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Bat sizing rev Battery Sizing Sizing

Bat sizing rev List of contents Head lines Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev Battery load... Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev UPS inverter Battery load Calculate the battery load... P bat + - D C A C UPS load = P out Pbat=the battery load power Pout=the output load power  Inv.=the inverter efficiency PF=The power factor What is the required battery load - for a given UPS load…? * P Bat = P out x PF /  Inverter From kVA to kW Cal. the  Battery load Calculating

Bat sizing rev What is the total battery load (kW)…? Battery load Battery load - example... P bat + - P Bat = P out x PF /  Inverter P Bat = 56 x 0,8 / 0,95 = 47,2 kW Example: UPS load/ Pout……..…………....56kVA UPS load, PF………………… ,8 UPS inverter efficiency………....95% or 0,95 You need to know... * Battery load Total load is the three phase loads added together

Bat sizing rev  N cell= Number of battery cells to be used  V low= The lowest DC voltage (before inverter shut down will take place)   Inv.= The inverter efficiency with the actual load.  I ch-max= The max. battery charging current.Parameters... For the most used battery type - the lead acid - the following parameters are used: For a specific Silcon DP300E type and an actual output load, the above data can be found in the Quick Reference Manual, section “DC Data”. Battery load

Bat sizing rev Battery Bank... Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev Battery bank Battery cells and blocks x 2 volt = 2 V - battery cell 3 x 2 volt = 6 V - battery block 6 x 2 volt = 12V - battery block *

Bat sizing rev Battery bank Battery string... Serial connected battery blocks - forms a battery string. More strings can be connected in parallel - to increase the battery bank capacity

Bat sizing rev Battery pack for DP300E... How to make a battery pack for DP300E…? 2 x192 battery cells = 2 x 384 VDC 2 x 32 battery blocks of 12V = 2 x (32 x 12 V) = 2 x 384 VDC Battery bank

Bat sizing rev Cell Specification Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev Cell specifications Cell LOAD... Actual Cell LOAD / Matching Battery Size Calculating the watt/ cell capacity…? Cell load = Total battery load / Number of cells Example1: W / (2 x 192 cells) = 123 W/cell During battery operation the load on the battery bank is supposed to be constant at the max. specified load… * Watt + - Example 1: P Bat = P out x PF /  Inverter P Bat = 56 x 0,8 / 0,95 = 47,2 kW

Bat sizing rev Lowest cell voltage... The lowest battery voltage - “ when the back-up time expires” - is defined from the battery spec. and programmed into the UPS Cell-end voltage - and how to find it…? Example 1: V cell low = 2X326V / 2X192 cells = 1,7V/cell V cell low = V Inverter low / number of cells Cell voltage Time Cell specifications 1,7 V

Bat sizing rev Example 2... Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev A customer want to protect a 3x400V computer load… - with an 10min. UPS Back-up time The highest phase current is determine the Silcon DP300E size. Silcon DP380E has a 400V full load output current at 3 x 115A and is therefore sufficient for I L2 Choice: Silcon DP380E Example 2 Result from measuring - full load current on the 3 phases... I L1 100APF 0,8 I L2 112APF 0,9 I L3 105APF 0,8 - example 2

Bat sizing rev Calculating the total power... Line to line voltage……...400V Line to neutral voltage….230V P L1 = 230 x 100 x 0,8 = W P L2 = 230 x 112 x 0,9 = W P L3 = 230 x 105 x 0,8 = W Total = W - or close to 61kW P Batt = 61 / 0,94 = W from 384 cells P cell = / 384 = 169W/cell V Low = 2 x 326 / 384= 1,7V/cell Example 2 - calculating cell load - and lowest cell voltage Required data... Silcon DP380E max load…..…80kW Actual load……………………..61 kW Load percentage………………75% Inverter efficiency: Linear load……………….…….96% SMPS load……………….…….94% - example 2 Example 2 - Load spec. Voltage3x400V I L1 100APF 0,8 I L2 112APF 0,9 I L3 105APF 0,8 Back-up time10 min.

Bat sizing rev  Type UPS12-140:  Capacity……….174W/cell  Back-up time…..10 min.  End point cell voltage……1,7V Example 2 - choosing battery Min.Type UPS UPS UPS Data sheet example: JOHNSONS CONTROL - fits the demand of 169 W/cell. - example 2 Example 2 - Load spec. Voltage3x400V I L1 100APF 0,8 I L2 112APF 0,9 I L3 105APF 0,8 Back-up time10 min.

