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Bat sizing rev 1.3

1

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Bat sizing rev 1.3

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BatteryBattery

SizingSizing

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List of contentsList of contents

Head linesHead lines

Battery Load

Battery Bank

Cell specifications - example 1

Example 2...

Battery ambient temperature

Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review

Battery parallel connection

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Battery load...Battery load...

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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UPS inverter

Battery load

Calculate the battery load...Calculate the battery load...

Pbat

+-

D C

A C

UPS load = Pout

Pbat = the battery load powerPout = the output load power

Inv. = the inverter efficiency

PF = The power factor

What is the required battery load - for a given UPS load…?

*

PBat = Pout x PF / Inverter

From kVA to kWCal. the Battery load

Cal

cula

tin

g

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What is the total battery load (kW)…?

Battery load

Battery load - example...Battery load - example...

Pbat

+-


PBat = 56 x 0,8 / 0,95 = 47,2 kW

Example:

UPS load/ Pout……..…………....56kVA

UPS load, PF…………………......0,8

UPS inverter efficiency………....95% or 0,95

You need to know...You need to know...

*

Battery load

Total load is the three phase loads added together

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Ncell = Number of battery cells to be used

Vlow = The lowest DC voltage

(before inverter shut down will take place)

Inv. = The inverter efficiency with the actual load.

Ich-max = The max. battery charging current.

Parameters...Parameters...

For the most used battery type - the lead acid - the following parameters are used:

For a specific Silcon DP300E type and an actual output load,the above data can be found in the Quick Reference Manual, section “DC Data”.

Battery load

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Battery Bank...Battery Bank...

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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Battery bank

Battery cells and blocks...Battery cells and blocks...

+ -

+ -

+ -

1 x 2 volt = 2 V

- battery cell

3 x 2 volt = 6 V

- battery block

6 x 2 volt = 12V

- battery block

*

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Battery bank

Battery string...Battery string...

Serial connected battery blocks - forms a battery string.

More strings can be connected in parallel - to increase the battery bank capacity.

- - -+ + +

- - -+ + +

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Battery pack for DP300E...Battery pack for DP300E...

How to make a battery pack for DP300E…?

2 x192 battery cells = 2 x 384 VDC2 x192 battery cells = 2 x 384 VDC

2 x 32 battery blocks of 12V = 2 x (32 x 12 V) = 2 x 384 VDC2 x 32 battery blocks of 12V = 2 x (32 x 12 V) = 2 x 384 VDC

Battery bank

12 V12 V- - -+ + +12 V12 V

- - -+ + +12 V12 V

32 blocks of 12V

32 blocks of 12V

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Cell Specification... Cell Specification...

+ -

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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Cell specifications

Cell LOAD... Cell LOAD... Actual Cell LOAD / Matching Battery SizeActual Cell LOAD / Matching Battery Size

Calculating the watt/ cell capacity…?

Cell load = Total battery load / Number of cells

Example1: 47.200W / (2 x 192 cells) = 123 W/cell

During battery operation the load on the battery bank is supposed to be constant at the max. specified load…

*

Watt+ -

Example 1:


PBat = 56 x 0,8 / 0,95 = 47,2 kW

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Lowest cell voltage...Lowest cell voltage...

The lowest battery voltage - “when the back-up time expires”

- is defined from the battery spec. and programmed into the UPS

Cell-end voltage - and how to find it…?

Example 1:

Vcell low = 2X326V / 2X192 cells =

1,7V/cell

Vcell low = VInverter low / number of cellsCell voltage

Time

Cell specifications

1,7 V

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Example 2...Example 2...

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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A customer want to protect a 3x400V computer load…- with an 10min.

UPS Back-up time

The highest phase current is determine the Silcon DP300E size.Silcon DP380E has a 400V full load output current at 3 x 115A and is therefore sufficient for IL2

Choice: Silcon DP380E

Example 2 Example 2

Result from measuring- full load current on the 3 phases...

