MEETING THE CHALLENGES

OF BATTERY PROTECTION
TWO STAGE POWER DISTRIBUTION

Contents
1. Introduction 3
2. Power distribution and fault paths 3
3. Fuses 3
3.1 DC Circuit and Time Constant 4
3.2 Main interrupting tests 4
3.2.1 Maximum energy test 4
3.2.2 Breaking capacity test 5
3.2.3 Minimum interrupting capability (or overload test) 5
3.2.4 Comment on the Fuse rated Voltage 5
3.2.5 Example of the DC capability for an AC rated fuse 6
3.3 Curves 7
3.3.1 Time vs Current curve (prearc time vs RMS current value) 7
3.3.2 Peak let through current vs short circuit curent 7
3.3.3 I²t vs Short circuit current 7
3.3.4 Arc voltage 7
3.4 Calculation of the fuse Operation 7
3.5 Conclusion and DC fuse selection criteria 8
4. Circuit Breaker selection in a direct current application 8
4.1 Low-voltage switchgear and controlgear 8
4.2 Fault current 8
5. Case studies 9
5.1 Case study Fuse #1 9
5.1.1 UPS data (EXL-S1) 9
5.1.2 Battery data 9
5.1.3 Battery Fault current 10
5.1.4 Discharging data 10
5.1.5 Fuse sizing 10
5.16 A70QS 700Vdc 10
5.1.7 A070URD-31 690Vac 11
5.1.8 Conclusions 14
5.2 Case study #2 14
5.2.1 UPS data (EXL-S1) 14
5.2.2 Battery data 14
5.2.3 Battery Fault current 14
5.2.4 Discharging data 15
5.2.5 Fuse sizing 15
5.2.6 ETI fuse NH serie 15
5.2.7 Conclusion 19
5.3 Case study Fuse #3 19
5.3.1 UPS data (EXL-S1) 19
5.3.2 Battery data 19
5.3.3 Battery Fault current 19
5.3.4 Discharging data 19
5.3.5 Fuse sizing 20
5.4 Case study #4 20
5.4.1 UPS data (EXL-S1) 20
5.4.2 Battery Fault current 20
5.4.3 Discharging data 20
5.4.4 CB selection ABB TMAX T6 21
5.4.5 Conclusion 23

2
1. Introduction
The UPS is supplied by AC and DC sources.
Unlike the short circuit current generated by the AC sources, generally predictable, the short circuit current generated by the
battery is variable and not easily predictable.
With an unpredictable fault current the selection of the rating of the protection is quite challenging.
The purpose of this document is to go more in depth in the analysis of the selection of the suitable current protection devices.
(see “Liebert Design for Safe and Reliable electrical protection of bettery systems” for more details).

2. Power distribution and fault paths

The fault on the DC input of the UPS can be between the b) Transformer less units (e.g. EXL S1, Trinergy CUBE)
poles or poles to ground. Depending by the type of fault the without the battery mid-point available. In case of
available fault current and the voltage across the protection power distribution with grounded Neutral the voltage
devices change. across the protection devices will be (Fig. 2):
The single fault of a battery polarity to earth will deal with yyGround Fault on the negative pole (NEG to GND).
a different voltage depending on the power distribution: Assuming DC_NEG =370Vdc, the Over Current
grounded Neutral; not grounded Neutral. Proetction Device on the negative side has to be
The single fault between the battery poles will deal with the able to open 370Vdc.
battery voltage and the fault current provided by the battery. yyGround Fault on the positive pole (POS to GND).
In some circumstances the protection device (Fuse, Assuming DC_NEG =370Vdc and 264Cells charged
Circuit Breaker) may be subjected to a voltage that can at 2,27V/Cell Vbatt=600Vdc, the Over Current
exceed the maximum arc voltage if not properly selected. Proetction Device on the positive side has to be able
In an IT distribution the single polarity failure doesn’t to open 600Vdc-370Vdc= 230Vdc.
affect the system that is the reason of why a Ground Fault
yyFault between poles (POS to NEG). Assuming
Detector device needs to be fitted in the installation, in the
264Cells charged at 2,27V/Cell Vbatt = 600Vdc, the
case of a second fault or a short circuit between the two
Over Current Proetction Device in total has to be
battery poles the breaker will be exposed to the full system
able to open the full battery voltage 600Vdc.
voltage, that with a number of cells over 264 elements can
exceed 600Vdc.
We can deal with two typical configurations (Fig. 1): Over Current DC POS
Protection Device Batt +
a) Units with the mid-point of battery voltage available + Neutral
-
(e.g. APM, NXC, EXS); the mid-point of the battery is Vbatt Over Current
Fault
POS to NEG
Protection Device DC NEG
connected thru the UPS to the Neutral. When the
Batt -
installation has the Neutral grounded, the mid-point is Ground Fault Ground Fault
referred to earth. NEG to GND POS to GND

yyIn case of an earthing fault and assuming 192Cells

charged at 2,27V/Cell (POS to GND, NEG to GND) Figure 2.
the Over Current Protection Device will open a
3. Fuses
voltage equal to Vbatt/2 = 436/2 = 218Vdc.
yyIn case of a fault between poles and assuming The absence of natural zero voltage makes the interruption
192Cells charged at 2,27V/Cell (POS to NEG), the of DC faults more difficult than the interruption of AC faults
Over Current Protection Device will open a voltage as only the fuse arc will force the current to decrease to zero.
equal to Vbatt = 436Vdc. Moreover when the time constant L/R of a DC circuit is large
the interruption of a fault is much more difficult. Another
Over Current
Protection Device
DC/DC
CONVERTER
arduous operating condition is the interruption of a low over
current. DC rated fuses must have passed specific tests in
Vbatt/2
order to publish all necessary information on the DC
POS to GND POS to NEG
N DC capabilities of the fuse. Specific data are essential in order
DC
Vbatt/2 to safely apply fuses in DC circuits. However some appli-
Over Current
Protection Device cations are easier and do not require fuses with a special
NEG to GND design for DC interruption. In such cases AC rated fuses can
be used providing the fuse manufacturer publishes the DC
Figure 1. capabilities of the fuse.
3
TWO STAGE POWER DISTRIBUTION

3.1 DC Circuit and Time Constant

When a fault occurs in a DC circuit (Fig. 3) the current rises
Ifault
with an exponential component towards (figure 4) the value
of the available current (also named prospective current) Imelting

as follows:

Resistance R Inductance
t_melting t_clear

Figure 6.
G E Ua Fuse
3.2 Main interrupting tests
The Underwriters Laboratories (UL 248) and the
i
International Electro technical Commission (IEC 60269)
describe standard tests conditions for fuses under DC
Figure 3. voltage.

( R
( ))
i(t) = Ifault * 1 – exp – – * t
L
These are applied to industrial fuses, semi conductor
protection fuses and special DC rated fuses as well.
As for the testing under AC voltage there are 3 typical tests :
Ifault yyMaximum energy test (also named critical current)
yyBreaking capacity test (maximum interrupting ability)
yyOverload test (or minimum interrupting capacity)
The tests required by the standards are giving essential
information on the fuse DC capability. However it is
L t
necessary to provide more information and more specifically
Figure 4. the curve giving maximum L/R values as a function of the
DC working voltage U (see examples in figure 8).
Where:
This curve is an essential characteristic for the selection of
yyProspective current, Ifault = E/R fuses in DC applications.
yyCircuit Time constant = L/R 3.2.1 Maximum energy test
The equation of the current shows the L/R influence As shown earlier the arc energy depends upon a great
on the fuse prearcing time (or melting time). extent on the energy stored in the inductance. It has been
Therefore the larger is L/R, the slower is the rate of change demonstrated that the arc energy in the fuse is maximum
of the current (small di/dt), and longer is the prearcing when the energy stored in the inductance is maximum as
duration of the fuse (see figures 5 and 6). The arcing well.
duration and arcing I²t depend upon the energy dissipated A study of the energy stored in the inductance L shows that
inside the fuse during this period of time. a maximum is reached when the prearching time t_melting
of the fuse is about equal to the time constant L/R of the
circuit (Fig. 7).
Ifault
Once more the large influence of L/R on the fuse behavior
is demonstrated. This test tremendously stresses the fuse
Imelting
and consequently determines the maximum L/R value for a
given working voltage.
The L/R vs voltage curve (Fig. 8) is plotted according to
the maximum energy test results at various voltage values.
t_melting t_clear
It means larger values of L/R are acceptable when the
prearcing time is much smaller than L/R.
Figure 5.

