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1 Introduction o 1.1 Why do the calculation? o 1.2 When to do the calculation? 2 Calculation Methodology o 2.1 Step 1: Collect the AC UPS Loads o 2.2 Step 2: Load Profile, Design Load and Design Energy o 2.3 Step 3: Battery Sizing 2.3.1 Nominal Battery (or DC Link) Voltage 2.3.2 Number of Cells in Series o 2.4 Step 4: UPS Sizing 2.4.1 Overall UPS Sizing 2.4.2 Rectifier / Charger Sizing 2.4.3 Inverter Sizing 2.4.4 Static Switch Sizing 3 Worked Example o 3.1 Step 1 and 2: Collect the AC UPS Loads and Construct Load Profile o 3.2 Step 3: Battery Sizing o 3.3 Step 4: UPS Sizing 3.3.1 Overall Sizing 3.3.2 Rectifier Sizing 3.3.3 Inverter and Static Switch Sizing 4 Computer Software 5 What next?
Introduction
This calculation deals with the sizing of an AC uninterruptible power supply (UPS) system (i.e. rectifier, battery bank and inverter). In this calculation, it is assumed that the AC UPS is a double conversion type with a basic system topology as shown in Figure 1.
Figure 1 - AC UPS basic system topology An external maintenance bypass switch and galvanic isolation transformers are other common additions to the basic topology, but these have been omitted from the system as they are irrelevant for the sizing calculation.
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UPS loads that need to be supported Input / Output AC voltage Autonomy time(s) Battery type
Calculation Methodology
The calculation procedure has four main steps: 1) Determine and collect the prospective AC UPS loads 2) Construct a load profile and determine the UPS design load (VA) and design energy (VAh) 3) Calculate the size of the stationary battery (number of cells in series and Ah capacity) 4) Determine the size of the inverter, rectifier/ charger and static switch
The nominal battery / DC link voltage is often selected by the AC UPS manufacturer. However, if required to be selected, the following factors need to be considered:
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DC output voltage range of the rectifier the rectifier must be able to output the specified DC link voltage DC input voltage range of the inverter the DC link voltage must be within the input voltage tolerances of the inverter. Note that the battery end of discharge voltage should be within these tolerances. Number of battery cells required in series this will affect the overall dimensions and size of the battery rack. If physical space is a constraint, then less batteries in series would be preferable. Total DC link current (at full load) this will affect the sizing of the DC cables and inter-cell battery links. Obviously the smaller the better.
In general, the DC link voltage is usually selected to be close to the nominal output voltage. Number of Cells in Series The number of battery cells required to be connected in series must be between the two following limits:
(1)
(2) where Nmax is the maximum number of battery cells Nmin is the minimum number of battery cells Vdc is the nominal battery / DC link voltage (Vdc) Vi,max is the inverter maximum input voltage tolerance (%) Vi,min is the inverter minimum input voltage tolerance (%) Vf is the nominal cell float (or boost) voltage (Vdc) Veod is the cell end of discharge voltage (Vdc) The limits are based on the input voltage tolerance of the inverter. As a maximum, the battery at float voltage (or boost if applicable) needs to be within the maximum input voltage range of the inverter. Likewise as a minimum, the battery at its end of discharge voltage must be within the minimum input voltage range of the inverter. Select the number of cells in between these two limits (more or less arbitrary, though somewhere in the middle of the min/max values would be appropriate).
where IL,dc is the design DC load current (full load) (A) S is the selected UPS rating (kVA) Vdc is the nominal battery / DC link voltage (Vdc) The maximum battery charging current can be computed as follows:
where Ic is the maximum DC charge current (A) C is the selected battery capacity (Ah) kl is the battery recharge efficiency / loss factor (typically 1.1) (pu) tc is the minimum battery recharge time (hours) The total minimum DC rectifier / charger current is therefore:
Select the next standard rectifier / charger rating that exceeds the total minimum DC current above. Inverter Sizing
The inverter must be rated to continuously supply the UPS loads. Therefore, the inverter can be sized using the design AC load current (based on the selected UPS kVA rating):
where IL is the design AC load current (full load) (A) S is the selected UPS rating (kVA) Vo is the nominal output voltage (Vac) Select the next standard inverter rating that exceeds the design AC load current. Static Switch Sizing Like the inverter, the static switch must be rated to continuously supply the UPS loads. Therefore, the static switch can be sized using the design AC load current (as above for the inverter sizing).
Worked Example
Step 1 and 2: Collect the AC UPS Loads and Construct Load Profile
Load profile for this example For this example, we shall use the same loads and load profile detailed in the Energy Load Profile Calculation example. The load profile is shown in the figure right and the following quantities were calculated:
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A Suppose the minimum battery recharge time is 2 hours and a recharge efficiency factor of 1.1 is used. The maximum battery charging current is:
A A DC rectifier rating of 40A is selected. Inverter and Static Switch Sizing Suppose the nominal output voltage is 240Vac. The design AC load current is:
Computer Software