Bat sizing rev UPS specifications concerning batteries... Common Data from Quick reference:  Nominal voltage 2x384V  Number of battery cells2x192 pcs.  Charging window float2x(410V - 460V) Factory setting: 2x438V  Charging window boost2x(438V - 460V) Factory setting: 2x438V  Low bat. warning window 2x(336V - 384V) Factory setting: 2x346V  Low bat. shut down window 2x(316V - 336V) Factory setting: 2x326V - example 2

Bat sizing rev Battery ambient temperature Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev Battery… Capacity and life time °C Typ. battery specification temperature Ambient temperature - Battery capacity… General rule: - if ambient temp. is lowered from 25 °C to 20 °C - The battery must be 4% oversized Ambient temperature - Battery life time… General rule: - if ambient temp. increases 10 °C - The battery life time will be halved. But temperature compensated charging voltage - as in the Silcon DP300E series - reduces the influence to the half. + 4% oversized +- Battery amb. temperature

Bat sizing rev Battery life time... High temperature Poor charge control 80%100%Capacity The capacity of the battery falls with the age. The point where 80% is left is often used to define the life time. 20% oversizing is required for the W/cell if not included from manufacture Ageing End of life time Battery amb. temperature

Bat sizing rev Battery recharging hours Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev Recharging time is often specified 4-10 hours Battery recharging DP300E recharging normal capacity on batteries hours 0 1 hour Back-up time is often specified less than 1 hour Normal charging current

Bat sizing rev The following broad rule can be used for batteries where almost all the energy is taken out - this is the case with back-up times of 2-3 hours or more: FOR RECHARGE TIMES IN THE AREA OF HOURS: - it last t hours to recharge the battery to 80% capacity, 3xt to reach 90% and 8xt to reach 100% FOR RECHARGE TIMES IN THE AREA OF HOURS: - it last 2xt to reach 90% and 4xt to reach 100% But how to find t...? General rule about recharging... Battery recharging

Bat sizing rev Recharging general rule... FOR RECHARGE TIMES IN THE AREA OF HOURS: 1 x t3 x t8 x t Battery recharging

Bat sizing rev The following can be assumed:  We have to put the same energy back into the battery as taken out + the losses arising by recharging The losses by recharging are about 10%...  The Silcon DP300E will recharge with max. charging current, at least until 80% of the energy has been restored  The battery cells has a average voltage of 2V P bat + - P bat out P bat in 100%90% Battery losses... Battery recharging

Bat sizing rev If 4 hours back-up time is required... - it will take a week to reach the 100 % battery capacity level by too low charging current One week... One week charging …? Battery recharging

Bat sizing rev Example:  DP310E output load 8kW (3-phase)  Back-up time 4 hours  Max. 12 hours recharge time to 90% required. Let´s take an example...  Energy taken from battery during battery operation: Output load/DP310E bat.opr.efficiency = 8/0,9=8,9kW Discharge current=8900W/(2Vx384) cells=11,6A Energy used 11,6x4 hours=46,4AH  Energy to be recharged=46,4/0,9=51,5AH  If 90% is to be restored within 12 hours, 80% has to take place within 12/2=6 hours. Battery recharging

Bat sizing rev  If 51,5AH has to be restored within 6 hours… the charging current must be 51,5/ 6 = 8,6A This gives a required charging power of 384 x 2 x 8,6 = 6,6 kW As the standard DP300E has a charging capacity equal to 10% of the output power - The DP380E has to be used  But as the standard programming of the DP300E can be changed into a special setting - giving the double charging capacity  With a corresponding reduction of the max. output power - a DP340E can be used  8kW is then available for charging  A max. output load of 36kW is more than enough for the actual 8kW load.  A separate charger might be a better economic solution Let´s take an example... Battery recharging

Bat sizing rev Battery parallel connection... Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev Parallel strings Numbers of blocks, depends on type of battery pack and parallel strings. The battery type UPS12 have 6 cells of 2 volt and the UPS6 have 3 cells of 2 volt If the W/cell is above numbers in table it is necessary to make parallel strings Cell load [W/ cell] With ___ parallel string = = = _____ [W/ cell] Number of strings The numbers of cells in the Silcon DP300E series is... 2 x 192 pcs. = total 384 cells. - therefor divide the total 384 with the number of battery cells UPS12 = 384 : 6 = 64 battery block UPS 6 = 384 : 3 = 128 battery block And then multiply this with the number of strings

Bat sizing rev Example 3... Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev Example 3 Specify the battery... Example 3  UPS type:DP3120E  Total load:110 kVA  PF:0,8 SMPS  Requested back-up: 20 min Specify the battery…! Data:

Bat sizing rev Example 3 Specify the battery... Transfer output power to kW´s, if information is in kVA or Amps… P Total W % load on UPS = x 100 = x 100 = 73,3 [%] UPS 1/1 load W P Total W = P Total VA x PF = [VA] x 0,8 = [W] Calculate the percentage of the load compared with the capacity of the UPS... Example 3 Example 3 - Battery…?. UPS typeDP3120E Total load110 kVA PF0,8 SMPS Back-up time20 min.

