Industrial-grade uninterruptible power supplies (UPSs) provide reliable power protection for many applications, including oil and gas, public infrastructure, automation, and manufacturing. UPS systems provide consistent power and protect electronics and microprocessors from power-related damage. No matter what your power needs look like or how demanding your environment is, an industrial UPS can keep your equipment running during anything from momentary brownouts to full-on power outages.
We often get asked about the difference between industrial models and more typical off-the-shelf UPSes. Industrial UPS systems are more expensive, so customers rightly wonder whether the investment is worthwhile.
The short answer is yes: if you’re responsible for industrial, outdoor, or high-priority sites, then you need to protect equipment and systems with an industrial UPS to increase reliability.
Key Takeaways
- An industrial uninterruptible power supply (UPS) system delivers continuous, regulated power protection designed for harsh environments where standard UPS units fail.
- True online double-conversion technology ensures zero transfer time and isolates sensitive equipment from voltage fluctuations, surges, harmonics, and dirty power.
- Industrial UPS power supplies are engineered for extreme operating conditions, with models rated from –30°C to +65°C, making them suitable for outdoor and mission-critical applications.
- Battery reliability is significantly higher, with industrial UPS systems using 10–12 year rated batteries or LiFePO4 technology for extended lifespan and superior performance under temperature stress.
- Using a standard UPS in industrial settings increases the risk of premature failure, equipment damage, and costly downtime.
- Westward Sales supplies Falcon Electric and CyberPower industrial UPS systems ranging from 500 VA to 10,000 VA for high-performance industrial power protection.
Primary Differences Between a Typical UPS and Industrial UPS Systems
“Industrial grade” sometimes gets tossed around as a buzzword, but that isn’t the case in the technology sector. Here, there’s a significant difference between standard devices (whether consumer or business) and rugged hardware built for heavy industry.
This difference is pronounced when comparing the typical industrial uninterruptible power supply with your average model. You’ll find plenty of differences — ones that matter in the kinds of industrial settings we support.
1. Standby vs. Online
Basic UPS systems operate on a standby basis: they kick in when the power kicks off. In general, this is precisely what a UPS is supposed to do — but it isn’t enough for many industrial and high-tech settings. The day-to-day fluctuations in utility power, not to mention the more notable ones during power outages, brownouts, and other events, can be enough to degrade performance or even damage certain devices and components.
A line-interactive UPS is a more advanced non-industrial system that essentially monitors brownout conditions, stepping in to supply steady power when it detects a dip, not just a complete power loss. This technology is a step in the right direction, but it still isn’t enough for demanding and mission-critical applications.
An industrial UPS system typically operates online, and the best ones (like the ones we carry) use something called dual-conversion or double-conversion. It means that the UPS is constantly operating, receiving utility power (with all its fluctuations and imperfections) and outputting clean, regulated sine wave power.
In a dual-conversion design, the AC is converted to DC and then back to AC. This method regenerates a perfect AC sine wave output regardless of the AC input power characteristics. This method provides high power quality and isolates the load from irregularities on the primary power input. Should the primary power source fail, the batteries feed the load with no interruption (zero transfer time). The SSG1.5KRM is an example of a 1.5 kVA dual-conversion UPS that supports 120 and 240 VAC.
2. Temperature and Environmental Resistance
Most UPS systems are designed for use indoors, in temperature-controlled spaces. They aren’t rated for exceptionally high or low temperatures, and they don’t carry any ratings for water or dust resistance.
Using a typical UPS in harsh environments can quickly lead to device failure, leaving all downstream hardware unprotected and unpowered.
An industrial UPS power supply is built to withstand harsh environments and a wider range of temperatures. These units will be rated for more extended temperature ranges and operating conditions. For example, the Falcon SSG2.5KRP UPS carries an ultra-wide operational temperature range of at least -30°C to 65°C (-22°F to 149°F). Some UPSes, with 10-year rated batteries, can withstand even greater extremes. This temperature range includes all components within the industrial UPS, including the enclosure, backup batteries, and electronics.
3. Battery Type and Unit Lifespan
Standard UPSes use valve-regulated lead-acid batteries (VRLA) that are rated for 5 years of life — but only if consistently operated at 77°F.
