In our ever-connected world with the Internet of Things (IoT), reliable electrical power keeps our world communicating, electronics working, and critical industrial systems operating 24/7. This necessary level of power protection is assured with industrial-grade uninterruptible power supplies (industrial UPS).
Increased Complexity Puts Demands on Reliability
As the IoT rapidly takes hold, many innovative applications are leaping ahead, bringing added complexity.
Automation systems have now become as computerized and complex as any other industry system. Consequently, production costs have been reduced while operational safety levels have increased. Networked communications have centralized automated process management, further reducing costs. As a result of this networking, the subsystems controlling the individual automated processes have also become objects on the IoT. The Internet and its our ever-connected world with the Internet of Things (IoT), reliable electrical power keeps our world communicating, electronics working, and critical industrial systems operating 24/7. This necessary level of power protection is assured with industrial-grade uninterruptible power supplies (industrial UPS).
Increased Complexity Puts Demands on Reliability
As the IoT rapidly takes hold, many innovative applications are leaping ahead, bringing added complexity. Automation systems have now become as computerized and complex as any other industry system. Consequently, production costs have been reduced while operational safety levels have increased. Networked communications have centralized automated process management, further reducing costs. As a result of this networking, the subsystems controlling the individual automated processes have also become objects on the IoT. The Internet and its suppliers via the Internet, and the company’s network security must be robust enough to protect company data and trade secrets. Moreover, it has to prevent unauthorized access and hacking of the Ethernet-connected SCADA network.
Due to the large amount of computerization, the level of power quality demanded in industrial environments is high. Yet, due to the presence of large motors and pumps connected to the facility’s power system, the utility power supplied to the plant can become polluted with voltage sags, high-voltage transients, and sustained over-voltage conditions. Utility power itself can also create problems through short- and long-term outages in addition to destructive high-voltage transients. The solution is a true on-line uninterruptible power supply (UPS) that regenerates new, clean AC power from a dirty power source. They are often used to condition power to the SCADA systems, in addition to providing a backup power source. In the case of the bottling company, an on-line UPS installed ahead of the filling PLC solved the problem.
Most on-line UPS products offer networked communications options for their remote monitoring and control. They support Ethernet connectivity, providing SNMP, HTTP, HTTPS, Telnet, and other communications protocols. The HTTP/HTTPS is supported by on onboard webserver. Every network-connected device in a data or SCADA network is a potential backdoor into the network or at a minimum, a security risk. For instance, a UPS powering a PLC responsible for controlling a key mixing process of a controlled substance on a pharmaceutical production line may be subject to outside sabotage through its unsecured SNMP/HTTP network interface. As the UPS is connected to the company’s Ethernet network for the purpose of remote monitoring and management, it could be compromised through the collusion between an inside employee and a hacker-friend outside the company. Should the UPS’s network interface not be configured properly, the unsecured UPS IP address could allow the UPS to be shut down and restarted remotely to cover thefts of a small amount of the controlled substance. The only truly secure UPS communications protocol is SNMPv3, which supports password hashing and full data encryption. In addition, all used communications ports should be turned off to reduce the potential of unauthorized backdoor access.
Industrial Power Protection
As one wouldn’t use a hammer when a drill is required, the same applies to power protection. Office-grade power protection is simply unable to protect critical systems with the required high level of reliability – especially those to be installed in harsh industrial environmental conditions. The operational temperature specification for the vast majority of on-line UPS products on the market today are stated as 0°C to 40°C (32°F to 104°F). These UPS products have been designed for use in an indoor, temperature-controlled environment. Furthermore, safety agency testing and certification is valid only when used in controlled environments over the manufacturer’s stated operational temperature range. Typically, they have received a NRTL or Underwriters Laboratories (UL) listing status. As part of the safety agency product evaluation process, the temperature ratings of key electronic components, displays, plastics, circuit board materials, insulating materials, and batteries are verified to remain within their manufacturers’ stated maximum temperature ratings. This testing is performed while the UPS is operating at the limits of the UPS manufacturer-specified operational temperature range. The upper temperature limit is of specific concern.
UPSs used in industrial applications often need to be installed in locations with severe operating environments. This means locations that require a wider operating temperature range. Installing a commercial office-grade UPS in harsh environments is not a wise decision for many reasons, including reduced reliability and the potential liabilities of operating outside the UPS manufacturer’s safety agency listing status. This is an unnecessary decision as wide-temperature, industrial-grade on-line UPS models are available with safety agency listing for operational temperature ranges up to -30°C to 65°C (-22°F to 149°F). These units have been specifically designed to be more efficient and manufactured with high-temperature rated components.
As the IoT continues on its march to connect all things electronics, it’s important to safeguard industrial systems against demanding environments and Internet security breaches. Installing the wrong UPS for critical industrial applications in harsh conditions may incur liabilities that are more than financial