BATTERY SIZING

The basic data necessary for sizing a battery are: the requisite operating time, the
power or discharge current to be supplied and the permissible voltage range,
particularly the end-point voltage. Other data, such as ambient temperature,
frequency of mains failure and specific load cycles influence sizing.

Battery selection is based on the manufacturer’s literature, the appropriate type being
chosen in relation to current, capacity, discharge time and voltage range.

Sizing calculations formulas

With parallel operation, the number of cells in any battery is calculated from the
maximum trickel-charge voltage and the maximum permitted continuous demand
voltage:

Vmax
n=
Vc max

where;
n Number of cells
Vmax Maximum permitted continuous demand voltage
Vcmax Maximum charge voltage per cell

Static or dynamic loading must at no time during the discharge period allow the
battery voltage to drop below the minimum value demanded by the consumers Vmin:

Vmin + ΔVmax
Vc min =
n

where;
Vcmin Minimum voltage of individual cell
Vmin Minimum permitted continuous demand voltage
ΔVmax Largest possible voltage drop between battery terminals and
consumer

The battery rating is selected by reference to the capacity Curve or Performance Data
Tables of the chosen cell type such that the voltage according to the current/time
discharge data does not fall below the minimum value Vmin while power is being
drawn.
 Worked Examples

Example 1 (Lead-acid):

A battery is required for an uninterruptible power supply system with a nominal

voltage 220 V, which will be capable of supplying consumers with 60 A direct current
for 1 hour. The maximum voltage tolerances for the connected loads are +10% and -
10%. How many cells will be required and what capacity must they have?

Known values:

Vnom = 220 V
Vmax = 242 V
Vmin = 198 V
ΔVmax = 0 (voltage drop is negligible)
I = 60 A
t = 1 hour

The battery cannot be disconnected from the consumer for recharging. Therefore, a
maximum charge voltage of Vcmax = 2.23 V per cell only is acceptable.

242
n= ≈ 108 cells
2.23

108 cells are required for the battery. During discharge, however, the voltage must
not fall below Vmin. A definite end voltage per cell is therefore fixed.

198 + 0
Vc min = = 1.83 V ‘minimum voltage per cell‘
108

Therefore, the required cell capacity is calculated using the selection table for Vcmin =
1.83 V per cell (Varta Block battery).

The 1 hour discharge time is found in the x axis, the column is followed down to the
appropriate current of 60 A, and the battery type read off on the left = Vb 624
(C10=100 Ah).

Example 2 (NiCd):

On mains failure consumers are to be fed with current for 3 hours. The equipment has
a rated voltage of 110 V and calls for a current of 40 A. The maximum voltage
tolerance for the connected loads are +10% and -20%. A NiCd battery is specified.

Since the maximum charge voltage per cell is 1.55 V/cell- the battery will consist of:

11. x110
n= = 78 cells
155
.
assume that the voltage drop ΔVmax = 0, we have;
 0 .8 x110 + 0
Vc min = = 113
. V/cell “take Vcmin = 1.14 V/cell”
78

Therefore, the required cell capacity is calculated using the selection table for Vcmin =
1.14 V per cell (Varta TP battery).

The 3 hour discharge time is found in the x axis, the column is followed down to the
appropriate current of 40 A, and the battery type read off on the left = TP 140
(C5=140 Ah).

Important: cell capacities obtained in the above examples need to be corrected to

include design margin (up to 10%), age factor (15 to 20 %), and ambient temperature
correction factor.

Example 3 (Charger size):

Determine the required charger output to recharge a lead-acid battery of example 1 in

10 hrs. while serving a dc system load of 60 A.

( AH )K
Charger amps = +L
T

Where;
AH = ampere-hours removed from the battery
K = charging factor
T = desired recharge time in hours
L = steady-state dc load to be served by the charger while the battery is
being recharged

(100)11
.
Charger amps = + 60 = 71 A
10

Select the next standard-rated charger with an output that is greater than 71 A.

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