The Tool Desk
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UPS capacity and battery runtime are different calculations
The UPS must carry the connected equipment continuously, including its real-power limit in watts and its apparent-power limit in VA. The battery system must then supply the UPS for the outage interval defined by your operating plan. A UPS can have enough watt capacity but insufficient VA capacity, or enough installed battery energy but too little runtime at the actual discharge rate.
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| Question | What you calculate | Evidence required |
|---|---|---|
| Can the UPS carry the load? | Protected watts and VA, plus growth and usable redundancy | Measured load, equipment electrical data and the UPS watt/VA ratings |
| How long will it run? | Runtime at the selected load and end-of-discharge voltage | UPS-specific runtime tables or an approved battery-sizing calculation |
| Will it remain available after a failure? | Capacity with one unit or module unavailable | Single-unit, modular, parallel or N+1 architecture calculations |
Eaton summarizes the distinction this way: a UPS needs enough capacity for the full load, while the battery system must support that load long enough to restore power or shut systems down safely. Treat those as separate design decisions.
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Start with a complete load inventory
List every load that must stay online
Create an equipment schedule covering servers, storage, network switches, routers, firewalls and other IT hardware. Decide explicitly whether cooling, environmental controls, access control, security systems, monitoring, lighting or other facility-support loads will be connected to the protected UPS bus. Eaton distinguishes facility-support loads from IT critical loads; combining them without documenting the decision can produce an undersized system.
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Record measured operating power whenever possible. Keep nameplate voltage and current for electrical compatibility and worst-case checks, but do not silently substitute breaker ratings or the sum of maximum nameplate draw for a measured operating profile. If you use a nameplate maximum as the design load, label that assumption and explain why.
Capture operating states, not just a single reading
- Record normal, busy and startup conditions where the equipment can produce materially different demand.
- Identify loads that can be shut off first, such as test servers, spare storage, displays or nonessential peripherals.
- Note equipment with dual power supplies and verify whether both feeds are intended to be on the same UPS system or on separate systems.
- Document planned additions over the design period rather than treating growth as an unspecified reserve.
Calculate watts and VA separately
Watts: real power
Sum the measured or design real power of the equipment that the UPS must support. If an item provides watts directly, use that value. If only voltage, current and power factor are available, calculate real power using the equipment’s stated relationship and power factor.
VA: apparent power
For equipment listed only with voltage and amperage, Eaton’s sizing guide uses:
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VA = volts × amps
Sum the VA values for all protected devices. When a device gives watts and power factor rather than VA, convert using:
VA = watts ÷ power factor
Compare the totals with the UPS’s separate watt and VA limits. Passing one limit does not compensate for exceeding the other. A low-power-factor load can require substantially more VA than its watt figure suggests.
Add a documented growth allowance
Eaton recommends at least 15% more UPS VA capacity than the current protected-equipment requirement as a five-year growth allowance. That is vendor guidance, not a universal code requirement. Your forecast may justify more, especially where server density, storage or cooling demand is expected to rise quickly.
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Apply the allowance to the design load, then check whether redundancy reduces the capacity actually available during a failure. Installed nameplate capacity is not the same as usable capacity.
Define autonomy from the outage response plan
Choose the event the batteries must cover
There is no universal runtime that fits every small data center. Eaton’s edge UPS guide says there is “no magic formula” for determining required battery runtime. Set the target from what the site must do during an outage:
- Bridge the interval until a generator starts and transfers.
- Allow virtual machines or workloads to migrate to another location.
- Complete an orderly operating-system and application shutdown.
- Keep critical services running for a longer period when no generator is available.
Measure or establish the actual generator-start and transfer interval, migration duration and controlled-shutdown time. Include communications, management systems and storage dependencies in that plan; shutting down a host is not complete if the storage or network path fails first.
