Power Systems & Controls, Inc.

GUIDEFORM SPECIFICATION FOR SERIES CONTINUUM (UPS)

The following specification is intended for use by consulting engineers to provide bidding specifications for products with the quality and performance characteristics provided by Power Systems & Controls' product listed above. The same specification can be used as a description of the listed Power Systems & Controls' product by substituting "provides" for "shall provide" or similar wording.

This specification is indexed according to the commercial standard instructions format and without this cover page has no reference to a particular vendor or product.

TECHNICAL SPECIFICATIONS FOR UNINTERRUPTIBLE POWER SYSTEM

1. GENERAL
1. Summary

This specification describes a three phase solid state on-line Uninterruptible Power System (UPS). The UPS shall automatically provide continuous, regulated AC power to critical loads under normal and abnormal conditions, including loss of input AC power. During normal operation, the UPS module rectifier/charger shall convert the incoming ac input power to dc power for the inverter and for charging the battery. The inverter shall supply ac power continuously. Inverter output shall be synchronized with the bypass ac power source, provided that the bypass ac power source is within the specified frequency range. The UPS system shall supply ac power to the critical loads. With a loss of normal input source power, the battery shall supply dc power to the inverter so that there is no interruption of ac power to the critical load whenever the ac input power sources deviate from the specified tolerances or fail completely.

2. System Description

The UPS module shall consist of a solid state static PWM rectifier/battery charger, a solid state static PWM inverter, a static bypass switch, external battery cabinet, protective fuses, synchronizing circuitry, protective devices and accessories as specified herein that shall automatically effect continuity of electric power within specified tolerance, without interruption, upon failure or deterioration of the normal AC power source. Continuity of electric power to the load shall be maintained for an emergency period with the inverter supplied by the battery, up to the specified protection time or until restoration of the normal AC power source.

2. UPS EQUIPMENT
1. Rectifier/Charger Unit

Rectifier/charger unit shall be a Pulse Width Modulated (PWM) power factor correcting, transistorized-type rectifier design and utilize insulated gate bipolar transistors (IGBTs). The Rectifier/charger unit shall provide direct current to the dc bus for the inverter and battery charging functions. The rectifier/battery charger shall have sufficient capacity to support a fully loaded inverter and recharge the battery to 95% of its full capacity within 10 times the discharge time.

2. Input Protective Device

Rectifier/charger unit shall be provided with input protective devices consisting of ac input circuit breaker. The protective device shall be capable of shunt tripping.

3. Power Walk-In

The rectifier/charger shall be capable of 100 percent step-load.

4. Sizing

Rectifier/charger unit shall be sized for the following two simultaneous operating conditions:

1. Supplying the full rated load current to the inverter.
2. Recharging a fully-discharged battery to 95 percent of rated ampere-hour capacity within ten times the discharge time after normal ac power is restored, with the input protective device closed.
5. Battery Charging Current

Primary current limiting: Battery-charging current shall be voltage regulated and current limited. DC current limit settings shall be customer programmable. After the battery is recharged, the rectifier/charger unit shall maintain the battery at full float charge until the next operation under input power failure. Battery charger shall be capable of providing equalizing charge to the battery.

6. DC Voltage Adjustment

Rectifier/charger unit shall have manual means for adjusting dc voltage for battery equalization, to provide voltage within plus 10 percent of nominal float voltage.

7. Battery Isolation Protective Device

Module shall have a dc protective device to isolate the module from the battery system. The protective device size and interrupting rating shall be as required by system capacity and shall incorporated a shunt trip as required by circuit design.

8. Inverter Unit

The UPS output shall be derived from a Pulse Width Modulated (PWM) variable frequency and variable pulse width, transistorized-type inverter design and utilize insulated gate bipolar transistors (IGBTs). The inverter shall be capable of providing the specified precise output power characteristics while operating over the battery voltage range.

9. Output Overload

The inverter shall be able to sustain an overload as specified across its output terminals. The inverter shall be capable of at least 300% current for short circuit conditions. If the short circuit is sustained, the load shall be transferred to the bypass source and the inverter shall disconnect automatically from the critical load bus.

10. Synchronism

The inverter shall normally operate in phase-lock and synchronism with the bypass source. Should the bypass source frequency deviate beyond a predetermined adjustable frequency window, the inverter shall run on an internal frequency reference. Upon restoration of the bypass source within the required tolerance, the inverter shall re synchronize with that source at a slew rate not exceeding the specified rate.

11. Output Protective Device

The output protective device shall be capable of shunt tripping and shall have interrupting capacity as specified.

12. Internal Protection

UPS module shall be self-protected against over current, sudden changes in output load and short circuits at the output terminals. UPS module shall have built-in protection against permanent damage to itself and the connected load for predictable types of failure within itself and the connected load. At the end of battery discharge limit, the module shall shut down without damage to internal components.

13. Microprocessor Controlled Logic

All UPS control operations are executed through the use of microprocessor controlled logic. The microprocessor's firmware has control over all the operations and parameters eliminating the need for manual adjustments and potentiometers.