4
 3.2.4 Comment on the Fuse rated Voltage
The three fundamental tests and the curve in figure 6
Ifault
show that it is not possible to select the DC voltage rating
Imelting of a fuse purely on the basis of the working voltage value
of the DC circuit to be protected.
It is absolutely necessary to plot the curve L/R = f(U).
This curve is plotted from the maximum energy tests
t_melting = L/R t_clear
results. Larger values of L/R are acceptable when the
prearcing time is much smaller than L/R.
Figure 7.

L/R (ms)
100
90
80

70
60

50
40

30
20

10

0
1000

1200

1400

1600

1800

2000

2200

2400

U (V)

Figure 8.

3.2.2 Breaking capacity test

When a fuse has passed the maximum energy test for
given values of the time constant L/R and the working
voltage U, it usually interrupts successfully much larger
fault currents under same values of U and L/R. As a
matter of fact greater values of L/R are easily accepted by
the fuse when the fault current (Ifault) is very large.
It must be noted that unfortunately the published breaking
capacity of fuses are not large values because they are
only the maximum current values the test circuit could
supply.
3.2.3 Minimum interrupting capability (or overload test)
The fuse may not be able to interrupt low overloads for
the same reasons as in AC conditions.
Two main problems can be met when the prearc time is
too long:
yyThe fuse body is damaged
yyThe arc goes out of the fuse through the terminals

5
TWO STAGE POWER DISTRIBUTION

3.2.5 Example of the DC capability for an AC rated fuse

The below set of graphs help to select a AC rated fuse for a DC application.

Application information cont. - All sizes

DC Voltage Capability vs. Time Constant

Retail Curves (*) and Ipm corresponding to the rating
current 30 31 32 33 2x32 2x33
L (ms) IN (A) * Ipm (A) * Ipm (A) * Ipm (A) * Ipm (A) * Ipm (A) * Ipm (A)
R
80 b a 63 a 230

70 80 a 300
100 a 360
60
Time Constant

125 a 460
50
160 a 650
40 200 a 880 a 850

30 250 a 1300 a 1150

315 a 1700 a 1450
20
350 a 1900 a 1600
10
400 a 2300 a 2200 a 2000
0 450 a 2500 a 2300
200 400 U (V) 500 a 3000 a 2600 a 2300
DC Voltage Capability 550 a 3400 a 3150 b 2500

Maximum L/R of the fault path versus the DC working voltage U. 630 a 5000 a 3700 b 3250
700 a 5600 a 4300 a 3900
L = 80 ms 800 a 5300 a 4800
R L = 25 ms
R 900 a 7800 a 5600
Um(V)
1000 b 9000 a 6600 a 5200
L = 10 ms
1000 R 1100 a 7700
1250 b 11000 a 7400 a 6500
800 1400 b 12500 a 8600 a 7800
1600 a 10600 a 9600
600
1800 a 15600 a 11200
2000 b 18000 a 13200
400
2200 a 15400
2500 b 22000
200
2800 b 25000
0
200 400 U (V) Letter a, b indicate the L/R curve to use in the L/R vs U graph.
Ipm is the minimum breaking current of each fuse.
Provides the DC Voltage capability of the fuse as a function of circuit time constant
(L/R ratio). * Consult Factory for DC capabilities on amper rating not shown.

Peak arc voltage Um of the fuse versus the DC working voltage U for
three values of the time constant L/R.

6
3.3 Curves points of the 2 following curves (figure 11 and figure 12) it is
possible to calculate:
3.3.1 Time vs Current curve (prearc time vs RMS current
value) yyUsing figure 12, the intersection between the curve
[time vs current] of the fuse (red curve) with the
The curve plotted with AC or DC tests is the same because
curve [current vs time] of the external circuit (black
of the use of the RMS value of the prearc current. This curve
curve), calculated with the formula in section 3.1 and
allows to calculate the prearc time as a function of the fault
rappresented in figure 11, gives the prearc time (21.6ms)
current and the time constant L/R as well as to calculate the
and the melting current (3700Arms)
peak let through current and the prearc I²t.
yyUsing figure 11, it is possible to see what is the peak
3.3.2 Peak let through current vs short circuit curent
value and rms value of the melting current.
There is a different curve for each different value of the time
Data:
constant L/R. There is an unlimited number of curves and
for this reason there is no published curve. It is possible to Fuse rated 600Vdc 500A gRB type in body size 73
calculate the peak current from the time current curve.
Fault characteristics:
3.3.3 I²t vs Short circuit current
yy10 KA
There is a different curve for each different value of the time
yy500 Vdc
constant L/R. There is an unlimited number of curves and
for this reason there is no published curve. It is possible yyL/R = t = 25 milliseconds
to calculate the prearc I²t from the time current curve, but Results:
there is no simple formula for the calculation of the arc I²t
and the total clearing I²t. yyPrearc time and Pre-arc Irms: 21,6 ms; 3700Arms (see
figure 12)
3.3.4 Arc voltage
yyPeak let through current: 5785 A (calculated with the
There is a specific curve for each value of the time constant equation of i at time 21.6 ms, see note 1)
L/R as shown in the figure 9.
yyEstimated arc time: 25 ms to 30 ms (see § 3.4.2 in docu-
ment EduPack 201-Behaviour and operation of the fuse).

Um (V)
yyTotal clearing time: 50 ms (pre-arc time + arc time)
2000
L/R=80ms
yyPrearc i²t: 295700 A²S (see note 2)
L/R=25ms

L/R=10ms
(A)
1500

5785

1000
3700

500
0 100 200 300 400 500 600 700 800 900 1000 21.6 50 ms

U (V) Figure 10.

Figure 9. Peak arc voltage (Um) of the fuse versus the DC working Ifault 10kA, L/R = 25 ms
voltage (U) for three values of the time constant L/R Ifault 10kA

3.4 Calculation of the fuse Operation

During fault conditions the available fault current (Ifault) Ipeak 5785A
and the time constant of the circuit (L/R) influence the the Irms 3700A
melting current (Imelting), the melting time and the total
clearing of the fault. 0
0 Pre arc 21 ms time(*)
The fuse suppliers usually provides curves that helps
to calculate the prearc time and prearc Irms. By crossing Figure 11. I and Irms of the fault

7
 Time current characteristics
4. Circuit Breaker selection in a direct current
10R
application.
The product standard for circuit breakers is IEC 60947-
1000
2:2016. The purpose of these CB is making, carring and
breaking currents in normal and fault conditions.
100
4.1 Low-voltage switchgear and controlgear
PSC 690 V gRB Circuit-breakers
10 500 A size 73
A Circuit Breaker in a direct current application needs to be
1
selected respecting the following parameters:
Irm=f(t) of the 10k
a) Ue: rated operation voltage, that is the voltage which the
0,1 fault with L/R=25ms circuit breaker is designed to operate. A single breaker
may be rated for several voltages and be compatible with
0,01
3700 A RMS 21,6 ms both AC and DC voltages.
b) In: current of the protection trip placed on the circuit
0,001 breaker.
100 1000 10K 100K
E.M.S current, A
c) Icu(kA): short-time withstand current the CB can
withstand when it is closed, making or breaking is not
Figure 12. Determination of the melting point of the fuse guaranteed.
d) Icm (%Icu): rated making short-circuits current
Note 1: (1 operation), it is usually expressed as a percentage of
The RMS value of he fault current is given by: Icu, typical values are 25%, 50%, 75%, 100%.
e) Ics (%Icu): rated service short-circuits current
(3 operations), it is usually expressed as a percentage
of Icu, typical values are 25%, 50%, 75%, 100%.
With L/R = 25ms and t=26,1ms Other electrical, mechanical, enviromental characteristics
yyi = 5785 A shall be taken in consideration as well but they are not in the
scope of this guide, for these latter refer to manufacturers
yyIrms = 12240 A specifications.
The scope of this paragraph is to define some common rules
for the UPS DC battery circuit protection with the use of
Note 2: circuit breakers (CB):
Prearc i²t can be calculated as follows 1. Identification of the power distribution and the fault
prearc: i²t = Ieff² x t = 3700² x 0,0216 = 295700 earthing paths (see cap. 2).
3.5 Conclusion and DC fuse selection criteria 2. Identification of Un, rated voltage of the system (Ue≥Un)
3. Current during battery discharge and at the EoD.
For all DC applications it is recommended to select the fuse
following the below steps: 4. Available fault current
a) Select a DC rated fuse, in case of a AC rated one make The opening time is another paramenter that should be
sure it is specified its with DC voltage capability. considered, for this rules describe in the above paragraph
will be taken in consideration.
b) Voltage Rating considering the downgrade due to the
L/R, the type of power distribution (see cap. 2). 4.2 Fault current
c) The time constant (L/R) of the circuit lower than 10ms Once estimated the available fault current, this should be
d) Available fault current compared with the magnetic threshold of the breaker
(I3). The Thermomagnetic trip units have a I3 that can be
It is required as well to get all necessary information about
typically set between 5 ÷ 10 x I1 (I1, nominal current of the
the rated current passing in the fuse as well as the load
CB) in the most common CB, it can be lower in some other
cycles and overloads to withstand in order to calculate the
types of breaker (e.g. 2 ÷ 2.5 x I1). A good selection criteria
current rating of the fuse so that its life time fits with the life
consists on selecting a body rated for an higher nominal
time of the equipment it must protect.
current than the one required by th system in order to fulfil
the Ue requirement and if possible a lower tripping units.

