AC UPS Sizing

Contents
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1 Introduction

1.1 Why do the calculation?

1.2 When to do the calculation?

2 Calculation Methodology

2.1 Step 1: Collect the AC UPS Loads

2.2 Step 2: Load Profile, Design Load and Design Energy

2.3 Step 3: Battery Sizing

2.3.1 Nominal Battery (or DC Link) Voltage

2.3.2 Number of Cells in Series

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

3.1 Step 1 and 2: Collect the AC UPS Loads and Construct Load Profile

3.2 Step 3: Battery Sizing

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 Template
5 Computer Software
6 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.

Why do the calculation?

An AC UPS system is used to support critical / sensitive AC loads. It is typically a batterybacked system which will continue to operate for a specified amount of time (called the
autonomy) after a main power supply interruption. AC UPS systems are also used as stable

power supplies that provide a reasonably constant voltage and frequency output, independent
of voltage input. This is particularly useful for sensitive electrical equipment on main power
supplies that are prone to voltage / frequency fluctuations or instability.
The AC UPS sizing calculation determines the ratings for the main AC UPS system
components: 1) rectifier, 2) battery banks and 3) inverter.
In some cases, the manufacturer will independently size the system and it is only necessary
to construct the AC UPS load schedule and load profile. However the calculation results will
also help determine the indicative dimensions of the equipment (e.g. size of battery banks)
for preliminary layout purposes.

When to do the calculation?

The AC UPS sizing calculation can be done when the following prerequisite information is
known:

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

Step 1: Collect the AC UPS Loads

The first step is to determine the type and quantity of loads that the
AC UPS system will be expected to support. For industrial facilities,
this will typically be critical instrumentation and control loads such
as the DCS and ESD processor and marshalling hardware, critical
workstations and HMI's, telecommunications equipment and
sensitive electronics. The necessary load data should be available
from the instrumentation and control engineers.

For commercial facilities, UPS loads will mainly be server, data /

network and telecommunications hardware.

Step 2: Load Profile, Design Load and Design

Energy
Refer to the Load Profile Calculation for details on how to construct a
load profile, calculate the design load (

) and design energy (

). The "Autonomy method" for constructing load profiles is typically

used for AC UPS systems.
The autonomy time is often specified by the Client (i.e. in their
standards). Alternatively, IEEE 446, "IEEE Recommended Practice
for Emergency and Standby Power Systems for Industrial and
Commercial Applications" has some guidance (particularly Table 3-2)
for autonomy times. Sometimes a single autonomy time is used for
the entire AC UPS load, which obviously makes the construction of
the load profile easier to compute.

Step 3: Battery Sizing

Refer to the Battery Sizing Calculation for details on how to size the
battery for the AC UPS system. The following sections provide
additional information specific to battery sizing for AC UPS
applications.

Nominal Battery (or DC Link) Voltage

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:

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).

Step 4: UPS Sizing

Overall UPS Sizing
Most of the time, all you need to provide is the overall UPS
kVA rating and the UPS vendor will do the rest. Given the
design load (

in VA or kVA) calculated in Step 2, select

an overall UPS rating that exceeds the design load.

Vendors typically have standard UPS ratings, so it is
possible to simply select the first standard rating that
exceeds the design load. For example, if the design load

12kVA, then the next size unit (e.g. 15kVA UPS) would be
selected.

Rectifier / Charger Sizing

The rectifier / charger should be sized to supply the
inverter at full load and also charge the batteries (at the
maximum charge current). The design DC load current can
be calculated by:

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).
For a three-phase UPS:

For a single-phase UPS:

where IL is the design

AC load current (full
load) (A)
S is the selected UPS rating (kVA)
Vo is the nominal output voltage (line-to-line voltage for a three phase UPS) (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