UPS Connection panel

WARNING: Ensure all power sources are switched off and safely isolated
before installation commences. All switches and MCBs should be in the OFF or
BYPASS position.

1. Remove the blanking plate from the top of the UPS housing revealing the UPS
Connection Panel.

2. The DIN rail mounted terminal blocks on the panel are clearly labelled. Cables
are to be terminated according to the following:
o ‘MAINS INPUT’ – Termination for a 3-core cable from the feeder pillar
supply.
o ‘OUTPUT’ – Termination for a 3-core cable to the traffic controller.
o ‘54VDC BUS’ – Termination for internal and Battery Expansion cabinet
battery cables. Clearly labelled ‘+’ and ‘-’.
o ‘C1’ to ‘C6’ – Termination for the UPS solution fault output contacts.
Clearly labelled ‘NO’, ‘C’ and ‘NC’ for Normally Open, Common and
Normally Closed respectively.

Figure 9-9: UPS Connection Panel

3. Replace the blanking plate.

See section 7 for further details on external cable specification details.

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9.9 Terminating External Cables into the DC Connection Panel

Step No. UPS Cabinet Battery Expansion Cabinet Refer to
8 N/A Terminate External Cables into Section 9.9
the DC Connection Panel

WARNING: Ensure all power sources are switched off and safely isolated
before installation commences. All switches and MCBs should be in the OFF or
BYPASS position.

1. Remove the blanking plate of the DC Housing module to reveal the DC

Connection Panel.

2. The DIN rail terminal blocks are clearly labelled. Terminate the Battery cable
from the UPS cabinet to the TBs marked ‘UPS DC’.

3. Replace the blanking plate.

See section 7 for further details on external cable specification details.

9.10 Terminating and Connecting the Ethernet Cable

Step No. UPS Cabinet Battery Expansion Cabinet Refer to
9 Terminate and connect the N/A Section 9.10
Ethernet Cable

If the FXM UPS unit’s LAN Interface feature is to be used, follow the instructions below to
properly terminate the Ethernet CAT5e cable.

1. Terminate the CAT5e cable into RJ45 jacks (531/4/03461/000) as a standard

straight-through Ethernet cable at both ends according the Table 9-2 below.

Pin Colour
1 White – Orange stripe

2 Orange Solid

3 White – Green stripe

4 Blue solid

5 White – Blue stripe

6 Green solid

7 White – Brown stripe

8 Brown solid

Table 9-2: RJ45 Interface Cable Connection

2. Plug the RJ45 jack into the Ethernet socket marked ‘LAN’ on the FXM UPS unit.

See section 7.3 for cable specification details.

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9.11 Fitting and Connecting the Batteries

Step No. UPS Cabinet Battery Expansion Cabinet Refer to
10 Fit and connect the batteries Section 9.11

WARNING: All battery safety information must be read and understood before
installation of the batteries begins. Refer to the safety information at the
beginning of this document.

WARNING: Use the insulated spanner when adjusting battery terminal fixings.
Terminals should not be exposed for extended periods. Replace the terminal
covers whenever possible. This reduces the risk of an accidental short-circuit.

WARNING: Ensure all power sources are switched off and safely isolated
before fitting the batteries. All switches and MCBs should be in the OFF or
BYPASS position.

Each Battery Housing module takes four 12V LC batteries, forming a 48V battery pack.
These will be referred to as Battery 1, 2, 3 and 4 from left to right respectively. Repeat the
following steps for each Battery Housing module within UPS cabinet AND Battery
Expansion cabinet.

1. Lower the battery retention bar of the Battery Housing module. Slide Battery 1
into the housing.

2. Connect the negative ring tag from the housing’s MCB to the negative terminal
on Battery 1. (grey cable)

WARNING: All battery terminals are to be made hand tight. DO NOT

OVERTIGHTEN as battery terminals can easily be damaged.

3. Slide Battery 2 into the housing. Connect the positive of Battery 1 to the negative
of Battery 2 using the terminal linking bar provided.

NOTE: When fitting batteries in the Battery Housing module directly below the
UPS Housing module, the Battery Temperature sensor is to be fitted as this
stage. Refer to section 9.12 before completing the following instructions.

4. Repeat this last step with Batteries 3 and 4.

Figure 9-10: Battery Terminals Connected with the Terminal Linking Bar

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5. Connect the positive ring tag from the housing MCB to the positive terminal of
Battery 4. (brown cable)

6. Replace the battery retention bar.

9.12 Fitting the Battery Temperature Sensor

Step No. UPS Cabinet Battery Expansion Cabinet Refer to
11 Connect the Batt. Temp. N/A Section 9.12
sensor

This sensor allows the FXM UPS unit to temperature compensate its battery charging
characteristics and is a vital part of the system installation. The sensor is to be fitted as
follows to the battery pack housed directly below the UPS unit.

Figure 9-11: Battery Temperature Sensor

1. Ensure the temperature sensor connector is securely fitted into the ‘BATTERY
TEMP’ socket of the FXM UPS unit.

2. Use tape to fix the sensor ring terminal to the exposed side of Battery 2.

3. On mounting Battery 3, ensure that it is flush with Battery 2 creating a secure fit
for the battery temperature sensor.

4. Tidy away the Battery Temperature Sensor cable.

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10 Isolation Switches
This section gives the names and locations of various switches and circuit breakers
throughout the UPS Solution that are used to isolate and switch on/off separate system
elements. These switches are used as during commissioning, start up and maintenance
of the UPS Solution and are referred to throughout the rest of this handbook by the
names listed here.

