How to Size a Battery Bank

Battery bank sizing can be one of the more complex and important calculations in your
system design. If the battery bank is oversized, you risk not being able to keep it fully
charged; if the battery bank is sized too small, you won't be able to run your intended loads
for as long as you'd planned.
written by Chris Brown
Many renewable energy (RE) systems incorporate batteries. Batteries can be used in all
types of systems including:
Photovoltaic or solar panels
Wind Power Systems using Wind Turbines
Hydroelectric generators
Hybrid Renewable Energy Ststems
Other DCpower sources
The energy stored in the batteries can then be used directly to power DC loads or it can be
inverted to power AC loads. The batteries recommended for RE systems are deep cycle
batteries. To ensure you have enough reserve capacity to provide the electricity you need
(without running additional generators), invest the time to size your battery bank properly.
Because of the various conditions affecting battery bank sizing, this process may be one of
the more challenging calculations youll have to do when planning your RE system.
Before tackling the calculations, start by identifying a few key pieces of information:

Watt Hours of electricity usage per day

Number of Days of Autonomy
Depth of Discharge limit
Ambient temperature at battery bank

Electrical Usage
The first thing youll need to know is the amount of energy youll be consuming per day. Its
worth the time to do a careful evaluation of exactly what loads (appliances, electronics,
etc.) you plan to use and for what lengths of time. Keep track of this information on a loads
list; youll refer to this list often for sizing other components as well. Your final tally should
be expressed in Watt-hours (Wh) per day. If you know the kilowatt hours (kWh) per day
just multiply that number by 1,000 to determine the Watt-hours per day. (Example: 1.2
kWh = 1,200 Wh)

Days of Autonomy
Next, you must determine the number of days of battery back-up that you want to have on
hand. In other words, if you are unable to charge your batteries by any means, and you still
need to draw power, you must provide this additional storage by increasing the size of your
battery bank. For solar panel
If you conclude that you need more then five days of battery backup, you may want to
explore multiple sources of electricity generation or backup generator options (like a fossilfueled generator). If your primary electricity source is wind power, determine the number of
days when there is little or no wind. This information can be found in the data youve
collected using your data-logging anenometer. Hydroelectric turbine systems are unique

because they usually operate continuously, and therefore do not require extensive storage.
If youre sizing a battery bank to be used in conjunction with an on-demand fuel-powered
generator, the number of days of backup will represent the number of days you wish to go
without using your generator.

Depth of Discharge

Another factor to consider is the planned Depth of Discharge (DoD) of your battery bank.
Flooded lead acid batteries (FLA), sealed AGM batteries and sealed gel batteries are all rated
in terms of charge cycles. A single cycle takes a battery from its fully charged state, through
discharge (use), then back to full charge via recharging. The depth of discharge is the limit
of energy withdrawal to which you will subject the battery (or battery bank). DoD is
expressed as a percent of total capacity. The further you discharge a battery, the fewer
cycles that battery will be capable of completing. Simply stated, deeper discharge shortens

battery life.
Battery Life based on Depth of Discharge
Its recommended that you never discharge a deep-cycle battery below 50% of its capacity;
however, many battery manufacturers recommend even shallower DoDs. For off-grid
applications, a 25% DoD will extend battery life significantly. On the other hand, if youre
only using the batteries occasionally, as a backup system, you can factor in a DoD of 50%
or perhaps more.

Temperature
Battery life and capacity are affected by temperature. Unlike PV modules

System Voltage
By this point, you will have identified your system voltage. This is typically 12V, 24V, or
48V.

Calculations
Once youve pinpointed all these variables, its time to calculate the size of your battery
bank! Lets go through the steps below, using the following example system:

A system load of 6,000 Watt-hours per day

Three Days of Autonomy (back up) needed
Planned Depth of Discharge (DoD): 40%
Battery bank ambient average low temperature 60 F.
A 48V system

Step
1
2
3

Process
Identify total daily use in Watt-hours (Wh)
Identify Days of Autonomy (backup days);
multiply Wh/day by this factor.
Identify Depth of Discharge (DoD) and convert to
a decimal value. Divide result of Step 2 by this
value.
Derate battery bank for ambient temperature
effect. Select the multiplier corresponding to the
lowest average temperature your batteries will be
exposed to. Multiply result from Step 3 by this
factor. Result is minimum Wh capacity of battery
bank:
Temp. in [degrees] F.
Factor
80+
1.00
70
1.04
60
1.11
50
1.19
40
1.30
30
1.40
20
1.59
Divide result from Step 4 by system voltage.
Result is the minimum Amp-hour (Ah) capacity of
your battery bank.