8
Electronic trip units can provide a more flexible selection 5. Case studies
(e.g. I3 = 1.1 x I1) with the drawback of an higher cost than
5.1 Case study Fuse #1
the previous ones.
The use of AC rated CB in a DC application is allowed if the 5.1.1 UPS data (EXL-S1)
supplier declares the Ue value in DC, and if the bimetal part yyRating: 100kVA; 90kW (PF=0.9)
is sensible to r.m.s and average current (no variation in the yyRuntime: 15 minute
tripping curves for overload times). It should be understood
yyBattery type: C&D UPS 12-475; 122Ah @ 10h rate
that the magnetic tripping can be affected by DC so that
I3 needs to be increased. In this latter case 5*I1<I3< 10 yyNumber of blocks/cells: 40/240
I3min=5*I1 -> I3min=5Km*I1 (with Km>1). yyFloat voltage: 540Vdc at 25°C ambient (2.25V/cell)
The factor Km is function of the circuit breaker, the yyEoD voltage: 396Vdc (1.65V/cell)
connection type and number of poles.
In case of battery cabinet in parallel (or battery strings)
it should be taken in consideration that an internal fault
(upstream the breaker) can drive current from the other
cabinets or strings and the ultimate short circuit breaking
capability should be selected accordingly (Icu>n°batt
cabinets*Ib).
5.1.2 Battery data
UPS12-475 - Specifications
Cells per Unit Voltage per Unit Weight Electrolyte Maximum Discharge Short Circuit Ohms Imped.
Current Current 60 Hz (w)
6 12.84 100 Ibs. Absorbed H2SO4 800 Amps 5000 Amps 0.0023 Ohms
45 kg @ 0.1 sec
475 watts per cell at the 15 minute rate to 1.67 volts per cell at 77°F (25°C)
Capacity 134 Ah @ 20hr. rate to 1.75 volts per cell@ 77°F (25°C)
122 Ah @ 10hr. rate to 1.80 volts per cell@ 20°C (68°F)
Discharge: -40° F (-40°C) to + 160° F (71°C), Charge: -10° F (-23° C) to +140° F (60°)
Operating Temperature Range
(With temperature compensation)
Nominal Operating Temperature Range +74° F (23° C) to + 130°F (27° C)
Float Charging Voltage 13.5 to 13.8 Vdc/Unit Average at 77° F (25° C)
Recommended Maximum Charging
C/5 amperes (27 amperes @ 100% depth of discharge)
Current Limit
Equilization and Cycle Service Charging
14.4to 14.8 Vdc/Unit Average at 77° F (25° C)
Voltage
0.5% rms or 1.5% p-p of float charge voltage racommended for best result
Maximum Ac Ripple (Charger) Maximum voltage allowed - 1.4% RMS (4% P-P)
Maximum voltage allowed - 6.7% amperes RMS (C/20)
Dynasty UPS batteries may be stored for up to 6 months at 77° F (25° C) and then a freshening
Self Discharge
charge is required. For higher temperatures the time interval will be shorter
Accessories Inter unit connectors, rack and cabinet system are available
Terminal Threaded brass insert to accept 0.25" (6 mm) bolt
Terminal Hardware Torque 110 In.-Ibs. (12.4 N-m)
* All dimensions in inches and (millimeters). All dimensions are for reference only. Contact a C&D Rapresentative for complete dimensional information.
Table 1.

Constant Power Discharge Rating - Watts per Cell @ 77°F (25° C) - Operating Time to End Point V dimensionoltage (in minutes)
End Point
5 10 15 20 30 40 45 50 60 90
Volt/Cell
1.75 685.0 515.0 437.3 366.3 283.4 236.1 217.4 201.7 172.8 122.8
1.70 725.0 542.9 451.5 379.2 293.2 221.6 221.6 205.5 177.8 125.0
1.67 750.0 577.0 475.0 393.0 302.0 227.0 227.0 210.0 182.0 129.0
1.65 770.1 588.6 481.4 401.9 311.2 233.1 233.1 214.9 185.2 131.0
1.60 785.2 606.1 488.4 410.4 315.9 238.0 238.0 220.1 188.0 135.5
Table 2.

9
 5.1.3 Battery Fault current
The battery fault current value is usually given by the
battery manufacturer and it is available on the product
datasheet. If it is not available, it can be requested to the
battery manufacturer.
For this specifc case see the above table 1:
yyShort circuit current: 5000A for 0.1 sec
yyIn accordance with the previous consideration, the
available battery short circuit current is affected by the
state of charge and the aging of the battery. Another
important parameter that will reduce the available fault
current is the impedance of the connection.
yyThe final fault current to be considerd for the sizing of
the protection will be 60% of the nominal hence 3kA.
5.1.4 Discharging data
The battery protection device MUST NOT open during a
battery discharge at risk of losing the UPS basic functionality
of the load supply in mains failure.
Battery power (Bw) = (Pn x PF) / (DC/AC) = (100 x 0.9) /
0.957 = 94kW.
Max discharge current at EoD = Bw / (ncell x 1.65) = 240A
Calculation of the Power x Cell = 94000 / 240 = 392W/Cell
Number of strings Calculation
From the above table 2 we can see that the watts per cell
during 15 minutes are 481W.
N.Strings = 392 / 481 = 0,82 therefore 1 strings
5.1.5 Fuse sizing
The key points for the selection of the fuse are:
a) DC rated fuse or AC rated with specified DC voltage
capability.
b) Voltage Rating considering also the downgrade due to
the L/R
c) The time constant (L/R) of the circuit lower than 10ms
d) Available fault current
The right type of fuse to use is a semiconductor fuse. These
type of fuses have a very Low l2t for improved protection of
equipment, compared to other types.
Looking at the Ferraz/Shamut brand (as an example), two
different models can be chosen: A70QS 700Vdc rated;
A070URD-31 690Vac rated.
5.1.6 A70QS 700Vdc
The four steps check list to be covered is:
a) It is rated 700Vdc. The actual DC voltage capability
should be checked based on the circuit time constant
L/R.
10
b) Voltage Rating considering the downgrade due to the
L/R. Assuming L/R = 10ms the DC voltage capability
remains 700Vdc (Fig. 13). The DC voltage capability
must be verified against the possible voltages present
during the different type of fault:
yyFault between the poles, POS to NEG. The fuse must be
able to open the float battery voltage 540Vdc that is well
below the DC capability of the sinlge fuse (700Vdc).
yyGround fault, worts case is NEG to GND. The fuse must
be able to open the negative DC link 370Vdc that is well
below the DC capability of the fuse (700Vdc).
c) The time constant (L/R) of the circuit lower than 10ms.
The time constant depends by the cabels and how they
are routed. Cables routed very close to each other will
have a L/R lower than connections with the cables
connected to the positive distant than the cables
connected to the negative. The inductance increase
by increasing the distance between the cables.
A time constant of 10ms is representative of a typical
installation.
d) Available fault current. The fault current provided by
the battery depends by various factors such as state
of charge, aging and connection cables. To take care of
the variable related to the battery (EoD and EoL) the
actual fault current will be 60% of the nominal one. The
selection of the connections cable (section and length)
should guarantee that the voltage drop between UPS
and battery, with max discharging current, is less than 1%
of the UPS battery voltage at the EoD.
e) Intervention time. The rating current of the fuse should
allow the UPS to operate in battery mode in all specified
conditions and open the fault in a limited time whit the
60% of the fault current in 100ms. The Melting curve
provide the following info: max current below which the
fuse dose not open; time to the melting of the fuse (tp).
The key data are:
yyGreen area, normal operating conditions. Max current
(EoD current) 240A.
yyRed area, fault conditions. Minimum fault current 5kA x
0,6 = 3kA.
The melting time of a 400A fuse at 60% of the nominal fault
current is about 50ms well below the expected 100ms. The
melting time of the fuses higher than 400A are greater than
100ms, this does not gurantee that the fuses reaches the
melting point (Fig. 14). For fuses smaller than 400A, the
melting time is smaller, it must be verified if the fuse carries
the discharging current.
 Clearing I2t at 700V DC, 100kA, L/R = 10 ms 5.1.7 A070URD-31 690Vac
Ampere Rating (A2sx103) Clearing I2t
35 0.25
The four steps check list to be covered is:
40 0.35 a) It is rated 690Vac with specified DC voltage capability
50 0.60
70 1.3 based on the time constant L/R. See below data sheet
80 1.8 (Tab 4.).
90 2.4
100 3.1 b) DC voltage rating considering the downgrade due to
125 5.3 the L/R. In the below “DC voltage capability vs Time
150 8.1
175 12 constant” curves, curve a Fig. 15 is the one that should
200 16
225 21.5 be used based on the possible current rating of the fuse
250 27.5 to be selected. Assuming L/R = 10ms the DC voltage
300 42
350 63 capability is 540Vdc. The DC voltage capability must be
400 85 verified against the possible voltages present during the
450 115
500 150 different type of fault:
600 201
700 325 yyFault between the poles, POS to NEG. The fuse must
800 450 be able to open the float battery voltage 540V that is
Table 3.
equal to the DC capability of the sinlge fuse (540Vdc).
DC Voltage Capability vs. Time Constant yyGround fault, worts case is NEG to GND. The fuse must
900
be able to open the negative DC link 370Vdc that is
well below the DC capability of the fuse (540Vdc).
800
c) The time constant (L/R) of the circuit lower than 10ms.
The time constant depends by the cabels and how they
are routed. Cables routed very close to each other will have
DC Voltage Capability

