Application Note

How to size Batteries for Eaton 9x55, 9390 and

9395 UPSs
How to Size Batteries Eaton Corp. 15.2.2010 1
Scope
This document describes the steps to follow to size a battery, considerations to take and quick
calculations to make. These notes are aimed to sales personnel.

Important factors
The best way to start the calculation for the right UPS for a customer is by looking into 4 important
things:

1. Load size (S) commonly in kVA
2. Specific output power factor (pf)
3. Desired Back-up time (Bt) in minutes or hours
4. Recharge time required (Rt) in minutes or hours


In order to define the right UPS it is necessary to calculate:

a. Real Power in demand
b. Total Real Power to be discharged
c. Power needed to recharge the battery kWh (kilo Watts hours)
d. Power needed in the (recharge + demand) time
e. Recharge current
f. Type of UPS and number of battery string required (in the case is needed)

In most of the cases, it should be calculated in this order (from a to f)

An example:

A customer is running an industrial process industrial process that demands 60 kVA. The pf
(power factor) is 0.8 and it is specified a back-up time of 2 hours and a recharge time of the
batteries is 20 hours (this configuration purely depends on the customer)

For this example:
S (Demand Power) 60 kVA
pf (Power Factor) 0.8
Bt(Backup time) 2 hours
Rt (Recharge Time) 20 hours


Calculations:

a. Real power in demand:
With the load size (60kVA) is possible to obtain the a Real more accurate power in demand P (in
kW) using the efficiency of the inverter (about a 94%),


Thus,




0.94
pf S
P

=
kW 51.06
0.94
0.8 kVA 60
P =

=
How to Size Batteries Eaton Corp. 15.2.2010 2

b. Total Power to be discharged (within back-up time)
Now that we got the Real Power (51.06 kW) we can calculate the total Power to be discharge in the
back-up time by multiplying it by the Back-up time (Bt), that is,


kWh 102.13 hours 2 kW 51.06 discharged power Total
Bt P discharged power Total
= =
=


c. Power needed to recharge the battery
After the UPS battery has been discharged in the back-up time, it will start recharging in a specific
time. In this example the customer demands 20hours of recharging time, that is:

kW 5.10
20h
102.13kWh
battery recharge to needed Power

Rt
discharged power Total
battery recharge to needed Power
= =
=


d. Power needed in the (recharge + demand) time
It is important to know the power needed to recharge the battery in the moment of maximum
demand, this moment comes when the power from the mains is back, and the UPS is supplying the
output load level in demand (51.06 kW in this example), plus the power needed to recharge the
battery whilst (5.10 kW).


Eff *
recharge to needed Power P
time demand) (recharge in needed Power
+
= +

kW 39 . 60
93 . 0
kW 10 . 5 kW 06 . 51
time demand) (recharge in needed Power =
+
= +


* Eff

corresponds to the system efficiency when the rectifier, inverter and charger are all together
in use at the time of recharge and demand time; this value is approximately about 93%


e. Recharge current (I)
It is important to know the input current limit to adjust it in the recharge + demand time, also, in
order to check if our UPS model chosen (lets say 9390 60kVA for now) can use that current
input level of current.

As a rule: I = P/V, Therefore:



How to Size Batteries Eaton Corp. 15.2.2010 3
A 9.21
V 554.4
5.10kW

battery the of V
battery for the needed P Total
I = = =

This value of Voltage is constant over the battery when it is being charged
(about 2.31V/cell) and depending on the UPS model varies, for instance, for 9390 60kVA is 554.4
V, here is a table for other models:


Model Voltage
9390 & 9395 models 554,4 V
9355 20 - 40kVA 498,96 V
9355 8kVA 443,52 V


f. Number of battery strings required
To calculate battery strings needed, it is taken into account the UPS model, Battery type and back-
up time. Eaton 9390 uses 40 blocks of 12V batteries, 9355 (20, 30 and 40kVA) uses 36 blocks and
9355 (8 15kVA) uses 32 blocks. There are battery back-up time tables that we can use to size the
quantity of strings required. These tables can be found from http://pqsalesweb.eaton.com
under this logic:

Salesweb products & services Backup Power (UPS) and then select the product
e.g., Eaton 9155, 9355, 9390 or 9395Technical Information Runtime chart or Runtime
Matrix.