Example
6,000 Wh/day
3 Days of Autonomy:
6,000 x 3 = 18,000 Wh
40% DoD:
18,000 / 0.4 = 45,000 Wh
60 F. = 1.11
45,000 x 1.11 = 49,950 Wh

49,950 / 48 = 1,040 Ah

Selecting batteries to meet the Amp-hour capacity

Now that you know the Amp-hour (Ah) capacity that will give you the storage you need, you
may need a little guidance in selecting specific batteries. Keep in mind that its best to keep
the number of parallel strings of batteries to three or fewer. If you parallel more than three
strings of batteries, you risk shortening battery life due to uneven charging1
When batteries are cabled together in series, the voltage is additive. For example, you can
put two 12V, 100 Ah batteries in series for a 24V bank. The capacity of that bank would still
be 100 Ah. When batteries are connected in parallel, the voltage remains constant and the
Ah capacity is additive. In our example with the 12V, 100 Ah batteries, connecting them in
parallel would result in a 12V system with a capacity of 200 Ah.
The batteries you select must meet both your system voltage requirements AND the Ah
capacity you calculated. In our example of the 48V system, we calculated that we needed
1,040 Ah to produce 6,000 Wh per day with 3 days of storage. More than one configuration
of batteries can meet this need. For example, you could have four 12V batteries in series,
each with a capacity of 1,040 Ah or more. Or you could use eight 12V batteries wired in two
parallel strings where each battery had a 520 Ah capacity. Or you could use twelve 2V
batteries in series, again with appropriate Ah capacities. In any given case, there may be
multiple solutions. Your choices will be limited by battery availability and budget.

Building the bank: Amps, then Volts

To build your bank, try first to select a battery that is rated close to the Ah capacity you calculated in Step 5
above. Ignore voltage for a moment. If you cant find one thats very close, look for one that has a capacity
either one-half or one-third your needed Ah figure. These fractions represent the number of series strings of
such batteries you would need, in parallel, to complete your bank (1/2 = 2 strings, 1/3 = 3 strings). Once
you find a candidate battery, divide your system voltage by the batterys voltage. This will give you the
number of such batteries you would need in each series string.
The total number of individual batteries you will need to complete your battery bank will be the product of
the number of strings needed to meet your Ah requirement and the number of batteries per string needed
to meet your system voltage requirement.
Total # batteries in bank = (# series strings) X (# batteries per string)
You can then compare your candidate battery banks against price, size and availability. You may want to
talk with people who have used these batteries and learn what their experiences have been, compare
warranties and advertised features, and finally buy the batteries you feel are best for you.
In any battery-based RE system, batteries are a major component investmentsecond in cost only to the
PV modules in most casesand they are a critical part of the system. Careful planning and battery selection
is vital to ensure that your battery bank meets your needs and provides many hundreds or thousands of
charge cycles. Take your time, run the numbers more than once, and youll avoid the worst pitfalls of RE
system design.

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Battery Bank Sizing Recommendations

These calculations are intended for off-grid systems, not for grid-connected systems with battery backup.

PV
system
size

1 kW

2 kW

3 kW

4 kW

Ave. daily PV
generation
(kWh)1
Min.

1.54

3.08

4.62

6.16

Max.

4.06

8.12

12.2

16.2

Recommended
battery
capacity (kWh)2
Ave.

2.87

5.74

8.61

11.5

Min.3

3.08

6.16

9.24

12.3

Max.4

8.12

16.2

24.4

32.5

Ave.5

5.74

11.5

17.2

23.0

Battery
bank
voltage6

Recommended
battery
capacity (Ah)2

Estimated cost
of batteries7

Min.3

Max.4

Ave.5

Min.

48

64

169

120

24

128

338

239

12

257

677

478

48

128

338

239

24

257

677

478

12

513

1,353

957

Due to recent market

volatility in the cost of lead,
it is next to impossible to
give a good cost estimate
for a lead-acid battery bank
at this time.
As of mid-August, 2007,
costs were around $400 per
kWh of battery capacity.