IL1 100A PF 0,8

IL2 112A PF 0,9

IL3 105A PF 0,8

- example 2

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Calculating the total power...

Line to line voltage……...400V

Line to neutral voltage….230V

PL1 = 230 x 100 x 0,8 = 18.400W

PL2 = 230 x 112 x 0,9 = 23.184W

PL3 = 230 x 105 x 0,8 = 19.320W

Total =

60.904W

- or close to 61kWPBatt = 61 / 0,94 = 64.890 W from 384 cells

Pcell = 64.890 / 384 = 169W/cell VLow = 2 x 326 / 384 = 1,7V/cell

Example 2 Example 2 - calculating cell load- calculating cell load

- and lowest cell voltage - and lowest cell voltage

Required data...

Silcon DP380E max load…..…80kW

Actual load……………………..61 kW

Load percentage………………75%

Inverter efficiency:

Linear load……………….…….96%

SMPS load……………….…….94%

- example 2

Example 2 - Load spec.Voltage 3x400V

IL1 100A PF 0,8

IL2 112A PF 0,9

IL3 105A PF 0,8Back-up time 10 min.

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Type UPS12-140: Capacity……….174W/cell Back-up time…..10 min. End point cell voltage……1,7V

Example 2Example 2- choosing battery- choosing battery

Min.Min.TypeType 5 10 15 20

UPS12-140 254 174 137 111

UPS12-170 272 204 165 136

UPS12-200 360 200

Data sheet example: JOHNSONS CONTROL

- fits the demand of 169 W/cell.

- example 2

Example 2 - Load spec.Voltage 3x400V

IL1 100A PF 0,8

IL2 112A PF 0,9

IL3 105A PF 0,8Back-up time 10 min.

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UPS specificationsUPS specifications concerning batteries...concerning batteries...

Common Data from Quick reference:

Nominal voltage 2x384V Number of battery cells 2x192 pcs. Charging window float 2x(410V - 460V) Factory setting:

2x438V Charging window boost 2x(438V - 460V) Factory setting:

2x438V Low bat. warning window 2x(336V - 384V) Factory

setting: 2x346V Low bat. shut down window 2x(316V - 336V) Factory

setting: 2x326V

- example 2

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Battery ambient temperatureBattery ambient temperature

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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Battery…Battery…Capacity and life timeCapacity and life time

°C

20

21

22

23

24

25

Typ. battery specification temperature

26

27

28

29

30Ambient temperature - Battery capacity…General rule:

- if ambient temp. is lowered from 25 °C to 20 °C- The battery must be 4% oversized

Ambient temperature - Battery life time…

General rule:- if ambient temp. increases 10 °C - The battery life time will be halved.

But temperature compensated charging voltage - as in the Silcon DP300E series- reduces the influence to the half. +

4% oversized

+ -

Battery amb. temperature

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Battery life time...Battery life time...

High temperature

Poor charge control

80%100% Capacity

The capacity of the battery falls with the age.

The point where 80% is left is often used to define the life time.

20% oversizing is required for the W/cell if not included from manufacture

Ageing

End of life time

Battery amb. temperature

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Battery rechargingBattery recharging

2 4 6 8

0

10 hours

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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Battery recharging

DP300E rechargingDP300E recharging normal capacity on batteries...normal capacity on batteries...

2 4 6 8

0

10 hours

0

1 hour

Back-up time is often specified less than 1 hour

Normal charging current

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The following broad rule can be used for batteries wherealmost all the energy is taken out

- this is the case with back-up times of 2-3 hours or more:

FOR RECHARGE TIMES IN THE AREA OF 4 - 6 HOURS: - it last t hours to recharge the battery to 80% capacity,3xt to reach 90% and 8xt to reach 100%

FOR RECHARGE TIMES IN THE AREA OF 10 - 12 HOURS:

- it last 2xt to reach 90% and 4xt to reach 100%

But how to find t...?But how to find t...?

