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UPS/INVERTER BATTERS PRODUCT DETAILS AND APPLICATION ENGINEERING - A.S.NAGARAJ V.P.TECHNICAL

UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

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Page 1: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

UPS/INVERTER BATTERS PRODUCT DETAILS AND APPLICATION ENGINEERING

- A.S.NAGARAJ

V.P.TECHNICAL

Page 2: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

What is an inverter? An inverter is an electrical device that converts direct

current (DC) to alternating current (AC); the converted AC can be at any required voltage and frequency with the use of appropriate switching, and control circuits

Page 3: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Specifications and standards: IS 13369 Stationary lead - acid batteries (with tubular

positive) in mono block containers

Page 4: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Sizing CalculationsExample of Load Calculations Suppose you were to run a microwave oven for 10 minutes a day, which draw about 1000

Watts, despite their size. To keep it simple, think of the inverter as electrically transparent. In other words, the 1000 Watts required to run the oven come directly from the batteries as if it were a 12 VDC microwave. Taking 1000 Watts from a 12-Volt battery requires the battery to deliver approximately 84 Amps.

(1000 Watts ÷ 12 Volts = 84 Amps) A full-sized refrigerator draws about 2 Amps at 120 Volts AC. By multiplying 2 Amps x 120

Volts, you find out the refrigerator uses 240 Watts. The batteries will need to deliver 20 Amps to run the refrigerator

(240 Watts/12 Volts = 20 Amps). Typically, refrigerators operate about 1/3 of the time (1/3 "duty cycle"), or 8 hours a day.

Therefore, the A.H. drain will be 160 A.H.

(8 hours x 20 Amps = 160 A.H.). After the load and running time is established, the battery bank size can be calculated. The

first calculation is to divide the load (in Watts) by 10 for a 12-Volt system or by 20 for a 24-Volt system resulting in the number of Amps required from the battery bank.

Page 5: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Example of Input Calculations

1. Total Watts = 1000 W

2. Amps from 12-Volt battery = 1000 ÷ 10 = 100 Amps DC

3. Amps from 24-Volt battery = 1000 ÷ 20 = 50 Amps DC

Next, the number of DC Amps must be multiplied by the time in hours that the load is to operate.

Example of Amp-Hour Calculations

If the load is to operate for 3 hours:

For a 12-Volt battery: 100 Amps DC x 3 hours = 300 A.H.

For a 24-Volt battery: 50 Amps DC x 3 hours = 150 A.H.

Now, the proper type and amount of batteries must be selected. Traction batteries, (also called deep cycle or golf cart type), should be used in order to be able to handle the repeated discharge/charge cycles that are required.

Page 6: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Battery Selection Chart

Electrical LoadTV

Recommended Inverter rating(VA)

Wattage Battery Voltage

Recommended Power Build battery (In AH) For backup of

1 2 3 4 5

1 Fan + 1 Tube light 150-200 190 12 16 32 48 63 79

2 Fans + 1 Tube light 200-250 310 12 26 52 78 103 129

2 Fans + 2 Tube Lights 300-350 380 12 32 63 95 127 158

1 Fan + 1 Tube light + TV 250-300 390 12 33 65 98 130 163

2 Fans + 1 Tube light + TV 350-400 510 12 43 85 128 170 213

3 Fans + 3 Tube Lights 400-450 570 12 48 95 143 190 238

TV 200FAN 120

TUBE LIGHT 70

General Wattage:

Page 7: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Basic parts of inverter

Take any Inverter and you will find the 3 basic parts Charger Unit Control Unit Inverter Unit

Page 8: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

How The Charger Circuit works

The Charger Unit coupled with Electronic Circuit charges the Battery till it is fully charged. An electronic overcharge cut out stops further charging of Battery thus preventing damage to the Battery.

The example could be just as in any Water Tank. Once the water gets filled up to a specific mark, the BALL COCK stops water inflow. This is a mechanical phenomenon.

In Inverter similar action is achieved electronically.