48

193

508

359

24

385

1,015

718

12

770

2,030

1,435

48

257

677

478

Max.

Ave.

5 kW

6 kW

7 kW

8 kW

9 kW

10 kW

7.70

9.24

10.8

12.3

13.9

15.4

20.3

24.4

28.4

32.5

36.5

40.6

14.4

17.2

20.1

23.0

25.8

28.7

15.4

18.5

21.6

24.6

27.7

30.8

40.6

48.7

56.8

65.0

73.1

81.2

28.7

34.4

40.2

45.9

51.7

57.4

24

513

1,353

957

12

1,027

2,707

1,913

48

321

846

598

24

642

1,692

1,196

12

1,283

3,383

2,392

48

385

1,015

718

24

770

2,030

1,435

12

1,540

4,060

2,870

48

449

1,184

837

24

898

2,368

1,674

12

1,797

4,737

3,348

48

513

1,353

957

24

1,027

2,707

1,913

12

2,053

5,413

3,827

48

578

1,523

1,076

24

1,155

3,045

2,153

12

2,310

6,090

4,305

48

642

1,692

1,196

24

1,283

3,383

2,392

12

2,567

6,767

4,783

Ave. daily PV generation (kWh) assumes a minimum insolation for Binghamton NY of 2.2 hr/day of "full sun"
(1000W/m2) in December, a maximum of 5.8 hr/day in June, and an average of 4.1 hr/day annually, a year-toyear uncertainty of +/-11% (NREL data), and an overall PV system efficiency factor of 0.70.
2
Recommended battery capacity (kWh or Ah) is set equal to twice the average daily PV generation. For longest
life, sealed maintenance-free batteries (aka VRLA, gelled electrolyte, AGM, etc.) should not be discharged to
greater than 50% of their total capacity rating (at the 24hr discharge rate). As a rule-of-thumb, recommended
battery capacity (in kWh) turns out to be approximately 3x the PV system rating (in kW).
3
Min. recommended battery capacity (kWh or Ah) is the largest battery bank size that the PV system can
recharge from 50% depth-of-discharge (DoD) on an average mid-winter day. Min. recommended battery
capacity (kWh or Ah) assumes no other means of battery charging other than the PV system. A battery bank of
this size or smaller would be fully charged (on average) by the PV system every day of the year without other
charging sources. This is usually the best choice unless expected daily energy usage is more than 1/2 of the
min. battery capacity.
4
Max. recommended battery capacity (kWh or Ah) is the largest battery bank size that the PV system can
recharge from 50% depth-of-discharge (DoD) on an average mid-summer day. In general, other charging
sources (such as an auxiliary generator or utility grid) will be needed at other times of the year to bring the
battery bank to a full state of charge at regular intervals (at least once per week is recommended). Without

other charging sources, in order for this battery bank to remain fully charged at times of the year other than
the summer months, energy usage must be equal to or less than that provided by the PV system on any given
day. This can be difficult to achieve, especially during winter months.
5
Ave. recommended battery capacity (kWh or Ah) is the largest battery bank size that the PV system can
recharge from 50% depth-of-discharge (DoD) on an average day. In general, other charging sources (such as
an auxiliary generator or utility grid) will be needed during the winter months to bring the battery bank to a full
state of charge at regular intervals (at least once per week is recommended). Without other charging sources,
in order for this battery bank to remain fully charged in winter months, energy usage must be equal to or less
than that provided by the PV system on any given day.
6
Battery bank voltage is the nominal value, not the fully-charged voltage. 48V values are highlighted due to
better economics and efficiency of higher voltage battery charging systems utilizing 48V DC-to-AC inverters.
7
Estimated cost of batteries includes batteries, cabling, conduit and enclosure(s) - all of which are required for