10.1 Housing Module MCBs

Mains Input MCB – UPS Connection Panel, UPS Housing, UPS cabinet
Battery Expansion MCB – DC Connection Panel, DC Housing, Battery Expansion
cabinet
Battery Housing Isolation MCB – Battery Housing(s), UPS and Battery Expansion
cabinets

10.2 Universal Automatic Transfer Switch (UATS)

The UATS is mounted within the UPS Housing module at the top of the UPS Cabinet.
Manual Bypass Switch (SW1)
UPS Supply Breaker (CB1)

Figure 10-1: UATS Switches

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10.3 FXM UPS Unit

The UPS Unit is mounted within the UPS Housing module at the top of the UPS Cabinet.
Battery Breaker
Input Circuit Breaker

Figure 10-2: Alpha FXM UPS Circuit Breakers

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11 Commissioning
The following subsections detail the procedure required to commission and start up the
UPS Solution. Refer to section 10 for details on isolation switch locations and section
12.3.1 for information on the Alpha FXM UPS unit’s three-button interface.

All commissioning results must be recorded within the UPS Commissioning Certificate
found in APPENDIX D – UPS Commissioning Certificate. The certificate must then be
presented to the customer as part of the installation handover process. A copy must also
be retained by Siemens Traffic Solutions.

NOTE: In order to avoid unduly stressing the UPS Solution it is advisable to

follow the switch on procedure set out below.

WARNING: Ensure all power sources are switched off and safely isolated
before starting the commissioning process. All switches and MCBs should be in
the OFF or BYPASS position.

11.1 Electrical Safety Testing

Upon completion of UPS Solution installation, the following Electrical Safety Tests are to
be carried out before the solution is powered or switched on.

Tests required are set out in the TS Traffic Installation Testing Document
(667/HE/20664/000):
2.1 Test Gear Requirement
2.2 Core to Core Testing – This applies to all cables between Feeder Pillar and
UPS Cabinet, UPS cabinet and Battery Expansion Cabinet, and UPS
Cabinet and Traffic Control Equipment.
2.3 Visual Inspection
2.4 Circuit Protective Conductor Test – This applies to all cables between Feeder
Pillar and UPS Cabinet, UPS cabinet and Battery Expansion
Cabinet, and UPS Cabinet Traffic Control Equipment.
2.5 Basic Polarity Test
2.6 Site Insulation Test
2.7 Polarity Test
2.8 Earth Loop Impedance Tests

11.2 Putting the UPS Solution in BYPASS

1. Make sure all switches listed in section 10 are in the OFF position and the
Manual Bypass Switch (SW1) on the UATS is in the BYPASS position.

2. Switch the Mains Input MCB on UPS Housing to ON.

The UPS Solution is now in BYPASS via the UATS. When present, power from the site’s
mains supply feeder pillar passes directly to the traffic intersection controller without
interacting with the FXM UPS unit.

NOTE: The UPS Solution is in BYPASS as long as long as the Mains Input
MCB in the UPS Connection Panel and the Manual Bypass Switch (SW1) on
the UATS are in the ON and BYPASS position respectively, no matter the state
of other isolation switches within the solution.

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11.3 Powering and Commissioning the Controller

1. Commission the traffic intersection controller in accordance with its related
Installation, Commissioning and Maintenance Handbook. See section 1.2.

2. Switch on mains power within the site’s supply feeder pillar at the appropriate
stage of controller commissioning.

The traffic intersection controller should now be fully operational.

11.4 Starting Up the UPS Solution

NOTE: Enter all results into APPENDIX D – UPS Commissioning Certificate.

1. Switch all Battery Shelf Isolation Switches on the Battery Housing modules
within the UPS Cabinet and Battery Expansion Cabinet, if installed, to ON in turn.

2. If a Battery Expansion Cabinet is installed, switch the Battery Expansion MCB

in the cabinet’s DC Housing module to ON. The Battery Expansion Cabinet can
now be closed.

3. In the UPS Cabinet, switch the Battery Breaker on the UPS Unit to ON.

4. Ensure the UPS unit is now on and displays ‘STANDBY’.

5. Switch the UPS Supply Breaker (CB1) on the UATS to ON.

6. Switch the Input Circuit Breaker on the UPS Unit to ON.

7. Wait for the UPS Unit to display ‘LINE’.

8. Switch the Manual Bypass Switch (SW1) on the UATS to UPS.

9. Check that the green STATUS LED on the Alpha FXM UPS unit is solidly
illuminated.

10. Check that the red ALARM LED on the Alpha FXM UPS unit is not lit or flashing.

11. Note down the model name from the bottom left of the display (e.g. ‘FXM 2000’)

12. Note down the at-a-glance settings from the top right of the display (e.g.
‘230/50/N’).

The UPS Solution is now switched on and supporting the traffic Intersection. Mains power
from the site supply feeder pillar is now fed through the UPS unit before being passed on
to the controller.

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11.5 Testing the UPS Battery Support Function

NOTE: Enter all results into APPENDIX D – UPS Commissioning Certificate

1. Switch the Mains Input MCB on the UPS Housing to OFF.

2. Ensure the UPS unit now displays ‘INVERTER’ and that traffic intersection is still
fully operational.

3. Check that the green STATUS LED on the Alpha FXM UPS unit is now flashing.

4. Switch the Mains Input MCB on the UPS Housing to ON.

5. Wait for the UPS unit to display ‘LINE’.

6. Ensure the traffic intersection is still fully operational.

7. Check that the green STATUS LED is now solidly illuminated.

8. Check that the red ALARM LED is not lit or flashing

Commissioning of the UPS Solution is now complete.