General rule about recharging...General rule about recharging...

Battery recharging

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Recharging general rule ...Recharging general rule ...

FOR RECHARGE TIMES IN THE AREA OF 4 - 6 HOURS:

1 x t 3 x t 8 x t

1009080

Battery recharging

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The following can be assumed:

We have to put the same energy back into the battery as taken out + the losses arising by rechargingThe losses by recharging are about 10%...

The Silcon DP300E will recharge with max. charging current, at least until 80% of the energy has been restored

The battery cells has a average voltage of 2V

Pbat

+ -Pbat outPbat in

100% 90%

Battery losses...Battery losses...

Battery recharging

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If 4 hours back-up time is required...

- it will take a week to reach

the 100 % battery capacity level

by too low charging current

One week...

One week charging …?One week charging …?

Battery recharging

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Example: DP310E output load 8kW (3-phase) Back-up time 4 hours Max. 12 hours recharge time to 90% required.

Let´s take an example...Let´s take an example...

Energy taken from battery during battery operation:Output load/DP310E bat.opr.efficiency = 8/0,9=8,9kWDischarge current=8900W/(2Vx384) cells=11,6AEnergy used 11,6x4 hours=46,4AH

Energy to be recharged=46,4/0,9=51,5AH

If 90% is to be restored within 12 hours, 80% has to takeplace within 12/2=6 hours.

Battery recharging

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If 51,5AH has to be restored within 6 hours…the charging current must be 51,5/ 6 = 8,6AThis gives a required charging power of 384 x 2 x 8,6 = 6,6 kWAs the standard DP300E has a charging capacity equal to 10% of the output power - The DP380E has to be used

But as the standard programming of the DP300E can be changed into a special setting - giving the double charging capacity

With a corresponding reduction of the max. output power - a DP340E can be used

8kW is then available for charging

A max. output load of 36kW is more than enough for the actual 8kW load.

A separate charger might be a better economic solution

Let´s take an example...Let´s take an example...

Battery recharging

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Battery parallel connection...Battery parallel connection...

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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Parallel stringsParallel strings

Numbers of blocks, depends on type of battery pack and parallel strings.

The battery type UPS12 have 6 cells of 2 volt and the UPS6 have 3 cells of 2 volt

If the W/cell is above numbers in table it is necessary to make parallel strings

Cellload [W/ cell] With ___ parallel string = = = _____ [W/ cell] Number of strings

The numbers of cells in the Silcon DP300E series is...

2 x 192 pcs. = total 384 cells.

- therefor divide the total 384 with the number of battery cells

UPS12 = 384 : 6 = 64 battery block

UPS 6 = 384 : 3 = 128 battery block

And then multiply this with the number of strings

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Example 3...Example 3...

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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Example 3 Example 3 Specify the battery...Specify the battery...

Example 3

UPS type: DP3120E Total load: 110 kVA PF: 0,8 SMPS Requested back-up: 20 min

Specify the battery…!

Data:

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Transfer output power to kW´s, if information is in kVA or Amps…

PTotal W 88.000% load on UPS = x 100 = x 100 = 73,3

[%] UPS1/1 load W 120.000

PTotal W = PTotal VA x PF = 110.000 [VA] x 0,8 = 88.000 [W]

Calculate the percentage of the load compared with the capacity of the UPS...

Example 3

Example 3 - Battery…?.

UPS type DP3120E

Total load 110 kVA

PF 0,8 SMPS

Back-up time 20 min.