Bat sizing rev Inverter Data Efficiencies DC to AC DP 3120 E and 73,3 % SMPS loaded Find the efficiencies DC to AC percentage..! Example 3

Bat sizing rev Example 3 Specify the battery... Calculate the battery load and the cell load - decide if parallel strings is needed... Battery Load [W] Cell load = = = 247 [W/ cell] Number of cells2 x 192 P Total [W] Battery load = 100 = x 100 = [W] Inv. eff. [%] 92,9 Cell load: Battery Load: Efficiencies DC to AC (table)= 73,3 % (SMPS-% load of the UPS) = 92,9 inv. Eff %. Example 3 Example 3 - Battery…?. UPS typeDP3120E Total load110 kVA PF0,8 SMPS Back-up time20 min.

Bat sizing rev Example 3 Specify the battery... Find the necessary battery type, table Johnson battery. 247 [W/cell] in 20 min... Min.Type UPS UPS ,674,46546,7 UPS UPS UPS UPS UPS UPS Example 3 Example 3 - Battery…?. UPS typeDP3120E Total load110 kVA PF0,8 SMPS Back-up time20 min.

Bat sizing rev Battery pack specifications... Find the weight and dimension of the battery pack MODEL WATT/CELL 15 Min./167 V/C LENGTH IN (MM) WIDTH IN (MM) HEIGHT IN (MM) WEIGHT LBS. (KGS) UPS (197)5.22 (132))7.26 (184)27 (12) UPS (228))5.47 (139)8.74 (222)40 (18) UPS (261)6.83 (173)8.74 (222)57 (26) UPS (307)6.87 (174))9.51 (241)66 (30) UPS (343)6.76 (172)9.48 (240)75 (34) UPS (344)6.76 (172)10.93 (276)105 (48) UPS (321)7.00 (177)10.21 (259)72 (33) Example 3 Example 3 - Battery…?. UPS typeDP3120E Total load110 kVA PF0,8 SMPS Back-up time20 min.

Bat sizing rev Example 3 Specify the battery... Battery Specification/Pack TypeUPS MakeJohnson Number of cells384 Cell load247 W/cell Min. cell voltage1,7 V Back-up time20 min. Number of blocks 64 Block dim. (HxWxL) 241x174x307mm Total weight 1920kg Solution... Example 3 Example 3 - Battery…?. UPS typeDP3120E Total load110 kVA PF0,8 SMPS Back-up time20 min.

Bat sizing rev Your turn... Now - your turn...

Bat sizing rev Task 1 Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev Task 1 Specify the battery...  UPS type:DP380E  Total load:66 kW  PF load:1  Requested back-up: 10 min Specify the battery…! Data: Task 1

Bat sizing rev Task 1 P Total W % load on UPS = x 100 = x 100 = 82,5 [%] UPS 1/1 load W P Total W = P L1 + P L2 + P L3 = [W] Total Load: UPS load: Task 1  UPS type:DP380E  Total load:66 kW  PF load:1  Back-up time: 10 min Task 1

Bat sizing rev Inverter Data Find the efficiencies DC to AC percentage..! Efficiencies DC to AC DP 380E and 82,5% Linear Task 1  UPS type:DP380E  Total load:66 kW  PF load:1  Back-up time: 10 min Task 1

Bat sizing rev Task 1 Calculate the battery load and the cell load - decide if parallel strings is needed... Battery Load [W] Cell load = = = 179 [W/ cell] Number of cells2 x 192 P Total [W] Battery load = 100 = x 100 = [W] Inv. eff. [%] 96 Cell load: Battery Load: Efficiencies DC to AC (table)= 73,3 % (linear-% load of the UPS) = 96 inv. Eff %. Task 1  UPS type:DP380E  Total load:66 kW  PF load:1  Back-up time: 10 min Task 1

Bat sizing rev Results of task 1 Battery Specification/Pack TypeUPS MakeJohnson Number of cells384 Cell load179 W/cell Min. cell voltage1,7 V Back-up time10 min. Number of blocks 64 Block dim. (HxWxL) 222 x 139 x 228mm Total weight 1152kg Results... Task 1  UPS type:DP380E  Total load:66 kW  PF load:1  Back-up time: 10 min Task 1