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12 UPS System Operation

12.1 Operating Modes
The UPS Solution has four main operating modes that are automatically selected by the
Alpha FXM UPS unit depending on the state of the mains power supply to the site and
battery pack SOC. These are listed and described in Table 12-1 below.

Operating Mode Description

‘LINE’ The normal operating mode of the UPS Solution.
Mains power is available from the site supply feeder pillar and is being
passed through the UPS to the traffic controller load.
Batteries are being charged or maintained using the mains supply.
‘INVERTER’ Mains power is unavailable from the site supply feeder pillar.
The UPS Solution is providing battery backup power from all connected
battery packs.
‘RETRAN’ Mains power from the site supply feeder pillar has been restored.
The UPS Solution assesses and qualifies the available mains supply
before switching back to ‘LINE’ mode.
‘SHUTDOWN’ Mains power from the site supply feeder pillar is unavailable and the
batteries have been discharged to the UPS unit’s over discharge
threshold. The UPS Solution switches off. Power is no longer supplied to
the traffic controller load.
When mains power is restored at the site supply feeder pillar, the UPS
solution will automatically switch to ‘RETRAN’ mode.
Table 12-1: Key UPS Solution Operating Modes

NOTE: The current mode of operation is shown on the Alpha FXM UPS Unit’s
LCD Display. Press any of the three buttons directly below the unit’s display to
activate the backlight

For more information on all Alpha FXM UPS unit modes please refer to
667/HB/47760/000.

12.2 Active Fault Monitoring

The UPS Solution offers extensive fault monitoring options as described in the following
subsections. More information on all available fault information is detailed in the Alpha
FXM UPS Operating Manual – 667/HB/47760/000.

12.2.1 Fault / Alarm Relay Contacts

The UPS Solution provides six relay outputs via the UPS Connection Panel that can be
cabled directly to the traffic controller cabinet for fault monitoring with Siemens UTMC or
RMS systems. See section 12.2.2 for details.

Each relay offers a Normally Closed (NC), Common (C) and Normally Open (NO)
contact, making a total of 18 possible termination points.

Table 12-2 lists and describes the default names and settings for these contacts.

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Default
Contact ID Name Voltage Energised When:
Setting
C1 On Battery Dry Contact The UPS Solution is running on N/A
battery backup power rather
than mains input

C2 Low Dry Contact The battery voltage drops 47Vdc

Battery 1 below the a configurable (40% SOC)
threshold
C3 Low Dry Contact Matches C2 47Vdc
Battery 2 (40% SOC)

C4 Timer Dry Contact The UPS Solution has been 5 minutes

running on battery backup for a
user-defined length of time

C5 Alarm Dry Contact General Fault on UPS Unit5 N/A

C6 UPS On 48Vdc at The UPS is providing a mains N/A

DO NOT USE (500mA) from output independent of the
(See warning battery packs power source
below)
Table 12-2: Default Fault Contact Settings

WARNING: C6 is factory configured as a 48Vdc supply and is not to be used

with Siemens traffic equipment.

Details of all other fault and alarm flags are available within the Alpha FXM UPS
Operating Manual – 667/HB/47760/000.

All fault and alarm flags can be interrogated by any one of three UPS interfaces as
described in section 12.3.

5
All possible Alarm Contact triggers are listed in APPENDIX B – FXM UPS Faults and Alarms
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12.2.2 Fault Monitoring using Siemens RMS and UTMC Systems

The UPS Solution’s fault / alarm relay contacts can be used to send indications back to
the central office Instation via an OTU or OMU6. The following are the recommended
naming conventions for bit and possible connection scenarios.

Bit Description
ONBAT (C1) On Battery support. UPS is in inverter mode. Site mains is off
Usually HLD WARN (C4) below is recommended for this
purpose.
LOWB1 (C2) Low Battery Warning 1 – Urgent indication that the UPS is
approaching its maximum support time and action should now
be taken to either provide additional support or take other
action (suitable site signing etc).
HLD WARN (C4) Hold Up Warning. Triggered from the Timer alarm (5
minutes), Urgent indication that the UPS is powering the load
(Avoids nuisance reports when short mains breaks occur).
UPS ALRM (C5) UPS Alarm. Urgent – There is a fault with the UPS. Site visit
or remote investigation required.
Table 12-3: RMS Bit Labelling and Description
Example Scenario:
The LOWB1 (C2) contact can be used in two ways. The first is as an indication to the
controller that the UPS has been running on battery power for some time, allowing
special conditions or similar controller logic to perhaps dim lights or put the junction into a
flashing state to prolong support.

NOTE: Customers should decide on a site by site basis if the use of dimmed
signals during the day is acceptable.

The second would be to pass this back through an OTU or OMU to a central office
Instation to warn that the UPS has used more than half of its back up supply.

All contacts6 can either be passed through the controller (i.e. controller input to output to
OTU/OMU input to Instation) or may be connected directly to the OTU/OMU inputs for
forwarding to the central office Instation.

Review the controller and any OTU/OMU configurations supplied by the customer to
determine the connections that need to be made.

Figure 12-1: Fault Monitoring Connectivity Example

6
C6 is not to be used with Siemens traffic Equipment. See section 12.2.1
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12.3 Communicating with the UPS Solution

12.3.1 Three-Button Interface

The Alpha FXM UPS unit includes a simple three-button button interface and LCD display
for basic system interrogation while present on site.

Using the three buttons, CANCEL, SCROLL and SELECT, it is possible to access the
following menus:

Control Menu - Control, program and adjust a limited number of system

options including forcing the UPS unit into ‘INVERTER’
mode.

System Status Menu - Measure various inputs, outputs and related system values
including the current battery voltage and estimated support
time available.