Page 9: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

How control circuits work A Control unit is responsible for all the activities of Charger and Inverter

Circuits. It is just like a Mini Computer that acts automatically through the set of desired commands.

It directs the Charger Circuit to charge the Battery during Mains presence. It starts Inverter Circuit upon power failure.

Page 10: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Battery Models for Inverters

Model NominalVoltage

Rated Capacity (AH) at 27oC Dimensions Dry wt.(Kgs.)

Wet wt.(Kgs.)

Acid Vol. (Ltrs)20 hr 10 hr 5 hr 3 hr 2 hr 1 hr L*B*H(mm)

S T Series-Standard Tubular Batteries

80ST 12V 75 60 50 43 38 30 410*172*245 18 28 8

100ST 12V 100 80 67 57 51 40 512*210*250 28 41.5 12

120ST 12V 120 100 80 68 61 48 518*273*255 33 45 10.8

E T Series-Tall Tubular batteries

120 ET 12V 120 100 80 68 61 48 502*185*380 32 57.4 21

150 ET 12V 150 120 101 86 77 60 502*185*380 37 61.8 20.5

180 ET 12V 180 145 121 103 92 72 502*185*380 43 66.5 19.2

200 ET 12V 200 160 134 114 102 80 502*185*380 53.5 74.6 18

Page 11: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

PRODUCT CLASS Vs APPLICATION MATRIXIT SERIES TUBULAR

IS 13369 - 1992

YES YES YES

T SERIES TUBULAR

IS 13369 - 1992 YES YES YES

F SERIES FLAT IS 13369 - 1992 YES YES YES

ZIP ET SERIES TUBULAR

IS 13369 - 1992 YES YES YES

ZIP T SERIES TUBULAR

IS 13369 - 1992 YES YES YES

ZIP F SERIES INVERTER

IS 13369 - 1992 YES YES YES

STATIONARY TUBULAR

IS 1651 YES YES YES

HR EL SERIES IS 1651 YES YES YES

HR SERIES IS 1651 YES YES YES

AUTOMOTIVE IS 14257 - 1995 YES YES

PRODUCT CLASS

SPECIFICATION INVERTER SOLAR UPS RAILWAYS S & T

SLI DG START

APPLICATION

PR

OD

UC

T

CLA

SS

Page 12: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

PRODUCT CLASS Vs TARGETED MARKETPRODUCT CLASS

BRAND JAR & COVER

NOMINAL RATING

MODEL CAP ( Ah)

FAST MOVING SLOW MOVING

TARGET APPLICATION

ZIP T SERIES TUBULAR

ZIP TUBULAR 36 MONTHS WARRANTY PP C10 20 T

40 T60 T80 T100 T100 TB120 TUNIK

20406080100105120105

FAST MOVE

FAST MOVE

SLOWSLOWSLOWSLOW

SLOW

SLOW

INVERTERUPSSOLAR

ZIP F SERIES INVERTER

ZIP LOW MAINTENANCE PP C10 100 F

130 F150 F180 F

100120150180

SLOWSLOWSLOWSLOW

INVERTERUPSSOLAR

Page 13: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

PRODUCT CLASS Vs TARGETED MARKETPRODUCT CLASS BRAND JAR &

COVERNOMINAL RATING

MODEL CAP ( Ah)

FAST MOVING SLOW MOVING

TARGET APPLICATION

IT SERIES TUBULAR

CAPTAIN PP C20 1200 IT1500 IT1800 IT2000 IT

120150180200

FAST MOVEFAST MOVE

SLOWSLOW

INVERTERUPSSOLAR

T SERIES TUBULAR

JUMBO GOLD PP C10 20 T40 T60 T80 T100 T100TB120 TUNIK

20406080100105120105

FAST MOVE

FAST MOVE

SLOWSLOWSLOWSLOW

SLOW

SLOW

INVERTERUPSSOLAR

F SERIES FLAT JUMBO SILVER PP C10 100 F130 F150 F180 F

100120150180

SLOWSLOWSLOWSLOW

INVERTERUPSSOLAR

ZIP ET SERIES TUBULAR

ZIP 42 MONTHS WARRANTY

PP C20 120 ET150 ET180 ET200 ET

120150180200

FAST MOVEFAST MOVE

SLOWSLOW

INVERTERUPSSOLAR

Page 14: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

PRODUCT CLASS Vs TARGETED MARKETPRODUCT CLASS

BRAND JAR & COVER

NOMINAL RATING

MODEL CAP ( Ah)