700
a L/R lower than connections with the cables connected
to the positive distant than the cables connected to the
negative. The inductance increase by increasing the
600
distance between the cables. A time constant of 10ms is
representative of a typical installation.
d) Available fault current. The fault current provided by
500
the battery depends by various factors such as state of
charge, aging and connection cables. To take care of the
variable related to the battery (EoD and EoL) the actual
400
fault current will 60% of the nominal one. The selection
0 10 20
L/R Time Constant (ms)
30 40 50 of the connections cable (section and length) should
Figure 13. guarantee that the voltage drop between UPS and
Melting Time - Current Data, 700V Fuses battery, with max discharging current, is less than 1% of
100
70 200A the UPS battery voltage at the EoD.
225A
50
250A e) Intervention time. The rating current of the fuse should
30
20
300A
350A allow the UPS to operate in battery mode in all specified
10
400A
450A conditions and open the fault in a limited time whit the
7 500A
600A 60% of the fault current in 100ms. The Melting curve
5
3
700A provide the following info: max current below which the
800A
2 fuse dose not open; time to the melting of the fuse (tp).
Time in Seconds

1 The key data are:

7
5
yyGreen area, normal operating conditions. Max
3 35A current (EoD current) 240A.
40A
2
50A yyRed area, fault conditions. Minimum fault current
60A
1 70A 5kA x 0,6 = 3kA.
0.7 80A
0.5 90A The melting time of a 450A fuse at 60% of the nominal
100A
0.3
125A fault current is about 25ms in line with the expectation.
0.2 150A
175A
The melting time of the fuses higher than 450A are greater
0.1 than 100ms. For fuse smaller than 450A, the melting time is
70
100

200

300

500

700

1000

2000

3000

5000

7000
10000

Current in Amperes
smaller than 100ms but make sure that it carries they carry
Figure 14. the discharging current. (Fig. 17).

11
 690 Volt European/IEC Style Ratings and Application Data
Body Amp Rated Melting Total I�t ***Watts DIN 110 DIN 80 French Blade Tapped Single
Size Rating Voltage I2 t @ 660VAC Loss Catalog NO. Catalog NO. Catalog NO. Catalog NO.
(A2s x 103) (A2s x 103) @ Rated Type D11A Type D08A Type EF TypeTTF
Current (W)

50 690 0.116 0.68 9 6,9URD30D11AOO50 6,9URD30D08A0050 6,6URD30EF0050 6,9URD30TTF0050

63 690 0.2 1.09 14 6,9URD30D11AOO63 6,9URD30D08A0063 6,9URD30EF0063 6,9URD30TTF0063
80 690 0.33 1.75 19 6,9URD30D11AOO80 6,9URD30D08A0080 6,9URD30EF0080 6,9URD30TTF0080
100 690 0.47 2.5 26 6,9URD30D11AO100 6,9URD30D08A0100 6,9URD30EF0100 6,9URD30TTF0100
125 690 0.85 4.5 30 6,9URD30D11AO125 6,9URD30D08A0125 6,9URD30EF0125 6,9URD30TTF0125
30 160 690 1.6 8.5 37 6,9URD30D11AO160 6,9URD30D08A0160 6,9URD30EF0160 6,9URD30TTF0160
200 690 3 15.5 42/43 6,9URD30D11AO200 6,9URD30D08A0200 6,9URD30EF0200 6,9URD30TTF0200
250 690 5.8 30 48/50 6,9URD30D11AO250 6,9URD30D08A0250 6,9URD30EF0250 6,9URD30TTF0250
315 690 12 62 53/55 6,9URD30D11AO315 6,9URD30D08A0315 6,9URD30EF0315 6,9URD30TTF0315
350 690 15.5 80 57/60 6,9URD30D11AO350 6,9URD30D08A0350 6,9URD30EF0350 6,9URD30TTF0350
400 690 23 120 60/65 6,9URD30D11AO400 6,9URD30D08A0400 6,9URD30EF0400 6,9URD30TTF0400
450 660 26 153 80/88 6,6URD30D11AO450 6,6URD30D08A0450 6,6URD30TTF0450
500 660 41 245 80/88 6,6URD30D11AO500 6,9URD30D08A0500 6,9URD30TTF0500
550 660 52 305 80/90 6,6URD30D11AO550 6,6URD30D08A0550 6,6URD30TTF0550
200 690 2.6 14 45 6,9URD31D11AO200 6,9URD31D08A0200 6,9URD31EF0200 6,9URD31TTF0200
250 690 4.7 25 52 6,9URD31D11AO250 6,9URD31D08A0250 6,9URD31EF0250 6,9URD31TTF0250
315 690 7.5 48 65 6,9URD31D11AO315 6,9URD31D08A0315 6,9URD31EF0315 6,9URD31TTF0315
350 690 10.5 55 67 6,9URD31D11AO350 6,9URD31D08A0350 6,9URD31EF0350 6,9URD31TTF0350
400 690 19 100 68 6,9URD31D11AO400 6,9URD31D08A0400 6,9URD31EF0400 6,9URD31TTF0400
31 450 690 26.5 140 70 6,9URD31D11AO450 6,9URD31D08A0450 6,9URD31EF0450 6,9URD31TTF0450
500 690 37 195 70/72 6,9URD31D11AO500 6,9URD31D08A0500 6,9URD31EF0500 6,9URD31TTF0500
550 690 52 280 70/75 6,9URD31D11AO550 6,9URD31D08A0550 6,9URD31EF0550 6,9URD31TTF0550
630 690 75 390 75/85 6,6URD31D11AO630 6,6URD31D08A0630 6,6URD31EF0630 6,6URD31TTF0630
700 690 95 400 85/95 6,9URD31D11AO700 6,9URD31D08A0700 6,9URD31EF0700 6,9URD31TTF0700
800 660 140 815 105/120 6,6URD31D11AO800 6,6URD31D08A0800 6,6URD31TTF0800
400 690 15 80 72/75 6,9URD32D11AO400 6,9URD32D08A0400 6,9URD32EF0400 6,9URD32TTF0400
450 690 22 115 77/80 6,9URD3�D11AO450 6,9URD32D08A0450 6,9URD32EF0450 6,9URD32TTF0450
500 690 28 145 85/90 6,9URD32D11AO500 6,9URD32D08A0500 6,9URD32EF0500 6,9URD32TTF0500
550 690 37 195 90/95 6,9URD32D11AO550 6,9URD32D08A0550 6,9URD32EF0550 6,9URD32TTF0550
630 690 54 280 95/105 6,9URD32D11AO630 6,9URD32D08A0630 6,9URD32EF0630 6,9URD32TTF0630
700 690 76 400 100/110 6,9URD32D11AO700 6,9URD32D08A0700 6,9URD32EF0700 6,9URD32TTF0700
32 800 660 115 600 110/120 6,9URD32D11AO800 6,9URD32D08A0800 6,9URD32EF0800 6,9URD32TTF0800
900 660 170 900 110/125 6,6URD32D11AO900 6,6URD32D08A0900 6,6URD32EF0900 6,6URD32TTF0900
1000 660 240 1250 115/135 6,6URD32D11A1000 6,6URD32D08A1000 6,6URD32EF1000 6,6URD32TTF1000
1100 600 270 1620 140/165 6URD32D08A1100 6URD32TTF1100
1250 500 410 1940 150/180 5URD32D08A1250 5URD32TTF1250
500 690 19 100 105 6,9URD33D11AO500 6,9URD33D08A0500 6,9URD33EF0500 6,9URD33TTF0500
550 690 27 140 105/110 6,9URD33D11AO550 6,9URD33D08A0550 6,9URD33EF0550 6,9URD33TTF0550
630 690 40 130 110/120 6,9URD33D11AO630 6,9URD33D08A0630 6,9URD33EF0630 6,9URD33TTF0630
700 690 55 300 115/125 6,9URD33D11AO700 6,9URD33D08A0700 6,9URD33EF0700 6,9URD33TTF0700
800 690 95 490 120/130 6,9URD33D11AO800 6,9URD33D08A0800 6,9URD33EF0800 6,9URD33TTF0800
900 690 135 700 120/135 6,9URD33D11AO900 6,9URD33D08A0900 6,9URD33EF0900 6,9URD33TTF0900
1000 690 170 900 135/155 6,9URD33D11A1000 6,9URD33D08A1000 6,9URD33EF1000 6,9URD33TTF1000
33 1100 690 240 1260 135/160 6,9URD33D11A1100 6,9URD33D08A1100 6,9URD33EF1100 6,9URD33TTF1100
1250 660 350 1850 150/180 6,6URD33D11A1250 6,6URD33D08A1250 6,6URD33EF1250 6,6URD33TTF1250
1400 660 480 2500 160/200 6,6URD33D11A1400 6,6URD33D08A1400 6,6URD33EF1400 6,6URD33TTF1400
1500 600 500 220 6URD33D11A1500 6,6URD33D08A1500 6,6URD33DTTF1500
1600 600 555 210/240 6URD33D11A1600 6URD33D08A1600 6URD33TTF1600
1800 600 720 225/260 6URD33D11A1800 6URD33D08A1800 6URD33TTF1800
2000 550 950 250/290 5,5URD33TTF2000
2250 500 1250 280/330 5URD33TTF2250
2500 450 1870 280/330 4,5URD33TTF2500
**Watts loss data is published for both blade and tapped style mounting configurations. When two watts loss values are show this represents tapped/blade values respectivety.
Table 4.