Alarm and Fault - Disabled unless the UPS unit has a fault, these menus
display and fault or alarm flags that are currently active.

Event Status Menu - Allows the user to scroll through the last 25 items listed in the
UPS units 100-event log.

For details on all the options available within these menus, please refer to the Alpha FXM
UPS Operating Manual – 667/HB/47760/000.

Access to many more system settings can only be achieved through the RS232 or LAN
interfaces as described in sections 12.3.2 and 12.3.3.

12.3.2 RS232 Interface

The Alpha FXM UPS unit’s RS232 interface can be accessed via the female 9-way D-
type connector on the unit itself. Table 12-4 below lists the necessary connection details.

Connection Parameters Required Setting

Duplex Mode Half Duplex
Handshaking Software Handshaking
Baud Rate 2400 bps
Data Format 8-bit Data, No Parity, 1 Stop Bit, No Flow Control
Default Password 1111

Table 12-4: RS232 Interface Connection Information

The RS232 Interface’s main menu screen gives the user access to four main subsections
as well as displaying status and fault / alarm information in the following format.

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Figure 12-2: Alpha FXM Series UPS RS232 Interface Screenshot

Submenus 1, 2 and 4 are read-only and are used to view snapshots of input and output
measurements (the RS232 interface does not auto-refresh) and Factory configured unit
specification information.

The Maintenance submenu allows the user to adjust a limited number of UPS settings
including changing the connection password and switching systems timers on or off.

NOTE: The connection password applies to all UPS communication interfaces

described in section 12.3.

Special command prompts can be entered directly into the RS232 interface to configure
more specific UPS settings such as reprogramming and reconfiguring the six relay
contacts or viewing the 100-event log. Details of all available commands are available
within the Alpha FXM UPS Operating Manual – 667/HB/47760/000.

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12.3.3 LAN Interface

The UPS Solution’s LAN interface can be accessed via the Alpha FXM UPS unit’s
embedded SNMP (LAN) card using the RJ45 socket on the unit itself. If the solution’s
Ethernet Cable is fitted and a TCP/IP based network connection is available within the
traffic controller, the LAN interface can be accessed remotely from any other active
network device.

To connect to the LAN interface, type the Alpha FXM UPS unit’s IP address into a web
browser. Individual unit’s IP addresses can be configured to match networking required.
The default IP address and password for all UPS units are shown in Table 12-5.

Connection Parameters Default Settings

IP Address 192.168.0.90
Password 1111

Table 12-5: LAN Interface Connection Information

NOTE: The connection password applies to all UPS communication interfaces
described in section 12.3.

Connecting to the LAN interface presents the user with a simple GUI that gives access to
the greatest number of system settings and configurations under the following top level
page menu.

UPS Specification
UPS Monitoring
UPS Maintenance
Event Manager
Upgrade Files
Configure Site Information
Communications
Keep Alive

The UPS Solution’s operating mode and fault / alarm flags are always displayed at the
top of each page for easy system monitoring.

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Figure 12-3: LAN Interface Screenshot – Relay Contact Configuration

NOTE: A similar, though slightly restricted GUI can be used with the UPS
Solution via the use of the Alpha UPS Monitor software package, available for
7
free download from the Alpha Technologies website .

In depth information on the use of the Alpha UPS Monitor Software and the LAN interface
GUI is available within the Alpha FXM UPS Operating Manual – 667/HB/47760/000.

7
http://www.alpha.ca/web2/service-and-support/support/software-firmware-downloads
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12.4 Battery Charging

The Alpha FXM UPS unit has four specific has four specific modes for battery charging
that are automatically cycled according to the battery pack voltage and State of Charge.
These are described below.

NOTE: All values given in the descriptions below apply to a UPS Solution
operating at an ambient temperature of 25°C. See section 12.5.2 for details on
temperature compensated battery charging.

Bulk Charging - Used to recharge the batteries after discharge. The

charger within the FXM UPS unit operates in constant
current mode with an upper limit of 10Amps. The target
battery voltage is set to 54Vdc (2.25V per cell). The battery
voltage rises steadily as the batteries charge. As the battery
voltage approaches its target voltage value, the current
drawn starts to decrease. The charger voltage is then held at
54Vdc and the charger moves into Absorption mode.

Absorption - Used to complete the final stage of battery recharge. The

charger is now in constant voltage mode and holds the
battery voltage at 54Vdc. The battery pack is allowed to draw
current based on its capacity and chemistry. The current
drawn continues to decreases as the battery charges.

Float - Used to maintain fully charged batteries. As the battery

pack nears full charge, the current drawn drops to roughly
1A. The battery voltage is held at 54Vdc. If the current drawn
is roughly 1A or less for 10 to 20 minutes, the FXM UPS
Unit’s battery charger moves to the next state.

Charger Off - Used to monitor the battery pack and check for any
faults. The battery charger switches itself off on leaving Float
mode. If the battery pack is bad or faulty, its voltage will drop
rapidly and the FXM UPS unit’s ‘Bad Battery’ alarm is
triggered. If the battery pack is in good condition, the battery
voltage will drop slowly. When the battery voltage drops to
52.6Vdc, the charger switches back on and enters Bulk
Charging mode.

Figure 12-4 displays the battery charging cycle in terms of voltage and charging current.

WARNING: Even with no battery packs connected, if mains power is available

a voltage of 32Vdc is normally present at the Alpha FXM UPS Unit’s battery
terminals. This is voltage is periodically raised to 56Vdc or above as the UPS
unit looks for a battery connection.