Use load segments to preserve critical runtime
Separate essential and nonessential equipment onto switched outlets or load segments when the UPS supports that feature. Shedding noncritical devices during a prolonged outage can extend runtime for the systems that must remain online. Document the shedding order and test that the remaining workloads continue to operate.
If there is no generator, decide whether the objective is a short bridge, an orderly shutdown or sustained operation. The available guidance does not establish one preferred autonomy for every small data center.
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Use energy arithmetic only as a first check
A conceptual estimate starts with:
Battery-side power ≈ AC load power ÷ UPS efficiencyBattery energy ≈ battery-side power × required hours
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This illustrates why the battery must supply more power than the AC load consumes. It is not a procurement calculation. UPS efficiency changes with load and operating mode, and battery voltage, current, discharge rate and cutoff behavior determine how much of the nominal energy is usable.
Obtain the exact discharge data
For final sizing, obtain the UPS manufacturer’s supported battery configurations and the battery manufacturer’s constant-power or discharge tables. Match all of these variables:
- UPS model, power rating, firmware or configuration where relevant
- Battery model and chemistry
- Number of series cells and parallel strings
- Required load in watts or VA and its power factor
- Required runtime
- UPS low-voltage cutoff and the table’s end-of-discharge voltage
- Design temperature and the required end-of-life capacity
- Inverter, converter and charging losses
Battery capacity cannot be inferred from amp-hours alone. Two batteries with the same nominal amp-hour rating can deliver different power at the discharge rate imposed by a UPS. ABB identifies battery power, power factor and inverter efficiency as sizing considerations; Fuji Electric also directs designers to account for inverter and converter losses, aging, temperature and design margin.
Understand why runtime tables are configuration-specific
Eaton’s Power Xpert 9395P runtime document is an example of the required specificity. Its tables distinguish battery models, string counts, UPS load and power factor, and state test conditions of 25°C with a 1.67-volt-per-cell end voltage. Those runtime values apply only to the configurations shown in that document. Do not transfer them to another UPS model, battery type, string count or cutoff setting.
Choose an architecture that survives the expected failure
Single UPS
A single unit is the simplest arrangement and may suit a small site whose maintenance and outage requirements are modest. It has one principal conversion path, so a planned service event or unit failure can interrupt the protected bus unless a bypass or alternate feed is engineered.
Modular or parallel UPS system
Modular and parallel designs can add capacity or allow maintenance without taking the whole load offline, but only if the controls, bypass path, distribution and maintenance procedures support that operating mode. Confirm how many modules may be removed while the remaining system continues to carry the design load.
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N+1 redundancy
In an N+1 arrangement, one additional unit or module is installed beyond the number required for the design load. After one unit fails, the remaining units must still support that load. Calculate the post-failure capacity explicitly; a large total installed rating does not prove N+1 capability if the load already consumes the capacity of all but one unit.
Plan growth separately from redundancy. A unit held as the spare for failure is not automatically spare capacity for new servers.
Account for chemistry, temperature and service life
Battery chemistry is a site decision
Compare lithium-ion and valve-regulated lead-acid (VRLA) batteries on more than nominal energy. Evaluate installed cost, cabinet space, weight, monitoring, maintenance access, charging behavior, replacement logistics, manufacturer support and compatibility with the selected UPS.
Eaton’s edge guide gives vendor-reported average service-life ranges of about eight years for lithium-ion and three to five years for VRLA. These are general figures, not a guarantee for an installed system. Actual life depends on temperature, operating conditions, depth of discharge, charging and maintenance.
Design for end of life, not a new battery
ABB advises considering beginning- or end-of-life performance, operating temperature, depth of discharge, cutoff voltage and charging time. Specify the capacity that must remain available at the end of the planned service interval, then use the manufacturer’s aging factors and temperature corrections. A design that meets runtime only with a new battery can fail its purpose years before replacement.
Validate electrical and environmental requirements before buying
- Confirm the electrical interface. Check input and output voltage, phase, frequency, neutral arrangement and allowable power factor against the site and the exact UPS documentation.
