Sizing battery banks for switchgear and control applications is commonly performed using software designed

specifically for that purpose. Just input the required load profile, and the program selects the optimum battery
configuration. Although this is quite simple, an engineer should be capable of performing a straightforward hand
calculation — either to confirm the results of a software-generated solution or to serve as an accurate design for a
simple battery system.

Do you know how to perform these calculations by hand? If not, then read on. This article will help you understand
the basic premise of sizing switchgear battery systems and provide an example calculation for clarification of the
concept. IEEE Standard 485-1997, “Recommended Practice for Sizing Lead-Acid Batteries for Stationary
Applications,” also provides detailed guidelines for battery sizing.

Number of cells
Battery banks for switchgear and control applications are made up of many cells. These cells are typically wired in
series to achieve a desired voltage and may also be wired in parallel to achieve additional ampere capacity. Sizing of
these battery banks, therefore, includes selecting the number and type of cells to be used.

The terminal voltage per cell varies with the battery's chemical composition. The required number of series wired
cells to achieve the more common DC control voltages for switchgear control is shown in Table 1. Selection of the
type of cell is based on the required peak ampere output and total Ampere-hour (Ah) output capacity for the load and
duration.

Table 1

Load type
IEEE Standard 485-1997 classifies individual DC loads as continuous, non-continuous, and momentary. Typical
continuous loads include lighting, continuously energized coils, and power to protective relay and communications
systems. Non-continuous loads are less common and include critical ventilation system motors and valve actuators
with operating times exceeding 1 minute. Momentary loads do not exceed 1 minute in duration and include inrush
currents and circuit breaker operations.

The duty cycle imposed on switchgear batteries usually consists of momentary high ampere loading during charging
of the respective tripping or closing springs, in addition to the small continuous load of powering protective relays and
lights.

While both motors for charging the tripping or closing springs can be DC, the more common switchgear design uses
an AC closing motor and a DC tripping motor. Such a design reduces the total DC load because tripping is of the
utmost importance — particularly when a fault occurs. However, this only allows one full operational cycle following a
power failure because there is no AC to charge the closing spring.
Sizing guidelines
Since the momentary load on a switchgear battery bank is much higher than the continuous load, the required 1-
minute (peak) ampere rate typically determines the battery cell type. However the Ampere-hour rate should also be
checked. The battery cell type that meets the worst-case condition between the two should be selected.

These rates are tabulated in the manufacturer's standard literature at several final voltages. Use the rates published
at a final voltage of 1.75 volts-per-cell for lead acid cells or 1.14 volts-per-cell for nickel cadmium cells. As an
example, the data in Table 2 on page 43 is excerpted from a manufacturer's Web site. (The model designations are
fictitious.)

Table 2

To calculate the required 1-minute ampere rate, assume the peak rate to be equal to the sum of the loads (i.e. in-rush
current for all breaker charging motors, load currents for all relays and other loads, and ignore pilot lights).

Although momentary loads usually exist for much less than a minute — perhaps only a fraction of a second — it is
common practice to use the full ampere value for an entire minute. Assign a required 1-minute rate equal to this peak
rate divided by the ambient temperature derating factor, the battery aging factor, and a design margin as listed in
Table 3 on page 43.

Table 3

To calculate the required Ampere-hour rate, compute the average continuous load and divide by the ambient
temperature-derating factor and battery-aging factor, as listed in Table 3. Use the manufacturer's data to select the
battery cell type that meets both the ampere and Ampere-hour requirements.

Sample calculation
To use a hypothetical real-world example, calculate the battery size for the 69kV substation loads listed in Table 4.
The battery type shall be lead acid, operate the given loads for 8 hours at 125VDC, and be housed in a climate-
controlled building.

Table 4

Step 1: Calculate the required 1-minute discharge rate.

As can be seen in Table 4, the peak discharge rate is 96.2A. Divide this number by an ambient temperature factor of
one for a 77°F room, by a 0.8 battery-aging factor, and by 0.85 for the design margin.

Required 1-minute discharge rate = 96.2 A ÷ 0.8 ÷ 0.85 = 141.5A

Step 2: Calculate the required Ampere-hour (Ah) rate.