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Figure 12-4: Battery Charging Cycle

12.5 Temperature De-Rating

WARNING: For the majority of UK installations, it is reasonable to assume a
worst case cabinet temperature range of 0°C to 65°C.The UPS Solution must
be derated to at least these values to help ensure correct operation.

12.5.1 Power output

The Alpha FXM1100 and FXM2000 UPS units offer a maximum power output of 1100VA
and 2000VA respectively. See section 4.1. In high ambient temperatures, the maximum
power available decreases as the FXM UPS units reach the limits of their operating
range.

The FXM1100 UPS unit is de-rated by 1.25% for every degree above 55°C. The
FXM2000 UPS unit is de-rated by 1.0% for every degree above 50°C. Table 12-6 below
gives specific figures showing how this affects the maximum power output available.

Ambient
FXM1100 Max. O/P FXM2000 Max. O/P
Temperature
-40°C 1100 W/VA 2000 W/VA
0°C 1100 W/VA 2000 W/VA
25°C 1100 W/VA 2000 W/VA
50°C 1100 W/VA 2000 W/VA
55°C 1100 W/VA 1900 W/VA
60°C 1031.25 W/VA 1800 W/VA
65°C (UK worst case) 962.5 W/VA 1700 W/VA
70°C 893.75 W/VA 1600 W/VA
74°C 838.75 W/VA 1520 W/VA
Table 12-6: Maximum Output Power against Ambient Temperature
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12.5.2 Battery Charging

The UPS Solution offers temperature compensated battery charging to help keep all
battery packs in optimum condition across its extended operating ambient temperature
range. The battery charging voltage is adjusted by -5.0mV/°C/cell.

12.5.3 Battery Support Hold Up Times

Ambient temperature plays a big part in determining how much a battery support hold up
time is available. As temperature decreases, the available capacity of each battery pack
is reduced as battery chemistry becomes increasingly inert. This becomes very apparent
and extremely low ambient temperatures.

APPENDIX A – Estimated Hold Up Times shows battery hold up runtime charts (such as
in section 5) adjusted for ambient cabinet temperatures of +20°C, 0°C and -25°C.

12.6 Generators

12.6.1 The Generator Connect Feeder Pillar

As stated in section 2.4, a diesel generator must be connected via the Siemens
Generator Connect Feeder Pillar as shown below.

Figure 5: Generator Connect Feeder Pillar

This feeder pillar variant incorporates a lockable cable entry point, a 2P+E8 IP44 rated
appliance inlet connector and a 63A double-pole changeover switch for isolation and
source selection.

Detailed information on the Generator Connect Feeder Pillar is available in the Isolators
and Feeder Pillar General Handbook – 667/HB/45040/000.

8
Two Pole and Earth
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12.6.2 Generator Selection

Generators to be used with the Siemens UPS solution must adhere to the following
conditions.

WARNING: Using a Generator that does not meet all the conditions below is a
major safety risk and may also cause permanent damage to the UPS solution.

The generator:

Must have an output rating not exceeding 7.4kVA but at least double that of the
FXM UPS unit fitted within the UPS solution.
o Suggest 3kVA for the FXM1100
o Suggest 6kVA for the FXM2000

Must be 230V single phase.

Must be fitted with a link between Neutral and Earth (i.e. not floating earth).

12.6.3 Protection and Reference Earthing

In all cases, all generator outlets must be protected by 30mA RCDs.

Additional reference earthing is not required if all three of the following statements are
true for the site:

The controller is ELV.

There are no other metallic items within touching distance (2m) of the generator,
feeder pillar, UPS solution, controller cabinet or any other part of the traffic
installation including all signal columns.

The generator will be connected for no more than 24 hours.

If one or more of the above statements does not apply, the generator must be provided
with a dedicated earth electrode, such as an earth spike, for reference earthing.

Earth electrodes should have a resistance less than 200 OHMS.

NOTE: Earth electrodes cannot be tested with an earth fault loop impedance
tester as they do not actually form part of the fault path. A priority earth
electrode tester must be used instead.

Where it is impossible to install an earth electrode, it is acceptable to bond the main earth
terminal of the generator to simultaneously accessible metallic items that do not form part
of the traffic signal installation (i.e. a lamp column and/or guard rail). An earth wire with a
cross-sectional area no less than 16mm2 should be used for this bond.

12.6.4 Connecting and Removing a Generator

To connect a suitable generator to the UPS solution:

1. Ensure the generator is off and not energised.

2. Install and connect an earth electrode if required.

3. Open the Generator Connect Feeder Pillar locate the changeover switch.

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Figure 6: Three-position Changeover Switch

4. Connect the generator to the appliance inlet directly below the switch.

5. Switch the changeover switch to OFF.

6. Start the Generator and allow at least 10 seconds for its output to settle.

7. Switch the changeover switch to GEN.

8. Feed the connecting cable through the cable entry slot in the pillar door then
close and lock the Generator Connect Feeder Pillar.

NOTE: The UPS solution should now be in LINE mode, using the generator
power in the place of the mains supply. See section 12.1 for more information
on operating modes.

To disconnect a generator from the UPS solution:

1. Open the Generator Connect Feeder Pillar and locate the changeover switch.

2. Switch the changeover switch to OFF and wait 5 seconds.

3. Switch the changeover switch to MAINS.

4. Switch off the generator and allow at least 10 seconds for it to de-energise.

5. Disconnect the generator from the appliance inlet within the pillar.

6. Remove the connecting cable then close and lock the pillar.

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13 Maintenance
This section gives a brief description of some key maintenance routines necessary for
upkeep of the UPS Solution. For detailed information see the UPS Method Statement
and hardware operating manuals listed in section 1.2.