Marine Products

HOW TO SIZE AND USE YOUR BATTERY BANK

Introduction.
Glacier Bay manufactures a complete line of AC, DC, engine and hydraulically driven refrigeration
systems. Unlike manufacturers who specialize in one type of system, Glacier Bay can provide
whatever is most appropriate for the application. From experience, we have found the best system for
the vast majority of cruisers to be a DC driven system coupled with a properly designed battery bank
and charging system.
We encourage you to ignore some "conventional wisdom" on energy management, gain your own
clear understanding of DC storage and charging systems and apply that knowledge to your boat. By
doing so, you can reduce the engine run time required by your refrigeration system to 50% to 80%
less than would be needed with a direct engine-driven system. Also remember, the money and effort
you put into your battery and charging system benefit the entire boat, not just the refrigeration system.
What size battery bank should you have?
If you are a cruiser the answer to this one is quite simple - The largest one you can afford in terms of
space, weight and money. This is equally true no matter what the electrical load is! To see why, let's
take a look at two different approaches to estimating the "correct" battery capacity.
Energy Analysis - the conventional wisdom.
It is common practice among the energy gurus to perform an energy analysis of a cruising boat and
advise a battery bank capacity based on the results. To perform such an analysis, assumptions are
made about the length of time the lights, appliances, navigational equipment, water maker, etc. will be
operating and the amount of current they will draw while they are on. An amp-hr (current draw x
operating time) total over a 24 hour period is then calculated for every device which consumes
electrical energy. For example;

Assumption
Three reading lights drawing 1 amp
each will be used an average of
3.5 hours per day.
The refrigerator draws 6 amps
while it's running and runs an
average of 18 hrs per day.

Calculation

Usage per 24 hrs

(3 x 1) x 3.5 = 10.5

10.5 amp-hrs

6 x 18 = 96

96 amp-hrs

Making accurate estimates for some items is relatively easy, for others such as electric autopilots it is
nearly impossible. Nevertheless, to complete the analysis, the total estimated energy consumption of
all such devices is added together to provide an estimated average total daily energy consumption in
amp-hrs. As you can imagine, the totals vary tremendously from boat to boat. However, for illustration
purposes, let's assume that our particular cruiser calculates a total estimated use of 140 amp-hrs per
24 hours.
In the next step of the analysis it is assumed that our cruiser will not want to discharge their batteries
more that 50% since it is commonly believed that doing so will disproportionately shorten their life
span. The cruiser must now decide how often they wish to run their engine or generator recharge
their batteries. This, in combination with their estimated daily energy consumption then forms the
basis for calculating the battery bank size required. For example;

Recharge Frequency Desired

twice per day
once per day
once every two days
once every three days

Bank Size Required

140 amp-hr
280 amp-hr
560 amp-hr
840 amp-hr

So it is seen that, by using the energy analysis method, the calculation of appropriate battery bank
size is made purely on the basis of energy usage and the frequency of recharge cycles. Sounds
good. So what's the problem?
Why energy consumption is irrelevant when sizing your battery bank.
While it can be helpful to have an idea of how much energy you are likely to use in a day, it should
not form the basis for sizing your battery bank. Why? Because it leaves out the single most important
consideration in battery bank sizing - the recharge, or acceptance, rate. The energy consumption
analysis gives you an idea of how often you will need to run your charging engine but gives no
indication of how long the engine will need to be run. For most cruisers, particularly those who have
already had the experience of sitting in their island paradise amidst the diesel fumes waiting for their
batteries to recharge, minimizing their engine run time is the top priority.
The proper size alternator for the battery bank.
To fully appreciate why the acceptance rate is so important it is first necessary to gain an
understanding of the relationship between alternator size battery bank size. It is only possible to
select right alternator(s) after the capacity and type of battery bank have been determined.
Capacity While the power output of a battery is rated in several ways, the only rating generally useful to the