14. Display and Controls

The UPS module shall be provided with a control/indicator panel. The panel shall be on the front of the UPS module. Controls, meters, alarms and indicators for operation of the UPS module shall be on this panel.

15. The following functions shall be monitored and displayed:
1. Input voltage, phase-to-phase.
2. Input current.
3. Input frequency.
4. Battery voltage.
5. Battery current (charge/discharge).
6. Output voltage, phase-to-phase and phase-to-neutral.
7. Output current.
8. Output frequency.
9. Output kVA and kilowatts.
10. Elapsed time meter to indicate hours of operation.
11. Bypass input voltage, phase-to-phase and phase-to-neutral.
12. Output kilovars and power factor.
13. Output kilowatt hours.
14. While connected to battery only, the number of minutes before UPS disconnects from critical load.
15. Bypass input frequency.
16. DC bus voltage.
17. Crest factor per phase.
18. Battery cabinet temperature.
16. Module Alarm Indicators

Module shall have indicators for the following alarm items. Any one of these conditions shall turn on an audible alarm and the appropriate summary indicator. Each new alarm shall register without affecting and previous alarm.

1. Input ac power source failure.
2. Input protective device open.
3. Output protective device open.
4. Overload.
5. Overload shutdown.
6. Dc over voltage.
7. Low battery.
8. Battery discharge.
9. Battery protective device open.
10. Equipment over temperature.
11. Charger off.
12. Inverter off.
13. Inverter fault.
14. Emergency off.
15. UPS on battery.
16. Critical load on static bypass.
17. Inverter output over voltage.
18. Inverter output under voltage.
19. Inverter output over frequency.
20. Inverter output under frequency.
21. Bypass source over voltage.
22. Bypass source under voltage.
23. Bypass source over frequency
24. Bypass source underfed
25. Bypass source to inverter out of synchronization.
17. Power Flow Indications

A power flow diagram shall graphically depict whether the load is being supplied from the inverter, bypass, or battery and provide, on the same screen, the status of the following components:

1. AC input circuit breaker.
2. Battery circuit breaker.
3. Inverter output circuit breaker.
4. Bypass circuit breaker.
5. Static Transfer Switch.
18. Programmable Logic Controller

A programmable logic controller provides the control logic the means to interface with the various UPS system controllers and equipment. The PLC shall be a complete and self-contained control system that facilitates a very flexible and adaptable control system. The PLC shall contain an Ethernet communication port for communicating to a remote facility management system.

19. Modbus TCP/IP over Ethernet Communication

RS-485 communications port shall be provided that shall allow real time system status, alarm indication, system measurements, and all historical information to be remotely accessed through Modbus TCP/IP over Ethernet protocol connected directly to a HTTP server or LAN network.

20. Battery

The battery pack shall be housed in a cabinet matching the UPS module design. The battery pack shall consist of sealed maintenance free lead acid cells. The battery pack shall include a properly rated circuit breaker that shall provide a means of isolating the battery from the other UPS system modules. The UPS shall provide a pushbutton on the control panel to trip the battery pack circuit breaker.

3. MATERIALS & CONSTRUCTION

The contractor shall select materials and components not definitely specified. All components and parts shall be new and standard production items. All items such as bolts, screws, nuts, and washers shall be of an approved corrosion-resistant material or shall be suitably treated to resist corrosion. The number of different sizes and types of hardware shall be kept to a minimum.

1. Corrosion-Resistant Materials

The following are the only acceptable corrosion-resistant metals (as distinguished from corrosion-resisting treatments:

1. Corrosion-Resisting Steel, with chromium
2. Copper
3. Aluminum
4. Brass
5. Bronze
6. Beryllium-Copper
7. Alloys of Copper & Nickel
2. Corrosion-Resistant Treatments

Uniform coating of a sufficient thickness of chromium, copper, silver or zinc are approved corrosion-resistant treatments.

3. Thermal & Sound Insulating Materials

Thermal and sound insulating material shall be non capillary, non hygroscopic and free from precipitable odors; resistant to attack by vermin, insects, rodents and mildew; fire retardant; capable of maintaining its shape, position and consistency inherently or by suitable retaining under conditions of vibration specified herein; resistant to or protected from abrasion; paintable and bondable to metal; and replaceable.

4. Dissimilar Metals

Contact between dissimilar metals, which could cause deterioration of parts by galvanic action, shall be avoided whenever possible. If contact between dissimilar metals cannot be avoided, the surfaces shall be treated.

5. Finish

Cleaning, painting, plating anodic films, and chemical treatment shall be in accordance with the manufacturer's/contractor's standard practices.

6. Push-Buttons

Push-button switches shall be UL recognized components.

7. Relays

Relays shall be the plug-in type with dust cover.

8. Hinges & Latches

Hinges and movable parts of latches shall be made of corrosion-resistant material. Provisions shall be made to prevent hinge pins from being removed.