FAST MOVING SLOW MOVING

TARGET APPLICATION

STATIONARY TUBULAR

IRS SERIES HR C10 PBS 20PBS 40PBS 60PBS 80PBS 100PBS 120PBS 150PBS 200PBS 300PBS 400PBS 500PBS 600PBS 700PBS 800PBS 900PBS 1000

204060801001201502003004005006007008009001000

FAST MOVE

FAST MOVE

FAST MOVE

SLOWSLOWSLOW

SLOW

SLOW

SLOWSLOWSLOWSLOWSLOWSLOWSLOWSLOW

1) TRAIN LIGHTING2) SOLAR3) ELECT RICITYBOARDS

Page 15: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

PRODUCT CLASS Vs TARGETED MARKETPRODUCT CLASS

BRAND JAR & COVER

NOMINAL RATING

MODEL CAP ( Ah)

FAST MOVING SLOW MOVING

TARGET APPLICATION

HR EL SERIES HR C20 80 EL100 EL120 EL140 EL

80100120140

SLOWSLOWSLOWSLOW

INVERTERUPSSOLAR

HR SERIES HR C10 40 HR60 HR80 HR100 HR120 HR150 HRJ180 HRJ200 HRJ

406080100120150180200

SLOWSLOWSLOWSLOWSLOWSLOWSLOWSLOW

INVERTERUPSSOLAR

Page 16: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

PRODUCT CLASS Vs TARGETED MARKETPRODUCT CLASS BRAND JAR & COVER NOMINAL

RATINGMODEL CAP

( Ah)

FAST MOVING

SLOW MOVING

TARGET APPLICATION

AUTOMOTIVE TRUCK MASTER PP C20 NS 40

N-50N-70N-88 TRN-100N-120N-150N-180N-200

36607588100120150180200

FAST MOVE

FAST MOVE

FAST MOVE

SLOWSLOW

SLOWSLOW

SLOWSLOW

AUTOMOTIVE & DG STARTING

Page 17: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Pricing

Description 150 120 100 80

BOM Price 4.67 5.61 5.70 6.45

Overheads 1 1 1 1

Profit Margin 0.75 0.75 0.75 0.75

Economic selling priceESP/Basic

6.42 7.36 7.45 8.20

Example for pricing calculation:

Model

Basic Price for Distributor

/OEM

Distributer/OEM Price with Vat @

13.5%

Distributer /OEM Margin

10%

Distributer /OEM price with Margin

10%

Dealer basic with VAT

13.5%

Dealer Margin(35%)(MRP)

MRP with VAT 13.5%

20ST 1200 1362 136 1498 1700 2296 260640ST 2400 2724 272 2996 3401 4591 521160ST 3600 4086 409 4495 5101 6887 781780ST 4560 5176 518 5693 6462 8723 9901

100ST 5700 6470 647 7116 8077 10904 12376120ST 6840 7763 776 8540 9693 13085 14851

Models wise price/AH for N-series:

BOM ET SERIES

PRICE CALCULATION SHEET

Page 18: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

COMPETITOR SURVEY FOR INVERTER BATTERIES

Page 19: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

COMPETITORS SURVEY EXIDE SOUTHERN LUMINOUS OKAYA SU-KAM RELICEL EASTMAN – ADDO ORCHID

Page 20: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

EXIDE INVERTER BATTERIES INVARED 300, 400,500,500+ with capacities of 80 Ah, 506 Ah, 506 ah, 506 ah

respectively is rated at C 20 @ 27 Deg C upto 1.75 ECV ( 1.280 Sp.gr) INVAQUEEN 300, 450, 500+, 500+MF with capacities of 90ah, 135 Ah, 150 Ah,