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Inverter DataInverter Data

25% 50% 75% 100% 25% 50% 75% 100%DP310E 88,8% 92,6% 93,0% 93,5% 85,5% 89,0% 89,5% 90,0%DP320E 89,3% 93,1% 93,5% 94,0% 86,0% 89,3% 90,0% 90,5%DP340E 91,0% 94,0% 94,5% 94,5% 88,0% 90,1% 91,7% 92,3%DP360E 93,0% 94,5% 95,5% 96,0% 89,0% 92,0% 92,8% 93,2%DP380E 93,2% 95,5% 96,0% 96,1% 90,0% 92,8% 93,2% 93,5%DP3120E 88,6% 93,0% 94,2% 94,6% 89,7% 92,5% 92,9% 93,2%DP3160E 91,2% 93,9% 94,6% 94,7% 90,0% 92,8% 93,2% 93,5%DP3240E 90,0% 94,2% 95,2% 95,4% 88,5% 92,0% 93,0% 93,2%DP3320E 92,2% 95,0% 95,4% 95,5% 90,0% 92,8% 93,2% 93,5%DP3480E 91,7% 94,5% 94,8% 95,0% 90,0% 92,8% 93,2% 93,5%

Linear Load SMPS Load Load DP

Efficiencies DC to AC DP 3120 E and 73,3 % SMPS loaded

Find the efficiencies DC to AC percentage..!

Example 3

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Calculate the battery load and the cell load

- decide if parallel strings is needed...

BatteryLoad [W] 94.725Cell load = = = 247 [W/ cell]

Number of cells 2 x 192

PTotal [W] 88000Battery load = 100 = x 100 = 94.725 [W]

Inv. eff. [%] 92,9

Cell load:

Battery Load:

Efficiencies DC to AC (table)= 73,3 % (SMPS-% load of the UPS) = 92,9 inv. Eff %.

Example 3


UPS type DP3120E

Total load 110 kVA

PF 0,8 SMPS


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Find the necessary battery type, table Johnson battery.

247 [W/cell] in 20 min...

Min.Min.TypeType 5 10 15 20 30 40 50 60 90

UPS12-140 254 174 137 111 82 54 53 46

UPS12-170 272 204 165 136 105 86,6 74,4 65 46,7

UPS12-200 360 251 200 167 124 100 73 53

UPS12-270 457 336 263 218 163 132 111 94

UPS12-310 560 400 304 248 184 150 125 108

UPS12-370 610 450 355 293 219 171 142 123

UPS12-475 725 555 460 375 302 245 205 178

UPS6-620 890 720 600 520 405 332 280 243 170

Example 3


UPS type DP3120E

Total load 110 kVA

PF 0,8 SMPS


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Battery pack Battery pack specifications...specifications...

Find the weight and dimension of the battery pack

MODELWATT/CELL15 Min./167

V/C

LENGTH

IN (MM)

WIDTH

IN (MM)

HEIGHT

IN (MM)

WEIGHT

LBS. (KGS)

UPS12-140 140 7.78 (197) 5.22 (132)) 7.26 (184) 27 (12)

UPS12-170 170 8.99 (228)) 5.47 (139) 8.74 (222) 40 (18)

UPS12-270 270 10.30 (261) 6.83 (173) 8.74 (222) 57 (26)

UPS12-310 310 12.08 (307) 6.87 (174)) 9.51 (241) 66 (30)

UPS12-370 370 13.51 (343) 6.76 (172) 9.48 (240) 75 (34)

UPS12-475 475 13.57 (344) 6.76 (172) 10.93 (276) 105 (48)

UPS12-520 620 12.65 (321) 7.00 (177) 10.21 (259) 72 (33)

Example 3


UPS type DP3120E

Total load 110 kVA

PF 0,8 SMPS


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Battery Specification/Pack

Type UPS 12 - 310

Make Johnson

Number of cells 384

Cell load 247 W/cell

Min. cell voltage 1,7 V


Number of blocks 64

Block dim. (HxWxL) 241x174x307 mm

Total weight 1920 kg

Solution...

Example 3


UPS type DP3120E

Total load 110 kVA

PF 0,8 SMPS


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Your turn...

Now - your turn...