As can be seen in Table 5, the total Ampere-hour rate is 27.1 Ah. Divide by an ambient temperature factor of one for
a 77°F room, and by a 0.8 battery-aging factor.

Required total Ah rate = 27.1 Ah ÷ 0.8 = 33.9 Ah

Table 5

Step 3: Select the appropriate cell from the manufacturer's literature.

Referring back to Table 2, a Model A battery has a 1-minute discharge rate of 177A and an 8-hour Ah rate of 180 Ah,
down to 1.75V. This type of battery is, therefore, more than sufficient for this particular load. The 125VDC, 180 Ah
battery bank would be composed of 60 Model A cells.

Back to basics
So whether you're one of those people that refuses to trust a computer farther than you can throw it — or you simply
feel more comfortable double checking calculations by hand — possessing the knowledge to size battery banks for
switchgear the old-fashioned way is a good skill for any engineer to master. Not only will you impress your peers, but
you'll also feel more confident about recommending a rock solid switchgear solution.

Hall is an electrical engineer based in the Las Vegas office of CH2M HILL, Inc.

Table 1. String together 37 individual Ni-Cad batteries in series to achieve a control voltage of 48V.
Battery Type
Control Voltage
Ni-Cad Lead acid
48VDC 37 cells 24 cells
125VDC 92 cells 60 cells
250VDC 184 cells 120 cells
Table 2. Ampere-hour and ampere rates for four different battery models offered by one manufacturer.
Nominal Rates at 77°F (25°C)
Final Volts Models Ampere-Hours (Ah) Amperes (A)
8-hr 4-hr 3-hr 1.5-hr 1-hr 30 min 15 min 1 min
1.75V A 180 142 132 65 81 109 134 177
B 250 210 195 98 126 172 219 303
C 330 280 260 130 168 230 292 404
D 410 350 326 163 204 285 362 500
Table 3. Design factors to be used when calculating Ampere-hour rates for Ni-Cad and lead-calcium batteries.
Battery Type
Derating Function
Ni-Cad Lead-Calcium
Ambient temperature
77°F 1.0* 1.0*
32°F 0.7 0.67
0°F 0.5 0.8
Battery aging factor 0.8* 0.8*
Design margin 0.85* 0.85*
*Per IEEE Std. 485 recommended practice
Table 4. Peak discharge rate for a hypothetical 69kV substation load.
125VDC Load Description Quantity Current (A) Subtotal (A)
69kV circuit switchers 2 15.0 30.0
69kV substation relays 8 0.2 1.6
5kV vacuum breakers 9 7.0 63.0
5kV switchgear relays 8 0.2 1.6
5kV switchgear indicating lights Ignore 0.0 0.0
Total 96.2A
Table 5. Required Ampere-hour rate for a hypothetical 69kV substation load.
125VDC Load Description Quantity Current (A) Hours (h) Subtotal (Ah)
69kV circuit switchers 2 15.0 0.016* 0.5
69kV substation relays 8 0.2 8.0 12.8
5kV vacuum breakers 9 7.0 0.016* 1.0
5kV switchgear relays 8 0.2 8.0 12.8
5kV switchgear indicating lights Ignore 0.0 8.0 0.0
Total 27.1 Ah
*0.016 hours = 1 minute

Definitions
 battery duty cycle - the load (including duration) the battery is expected to
supply
 cell size - rated capacity of the battery
  equalizing charge - prolonged charge, at a rate higher than the normal float
voltage
 full float operation - operation with the batteries and load connected in
parallel
 period - time during which load is expected to be constant during sizing
calculations
 rated capacity - capacity of the battery cell (usually for a given discharge
rate and end of cell voltage)
 valve-regulated lead-acid (VRLA) cell - sealed lead-acid cell (with the
exception of a valve that opens when the internal pressure exceeds the
external pressure)
 vented battery - battery in which the products of electrolysis and
evaporation are allowed to escape freely to the atmosphere

[edit] Battery Selection

The selection of the physical battery (cells) is dependant on several factors:

 type of battery (sealed, vented, lead acid, NiCad, etc.)

 expected life of the battery
 usage of the batter (number of charge/discharge cycles)
 dimensions and weight of the battery
 construction materials
 connectors and terminals
 ambient environment and conditions
 maintenance requirements
 seismic characteristics

[edit] Ampere-hour and Watts/cell

The Ah or Ampere-hour capacity is the current a battery can provide over a
specified period of time. For example 100Ah @ C10 rate to end of discharge of
1.75 V/cell means the battery can provide 10 Amps for 10 hours to an end of
discharge voltage of 1.75 V per cell.
Different battery manufacturers will use different Cxx rates depending on the
market or application at which their batteries are targeted. Typical rates used are
C3, C5, C8, C10 and C20. Because of this it is important, when comparing
batteries from different manufacturers.