cruiser also happens to be the most common and is referred to as the 20 hour amp-hr rating. This
number represents the total amount of energy that the fully charged battery can release when
discharged at a stable rate over a 20 hour period. A good quality 8D size (20"x11"x10") lead-acid type
deep cycle battery would have a 20 hour rating of 220 amp-hrs @ 12 volts. Gelled electrolyte type
batteries (gel cells) and absorbed glass mat batteries (AGM) are usually slightly less with about 200
amp-hrs in an 8D size. Remember, when determining the capacity of your battery bank use the
manufacturers ratings and add the amp-hr rating of all batteries which are connected in parallel and
discharged and recharged as a single bank. If you choose to use multiple house banks (not
recommended) count only those banks which are discharged and recharged simultaneously. Do not
simply add up the ratings of all the batteries on your boat.
Type This is not a question of brand name but one of electrolyte type. Your choice here is common leadacid, gelled lead-acid (gel cell) or absorbed glass mat (AGM).
Calculating your battery bank's acceptance rate.
The acceptance rate is the maximum rate at which a battery bank can be recharged. The acceptance
rate of the bank is determined by it's capacity, type and state-of-charge. Since we know (or can
determine) the capacity and type of the bank, we will need to make an assumption as to it's average
state of charge under cruising conditions. Batteries which are deeply discharged have a higher
acceptance rate than those which are more fully charged. Surveys have shown that cruisers typically
cycle their batteries between 50% and 80% of full charge under most conditions. Cruisers who have
large capacity banks in comparison to their energy needs tend to cycle between 70% and 90%, while
those with small banks tend to cycle between 40% and 70%.
For the sake of this exercise, we will estimate at the average acceptance rate when cycling the
batteries between 50% and 80% of full charge. Under these conditions lead-acid batteries have been
shown to have an acceptance rate equal to 25% of their total 20 hour amp-hr rating. Stated another
way, a lead-acid battery bank consisting of three 8D size 12 volt batteries @ 220 amp-hrs each (660
amp-hrs total) would have an acceptance rate of 165 amps.
One advantage in gel cell type batteries is that they have a higher acceptance rate than do the
common lead acid type. Acceptance rate calculations made with gel cell batteries should be based on
40% of their 20 hour amp-hr rating rather than the 25% figure used with lead acid.
Because of their lower 20 hour rating, the bank of three 8D batteries described in the example above
would have a total capacity of only 600 amp-hrs (rather than 660 with lead acid). However, they
would have an acceptance rate of 240 amps instead of 165 amps.
The highest acceptance rate is obtained with absorbed glass mat batteries (AGM). Acceptance rate
calculations made with AGM batteries should be based on 100% of their 20 hour amp-hr rating rather
than the 25% figure used with lead acid or 40% used with gel cells. Our bank of three 8D batteries (as
described in the other examples) would have a total capacity of 600 amp-hrs just as would the gel
cells. However, they would have an incredible acceptance rate of 600 amps instead of 165 amps
(lead acid) or 240 amps (gel cell).
As you can see, once you know the capacity and type of your battery bank you can calculate it's
acceptance rate. Simply multiply the total capacity by 25% for lead acid batteries, 40% for gel cells or
100% for AGMs.
What about the alternator?
Since the acceptance rate described the maximum rate at which a battery bank can be recharged, it
stands to reason that the proper size alternator can only be selected once the acceptance rate has
been determined. It is wasted money to charge a battery bank that has an acceptance rate of 70

amps with a 165 amp alternator. Likewise, using a 100 amp alternator to charge a battery bank with
an acceptance rate of 240 amps is pointlessly slow and inefficient. The goal is to get the output of
your alternator (under actual charging conditions) to match the acceptance rate of your battery bank
as closely as possible. Most alternator manufacturers will provide you with the output curve of the
alternator you are considering under hot conditions and at a variety of speeds. An alternator rated at
150 amps will likely only put out 130 amps once it gets hot and will only do that running at full speed.
Under realistic charging conditions, you may only be running your engine at 1100 - 1200 rpms. If your
alternator is belted at a 2 to 1 ratio it will be spinning at twice that speed, or 2200 - 2400 rpms. It is
quite possible that 150 amp alternator is now only going to putting out 80 amps or so.
Given this, how is it possible to get 200 to 300 amps of real charging capability? Sometimes it isn't,
but don't give up too quickly. Very large alternators with outputs 200+ amps are now quite common.
Additionally, it is often very practical to use two or more alternators to charge a single bank. Some
boats are already set up to have one alternator charge the engine start battery and a second to
charge the house bank. Usually the engine start battery needs little if any charging. An automatic
battery bank combiner can be used to allow both alternators to charge the house bank.
How much difference does this approach to battery sizing make?
Occasionally none, but often the results are surprising. Take a look back at our very first example
where our cruiser was required to replace 140 amp-hrs of energy per day. Let's assume that, using
the energy analysis approach, he determined that running the engine once per day would be ok. He
would then be advised to install a lead-acid battery bank of 280 amp-hrs capacity (ie. 50% max
discharge).
Now, using your knowledge of acceptance rate calculation, you know that the maximum rate at which
this bank can be recharged 70 amps (bank capacity x 25%). Therefore, it will take two hours of
engine run time per day to replace the electricity that the cruiser is using (70 amps x 2 hours = 140
amp-hrs).
If, on the other hand, the cruiser wants to minimize their engine run time, they could increase their
battery bank to far in excess of that recommended by the energy analysis approach to, say 600 amphrs. With this bank the acceptance rate would now be 150 amps, making it possible to replace the
same 140 amp-hrs in less than one hour, or only the time required by the smaller bank. If all that
sounds great but you don't have room for that many batteries, use gel cells or AGMs. You'll be able to
get that high charge acceptance rate in a much smaller bank.
By gaining a good understanding of battery acceptance rates, it is clear how large house battery
banks can be used to reduce the engine run time. It is equally easy to see why the popular practice of
separating house batteries into multiple banks is not the most efficient use of energy.
Battery life.
One cannot really discuss "battery life" without first defining the term. The same energy gurus who
promote the energy analysis method of battery bank sizing usually describe battery life by the number
of cycles (ie. discharge and recharge) which can be done before the battery fails. Through their
efforts, most people now recognize that depth of discharge has a direct impact on the number of
discharge/recharge cycles a battery can do. As a result, many cruisers endeavor to cycle their
batteries as "shallowly" as possible.
However, the number of cycles is only one measure of a battery's life and probably not the best.
Another way to look at battery life is by looking at the total number of amp-hrs which a battery will
store before failure. When viewed in this way, quite a different picture emerges as can be seen in the
chart below.