12
Application information cont. - All sizes

DC Voltage Capability vs. Time Constant Retail Curves (*) and Ipm corresponding to the rating
current 30 31 32 33 2x32 2x33
IN (A) * Ipm (A) * Ipm (A) * Ipm (A) * Ipm (A) * Ipm (A) * Ipm (A)
L (ms)
R 63 a 230
80 b a 80 a 300
100 a 360
70 125 a 460
160 a 650
60
Time Constant

200 a 880 a 850

250 a 1300 a 1150
50
315 a 1700 a 1450
40 350 a 1900 a 1600
400 a 2300 a 2200 a 2000
30 450 a 2500 a 2300
500 a 3000 a 2600 a 2300
20 550 a 3400 a 3150 b 2500
630 a 5000 a 3700 b 3250
10 700 a 5600 a 4300 a 3900
0 800 a 5300 a 4800
900 a 7800 a 5600
200 400 U (V) 540
1000 b 9000 a 6600 a 5200
1100 a 7700
Figure 15. 1250 b 11000 a 7400 a 6500
1400 b 12500 a 8600 a 7800
1600 a 10600 a 9600
1800 a 15600 a 11200
DC Voltage Capability 2000 b 18000 a 13200
L = 80 ms 2200 a 15400
R L = 25 ms 2500 b 22000
R 2800 b 25000
Um(V)
L = 10 ms Table 5.
1000 R
550A
350A
450A

700A
250A

400A
500A
200A

630A
315A

800
t (S)
Sec
600 C 3,5 mm

103 1000

400
100
102
200 30 C1

10
0 10
200 400 U (V)
Time in Seconds

a = 130
B1 = 1,25
1 A2 = 0,5
Figure 16. B2 = 0,6
C13 = 0,8
Provides the DC Voltage capability of the fuse as a function of circuit time constant
(L/R ratio). *Consult Factory for DC capabilities on amper rating not shown.
10 -1

10 -2

10 -3

10 -4
10 -2 10 -3 10 -4 I (A)
Current in Amperes
Figure 17.

13
 5.1.8 Conclusions 5.2 Case study #2
Both selected fuses, A70QS 400A and A070URD 450A 5.2.1 UPS data (EXL-S1)
models, are suitable to protect the battery against short yyRating: 400kVA; 400kW (PF = 1)
circuit, the Magnetic intervention time is below 100msec
yyRuntime: 5 minute
at 3-5kA.
yyBattery type: CSB GPL 121000; 100Ah @ 20h rate
The backup time of 15 minutes can be easily managed by
the fuses, the A70QS fuse curve does not provide Time in yyNumber of blocks/cells: 40/240 or 50/300
seconds above 100(s), therefore we have been forced to yyFloat voltage: 545V or 681V at 20°C ambient (2.27 V/cell)
ask the supplier about its capability at 15 minutes, 900(s). yyEoD voltage: 396V or 495V (1.65 V/cell)
The Interrupting ratings for both types are 100kA,
considering the worst-case scenario for the short circuit
current of 5kA, the fuses can safely trip.

5.2.2 Battery data

Specification Design according with IEC 60896-21/22: 2004
Nominal Voltage 12v (6 cells per unit)
Nominal Capacity 100 Ah @ 20hr-rate to 1.75V per cell @ 25°C (77°F)
Weight Approx. 33.50 kg (73.83 ibs)
Maximum Discharge Curent 800A (5 sec)
Internal Resistance Approx. 3.2 mΩ
Short Circuit Current 2606A
Maximum Charge Current 30.00A
Terminal Type 12 thead lead alloy terminal to accept M6 bolt
Terminal Breking Torque 138.6 Kgf cm/120.3 Ibf in /13.58 N m
Container Material PP(Ul 94-Hb) & Flame Retardant (94-vo) available upon request
Dimensions Length (L) 343.0�2.5 mm 13.50�0.10 Inch
Width (W) 170.0�2.0 mm 6.69�0.08 Inch
Container Height (H) 213.9�2.5 mm 8.42�0.10 Inch
Overrall Height (H) 216.9�2.5 mm 8.54�0.10 Inch
Table 6.

Constant Power Discharge Characteristic Unit: W (25°C, 77°F)

F.V/Time 5 Min 10 Min 15 Min 30 Min 60 Min 90 Min 2 Hr 3 Hr 5 Hr 8 Hr 10 Hr 20 Hr
1.60V 4159 2950 2331 1436 849 610 482 342 223 153 125 63.5
1.67V 4008 2837 2273 1417 843 607 480 340 222 152 124 63.3
1.70V 3863 2772 2252 1404 840 604 478 339 221 151 123 63.2
1.75V 3572 2623 2181 1372 830 599 475 337 220 150 122 62.4
1.80V 3184 2442 2049 1316 809 585 465 331 217 148 121 61.4
1.85V 2769 2227 1856 1234 767 557 444 320 210 142 117 60.0
Please refer to the official site for the latest rating confirmastion. URL: ww.csb-battery.com Issued: 180205
Table 7.