Ah is used for sizing batteries based on constant current methods and watts/cell
on constant power methods.

[edit] IEEE 485 Lead Acid Batteries for Stationary

Applications
This standard details methods for defining the dc loads and for sizing a lead-acid
battery to supply those loads in full float operation. A brief description of the
method presented by the standard follow. For a full and accurate description,
refer to the full standard.

[edit] Load Definition

Loads are classified as:

 continuous - loads continually present

 noncontinuous - loads lasting for a specific period
 momentary - loads lasting for less than 1 minute

Typical Loads

Continuous Noncontinuous Momentary

Emergency motors Switchgear operations

Lighting
Fire protection systems Valve operations ( < 1 min)
Continuous Motors Valve operations ( > 1 min) Isolating switch operations
Converters Field flashing of generators
Indicating Lights Motor starting currents
UPS Inrush currents
Control Systems

Note: commonly momentary loads are assumed to last for 1 minute during
battery sizing calculations.
[edit] Duty Cycle Diagram

The standard recommends a duty cycle be drawn showing the anticipated loads
(in Amperes or power) for the required duration of battery backup time.

IEEE 485 Std. Recommended Practice for Sizing Lead Acid Batteries for Stationary
Applications - Typical Duty Cycle

Considerations

 loads and times where known should be shown

 random loads should be shown at the most critical times

[edit] Calculation of Battery Size

Number of Cells and Cell Voltage The mumber of cells is estimated based on
the maximum battery voltage and float charge voltage:

The minimum battery voltage is the minimum system voltage (including voltage
drops across cables). Given the minimum cell voltage the minimum cell voltage is
given by:
Temperature Correction At temperature decreases the capacity of a cell
decreases (and vise verse as the temperature increases). Manufacturers quote
cell capacity at a given temperature and appropriate correction factors should be
used for other temperatures.

Aging Factor Battery performance is relatively stable through out its life,
dropping of rapidly towards the end. To ensure the battery can meet the design
requirements throughout its life the standard suggestions the initial capacity
should be 125% of the design capacity.

Design Margin To cater for unexpected circumstances (increased loads, poor

maintenance, recent discharge, etc.) it is common to allow a design margin of
10% to 15%.

IEEE 485 Std. Recommended Practice for Sizing Lead Acid Batteries for Stationary
Applications - Typical Duty Cycle

Sizing Methodology

The required capacity of the cell FS is given by:

Where S can be any integer from 1 to N depending on the section being

calculated and FS is expressed in watt-hours or ampere-hours depending on
which Ct is used.
The required uncorrected cell size F, is then given by:

where:

 F - is the uncorrected (temperature, aging and design margin) cell size

 S - is the section of duty cycle being studied (containing all previous
sections)
 N - is the number of periods in the duty cycle
 P - is the period being analyzed
 AP - the amperes required for period P
 t - the time in minutes from the beginning of period P through the end of
Section S
 Ct - is the capacity rating factor (for a given cell type, at the t minute
discharge rate, at 25 °C, to a definite minimum cell voltage
 FS - is the capacity required by each section

[edit] Capacity rating factor

There are two ways of expressing capacity:

Term Rt

The term Rt is the number of amperes each plate can supply for t minutes, at 25
o
C to a defined minimum cell voltage.

giving:

Term Kt

The term Kt is the ration of ampere-hour capacity, at a standard time rate, at 25

o
C and to a defined minimum voltage which can be delivered for t minutes.
 giving:

Rt is not equal to 1/Kt because each factor is expressed in different units.

[edit] References
 IEEE Std. 485 'IEEE Recommended Practice for Sizing lead-Acid Batteries
for Stationary Applications