Bat sizing rev Task 2 Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev Task 2 Specify the battery...  UPS type:DP3160E  Total load L1:50 kVA, PF 0,9 SMPS  Total load L2:40 kVA, PF 0,8 SMPS  Total load L3:45 kVA, PF 0,8 SMPS  Back-up time: 15 min Specify the battery…! Data: Task 2

Bat sizing rev Task 2 P Total W % load on UPS = x 100 = x 100 = 70,6 [%] UPS 1/1 load W P L1 = P L1 x PF1 = 50kVA x 0,9 = [W] P L2 = P L2 x PF1 = 40kVA x 0,8 = [W] P L3 = P L3 x PF1 = 45kVA x 0,8 = [W] P Total W = P L1 + P L2 + P L3 = [W] Total Load: UPS load: Task 2  UPS type:DP3160E  Total load L1:50 kVA, PF 0,9 SMPS  Total load L2:40 kVA, PF 0,8 SMPS  Total load L3:45 kVA, PF 0,8 SMPS  Back-up time: 15 min Task 2

Bat sizing rev Inverter Data Find the efficiencies DC to AC percentage..! Efficiencies DC to AC DP 3160E and 70,6% SMPS Task 2  UPS type:DP3160E  Total load L1:50 kVA, PF 0,9 SMPS  Total load L2:40 kVA, PF 0,8 SMPS  Total load L3:45 kVA, PF 0,8 SMPS  Back-up time: 15 min Task 2

Bat sizing rev Task 2 Battery Load [W] Cell load = = = 317 [W/ cell] Number of cells2 x 192 P Total [W] Battery load = 100 = x 100 = [W] Inv. eff. [%] 93 Cell load: Battery Load: Efficiencies DC to AC (table)= 70,6 % (SMPS-% load of the UPS) = 93 inv. Eff %. Task 2  UPS type:DP3160E  Total load L1:50 kVA, PF 0,9 SMPS  Total load L2:40 kVA, PF 0,8 SMPS  Total load L3:45 kVA, PF 0,8 SMPS  Back-up time: 15 min Task 2

Bat sizing rev Results of task 2 Battery Specification/Pack TypeUPS MakeJohnson Number of cells384 Cell load317 W/cell Min. cell voltage1,7 V Back-up time15 min. Number of blocks 64 Block dim. (HxWxL) 240 x 172 x 343mm Total weight 2176kg Results... Task 2  UPS type:DP3160E  Total load L1:50 kVA, PF 0,9 SMPS  Total load L2:40 kVA, PF 0,8 SMPS  Total load L3:45 kVA, PF 0,8 SMPS  Back-up time: 15 min Task 2

Bat sizing rev Task 3 Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection

Bat sizing rev Task 3 Specify the battery...  UPS type:DP3320E  Total load:315 kVA  PF load:0,8  Requested back-up: 20 min Specify the battery…! Data: Task 3

Bat sizing rev Task 3 P Total W % load on UPS = x 100 = x 100 = 78,8 [%] UPS 1/1 load W Total Load: UPS load: Task 3  UPS type:DP3320E  Total load:315 kW  PF load:0,8  Back-up time: 20 min P Total W = P Total VA x PF = x 0,8 = [W] Task 3

Bat sizing rev Inverter Data Find the efficiencies DC to AC percentage..! Efficiencies DC to AC DP 3320E and 78,8% Linear Task 3  UPS type:DP3320E  Total load:315 kW  PF load:0,8  Back-up time: 20 min Task 3

Bat sizing rev Task 3 Battery Load [W] Cell load = = = 688 [W/ cell] Number of cells2 x 192 P Total [W] Battery load = x 100 = x 100 = [W] Inv. eff. [%] 95,4 Cell load: Battery Load: Efficiencies DC to AC (table)= 78,8 % (SMPS-% load of the UPS) = 95,4 inv. Eff %. Task 3  UPS type:DP3320E  Total load:315 kW  PF load:0,8  Back-up time: 20 min Cell load [W/ cell] 688 With ___ parallel string = = = 344 [W/ cell] Number of strings 2 Strings: Task 3

Bat sizing rev Results of task 3 Battery Specification/Pack TypeUPS MakeJohnson Number of cells384 Cell load344 W/cell Min. cell voltage1,7 V Back-up time20 min. Number of blocks 128 Block dim. (HxWxL) 278 x 172 x 344mm Total weight 6144kg Task 3  UPS type:DP3320E  Total load:315 kW  PF load:0,8  Back-up time: 20 min Task 3

Bat sizing rev Review Review Battery Load Battery Bank Cell specifications - example 1 Example 2... Battery ambient temperature Battery recharging Example 3... Task 1... Task 2... Task 3... Review Battery parallel connection