150 ah respectively is rated at C 20 @ 27 Deg C upto 1.75 ECV ( 1.280 Sp.gr) INVA GOLD 500( THE PREMIUM AKKUMULATOREN) with capacity of 150 Ah

rated at C 20 @ 27 Deg C upto 1.75 ECV ( 1.280 Sp.gr) INVATUBULAR IT 500i with capacity of 150 Ah rated at C 20 @ 27 Deg C upto

1.75 ECV ( 1.280 Sp.gr) INVATUBULAR IT400, 500,550,650 with capcities of 110Ah, 150 ah, 165 Ah,

200 Ah respectively is rated at C 20 @ 27 Deg C upto 1.75 ECV ( 1.280 Sp.gr) INVAFLAT 1800, 2000 with capacities of 180 Ah, 200 Ah with capcities of

110Ah, 150 ah, 165 Ah, 200 Ah respectively is rated at C 20 @ 27 Deg C upto 1.75 ECV ( 1.280 Sp.gr)

INVASAFE 250, 600, 800 with capacities of 60 Ah, 150 ah, 200 ah respectively is rated at C 20 @ 27 Deg C upto 1.75 ECV ( 1.280 Sp.gr)

Page 21: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

LUMINOUS INVERTER BTY DETAILS

TYPE NOMINAL VOLTAGE

CAPACITY @ C20

LENGTH WIDTH HEIGHT ELECTROLYTE VOLUME

AH mm mm mm Litres

ILT 18000 12 150 518 275 265 14.50

ILT 22000 12 180 518 275 265 17.40

ILTT 18000 12 150 500 187 430 19.30

Page 22: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

SUKAM INVERTER BTY DETAILS – NO SPEC REFERENCE

S.No Battery Type Volts Capacity @ C20

Dimensions

AH mm L(mm) W(mm) H(mm)

1 SBT 1500 12 150 503 191 410

2 SBT 1800 12 180 503 191 410

Page 23: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

RELICEL INVERTER BTY DETAILS – BIS 13369 - 1992

S.No

Model Voltage

RATED CAPACITY ( Ah @ 27 Deg C ) Dimensions ( mm ) Bty Weight(Kgs)

Acid Volume ( Lites)

20 Hr

10 Hr 5 Hr 3 Hr 2 Hr 1 Hr L W H Dry Wet

1 REL 100T 12 100 80 67 57 51 40 513 215 250 23 39 13.2

2 REL 120T 12 120 100 83 72 64 50 513 215 250 28 44 12.7

3 REL 135T 12 135 115 96 82 71 56 515 275 270 34 52 15

4 REL 135T 12 150 120 100 86 76 60 518 275 265 37 55 14.5

RELICELL STANDARD TUBULAR BATTERIES

RELICELL TALL TUBULAR BATTERIESS.No

Model Voltage RATED CAPACITY ( Ah @ 27 Deg C ) Dimensions ( mm ) Bty Weight(Kgs)

Acid Volume ( Lites)