- Engineer distribution and protection. Verify feeder capacity, cable sizing, breakers, short-circuit ratings, bypass arrangements, grounding and coordination with qualified professionals.
- Check battery limits. Confirm permitted string count, battery voltage range, charging capacity, cabinet ratings, disconnects and maximum cable lengths.
- Verify room conditions. Check ambient temperature, ventilation, humidity, clearances, floor loading, fire protection and access for battery replacement.
- Define monitoring and maintenance. Decide how battery impedance or conductance, temperature, alarms, runtime estimates and capacity tests will be recorded, and who responds to alarms.
- Review local rules. The applicable electrical, fire, seismic, safety and disposal requirements depend on the jurisdiction and installation. Have local licensed electrical and safety professionals review the design; no single rule set applies to an unspecified location.
A worked sizing example (for method, not procurement)
Suppose a hypothetical rack area has a measured protected load of 6,000 watts and 6,700 VA. The owner expects a 15% five-year growth allowance and wants the UPS to carry the load after one module fails.
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- Apply growth:
6,700 VA × 1.15 = 7,705 VA. The UPS design must also satisfy the corresponding watt requirement, not just 7,705 VA. - For N+1, select enough modules that one module can be removed while the remaining modules still carry the 7,705-VA design load and its watt limit.
- Set autonomy from the operating plan—for example, the measured generator-transfer interval plus the time required to shut down noncritical workloads. Do not assume a battery duration from the arithmetic alone.
- Give the UPS and battery vendors the exact load, power factor, autonomy, temperature, end-of-life requirement and cutoff voltage. Use their discharge tables to determine series cells and parallel strings.
The example demonstrates the sequence. It does not establish a battery count because no UPS model, battery model, voltage, efficiency curve or discharge table has been specified.
Manufacturer examples and what they do—and do not—tell you
Eaton lists its 93PX family at 15–20 kVA/kW and positions it for edge, high-density rack and small-to-medium data-center use, with external battery modules as an option. The same data-center material describes the 93PS, 93E G2 and 93PM G2 families with other capacities and configurations.
These are manufacturer examples, not an independent recommendation or proof of site suitability. Before selecting any family, verify the exact voltage and phase, supported battery modules, runtime tables, bypass and distribution requirements, environmental limits and local approval requirements.
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- Using only watts: Calculate and check VA separately; power factor can make apparent power materially higher.
- Buying batteries by amp-hours: Use constant-power discharge data at the UPS’s actual load and cutoff voltage.
- Assuming a fixed five-minute runtime: Derive autonomy from generator transfer, migration or shutdown measurements.
- Applying a runtime table to another model: Match UPS, battery, strings, load, power factor, temperature and end voltage exactly.
- Counting all nameplate maximums without an assumption: Measure where possible and document whether the design uses measured, typical or worst-case demand.
- Calling installed capacity N+1: Recalculate capacity with the largest unit or module unavailable.
- Ignoring aging and heat: Size to the required end-of-life condition and design temperature.
- Putting cooling on the UPS without budgeting it: Decide which facility-support loads are protected and include their measured demand.
- Leaving maintenance undefined: Specify testing, monitoring, battery replacement access and alarm response before installation.
What a complete design package should contain
Before procurement, retain a load schedule with watts, VA and power factor; measured demand and stated assumptions; the growth forecast; autonomy and load-shedding logic; the redundancy calculation; exact UPS and battery models; manufacturer discharge tables; temperature and end-of-life assumptions; one-line diagrams; feeder, breaker and bypass details; room and environmental requirements; monitoring points; maintenance intervals; and the local professional review.
If any of those inputs is missing, the result is a planning estimate rather than a final battery count or stamped electrical design. A vendor or qualified engineer can produce the final configuration once the site load, runtime objective, electrical characteristics, jurisdiction and exact equipment are known.
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