Note: if there is no access, contact local Eaton local Marcom team.

Lets use a fragment from 9390 Runtime table for this example:
(extracted from Powerware 9390 External Battery Cabinets 40 - 160 kVA / battery runtime

Table 6. Powerware 9390 UPS + Large battery cabinet(s) (part numbers 1025468* /
1025471**)
CSB HRL 40 kVA 60 kVA 80 kVA 100 kVA 120 kVA 160 kVA
9390+ 1*BAT(12-500) 80 49 35 24 18 12
9390+ 2*BAT(12-500) 180 120 81 60 48 34
9390+ 3*BAT(12-500) 288
174
123 95 80 57
Note! Above run times are approx. times for batteries after several discharge cycles.


The desired back-up time in this example is 2 hours (or 120 minutes) 3 battery strings attached will
enough to back-up for about 174 minutes and 2 strings exactly 120 minutes.

As a conclusion we can say that a 9390 60kVA UPS model with 3 string batteries attached will
back-up 2 hours a system load output of 60kVA and it will require about 5.10kW/hour or 9.21 A to
recharge in a period of 20hours to 90% of the battery capacity.
How to Size Batteries Eaton Corp. 15.2.2010 4
Appendix


A. Charging current and nominal voltage per string for different UPS models and loads


This table is from Eaton 9x55, 9390 and 9395 Datasheet (www.eaton.com/powerquality)




12V Batteries blocks:



a. For 9x55 cabinets b. For 9390 and 9395



9x55 (kVA)


9390 (kVA)

9395 (kVA)



8-15

20 - 40 40 60 80 100 120 160 275 550 825 1100






Nominal
current (A)

3


3
10 20 20 30 30 40 38 76 114 152

Max
current* (A)
30

60

20 40 40 60 60 80 83 166 249 332








Battery
Nominal
Voltage
(V) 384 432 480 480 480 480 480 480 480 480 480 480

32 battery
blocks
36 battery
blocks

40 battery blocks 40 battery blocks
192 cells 216 cells 240cells 240cells
*May be limited by maximum UPS input current rating
How to Size Batteries Eaton Corp. 15.2.2010 5
B. Overall efficiency according to the load level

9155 (kVA) Efficiency input/output


8 10 12 15 20 30

at 100% rated load 91 % 91 % 91 % 91 % 93 % 93 %
at 75% rated load 90 % 90 % 90 % 90 % 92 % 92 %
at 50% rated load 90 % 90 % 90 % 90 % 91 % 91 %
at 25% rated load 85 % 85 % 85 % 85 % 86 % 86 %

9155 (kVA) Efficiency input/output


8 10 12 15 20 30 40

at 100% rated load 91 % 91 % 91 % 91 % 92 % 93 % 93 %
at 75% rated load 90 % 90 % 90 % 90 % 91 % 92 % 92 %
at 50% rated load 90 % 90 % 90 % 90 % 90 % 91 % 91 %
at 25% rated load 85 % 85 % 85 % 85 % 85 % 86 % 86 %

9390 (kVA) Efficiency input/output


40 60 80 100 120 160

at 100% rated load 93,80 % 93,40 % 93,70 % 93,60 % 93,60 % 93,60 %
at 75% rated load 93,60 % 92,90 % 92,90 % 92,90 % 92,90 % 92,90 %
at 50% rated load 93,10 % 91,80 % 92,50 % 92,50 % 92,50 % 92,50 %
at 25% rated load 89,60 % 87,60 % 89,60 % 89,60 % 89,60 % 89,60 %



9395 (kVA) Efficiency input/output


225 275 450 550 825 1100

at 100% rated load 94 % 94 % 94 % 94 % 94 % 94 %
at 75% rated load 94 % 94 % 94 % 94 % 94 % 94 %
at 50% rated load 93 % 93 % 93 % 93 % 93 % 93 %
at 25% rated load 90 % 90 % 90 % 90 % 90 % 90 %

These tables are from Eaton 9x55, 9390 and 9395 Technical Information in Salesweb.
(http://pqsalesweb.eaton.com/Products/ThreePhase)