20 Hr

10 Hr 5 Hr 3 Hr 2 Hr 1 Hr L W H Dry Wet

1 REL 120XLTT 12 125 100 83 72 64 50 452 180 390 31 49 14.5

2 REL 150XLTT 12 150 120 100 86 76 60 452 180 390 37 55 14

3 REL 190XLTT 12 190 150 125 108 95 75 505 190 415 44 65 20.8

4 REL 210XLTT 12 220 180 150 129 114 90 505 190 415 52 71 18

Page 24: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

SOUTHERN BATTERIES – HI POWER TUBULAR BATTERIES – NO SPEC REFTYPE CAP @ 10

Hr @ 27 Deg C

Discharge Current @ 10 Hr rate to an ECV 1.80

OVERALL DIMENSIONS ACID VOLUME

AH AMPS L( mm) W(mm) H(mm) Litres

12 V RANGE

6SB 20 UPS 20 2 510 222 260 126SB 40 UPS 40 4 510 222 260 11.46SB 60 UPS 60 6 510 222 260 11

6SB 80 UPS 80 8 510 280 265 14.1

6SB 100 UPS 100 10 510 280 265 13.8

6SB 120 UPS 120 12 510 280 265 12.5

Page 25: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

SOUTHERN BATTERIES – HI POWER XL TUBULAR BATTERIES – NO SPEC REFTYPE CAP @ 10

Hr @ 27 Deg C

Discharge Current @ 10 Hr rate to an ECV 1.80

OVERALL DIMENSIONS ACID VOLUME

AH AMPS L( mm) W(mm) H(mm) Litres

12 V RANGE

6SB 80 UPS 80 8 440 185 410 12.46SB 100 UPS 100 10 440 185 410 12.66SB 120 UPS 120 12 440 185 410 11.8

6SB 130 UPS 130 13 440 185 410 11.5

Page 26: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

SOUTHERN BATTERIES – HI POWER XL SUMO TUBULAR BATTERIES – NO SPEC REFTYPE CAP @ 10

Hr @ 27 Deg C

Discharge Current @ 10 Hr rate to an ECV 1.80

OVERALL DIMENSIONS ACID VOLUME

AH AMPS L( mm) W(mm) H(mm) Litres

12 V RANGE

12V150AH 150 15 510 244 432 2512V180AH 180 18 510 244 432 2412V200AH 200 20 510 244 432 23.5

12V220AH 220 22 510 244 432 22

12V240AH 240 24 510 244 432 21.5

Page 27: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Power Build catalogue

Page 28: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Test Reports

Page 29: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Distributer & Dealer policy

PLEASE PROVIDE CLAUSE WISE COMPLIANCE AND REMARKS TO THE POINTS GIVEN BELOW ON YOUR COMPANY LETTER HEAD WITH AUTHORISED SIGNATORY AND COMPANY STAMP BEFORE SIGNING THE CONTRACT

Dt 05.02.2011 DOCUMENT No : Mktg / 01 / 11-12

PBB (POWERBUILD BATTERIES) DISTRIBUTOR POLICY

1) Depending on the market, the distributor deposits the amount, for which fixed bank interest

for the current year will be paid by PBB at the end of the year.

2) He gets a credit for 30 days; however 40 days post dated cheque to be provided against

proforma invoice.

3) He assures monthly quantities for which PBB will plan and dispatch

4) 1 % of the basic total billing will be spent on the advertisements (promotional expenses).

The actual expenses incurred for advertisement and promotional expenses shall be

reimbursed by PBB on production of original bills.

5) The distributor shall submit all the company registration certificates along with sales tax,

VAT returns

6) Geographical periphery has to be clearly defined

7) In case he employs a sub-distributor under clear intimation to PBB.

8) Generally 3 to 4 districts will be handled by one sub-distributor.

9) Under one sub-distributor may be 5 to 10 dealers can be there depending on market

conditions

10) He should have sufficient godown facility with initial charging

11) The tenure of the contract will be one year, renewable every year depending mutual

consent and performance from both sides.

Page 30: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

UPS (Uninterrupted Power Supply)

Page 31: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

What about UPS (Uninterrupted Power Supply) An Uninterruptible Power Supply (UPS) is a device connected between the power source and a computer to ensure that electrical flow is not interrupted. UPS devices use batteries to keep the computer running for a period of time after a power failure

The UPS consists of three main components:1) Rectifier: Stores line power in the battery after converting the AC power into DC power. Power disruptions only affect the battery charging process because the battery is being charged by the rectifier.2) Battery: Stores the power for use when the power source is interrupted, and determines the length of time the UPS will support your equipment.3) Inverter: Converts the battery DC power into AC power for the equipment. The inverter supplies continuous power to the computer just as the battery provides uninterrupted power to the inverter.

