In the field of industrial precision testing equipment, Industrial CT acts as a core unit for non-destructive testing and quality inspection, which requires exceptionally stable and reliable power supply. As a pure inductive load, Industrial CT produces massive inrush current upon startup — 4 to 5 times its rated power. Ordinary power supplies are prone to overload tripping and unstable output, failing to support normal operation. Besides, most equipment rooms have limited installation space, so bulky traditional lead-acid UPS systems are no longer a viable option.
Recently, HIGHIDEA delivered a customized 3-phase industrial frequency lithium-ion UPS solution for an Industrial CT operator in Hubei. The system consists of a 60kVA 3-phase industrial frequency lithium UPS main unit and 8 sets of 48V 50Ah LiFePO4 battery packs. It fully meets the client’s requirements: supporting a 9.2kW inductive load with 1.5 hours of backup runtime, while adopting a space-saving design to fit compact installation environments. This project has become a classic reference case for deploying industrial UPS on heavy inductive loads.
Project Challenges
The client’s primary device is a 9.2kW Industrial CT, a typical heavy inductive load. The drastic current surge during startup poses a tough challenge to power equipment. Following industrial standards, the UPS capacity needs to be configured 4 to 5 times higher than the actual load power to ensure stable operation. Apart from reliable load handling, the client demanded 1.5 hours of backup power to prevent unexpected shutdowns, data loss and equipment damage during power outages. On top of that, the on-site machine room features narrow space, making a space-efficient UPS system an essential requirement.
After on-site surveys and technical calculations, our engineering team worked out the optimal power configuration to resolve all challenges, including inrush current from inductive loads, long backup duration and limited installation space.
Custom UPS System Configuration
The complete solution adopts the HIGHIDEA 60kVA 3-phase industrial frequency lithium UPS, paired with 8 pieces of 48V 50Ah LiFePO4 battery packs, perfectly tailored to the operating conditions of Industrial CT.
Equipped with an isolation transformer, the 60kVA 3-phase industrial frequency UPS boasts strong resistance against current surges. It achieves zero transfer time, switching to battery power instantly once mains power cuts out. With ample power margin, it easily copes with the high inrush current generated by the 9.2kW inductive load, enabling steady operation of the entire system without overload risks.
The supporting 48V 50Ah LiFePO4 battery packs feature a modular structure. Compared with traditional lead-acid batteries of the same capacity, these lithium battery packs greatly reduce overall volume and floor space, matching the compact layout of the machine room perfectly. LiFePO4 batteries also deliver longer cycle life and lower long-term maintenance costs. The combination of the UPS main unit and battery packs delivers continuous backup power for 1.5 hours as specified.
On-site Installation & Commissioning
Our professional technical team completed product delivery, on-site installation, wiring and full commissioning efficiently in compliance with industrial power safety regulations.
We first optimized the equipment layout according to the actual room dimensions to guarantee proper heat dissipation and safe wiring. The 3-phase UPS main unit was securely fixed in position, and all battery packs were neatly mounted on standard racks. After thorough wiring and connection inspections, we conducted a series of tests including no-load operation, full-load operation and power outage simulation. All electrical parameters, switching performance and backup runtime met the design standards.
The entire 3-phase industrial frequency lithium-ion uninterruptible power supply system has been fully put into operation. To date, the system runs stably around the clock. It delivers clean and stable power to the Industrial CT under normal grid conditions, and provides dependable 1.5-hour backup power during blackouts. The issue of unstable power supply caused by pure inductive loads has been completely eliminated.
Project Summary & Application Value
This Industrial CT UPS project fully demonstrates the superior performance of HIGHIDEA 3-phase industrial frequency lithium UPS when applied to industrial inductive loads. It offers a mature and replicable solution for Industrial CT, industrial motors, compressors and other equipment with high inductive loads across the industry.
Thanks to compact structure, powerful load capacity, long backup runtime and low maintenance needs, lithium-ion UPS is gradually replacing lead-acid UPS and becoming the mainstream choice for industrial power protection. HIGHIDEA will continue to focus on the real demands of industrial users, and provide high-reliability UPS power solutions for precision industrial equipment worldwide.