WARNING: Ensure the safety information at the beginning of this document

before beginning any maintenance procedures

13.1 Periodic inspection

Note any faults or alarms flagged by the Alpha FXM UPS unit. Clear faults and alarms
wherever possible in accordance with UPS Operating Manual – 667/HB/47760/000.
Report ALL faults and alarms to Line Manager.

Switch off mains supply during at the beginning of normal junction periodic inspection.
Observe the battery voltage via the UPS 3-button interface. Wait for voltage to settle and
note. Also note time.

Carry out junction periodic inspection as normal. Refer to 667/HA/45950/000 for details.

Observe the battery voltage. Note alongside the time.

Restore the mains supply

Note down other key figures from the UPS unit including:
Number of mains failures
Cumulative inverter time
Cumulative kWh output
Estimated battery support

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Check the individual Battery Voltages:

For each Battery Shelf:

1. Switch the Breaker on the Battery Shelf (Battery Housing Assembly) to the OFF
position

2. On each Battery (four per shelf) measure the voltage between the Positive and
Negative Terminals (there is no need to remove the linking bars). Note these
voltages on the PI sheet.
3. Switch the Breaker on the Battery Shelf back to the ON position

When all shelves are complete, please check that all of the Battery Breakers are set back
to the ON Position

13.2 Maintenance Bypass Switching

The Maintenance Bypass feature allows maintenance personnel to connect the controller
load directly to the mains supply from the site feeder pillar via the Alpha UATS bypassing
the FXM UPS unit and its connected battery packs. See section 10 for isolation switch
information.

Flip SW1 on the UATS from ‘UPS’ to ‘BYPASS’ to instantly set the UPS Solution to
Bypass mode. The controller load will not experience a break in power.

WARNING: When set to Bypass in this fashion, mains powers is still being
used by the UPS unit to charge connected battery packs and all terminals
directly connected to the UPS unit are live. To isolate and switch off the UPS
unit, see section 13.3.

NOTE: Use of the BYPASS Switch may cause the attached control equipment
to restart, it should only be used when replacement of the FXM unit is required
(Please see Section 13.4.3).

See section 4.2 for more information on the UATS.

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13.3 Switching Off the UPS Solution

WARNING: This will stop all equipment connected to the UPS from being
supplied Mains power. Ensure all traffic control equipment is safely
switched off before switching off the UPS.

To switch off the UPS completely, follow these steps (see section 10 for isolation switch
information):

1. Switch the UATS to BYPASS

2. Switch all Breakers on the Battery Shelves (Battery Housing Assemblies) in both
cabinets (UPS and Battery Expansion Cabinets) to the OFF position
3. Switch the Battery Breaker on the Front left of the FXM UPS unit to the OFF
position
4. Switch the UPS Supply Breaker (CB1) on the front of the UATS to the OFF
position
5. Switch OFF the Input Circuit Breaker on the front right of the FXM unit
6. Unplug the 48V Battery Connector from the front (left) of the FXM unit to
disconnect the battery circuits completely.
7. Switch OFF the Main Breaker on the UPS Connection Panel (at the top of the
rack)
8. Open the Feeder Pillar and Isolate the UPS Cabinet

The UPS Solution will now be completely isolated from Mains and Batteries.

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13.4 First Line Maintenance

13.4.1 Replacing the Alpha FXM UPS unit

The following Steps can be carried out to replace a faulty Alpha FXM unit while still
supplying Mains Power to the Traffic Control Equipment. If it’s not necessary to keep the
Traffic Control Equipment Energised, please follow section 13.3 to fully isolate the UPS
Solution before following steps 7 onwards below. See section 10 for isolation switch
information.

THESE INSTRUCTIONS NEED TO BE FOLLOWED CAREFULLY, FAILURE

TO DO SO MAY RESULT IN ELECTRIC SHOCK.

1. Switch the UATS to BYPASS (the Junction will now only run from the Mains
Supply)
2. Switch all Breakers on the Battery Shelves (Battery Housing Assemblies) in both
cabinets (UPS and Battery Expansion Cabinets) to the OFF position
3. Switch the Battery Breaker on the Front left of the Alpha FXM UPS unit to the
OFF position
4. Switch the UPS Supply Breaker (CB1) on the front of the UATS to the OFF
position
5. Switch OFF the Input Circuit Breaker on the front right of the FXM unit
6. Unplug the 48V Battery Connector from the front (left) of the FXM unit to
disconnect the battery circuits completely.
7. Remove the covers from the Mains Input and output cables on the front right of
the FXM unit
8. Using a Multi Meter set to AC (check it’s working using the mains supply in
the UPS Connection Panel), check that both the input and output cable
looms are no longer energised.
9. Remove both Input and output cable looms labelling them so you know where
they came from. Use Insulation tape to cover the ends of the cables
10. Unplug the alarm cable looms C1 – C6 and the Battery Temperature Sensor
11. The FXM Unit can now be removed from the 19” Rack.

12. Install the Replacement FXM unit, Switching OFF the Input Circuit Breaker AND
the Battery Circuit Breaker.
13. Plug alarm cable looms C1 – C6 into the FXM unit
14. Reconnect the Input and Output Mains Looms onto the FXM Unit, Replace the
Covers.
15. Plug the Battery Temperature Sensor into the FXM unit
16. Plug The 48V Battery Connector into the FXM unit
17. Switch all Breakers on the Battery Shelves (Battery Housing Assemblies) in both
cabinets (UPS and Battery Expansion Cabinets) to the ON position
18. Switch ON the Input Circuit Breaker on the front right of the FXM unit
19. Switch ON the Battery Breaker on the front left of the FXM unit
20. Switch the UPS Supply Breaker (CB1) on the front of the UATS to the ON
position
21. Switch the UATS to UPS
22. Check the UPS goes into LINE mode and check the alarms.

