UPS Systems Solutions

High-reliability power electronics for uninterruptible power systems

Reliable Solutions for Critical Power Protection

Uninterruptible power supply applications demand exceptional reliability, efficiency, and fast response to power disturbances. Semikron's UPS solutions are designed to provide continuous power protection for critical loads in data centers, hospitals, telecommunications, and manufacturing facilities. Our components address the specific requirements of various UPS topologies including on-line double conversion, line interactive, and standby systems. With extensive experience in UPS applications, we provide complete solutions from thyristor-based static bypass systems to high-frequency IGBT inverter stages. Our products are engineered to handle the continuous operation, switching stress, and thermal cycling common in UPS applications, ensuring maximum uptime for critical systems.

Maximum Reliability

Components designed for 24/7 operation with long MTBF

Fast Response

Rapid switchover for power protection

Versatile Topologies

Solutions for all common UPS configurations

UPS System Architecture

Typical power electronics configuration for UPS applications

UPS System Diagram

Rectifier Stage

The input rectifier converts AC line power to DC for the inverter and battery charger. For higher efficiency, active rectifier topologies with power factor correction may be implemented using IGBT modules. The rectifier must handle line voltage variations and provide stable DC power.

DC/AC Inverter

The DC/AC inverter converts battery or rectifier DC power to clean AC output power. This stage must provide precise voltage regulation, fast transient response, and low total harmonic distortion (THD) to meet critical load requirements.

Static Bypass

The static bypass provides immediate transfer to utility power during inverter malfunction. This is typically implemented with thyristors for high reliability and fast switching capability. The bypass must seamlessly transfer without interruption to critical loads.

Key Requirements

  • Continuous 24/7 operation with high reliability
  • Fast response to power disturbances (within 4-10ms)
  • Low THD for clean power output to sensitive loads
  • High efficiency to minimize operating costs

Technical Considerations

Key factors for UPS electronics design

Reliability and MTBF

UPS systems must operate continuously with minimal failure probability. Power semiconductors must be conservatively rated and derated for long-term reliability. Semikron's components are designed with robust process technology and validated for extended life under continuous operation.

Efficiency Optimization

UPS systems operate continuously, making efficiency critical for operating costs. The power semiconductors must maintain high efficiency across various load conditions, from light loads during low-demand periods to full loads during peak operation.

Fast Switching Response

UPS systems must respond rapidly to power disturbances. Semikron's thyristors provide fast, reliable switching for static bypass applications, while IGBTs offer fast control for inverter stages. Fast response is critical to maintain power quality for sensitive loads.

Thermal Management

Continuous operation requires effective thermal management to maintain semiconductor junction temperatures within safe limits. The thermal design must account for both steady-state operation and overload conditions while maintaining system reliability.

Application Notes

Technical resources for UPS designs

Case Study: Data Center UPS System

Implementation of Semikron solutions in critical power infrastructure

Challenge

The data center required high-efficiency UPS systems to support critical computing infrastructure with 99.999% availability (5.26 minutes of downtime per year). The system needed to handle high power density loads with minimal space and operating costs.

Solution

Semikron SEMiX modules were selected for their high efficiency and reliability in the inverter stage. SEMIPACK thyristors were used for static bypass applications to provide fast, reliable switchover capability.

Results

The installation achieved 96.5% efficiency at 50% load and 97.2% at 100% load. Over three years of operation, there were zero power semiconductor failures, contributing to the required availability target.

Bill of Materials

Essential components for UPS power systems

Main Power Modules

  • SEMIPACK 4 1200V/400A
  • SEMiX 1200V/200A Phase Leg
  • SEMiX 1700V/150A Phase Leg

Driver Solutions

  • SKYPER 17/12
  • Thyristor gate drives
  • Isolated power supplies

Support Components

  • DC-link film capacitors
  • EMI filters
  • Control boards

Thermal Management

  • Aluminum heatsinks
  • Thermal interface materials
  • Cooling fans with redundancy

FAE Technical Commentary

Expert insights on UPS applications

For static bypass applications, we recommend SEMIPACK thyristors with their proven reliability and fast switching capability. The thyristor's latching behavior provides robust bypass operation without the need for continuous gate drive during conduction.

When designing for high efficiency, utilize Semikron's latest IGBT technology with optimized VCEsat and switching characteristics. The balance between conduction and switching losses is particularly important for UPS systems that operate continuously at partial load.

For critical applications, implement redundant power semiconductors in parallel for N+1 reliability. Semikron's components are well-matched for parallel operation, simplifying redundant system design.

Additional Resources

Comprehensive documentation for UPS designs

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