High-performing industrial UPS units utilize batteries designed to operate at wider temperature ranges. These are rated at 10 or 12 years at 77°F. The Falcon SSG series industrial UPS utilizes newer and more reliable battery technology, specifically lithium-iron-phosphate (LiFePO4).
With batteries that last longer and controllers built to withstand the rigors of industrial use, industrial UPS models can operate twice as long or more, saving time and money on component and unit replacements.
The Risks of Using Standard UPS in Industrial Situations
Standard UPS units are common, inexpensive, and readily available. So, it’s no surprise that some businesses are using what they have, even if it isn’t built for the job.
But using a standard-grade UPS in industrial situations is risky. These units were never designed to operate outside or in non-temperature-controlled spaces, so they are vulnerable to early failure due to heat, cold, or environmental contaminants.
Standard-grade devices are also almost always standby units, offering the lowest level of protection and performance. This technology is insufficient to keep high-value, sensitive components running smoothly and free from damage. Standard units offer minimal help with cleaning up “dirty” power, and they don’t kick in until power is lost.
Selected Model Recommendations
With a wide range of devices, configurations, and specifications, we can supply you with the industrial UPSes you need to keep your systems safe and secure.
Falcon Precision Voltage Regulators
This series of active solid-state generators takes the concept of a power conditioner to the next level. These units accept a wide input voltage range and output ultra-precise AC power. These SVR Pro and PL models offer battery backup capability as an optional feature.
- SVRP1.5KRM, (1.5 kVA)
- SVRP2.2KRM, (2.2 kVA)
- SVRPL1KRM, (1 kVA with ultra-high operating temperature)
Falcon SSG UPSes
These powerful industrial UPS units provide true online UPS support with long life at wide and ultra-wide temperature ranges. Integrated XTV VRLA batteries are designed to withstand high temperatures, lasting eight times longer in extreme heat compared to conventional batteries. Optional LiFePO4 batteries provide even stronger performance, offering up to 72 hours of backup.
KRP models include 10-year batteries and ultra-wide temperature ratings (-30 to 65°C / -22 to 149°F), while rackmount (KRM) models extend the battery rating to 12 years but support only a wide temperature range (-20° to 55°C / -4° to 131°F).
- SSG1KRP, (1 kVA with ultra-high operating temperature)
- SSG2.2KRM, (2.2 kVA)
- SSG2.5KRP, (2.5 kVA with ultra-high operating temperature)
- SSG3KRM, (3 kVA)
Westward Sales is Your Partner for Industrial Technology
Westward Sales offers a wide range of high-quality industrial UPS solutions, primarily from two makers, Falcon Electric and Cyberpower. We sell single-phase systems with nominal Volt-Amps (VA) ranging from 500 to 10,000 VA, and from 120 Watts to 10,000 Watts. These units also offer power factor correction, frequency regulation, surge suppression, and filtering.Westward Sales supports businesses throughout North America with industrial networking, antennas, audio, video, power solutions, and more. Our team understands the unique needs of industrial and commercial customers, and we know what it takes to achieve uncompromising high performance in any environment. Contact our team today to discuss your power management and UPS requirements.
Frequently Asked Questions
A standard UPS typically operates in standby or line-interactive mode and only activates during power loss. An industrial UPS system runs in true online double-conversion mode, continuously delivering clean, regulated power and zero transfer time for critical applications. An industrial-grade UPS is built to withstand harsh environmental conditions and is more expensive than a commercial-grade UPS. A commercial-grade UPS is designed for benign environments.
Double-conversion technology converts incoming AC power to DC and back to pure AC output, eliminating voltage distortion, surges, and power instability that can damage sensitive industrial equipment.
No. Standard UPS units are designed for climate-controlled indoor use and lack the durability and environmental resistance required for industrial and outdoor conditions. Installing a regular UPS in a demanding environment can lead to rapid failure and unprotected equipment.
Standard VRLA batteries are typically rated for 5 years at 77°F. Industrial UPS systems use 10–12 year batteries or LiFePO4 technology designed to perform reliably across wide temperature ranges.
Industrial UPS systems from Falcon Electric operate in ranges from –30°C to +65°C (–22°F to 149°F), depending on the model, making them suitable for extreme and mission-critical environments.
Yes. The improved reliability, power quality, extended lifespan, and ability to withstand harsh conditions make industrial UPS systems a cost-effective investment for critical infrastructure and industrial operations.
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