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13.4.2 Replacing a Battery Pack

If a Battery in a Battery Pack (string) has been found to be faulty, all four batteries in that
pack will need to be replaced together. Follow the Instructions below to safely replace a
battery pack. See section 10 for isolation switch information.

WARNING: All battery safety information must be read and understood before
installation of the batteries begins. Refer to the safety information at the
beginning of this document.

WARNING: Use the insulated spanner when adjusting battery terminal fixings.
Terminals should not be exposed for extended periods. Replace the terminal
covers whenever possible. This reduces the risk of an accidental short-circuit.

WARNING: Batteries must NOT be shorted to earth at any time, Risk of

explosion and/or burning due to High Current. Do not attempt this process
without the correct 1000V Insulated Spanner.

Before Disconnecting the Battery Pack:

1. Switch all Breakers on the Battery Shelves (Battery Housing Assemblies) in both
cabinets (UPS and Battery Expansion Cabinets) to the OFF position
2. Switch the Battery Breaker on the Front left of the Alpha FXM UPS unit to the
OFF position
3. Unplug the 48V Battery Connector from the front (left) of the FXM unit to
disconnect the battery circuits completely.

Removing the Battery Pack:

1. Remove the Brown cable form the +ve (right hand side) of the Battery Pack,
insulate the ring crimp using electrical tape.
2. Remove all three linking bars from between the batteries in the pack.
3. Lower the battery retention bar of the Battery Housing module.
4. Remove the three batteries from right to left leaving the furthest left battery until
last
5. Remove the Grey –ve cable form the final battery
6. Remove the last Battery from the Battery Housing Assembly

Install the new batteries:

1. Slide Battery 1 into the housing.

2. Connect the negative ring tag from the housing’s MCB to the negative terminal
on Battery 1. (grey cable)

NOTE: All battery terminals are to be made hand tight. DO NOT

OVERTIGHTEN as battery terminals can be easily damaged.

3. Slide Battery 2 into the housing. Connect the positive of Battery 1 to the negative
of Battery 2 using the terminal linking bar provided.

NOTE: When fitting batteries in the Battery Housing module directly below the
UPS Housing module, the Battery Temperature sensor is to be fitted as this
stage. Refer to section 9.12 before completing the following instructions.

4. Repeat this last step with Batteries 3 and 4.

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Figure 13-1: Battery Terminals Connected with the Terminal Linking Bar

5. Connect the positive ring tag from the housing MCB to the positive terminal of
Battery 4. (brown cable)

6. Replace the battery retention bar.

After Replacing the Battery Pack:

1. Plug the 48V Battery Connector back into the FXM Unit
2. Switch all Breakers on the Battery Shelves (Battery Housing Assemblies) in both
cabinets (UPS and Battery Expansion Cabinets) to the ON position
3. Switch the Battery Breaker on the Front left of the Alpha FXM UPS unit to the ON
position

Finally check that there are no alarms active on the UPS and that the UPS is in Line
mode.

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13.4.3 Replacing an Alpha UATS unit

The UPS Cabinet needs to be Isolated before carrying out any work on the UATS or UPS
connection shelves. Please Isolate the cabinet by following the instructions in Section
13.3

Once the Cabinet is Isolated and the UPS is completely switched off, the following steps
can be followed:

1. Test the input and output terminals to ensure that the unit is completely isolated
from Mains and UPS

2. Remove the Covers from both sides of the UATS Shelf

3. Remove the four cable looms from the UATS, ensuring that you know where they
came from.
4. Replace the UATS Shelf
5. Wire the Cable looms into the replacement UATS and replace all of the covers.
6. Switch the UPS back on and check that it’s working properly.

13.5 Second Line Maintenance

It is recommended that undamaged parts are reused where possible.

All other parts must be sent for repair or disposal. Further details are held in the ‘Global
Service Support Plan (ref. 667/PA/47750/000).

NOTE: Observe Anti-static Precautions at all times.

Faulty parts being returned must always be sent back in the original packaging if
available or in an approved anti-static packaging, along with a fully completed fault label,
to;

Logistics Spares Returns Centre

Siemens Mobility,
Traffic Solutions,
Coalfield Way,
Ashby Park,
Ashby de la Zouch,
LE65 1JD

Any queries should be directed to the Service Logistics Manager on (01530) 258181.

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14 Disposal
14.1 Under Maintenance Contract
All items that have been replaced under a maintenance contract are sent back for
replacement. The items will either be sent to the OEM or Registered Distributor for
repair/replacement/disposal.

All Traffic Solutions, Siemens depots operates an Environmental Management System

(EMS).

In accordance with its Environmental Policy Siemens applies the Waste Hierarchy
when managing waste, segregating waste into a number of waste streams to optimise
the re-use/recycling carried out by the approved waste contractors that take the waste
away.

14.2 End of Life and Scrapping

End of life items and items involved in RTAs will normally be disposed of locally. In this
situation the local depot will dispose of all elements under the local EMS policy.