5.2.3 Battery Fault current
The battery fault current value is usually given by the
battery manufacturer and it is available on the product
datasheet. If it is not available, it can be requested to the
battery manufacturer.
For this specifc case see the above table 6:
14
yyShort circuit current: 2606A, not specified the duration.
yyThe available battery short circuit current is affected by
the state of charge and the aging of the battery. Another
important parameter that will reduce the available fault
current is the impedance of the connection.
yyThe final fault current to be considerd for the sizing of
the protection will be 60% of the nominal hence 1.6kA.
5.2.4 Discharging data
The battery protection device MUST NOT open during a
battery discharge at risk of losing the UPS basic functionality
of the load supply in mains failure.
Battery power = (Pn x PF) / (DC/AC)η = 400 kW / 0.96 =
417 kW.
Max discharge current at EoD = Battery Power / EoD
voltage = 417kW / 396V = 1050A for 240Cells and 417Kw /
495V = 843A for 300Cells.
Number of strings Calculation
From the above table 7 we can see that for 5 minutes the
battery power is 4008W/battery.
Total power of one string 4kW x 40 = 160kW or 4Kw x 50
= 200kW
N.Strings with 40 battery => 417kW / 160kW = 2,6 therefore
3 strings needed.
N.Strings with 50 battery => 417kW / 200kW = 2,1 therefore
3 strings needed.
Current at the EoD is 1050 A / 3 = 350A and 842A / 3 = 281A
Each string will have its own fuse.
5.2.5 Fuse sizing
The key points for the selection of the fuse are:
a) DC rated fuse or AC rated with specified DC voltage
capability.
b) Voltage Rating considering the downgrade due to the
L/R
c) The time constant (L/R) of the circuit lower than 10ms
d) Available fault current
5.2.6 ETI fuse NH serie
The four steps check list to be covered is:
a) It is available in two ratings 550Vdc and 700Vdc. The
actual DC voltage capability should be checked based
on the circuit time constant L/R.
b) Voltage Rating considering the downgrade due to the
L/R. Assuming L/R = 10ms the available DC voltage
capability is 550Vdc and 700Vdc. The DC voltage
capability must be verified against the possible voltages
present during the different type of fault:
yyFault between the poles, POS to NEG. The fuse must
be able to open the float battery voltage of 545Vdc
in case of 40 blocks and 681Vdc in case of 50 blocks.
yyGround fault, worts case is NEG to GND. The fuse
must be able to open the negative DC link 370Vdc.
A 700Vdc rated fuse covers 40 blocks and 50 blocks.
c) The time constant (L/R) of the circuit lower than
10ms. The time constant depends by the cabels and
how they are routed. Cables routed very close to each
other will have a L/R lower than connections with
the cables connected to the positive distant than the
cables connected to the negative. The inductance
increase by increasing the distance between the cables.
A time constant of 10ms is representative of a typical
installation.
d) Available fault current. The fault current provided by
the battery depends by various factors such as state
of charge, aging and connection cables. To take care of
the variable related to the battery (EoD and EoL) the
actual fault current will 60% of the nominal one. The
selection of the connections cable (section and length)
should guarantee that the voltage drop between UPS
and battery, with max discharging current, is less than
1% of the UPS battery voltage at the EoD.
e) Intervention time. The rating current of the fuse should
allow the UPS to operate in battery mode in all specified
conditions and open the fault in a limited time whit the
60% of the fault current in 100ms. The Melting curve
provide the following info: max current below which the
fuse dose not open; time to the melting of the fuse (tp).
The key data are:
yyGreen area, normal operating conditions. Max
current (EoD current) 350A and 281A
yyRed area, fault conditions. Minimum fault current
2.6kA x 0,6 = 1.6 kA.
The 224A rated one, size 2, can andle 422A for 5 minutes
(Tab 8).
It has a melting time of about 150ms slightly above the target
(100ms) but still acceptable (Fig. 20). The other variabile
that must be considered is the fuse switch disconnector
because the supplier indicated what is the Max. permissible
power loss fuse link in continuos operation. This introduces
a further limitation into the fuse selection:
yyMax operating current at EOD 350A for 240Cells and
281A for 300Cells
yyFrom the fuse data sheet (see below Tab. 9), the power
dissipation at rated nominal current is 37W. Considering
the discharging current ar 1.8V/cell and 240 cells hence
320A, the power dissipation of the fuse calculated with
the below formula is 75W
yyThe max power handled by the fuse switch disconnector
size 2 is only 34W (Tab. 10)
yyIn continuos operation the fuse supplier does not allow
to use this fuse with this switch disconnector for this
application. Since this fuse will not work with such
current continuously, it is necessary to consider to
use bigger fuse link size 3 , and also size 3 fuse switch
disconnector
15
 Power dissipation for 240Cells
When choosing fuse switch disconnector consider
Pd(IB) = (IB/In)2 x Pd (In)
fuse link power dissipation!
Pd(IB) = (320/224)2 x 37
Pd(IB) � Py
Pd(IB) = 75W
Power dissipation of fuse link at maximal operating
current (IB): Pd(IB) = (IB/In)2 x Pd (In)
IB Maximal operating current
Pd(IB) Power dissipation of link at maximal operating
current
Pd(In) Power dissipation of fuse link at nominal current
Py Maximal permessible fuse link power dissipation
mounted in fuse switch disconnector

700Vdc NH1 - NH3 Battery Fuse data

Fuse Current Rating
40A 50A 63A 80A 100A 125A 160A 200A 224A 250A 315A 350A 400A 425A 500A 630A
Time in Seconds Required Rupturing Current (A)
0.01s 290 370 500 700 900 1100 1400 1800 2100 2200 2800 3000 3300 3500 4100 5000
0.1s 220 280 380 520 670 800 1100 1400 1600 1700 2100 2200 2700 2800 3150 3800
1s 155 190 250 350 470 570 740 950 1200 1250 1500 1600 1800 1900 2200 2700
5s 120 150 200 280 350 430 550 710 850 900 1200 1300 1400 1500 1600 2000
10s 105 125 170 235 315 370 490 620 740 790 1000 1100 1200 1250 1350 1700
60s (1m) 73 92 120 170 220 255 335 440 525 550 700 745 860 930 1010 1210
120s (2m) 67 84 115 150 200 233 317 417 490 516 630 700 800 850 960 1170
180s (3m) 62.5 79 110 140 190 223 295 390 440 480 600 640 730 800 900 1150
240s (4m) 61.5 76 102 135 181 220 285 370 430 460 580 625 720 770 860 1100
300s (5m) 60 73 100 131 170 215 270 355 422 440 560 610 700 735 835 1050
600s (10m) 53.5 69 92 125 155 200 245 328 400 417 520 550 630 680 780 930
900s (15m) 52 65 88 121 149 185 237 320 380 400 500 530 615 650 730 900
3600s (60m) 46 59 79 115 133 163 220 280 330 342 440 480 540 590 650 800
Table 8.
NH Battery fuse link 700Vdc
Size In Standard Striker Standard Power Power Pre-arcing Operating Weight Pack. General characteristics
(A) indicator indicator indicator dissipation dissipation Joule integral Jouleintegral (g) (pcs)
pic.1 pic.1 S110mm (W) 0,7xIn L/R=10ms L/R=10ms
pic.2 (W) (A2s) (A2s)
40 004723289 004723309 004723299 6 2,7 250 1.000 Rated voltage:
50 004723290 004723310 004723300 7 3,1 449 1.796 700V d.c. (L/R=10ms)
63 004723291 004723311 004723301 9 4 700 2.800 Breaking capacity:
80 004723292 004723312 004723302 12 5,4 1.200 4.800 30kA d.c
1 100 004723293 004723313 004723303 15 6,7 1.650 6.600 420 3/24 Standard:
125 004723294 004723314 004723304 20 9 2.200 8.800 IEC 60269
160 004723295 004723315 004723305 26 11,7 4.300 17.200 Application:
200 004723296 004723316 004723306 32 14,4 8.500 34.000 Battery protection
224 004723297 004723317 004723307 37 16,6 10.000 40.000
250 004723298 004723318 004723308 43 19,3 15.000 60.000
125 004724290 004724310 004724300 20 9 2.200 11.682
160 004724291 004724311 004724301 26 11,7 4.300 22.833
200 004724292 004724312 004724302 32 14,4 8.500 45.135
2 224 004724293 004724313 004724303 37 16,6 10.000 53.100 660 3/24
250 004724294 004724314 004724304 43 19,3 15.000 79.650
315 004724295 004724315 004724305 57 26,6 20.000 106.200
350 004724296 004724316 004724306 67 30 28.000 148.680
400 004724297 004724317 004724307 76 34,2 32.000 170.000
250 004725290 004725304 004725297 43 19,3 15.000 75.000
315 004725291 004725305 004725298 57 26,6 20.000 100.000
350 004725292 004725306 004725299 67 30 28.000 140.000
3 400 004725293 004725307 004725300 76 34,2 32.000 160.000 870 3/24
425 004725294 004725308 004725301 84 37,8 40.000 200.000
500 004725295 004725309 004725302 110 49,5 44.000 220.000
630 004725296 004725310 004725303 160 72 80.000 400.000
Table 9.