Page 32: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Executive Summary At its most basic, a UPS is designed to provide backup power to support continuing operation of electrical or electronic devices in the event of a power failure. Today’s UPS systems usually also provide some level of power conditioning and protection against fluctuations in voltage from the grid.

There are four types of UPS architectures in use today: 1.Online or Double Conversion2. Line Interactive 3. Offline (Standby) 4. Controlled Ferro-resonant (CFR).

Page 33: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

1. Offline (Standby) UPS

typical offline backup power supply will continuously provide power with some filtering (typically the same as on a surge protection power strip) from the utility. When utility power fails, the device will start its internal inverter, and then mechanically transfer from utility power to inverter output. Pros Low cost: can be widely implemented in an organization Small size: unobtrusive Simple design: little or no training required to understand full functionality Cons No power conditioning Slow transfer time Simple battery charger may shorten battery life and increase recharge time Limited additional functionality may not meet enterprise needs Short back-up time

Page 34: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

2. Line Interactive During normal operation, the Line Interactive UPS takes utility power and passes it through a transformer with various tap selections on the output. When utility power is high, the Line Interactive UPS selects a tap to lower (buck) the output voltage. Similarly, when the utility voltage is low, the UPS selects a tap to increase (boost) the output voltage. Pros Low Cost Sine Wave Output Wider Input Range Buck & Boost regulation Efficient Surge Protection EMI/RFI/Noise Suppression

Cons Minimal Load Protection 4-6 ms transfer time Spike and surge protection components degrade over time

Page 35: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

3.Controlled Ferro Resonant UPS A Controlled Ferro Resonant UPS operates in the same manner as a line interactive UPS, however its transformer can hold the voltage on the load side long enough for the inverter to begin providing input power, eliminating transfer time. It also provides complete isolation from input to output, protecting against all kinds of noise. Pros Best spike & surge protection with complete output isolation. Zero transfer time On-Line Power 100% Power Conditioning Input Power Factor Correction Better Output Flexibility Longer Service Life Expectancy

Cons Larger/Heavier Higher Heat Output More Expensive Can be problematic with power factor corrected loads1

Page 36: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

4.Online (Double Conversion) The Online or Double Conversion UPS continuously rectifies incoming AC power to DC power to supply the internal DC bus of the UPS. The output inverter takes the DC power and produces regulated AC power to support the critical load. During an outage, the inverter continues to operate, drawing power from the batteries and the load sees no transfer time. Pros Zero transfer time Excellent surge and noise suppression Constant voltage output. 100% Power Conditioning Input Power Factor Correction Cons Higher Heat Output More Expensive Lower Efficiency No Neutral Conditioning Low MTBF Higher battery TCO

Page 37: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Types of battery Technologies

Although energy reserve technologies such as fuel cells, flywheels, and Nickel Cadmium batteries are being explored, today data center and network room UPS systems almost exclusively use Lead acid batteries with one of the following three Technologies: Vented (flooded or wet cell) - The oldest of the technologies is the flooded (or vented) cell. Commonly used in automotive and marine applications, this technology is predominantly used in UPS applications above 500 kVAValve Regulated (VRLA) - VRLA batteries have been utilized for approximately 20 years. This technology offers a higher power density and lower capital costs than traditional flooded cell solutions. VRLA batteries are typically deployed within power systems rated below 500kVA. Modular Battery Cartridges (MBC) - MBC battery technology was introduced several years ago. This solution utilizes modular, multi-cell VRLA cartridges arranged in a parallel-series architecture that allows for easy installation and replacement.

Page 38: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Installation requirements as a function of battery technology

Flooded VRLA MBC

Site specific battery rack/frame design Yes Varies No

Mechanical assembly required at site Yes Varies No

Site specific engineering required Yes Varies No

Field Wiring (electrical connections) Yes Varies No

Hazardous material per DOT regulations Yes No No

Acid filling required Yes No No

Potential Shock hazard when handled Yes Yes No

Page 39: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Life Expectancy Life expectancy varies with battery type. Flooded cell systems traditionally enjoy long lifetimes provided that they are regularly maintained and serviced. VRLAs and MBCs are sealed systems that do not require or even permit the maintenance needed on flooded batteries. As a result, the lifetime of these battery types is significantly shorter than flooded cell systems. as shows the battery lifetime expectations.

