Backup Generator Sizing Calculator

Plan backup power for offices, sites, and camps. Model mixed loads with growth and derating. Get a clear kVA target and ATS amperage guidance.

Calculator Inputs

Common: 230, 400/415, 480.
Future additions and load uncertainty.
Extra cushion for transient effects and aging.
Use manufacturer curves for final selection.
Example: 0.92 means 8% derate.

Load Schedule

Load name Type Qty Input Unit PF Eff Demand Start mult
PF = power factor. Eff = efficiency (motors). Demand allows diversity (0.7 means 70% typical). Start mult is motor starting kVA / running kVA (often 2–6).
Reset

Example Data Table

Use this as a quick reference for typical site loads. Adjust PF, demand, and starting multipliers to match your equipment and operating sequence.

Load Type Qty Input Unit PF Demand Start mult Notes
Site lighting Lighting 1 8 kW 0.95 1.00 1.0 Low surge
Water pump Motor 1 15 HP 0.85 1.00 3.5 DOL start
Welding outlets General 1 12 kW 0.80 0.70 1.2 Intermittent
Office / IT UPS/IT 1 6 kW 0.90 1.00 1.3 Rectifier inrush

Formula Used

This tool sizes a generator using running load, starting surge, and adjustment factors:

Running kW (per row) = Qty × Input(kW) × Demand
If input is HP: Input(kW) = (HP × 0.746) ÷ Efficiency

Running kVA (per row) = Running kW ÷ PF
Starting kVA (per row) = Running kVA × Start Multiplier

Peak Starting kVA = (Total Running kVA − Largest Motor Running kVA) + Largest Motor Starting kVA

Design kVA = max(Total Running kVA, Peak Starting kVA) × (1 + Growth%) × (1 + Safety%)
Recommended kVA = Design kVA ÷ Derating Factor

Full-load current (3φ) = (kVA × 1000) ÷ (√3 × V)
Full-load current (1φ) = (kVA × 1000) ÷ V

Notes: Derating is a rule-of-thumb approximation. Always verify with manufacturer derating curves, alternator limits, and transient performance requirements.

How to Use This Calculator

  1. Enter system voltage, phase, and frequency for the backup supply.
  2. Add all connected loads as separate rows and set quantity.
  3. Use HP for motors, and set realistic efficiency and PF.
  4. Apply a demand factor if loads won’t run simultaneously.
  5. Set a start multiplier for motors (typical 2–6).
  6. Include growth and safety margins for future and uncertainty.
  7. Adjust derating for altitude/temperature, then calculate.
  8. Download CSV/PDF for submittals and design documentation.
This calculator provides planning-level sizing. Final selection should be reviewed by a qualified engineer and matched to codes, load steps, motor starting method, and generator model data.

Professional Notes for Backup Generator Sizing

1) Start with an accurate load schedule

A dependable standby selection begins with a complete schedule of connected loads, quantities, and realistic operating patterns. For construction sites, lighting, offices, dewatering pumps, welding outlets, and compressors commonly dominate demand. Use demand factors to reflect diversity; for example, intermittent welding may be modeled at 0.6–0.8 rather than 1.0.

2) Convert inputs to kW and kVA consistently

This calculator converts motor horsepower to electrical input using kW = HP × 0.746 ÷ efficiency. It then converts kW to kVA using kVA = kW ÷ PF. Typical PF values are 0.80–0.90 for mixed site loads, 0.95 for lighting circuits with correction, and near 1.00 for resistive heaters.

3) Treat motor starting as a peak event

Motor starting can require several times the running kVA for a short duration. The tool models starting with a multiplier (often 2–6 for DOL starting), and estimates a worst case where all loads are running and the largest motor starts. If your sequence allows two large motors to start together, increase multipliers or add a dedicated row.

4) Apply growth, safety margin, and derating

Growth covers future additions and uncertainty; 10–25% is common for temporary works with evolving scope. A safety margin helps absorb transient impacts and measurement error. Derating accounts for reduced air density and cooling at high altitude and temperature; the auto mode applies rule‑of‑thumb reductions. Always verify with manufacturer curves for the chosen model and enclosure.

5) Confirm current and switching requirements

After selecting a standard kVA size, confirm full‑load current at site voltage and phase. The calculator suggests an ATS rating using a conservative step above 125% of full‑load current. Final equipment selection should also check short‑circuit withstand, generator transient response, harmonics from UPS loads, and any code requirements for emergency or legally required standby systems.

FAQs

1) Why does the calculator show both kW and kVA?

Generators are commonly rated in kVA, while many loads are listed in kW. Power factor links them: kVA = kW ÷ PF. Low PF increases kVA demand and can drive the generator size.

2) What starting multiplier should I use for motors?

For direct-on-line starts, 3–6 is typical. Soft starters or VFDs can reduce starting demand substantially. Use manufacturer data when available and model worst-case starting sequences for critical motors.

3) How should I choose the demand factor?

Use demand to represent diversity. If a load runs intermittently, set 0.5–0.8 based on duty. For life-safety or continuous loads, keep demand near 1.0 and avoid optimistic assumptions.

4) Does the tool account for harmonics from UPS loads?

It includes a starting multiplier option for UPS/IT inrush, but it does not calculate harmonic distortion. For large UPS systems, confirm generator compatibility, alternator sizing, and any K-factor or THD limits.

5) Why is derating important?

High ambient temperature and altitude reduce available engine power and cooling capacity. If you ignore derating, a generator may not deliver its nameplate rating in real site conditions, risking overload and voltage dip.

6) How accurate is the ATS rating suggestion?

It is a planning estimate based on 125% of full-load current, rounded up to a standard size. Final ATS selection should verify continuous rating, short-circuit withstand, and coordination with protection devices.

7) What is the most common sizing mistake?

Underestimating motor starting and future growth. A generator that meets running kW may still fail during starts due to kVA surge and voltage drop. Model the start sequence and choose a practical margin.

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