16
 Technical data (in accordance with IEC/EN 60947-3)
Fuse Current Rating
Size 2 3
Technical Characteristics
Rated operational voltage Ue V 400 AC 500 AC 690 AC 250 DC 440 DC 400 AC 500 AC 690 AC 250 DC 440 DC
Rated operational current Ie A 400 400 400 400 400 630 630 630 630 630
Conv. free air thermal current with fuse-links, * Ith A 400 630
Conv. free air thermal current with solid-links, * Ith A 520 910
Rated frequency f Hz 40-60 40-60 40-60 / / 40-60 40-60 40-60 / /
Rated insulation voltage Ui V 1000 AC 1000 AC
Total power loss (without fuse) Pv W 1P - 9W, 3P - 28W 1P - 17W, 3P - 51W
Power loss at 80% Ith (without fuse-links), ** Pv W 1P - 6W, 3P - 17.9W 1P - 10.9W, 3P - 32,6W
Rated impulse withstand voltage Uimp kV 8 8
Utilisation category*** AC-23B AC-22B AC-21B DC-22B DC-21B AC-23B AC-22B AC-21B DC-22B DC-21B
Rated conditional short-circuit current, ***, **** kA 120 (500V), 100 (690V) 120 (500V), 100 (690V)
Rated short-time withstand current Icw kA 15/1s 15/1s
Fuse links
Size - DIN VDE 0636-2 - - 2 3
Max. rated current (gG) In A 400 400 400 400 400 630 630 630 630 630
Max. permissible power loss per fuse link Pa W 34 48
* Mounting of several units in low voltage switchgear-combinations, please think aboout rated diversity factors acc. to DIN EN 61439.
** Reference value for replacement of devices acc. to DIN EN 61439-1 clause 10.10.4.2.
*** minimum distance to earthed, conductive parts: Lateral: 20mm/Above: 50mm
*** A) Lateral: 50mm/Above: 100mm
**** Type tested with NH fuse-links characteristic gG
***** 35°C Normal temperature, at 55°C with reduced operating current

Table 10.

Battery array

Battery string 1 F1

Battery string 2 F2

Battery string n Fn

Figure 18.

17
 Battery string n21
F

Figure 19.

2
500A
400A
200A

630A
350A
250A
100A

224A

425A
160A

315A
125A
40A

80A
50A
63A
35A

104
tv / s

6
4

103
6
4
2
102
6
4

2
101
6
4

2
100
6
4

2
101
6
4

2
102
6
4
4 6 102 2 4 6 103 2 4 6 104 2
Ip/A

Figure 20.

18
5.2.7 Conclusion:
yy A bigger fuse rated 250A, size 3 is the smaller rating
which can use size 3 fuse switch disconnector . It can
andle 440A for 5 minutes, but unfortunately it has a
melting time of about 200ms, which is above the target
and not acceptable too (Tab. 9).
yy From the fuse data sheet, the power dissipation at rated
nominal current is 43W. Considering the discharging
current ar 1.8V/cell and 300cells hence 257A, the
power dissipation of the fuse calculated with the below
formula is 45W.
yy The max power handled by the fuse switch disconnector
size 3 is 48W, therefore it is ok (Tab. 10).
Power dissipation for 300Cells
Pd(IB) = (IB/In)2 x Pd (In)
Pd(IB) = (257/250)2 x 43
Pd(IB) = 45W
For battery banks with parallel strings, a good practice is to
include overcurrent protection for each battery string (Fig.
18). This minimizes the potential of the bank backfeeding a
single shorted battery (Fig. 19), which can lead to fires and
property damage.
Battery-string fusing is best accomplished with appropri-
ately sized dc-rated fuses secured in bolt-in fuse holders
that are housed in a single enclosure. This arrangement
makes it easy to isolate one battery string for testing or
maintenance while allowing the system to continue opera-
tion. Individual battery-string fuses can provide protection
against catastrophic failure in the event of major fault in the
main disconnect breaker panel or elsewhere in the battery
bank. Series fuses on each battery string also reduce the
available short circuit current levels, allowing for the use of
lower ampere interrupting current rated circuit breakers for
the inverter/ charger disconnects. Without the fuses, the
amount of current that the circuit breaker has to interrupt
during a fault could potentially exceed it's rating.
5.3 Case study Fuse #3
5.3.1 UPS data (EXL-S1)
yyRating: 400kVA; 336kW (PF=0.84)
yyRuntime: 5 minute
yyBattery type: P12V2130 86Ah @ 10h rate
yyNumber of blocks/cells: 50/300
yyFloat voltage: 681V at 20°C ambient (2.27 V/cell)
yyEoD voltage: 495V (1.65 V/cell)
5.3.2 Battery data (Tab. 11)
5.3.3 Battery Fault current
The battery fault current value is usually given by the
battery manufacturer and it is available on the product
datasheet. If it is not available, it can be requested to the
battery manufacturer.
For this specifc case see the above table 11:
yyShort circuit current: 2180A, not specified the duration.
Max current 2130A for 5 sec
yyThe available battery short circuit current is affected by
the state of charge and the aging of the battery. Another
important parameter that will reduce the available fault
current is the impedance of the connection.
yyThe final fault current to be considerd for the sizing of
the protection will be 60% of the nominal hence 1.3kA.
Using the same ratio the max current for 5 sec is 1.28kA
5.3.4 Discharging data
The battery protection device MUST NOT open during a
battery discharge at risk of losing the UPS basic functionality
of the load supply in mains failure.
Battery power = (Pn x PF) / (DC/AC)η = 336kW / 0.96 =
350kW.

Specifications
Exide type Part number Nominal Nominal Power Lenght Width Height Weight Internal Short Max Therminal
designation Voltage Capacity 15 min. I b/w h1 approx. resistance circuit perm
V C10 1.60 max. max. max. kg mOhm current current
1.80 Vpc Vpc mm mm mm A 5
25°C 25°C secs.
A
P12V2130 NAPW122130HP0MA 12 86 2130 359.0 172.0 226.0 33.00 6 2180 2130 M-M8

Constant-power discharge in W/block (@25° C):

Part number Exide type Vpc 3 min. 5 min. 10min. 15 min. 20 min. 30 min. 45 min. 1 h 2h 3h 5h 8h 10 h
designation
NAPW122130HP0MA P12V 2130 1.90 2964 2578 1907 1517 1270 963.2 712.5 583.6 338.0 245.6 166.5 109.6 91.4
NAPW122130HP0MA P12V 2130 1.85 3680 3085 2224 1752 1445 1065 771.4 635.4 379.6 277.1 176.6 117.7 98.5
NAPW122130HP0MA P12V 2130 1.80 4172 3444 2440 1896 1558 1137 820.1 671.9 396.9 289.3 186.8 122.8 102.5
NAPW122130HP0MA P12V 2130 1.75 4510 3690 2593 2009 1637 1199 868.8 702.4 406.0 296.4 191.8 124.8 103.5
NAPW122130HP0MA P12V 2130 1.70 4798 3895 2695 2060 1677 1220 886.1 717.6 412.1 301.5 194.9 126.9 104.5
NAPW122130HP0MA P12V 2130 1.65 5054 4060 2756 2102 1698 1240 896.2 7237.7 417.2 305.5 196.9 127.9 105.6
NAPW122130HP0MA P12V 2130 1.60 5258 4192 2810 2130 1715 1250 901.3 727.8 420.2 307.5 197.9 127.9 105.6
Table 11.

19
 Max discharge current at EoD = Battery Power / EoD voltage For this specifc case see the below table 13:
= 350kW / 495V = 707A. yyShort circuit current: 5000A, not specified the duration.
Number of strings Calculation yyThe available battery short circuit current is affected by
From the above table we can see that for 5 minutes the the state of charge and the aging of the battery. Another
battery power is 4kW/battery. important parameter that will reduce the available fault
Total power of one string 4kW x 50 = 200kW current is the impedance of the connection.
N.Strings => 350kW / 200kW = 1,75 therefore 2 strings yyThe final fault current to be considerd for the sizing of
needed. the protection will be 60% of the nominal hence 2 x 5kA
Current at the EoD is 707A / 2 = 354A. x 0.6 = 6kA.
Each string will have its own fuse. 5.4.3 Discharging data
5.3.5 Fuse sizing The battery protection device MUST NOT open during a
Since the EoD current is similar to the one calculated on battery discharge at risk of losing the UPS basic functionality
case study #2, for the fuse selection applies the same of the load supply in mains failure.
consideration as before. Battery power per core = (Pn x PF) / (DC/AC)η = 300kW /
0.962 = 312kW.
5.4 Case study #4
Max discharge current at EoD = Battery Power / EoD voltage
5.4.1 UPS data = 312kW / 496V = 788A.
yyTrinergy CUBE with 2 x 400kVA cores w/ distributed Number of strings Calculation
battery
From the below table we can see that for 5 minutes the
yyLoad size: 300kW
battery power is 4883W/battery, 814W/cell (Tab. 12)
yyRuntime: 5 minutes
312.000/240 = 1300W/cell
yyBattery type: Enersys – Genesis XE95 40 x 95Ah
1300W/814W = 1,6 strings> to strings per core
yyFloat voltage: 545V at 20°C ambient (2.27 V/cell)
2 strings per core.
yyEoD voltage: 396V (1.65 V/cell)
Battery Short Circuit Current Identification
5.4.2 Battery Fault current
The battery short circuit current value is usually given by
The battery fault current value is usually given by the the battery manufacturer and is available on the product
battery manufacturer and it is available on the product datasheet. If it is not available, it can be acquired and
datasheet. If it is not available, it can be requested to the requested from the battery manufacturer (CSB, YUASA,
battery manufacturer. FIAMM, etc.).