Depth of discharge
10%
20%
30%
40%
50%
60%
70%
80%

Typical Cycle Life

(100 amp/hr Trojan Deep Cycle Battery)
Total amp-hrs provided
Number of cycles
during service life
6,200
62,000
5,200
104,000
4,400
132,000
3,700
148,000
2,900
145,000
2,400
144,000
2,000
140,000
1,700
136,000

From our previous look at acceptance rate we know that batteries can be recharged much faster
when they are permitted to cycle down to 50% and below. From this chart it is obvious that doing so
extends the useful life of the batteries as well.
Conclusion.
By first calculating how much energy your Glacier Bay DC refrigeration system will use (use our
published guidelines to get an accurate idea), and then applying the principles discussed in this paper
to your battery and charging system, you will see just how much better off you are with the DC
system rather than an direct engine-drive. For those who do not mind engine running, there is still a
place for engine-driven refrigeration. However, as you will see once your calculations are complete,
they rarely make sense on a cruising sailboat. At Glacier Bay, we manufacture both types of systems.
Correctly set up, our DC system will use typically require 1/2 to1/4 the daily engine run time of an
engine-driven system. By properly planning and setting up your DC system, and combining it with
energy efficient appliances such as refrigeration and watermakers, battery charge concerns really can
become a thing of the past.

Switchgear Battery Sizing by Hand

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Apr 1, 2006 12:00 PM, By Aaron J. Hall, P.E., CH2M HILL, Inc.

A refresher on how to size batteries sans software

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.
Link to Document
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 1minute (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.)
Link to Document
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.
Link to Document
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 climatecontrolled building.
Link to Document
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 77F 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 77F room, and by a 0.8 battery-aging factor.
Required total Ah rate = 27.1 Ah 0.8 = 33.9 Ah
Link to Document
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 77F (25C)
Final Volts

1.75V

Models

Ampere-Hours (Ah)

Amperes (A)

8-hr

4-hr

3-hr

1.5-hr

1-hr

30 min

15 min

1 min

180

142

132

65

81

109

134

177

250

210

195

98

126

172

219

303

330

280

260

130

168

230

292

404

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

77F

1.0*

1.0*

32F

0.7

0.67

0F

0.5

0.8

Battery aging factor

0.8*

0.8*

Design margin

0.85*

0.85*

Ambient temperature

*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

15.0

30.0

69kV substation relays

0.2

1.6

5kV vacuum breakers

7.0

63.0

5kV switchgear relays

0.2

1.6

5kV switchgear indicating lights

Ignore

0.0

0.0

Table 4. Peak discharge rate for a hypothetical 69kV substation load.

125VDC Load Description

Quantity

Current (A)

Total

Subtotal (A)
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

15.0

0.016*

0.5

69kV substation relays

0.2

8.0

12.8

5kV vacuum breakers

7.0

0.016*

1.0

5kV switchgear relays

0.2

8.0

12.8

5kV switchgear indicating lights

Ignore

0.0

8.0

0.0

Total

27.1 Ah