9. Fasteners
1. Non Electrical:
10. Each fastener shall be equipped with a suitable locking device to prevent loosening due to vibration. Locking shall be by locknut, castellated nuts with cotter pins, lock washers, self-locking nuts, lock wire or lock plate.
11. Electrical:
1. Locking devices shall be used for each fastener used in making an electrical connection except for the screws furnished with components. Fasteners shall not be depended on to carry current; they shall serve to hold current carrying parts in contact with each other. Where flow of current through a stud cannot be avoided, the stud and all associated hardware shall be made of corrosion-resistant material. Unused length of threads shall not exceed half the diameter of the stud.
12. Terminal Strips & Terminal Supports

Terminal strips shall be of sufficient size to accommodate the ringed terminal lugs used on #14 AWG wire or be of the type that accepts unterminated stranded wire.

13. Transformers

The instrument transformers shall be 600 volt insulation class. Instrument transformers shall conform to ANSI C57.13. The accuracy class burden rating shall be 2%.

14. Shunts

Shunts shall conform to MIL-S-61.

15. Wiring

All wire shall be with type suitable for the application. All conductors shall be identified at both ends within two inches of the connection point and so referenced on the drawings. Wire markers shall be of thermally labeled heat shrinkable type. For terminal blocks requiring wire lugs, pressure-type, insulated barrel ring lugs, which grip the insulation as well as the wire conductors, shall be used. A constant-pressure crimping tool, which conforms both crimps simultaneously, must be used. No solder connections shall be used. No wire smaller than #16 AWG shall be used.

16. Switches

Switches shall be UL recognized components.

17. Fungus & Moisture Resistance

The electrical circuitry, including all components and connections, except as specified below, shall be protected from the effects of fungus growth and moisture by treatment with a varnish:

1. Components or circuit elements that are inherently fungus and moisture resistant or which are hermetically sealed.
2. Components or circuit elements whose function will be affected by the varnish coating.

When used, the varnish shall be applied by spray, brush or a combination of both to give a dry-film of not less than one mil. The component or surface shall be cleaned and prepared so that surfaces are free from all foreign matter, which could interfere with adherence of function of the varnish.

4. SYSTEM RATING

Unless stated otherwise, the parameters listed are under full output load at 0.8 power factor, with batteries fully charged and floating on the dc bus and with nominal input voltage.

5. PERFORMANCE REQUIREMENTS
1. Input
1. Voltage 480 volts line-to-line.
2. Number of phases: 3-phase, 3-wire, plus ground.
3. Voltage Range: +10%, -20%, without affecting battery float voltage or output voltage.
4. Frequency: 60Hz, +5 %.
5. Power walk-in: 0 % to 100 % over 1 seconds, but capable of handling 100% step load.
6. Total harmonic current distortion (THD) reflected into the primary line: < 5% maximum from on load to full load.
2. Output
1. Voltage 480 volts line-to-line, 277 volts line-to-neutral.
2. Number of phases: 3-phase, 3-wire, plus ground.
3. Voltage Regulation: +0.5% for balance load, +3.0% for 100% unbalance load.
4. Frequency: 60Hz, +5 %.
5. Balanced load: Plus or minus 0.5 percent.
1. 100 percent load imbalance, phase-to-phase: Plus or minus 5 percent
2. No-load voltage modulation: Plus or minus 1 percent.
6. Voltage adjustment: Plus or minus 5 percent manually.
7. Frequency: 60 Hz.
8. Frequency regulation: Plus or minus 0.1 percent.
9. Harmonic content (RMS voltage): 1 percent single harmonic, maximum; 2 percent total maximum with 100% linear load.
10. Phase displacement:
1. Balanced load: Plus or minus 1 degree of bypass input.
2. 100 percent load imbalance phase-to-phase: Plus or minus 3 degrees of bypass input.
11. Overload capability (at full voltage) (excluding battery):
1. 125 percent load for 10 minutes.
2. 150 percent load for 30 seconds.
3. Voltage Transient
1. 100 percent load step: Plus or minus 5 percent.
2. Loss or return of ac input: Plus or minus 1 percent.
3. Automatic transfer of load from UPS to bypass to UPS: Plus or minus 1 percent.
4. Frequency
1. Transients: Plus or minus 0.5 Hz maximum free running. Plus or minus 2.0 Hz synchronized with bypass (Selectable in 0.25 Hz increments).
2. Slew Rate: Selectable in 0.5 Hz increments up to 2.0 Hz.
5. Efficiency
1. Minimum System Efficiency: 94 percent at full system load kW.
6. Environmental Conditions
1. Ambient Operating Temperature: 0° to 40°
2. Non-Operating Temperature: -20° to 70°
3. Relative Humidity: 0 to 95% non-condensing
4. Operating Altitude: To 4,000 ft. (1,219m) above Mean Sea Level without de-rating. (Consult factory for de-rating above 4,000 ft. (1,219m) elevation)
5. Acoustical Noise: 75dB at 5 feet
6. DOCUMENTATION

The manufacture shall furnish the owners an instruction manual covering the installation, operation and maintenance of the UPS and battery pack.