Constant Power Discharge Performance - Constant power discharge rate, watts per battery to 10.02V at 25°C (77°F)
Minutes Hours

Battery 5 10 15 30 1 5 8 10 20

XE13 701.0 443.0 330.0 195.0 111.0 27.0 17.0 14.0 7.0

XE16 857.0 546.0 412.0 247.0 143.0 36.0 24.0 19.0 10.0

XE30 1565.0 1017.0 767.0 455.0 258.0 62.0 41.0 33.0 18.0

XE40 2155.0 1426.0 1085.0 652.0 376.0 93.0 60.0 49.0 26.0

XE60 3337.2 2175.4 1644.2 976.8 556.3 137.1 90.3 74.2 40.7

XE70 3636.0 2411.0 1833.0 1091.0 615.0 142.0 90.0 73.0 37.0

XE95 4883.4 3241.0 2482.0 1494.0 861.6 212.4 139.8 114.0 61.2

Table 12.
Nominal Nominal Dimensions
Capacity (Ah)
10 hr rate to Overall Internal Typical
Nominal Length Width Height Torques
Type 1.67Vpc Weight Resistance Short Circuit
Voltage (V) (mΩ) Current (A)
@ 25°C/77°F mm in mm in mm in kg Ibs in-Ibs Nm

XE95 12 95 329.9 12.99 172.5 6.79 218.9 8.62 35.1 77.4 60 6.8 2.2 5000

Table 13.

20
5.4.4 CB selection ABB TMAX T6
Tmax T6 800A N type
Amp Rating Rated Service Voltage (DC) Rated Icu breaking capacity kA
800 750 16
Table 14.

1. Identification of Un, rated voltage of the system (Ue≥Un). 3. Coordination with the fault current
For 3 poles in series this CB is rated 750Vdc hence 750Vdc ≥ This Breaker has I3 = 4000A, designed for DC
545Vdc, usable in this specific application (Tab. 16). Km=1 hence 6000A (battery fault current) ≥ 4000A
2. Coordination with the EoD current (Tab. 14). (Tab. 15)
This is CB is rated 800A hence 800A ≥ 788A (EoD current)

T6 630/800 - TMA
I1 (400 Hz) I3 setting (MIN=5xln)
In MIN MED MAX I3 (50 HZ) Km I3 (400 HZ)
T6N 630 630 397 482 567 3150 1.5 4725
T6N 800 800 504 602 720 4000 1.5 6000
Table 15.

It is considered a TN power distribution, the minimum number of poles in series is 3 to get 750Vdc with a ultimate short circuit
current of 16kA (T6N) and a voltage umbalance between polarites and earth.

TMAX T6 (O)
Rated uninterrupted current (A) 630/800/1000
Poles (No.) 3/4
Rated service voltage, Ue (AC) 50-60 Hz (V) 690
(DC) (V) 750
Rated impulse withstand voltage voltage, Uimp (kV) 8
Rated insulation voltage, Ui (V) 1000
Test voltage at industrial frequency for 1 min. (V) 3500
Rated ultimate short-circuit breaking capacity, Icu N S H L V
(AC) 50-60 Hz 220/230 V (kA) 70 85 100 200 200
(AC) 50-60 Hz 380/400/415 V (kA) 36 50 70 100 150
(AC) 50-60 Hz 440 V (kA) 30 45 50 80 120
(AC) 50-60 Hz 500 V (kA) 25 35 50 65 85
(AC) 50-60 Hz 690 V (kA) 20 22 25 30 40
(DC) 250 V - 2 poles in series (kA) 36 50 70 100 -
(DC) 250 V - 3 poles in series (kA) - - - - -
(DC) 500 V - 2 poles in series (kA) 20 35 50 65 70
(DC) 500 V - 3 poles in series (kA) - - - - -
(DC) 750 V - 3 poles in series (kA) 16 20 36 50 50
Rated short-circuit breaking capacity, Ics
(AC) 50-60 Hz 220/230 V (%Icu) 100% 100% 100% 75% 100%
(AC) 50-60 Hz 380/400/415 V (%Icu) 100% 100% 100% 75% 75% (120)
(AC) 50-60 Hz 440 V (%Icu) 100% 100% 100% 75% 75% (100)
(AC) 50-60 Hz 500 V (%Icu) 100% 100% 100% 75% 75% (65)
(AC) 50-60 Hz 690 V (%Icu) 75% 75% 75% 75% 75%
Rated short-circuit breaking capacity, Icm
(AC) 50-60 Hz 220/230 V (kA) 154 187 220 440 440
(AC) 50-60 Hz 380/400/415 V (kA) 75.6 105 154 220 330
(AC) 50-60 Hz 440 V (kA) 63 94.5 105 176 264
(AC) 50-60 Hz 500 V (kA) 52.5 73.5 105 143 187
(AC) 50-60 Hz 690 V (kA) 40 46 52.5 63 84
Opening time 415 (V) (ms) 10 9 8 7 7
Utilisation category (IEC 60947-2) B (630A - 800A) (5) - A (1000A)
Reference Standard IEC 60947-2
Isolation behavior
Trip units Thermomagnetic
T fixed, M fixed TMF -
T adjustable, M fixed TMD -
T adjustable, M fixed, M adjustable (5...10 x In) TMA (up to 800A)(4)
T adjustable, M fixed (3 x In) TMG -
T adjustable, M fixed, M adjustable (2.5...5 x In) TMG
Magnetic only MA
Table 16.

21
 TMA Releases ThermoMagnetic, Thermal adjustable Magnetic threshold Thermal threshold
(0,7-1 In), Magnetic adjustable (5-10 In) Fig. 21. (5 to 10 x In) Adjustable(0.7 to 1 x In)

T6 800 - TMA
In = 800 A
Figure 21.

t (s)
104
2h

1h
30'

103 20'
Thermal Cold Trip* @
10' 2In 900 sec

5'
Thermal Typical Trip*@
2In 200 sec
102 2'

1'
Thermal Hot Trip* @
2In 40 sec

10

(Green area) 5minutes

@ 800A thermal trip
1 protection OK (setting
range 0,7-1In)
(Red area) 6-10kA short
circuit current
(Yellow area) 5-10kA
10 -1
magnetic trip protection
I2 =5...10 x In range (Must be set not
above 5In)
(Red Line) 20msec.
Safe magnetic intervention
10 -2
time expected for 6-10kA

10 -1 10 -1.05 10 102
x I,

Figure 22.

22
5.4.5 Conclusions (Fig. 22)
The Tmax T6 N type 800A 750Vdc model is suitable to
protect the battery against short circuit, the Magnetic
intervention time is below 100msec at 6-10kA.
The back up time of 5 minutes can be easily managed by
the breaker, with 2 strings in parallel the autonomy is even
larger, about 7 minutes without any risk of thermal tripping.
The Interrupting ratings for the N type is 16kA, considering
the worst case scenario for the short circuit current of 10kA,
the breaker can safely trip.
Another important consideration to be done is when one
string fail (open cell), OCV and impedance vary until only
one string remains active and able to supply the load for
only 1 minute. The breaker will be ineffective in this case
against short circuit, the current will be only 3kA and the
magnetic intervention time 10-200sec. During this period
the battery can burn, therefore is extremely important
to monitor the battery with BMS. Finally, It must be clear
that, on the basis of the conditions in which an overload is
presented, i.e. with the circuit breaker at thermal running or
not, the thermal relay trip varies considerably. For example,
for an overload current of 2 x In, the trip time is between 40
and 200sec. for hot trip, and between 200 and 900sec. for
cold trip.

23
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