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15 Part Numbers / Spares List

15.1 Hardware Spares
Part Number Description
667/7/47760/110 Alpha FXM1100 UPS unit
667/7/47760/200 Alpha FXM2000 UPS unit
667/7/47761/000 Alpha UATS
667/6/47754/000 Lead Crystal Battery 4 pack

15.2 Housing Modules

Part Number Description
667/6/47780/000 Battery Housing Assembly
667/6/47781/110 1100VA UPS Housing Assembly
667/6/47781/200 2000VA UPS Housing Assembly
667/6/47782/000 DC Housing Assembly

15.3 Outer Case and Stool

Part Number Description
667/6/47784/000 Vented Cabinet Outer Case - Grey
667/6/47784/500 Vented Cabinet Outer Case - Black
667/6/47785/000 Reinforced Cabinet Stool - Grey
667/6/47785/500 Reinforced Cabinet Stool - Black

15.4 Connection Panel and MCB Spares

Part Number Description
667/7/47762/000 20A Mains MCB
667/7/47762/002 63A Battery MCB

667/7/47763/000 DIN Rail Terminal Block 2.5mm2 BEIGE

667/7/47763/100 DIN Rail Terminal Block 6.0mm2 BEIGE
667/7/47763/110 DIN Rail Terminal Block 6.0mm2 GREEN/YELLOW
667/7/47763/200 DIN Rail Terminal Block 10.0mm2 BEIGE
667/7/47763/500 DIN Rail End Bracket

15.5 Connection Accessories

Part Number Description
531/4/04012/000 RJ45 Connector Jack

15.6 Generator Connect Feeder Pillar

Part Number Description
667/7/45043/000 Generator Connect Feeder Pillar – GALVANIZED
667/7/45043/100 Generator Connect Feeder Pillar – GREY
667/7/45043/200 Generator Connect Feeder Pillar – BLACK

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APPENDIX A – Estimated Hold Up Times

Figure A-1: Estimates of UPS Solution Performance at +20°C

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Figure A-2: Estimates of UPS Solution Performance at 0°C

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Figure A-3: Estimates of UPS Solution Performance at -25°C

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APPENDIX B – FXM UPS Faults and Alarms

Table B-1 below lists all the faults and alarms associated with the Alpha FXM UPS unit.

The relay UPS unit’s ‘Alarm’ contact C5, by default, will trigger when any of the faults or
alarms listed in Table B-1 occur.

Any one of the Faults listed will cause the FXM UPS unit to cease operation.

Alarms do not affect UPS operation but give warnings that a fault may be imminent.

Name Description
Faults:
Short_Circuit The load (controller) has a short
Vout_Hi The output voltage is above unit specifications
Batt_Hi Battery packs cannot be charged
Batt_Lo Battery over-discharge threshold reached
Vout_Lo The output voltage is below specification
Overload The UPS unit is overloaded. Switch off excess loads
Backfeed A relay inside the UPS unit has failed causing a backfeed risk
Bad_Battery Battery pack voltage is extremely low
Temp_Hi The UPS Unit is operating above its internal temperature range
Alarms:
Overload The UPS unit is overloaded. Switch off excess loads
Temp_Hi The ambient battery temperature is too high
Temp_Lo The ambient battery temperature is too low
9
User_Input The user input contact “User Input: S2” is shorted
Line_Freq The line frequency is outside the UPS unit’s input specification
No_Temp_Probe The Battery Temperature Sensor is disconnected or has failed10
Weak_Battery Battery pack has failed the background scan in Line mode9
Batt_Low Battery pack voltage is low11
12
Batt_Brkr_Open The UPS unit’s Battery Breaker is open
Self_Test The UPS Unit is performing a self test
Fan_Fail The UPS unit’s internal fan has failed
Wrong_Softwre The Alpha UPS Monitor software package is invalid13
AC_Brkr_Open The UPS unit’s Input Circuit Breaker is open
Table B-1: FXM UPS Unit Fault and Alarms

9
Refer to 667/HB/47760/000
10
See sections 8.1 and 9.12 for details on the Battery Temperature Sensor
11
Default value of 47V relating to 40% SOC. Triggers C1. See section 12.2.1
12
See section 10.3
13
See section 12.3.3
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Sopers Lane, Poole, Dorset
BH17 7ER

APPENDIX C – Hardware Datasheets

Alpha FXM Series UPS Unit

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BH17 7ER

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BH17 7ER

Alpha Universal Automatic Transfer Switch (UATS)

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BH17 7ER

Betta Batteries 6CNFT-55 12V 55Ah Front Terminal Lead Crystal Battery

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BH17 7ER

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Sopers Lane, Poole, Dorset
BH17 7ER

APPENDIX D – UPS Commissioning Certificate

Siemens UPS Solution Commissioning Checklist
Name and address of client Installation address

Postcode Postcode
UPS Unit model Alpha FXM1100 Alpha FXM2000
At-a-glance Settings
STEP ACTIVITY PASS/Yes FAIL/No
1. Electrical Safety Tests completed and results recorded as
per TS Traffic Installation Testing Document
(667/HE/20664/000)? See section 11.1
2. UPS Solution set to BYPASS? See section 11.2
3. Traffic Controller commissioned correctly? See section 11.3
4. UPS Solution start up: See section 11.4
a. Display reads ‘STANDBY’ when Battery Breaker
switched ON?
b. Display reads ‘LINE’ when UPS Supply Breaker and
Input Circuit Breaker switched ON?
c. Traffic signals remain lit as normal when Manual
Bypass Switch switched to UPS?
d. STATUS LED is solid green?
e. ALARM LED is off?
5. Battery Support testing: See section 11.5
a. Display reads ‘INVERTER’ when Mains Input MCB
switched OFF?
b. STATUS LED is flashing green?
c. Traffic signals remain lit as normal?
d. Display reads ‘RETRAN’ then ‘LINE’ when Mains
Input MCB switched ON?
e. Traffic signals remain lit as normal?

Name (Print) .

Signature ..

Date carried out .. .

One copy of this form to be left with the client and one copy retained by Siemens

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