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Task 1Task 1

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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Task 1Task 1Specify the battery...Specify the battery...

UPS type: DP380E Total load: 66 kW PF load: 1 Requested back-up: 10 min


Data:

Task 1

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Task 1Task 1


[%] UPS1/1 load W 80.000

PTotal W = PL1 + PL2 + PL3 = 66.000 [W]

Total Load:

UPS load:

Task 1 UPS type: DP380E Total load: 66 kW PF load: 1 Back-up time: 10 min

Task 1

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Efficiencies DC to AC DP 380E and 82,5% Linear


Task 1

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Task 1Task 1

Calculate the battery load and the cell load

- decide if parallel strings is needed...



PTotal [W] 66.000Battery load = 100 = x 100 = 68.750 [W]

Inv. eff. [%] 96

Cell load:

Battery Load:

Efficiencies DC to AC (table)= 73,3 % (linear-% load of the UPS) = 96 inv. Eff %.


Task 1

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Results of task 1Results of task 1


Type UPS 12 - 170

Make Johnson

Number of cells 384




Number of blocks 64

Block dim. (HxWxL) 222 x 139 x 228mm


Results...


Task 1

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Task 2Task 2

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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UPS type: DP3160E Total load L1: 50 kVA, PF 0,9 SMPS Total load L2: 40 kVA, PF 0,8 SMPS Total load L3: 45 kVA, PF 0,8 SMPS Back-up time: 15 min


Data:

Task 2

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Task 2Task 2


[%] UPS1/1 load W 160.000

PL1 = PL1 x PF1 = 50kVA x 0,9 = 45.000 [W]PL2 = PL2 x PF1 = 40kVA x 0,8 = 32.000 [W]PL3 = PL3 x PF1 = 45kVA x 0,8 = 36.000 [W]

PTotal W = PL1 + PL2 + PL3 = 113.000 [W]

Total Load:

UPS load:

Task 2 UPS type: DP3160E Total load L1: 50 kVA, PF 0,9 SMPS Total load L2: 40 kVA, PF 0,8 SMPS Total load L3: 45 kVA, PF 0,8 SMPS Back-up time: 15 min

Task 2

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Efficiencies DC to AC DP 3160E and 70,6% SMPS




Task 2

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Task 2Task 2



PTotal [W] 113.000Battery load = 100 = x 100 = 121.505[W]

Inv. eff. [%] 93

Cell load:

Battery Load:

Efficiencies DC to AC (table)= 70,6 % (SMPS-% load of the UPS) = 93 inv. Eff %.


Task 2

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Type UPS 12 - 370

Make Johnson

Number of cells 384




Number of blocks 64



Results...


Task 2

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Task 3Task 3

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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UPS type: DP3320E Total load: 315 kVA PF load: 0,8 Requested back-up: 20 min


Data:

Task 3

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Task 3Task 3


[%] UPS1/1 load W 320.000

Total Load:

UPS load:

Task 3 UPS type: DP3320E Total load: 315 kW PF load: 0,8 Back-up time: 20 min

PTotal W = PTotal VA x PF = 315.000 x 0,8 = 252.000 [W]

Task 3

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Efficiencies DC to AC DP 3320E and 78,8% Linear


Task 3

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Task 3Task 3



PTotal [W] 252.000Battery load = x 100 = x 100 = 264.151 [W]

Inv. eff. [%] 95,4

Cell load:

Battery Load:Efficiencies DC to AC (table)= 78,8 % (SMPS-% load of the UPS) = 95,4 inv. Eff %.


Cellload [W/ cell] 688With ___ parallel string = = = 344 [W/ cell] Number of strings 2

Strings:

Task 3

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Type UPS 12 - 475

Make Johnson

Number of cells 384




Number of blocks 128




Task 3

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ReviewReview

Review

Battery Load

Battery Bank


Example 2...


Battery recharging

Example 3...

Task 1...

Task 2...

Task 3...

Review


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