Life expectancy Flooded VRLA Large

VRLA Medium

VRLA Small

MBC

Design Life 20 Years 20 Years 7-10 Years 5 Years 7-10 Years

Expected lifetime 15 Years 7-13 Years 5 Years 3 Years 3-5 Years

Page 40: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Failure modes

Page 41: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Internal and external components of avalve-regulated lead-acid (VRLA) battery.

Page 42: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING
Page 43: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Battery cell short due to positive grid growth oxidation

Page 44: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

What is thermal runaway?Thermal runaway occurs when the heat generated in a lead-acid cell exceeds its ability to dissipate that heat, which can lead to an explosion, especially in sealed cells. The heat generated in the cell may occur without any warning signs and may be caused by overcharging, excessive charging, internal physical damage, internal short circuit or a hot environment.

Page 45: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Simplified Illustration of Power Conversion Steps

Page 46: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

Operating principles 1 Single static DC UPS unit This basic DC UPS set-up shall be considered as the minimum requirement for a secured DC power source. It shall also be used to build up more complex multi-unit architectures.

Page 47: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

2 Parallel redundant static DC UPS unit A parallel redundant system shall comprise at least two DC UPS units, which are paralleled at the output through blocking diodes. This allows a significant increase of the system’s availability and improves the total power capability in regard to overloads and short circuits.

Page 48: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

S.No PARAMETER DESCRIPTION VALUE UNITS REMARKS

1 SYSTEM WATTAGE RATING 5000 WATTS

2 SYSTEM VOLTAGE 48 VOLTS

3 DISCHRAGE CURRENT 104 AMPS

=Sys Wattage Rating / Sys Volts

4 END CELL VOLTAGE 1.9 VOLTS

5 MIN AMBIENT TEMP 10 Deg C

6 BACK UP TIME 120 MINUTES

7 AGEING FACTOR 1.25

8 SAFETY FACTOR 1.1

9 TEMP CORRECTION FACTOR 1.19

10 BATTERY CAPACITY 330Ah

TEMP CORRECTION FACTOR TABLE

CELL TEMP ( Deg C ) CORRECTION FACTOR

-5 1.52

0 1.39

10 1.19

25 1

30 0.96

40 0.89

50 0.85

Page 49: UPS / INVERTER BATTERYS PRODUCT DETAILS AND APPLICATION ENGINEERING

METHOD 1 (Recommended for UPS Application)

FORMULA CALCULATION

BTY CAP = Rated cap at 27 Deg C X Ageing Factor X Temp Correction Factor X Safety Factor

BTY CAP= 330 X 1.25 X 1.19 X 1.1

=540Ah

METHOD 2 (Recommended for Sub- Station Applications)

FORMULA CALCULATION

BTY CAP = Discharge Current X K - Factor X Ageing Factor X Temp Correction Factor X Safety Factor

BTY CAP= 104 X 3.23 X 1.25 X 1.19 X 1.1

=550Ah

K-FACTORS at 27OC)

DISCHARGE TIME (MINUTES)

END CELL VOLTAGE

1.90V 1085V 1.80V 1.75V 1.70V 1.60V

5 0.74 0.68 0.67 0.64 0.57 0.52

10 0.92 0.85 0.83 0.79 0.69 0.67

15 1.08 1.02 0.97 0.93 0.84 0.78

30 1.44 1.03 1.29 1.22 1.14 1.11

60 1.96 1.85 1.75 1.69 1.59 1.56

120 3.23 2.99 2.86 2.74 - -

180 4.26 3.92 3.77 3.64 - -

300 6.67 6.25 5.88 5.71 - -

480 9.52 9.09 8.33 8 - -

600 11.76 10.53 10 10 - -