Rotary UPS Specification
The following specification is intended for use by consultant engineering firms to provide bidding specifications for products with the equality and performance characteristics required for a rotary uninterruptible support supply system. The rotary uninterruptible power supply, and hereafter, will be referred to as the “UPS” or “RUPS”. The RUPS is to provide continuous, regulated AC power to critical loads under normal and abnormal conditions, including loss of utlity power. The RUPS shall be an “online” type with a rotary regenerated true sinusoidal, phase to voltage relationship output. There shall be no electrical connects between the utility input and the regenerated output to the critical downstream load. The UPS shall include a synchronized electro-mechanical automatic bypass contactor to switch the critical load without interruption from the RUPS to the alternate power source in the case of a default condition.
1.2 Furnish with Equipment
- Factory Test Report
- Protective Packaging
- Installation Drawings
- O&M Manual
- Warranty Statement
1.3 Documents & Standards
National Electrical Code, NFPA 70-2005.
American National Standards Institute (ANSI).
NEMA Publications Number PB-1 and MG-1.
IEEE Standards 45.
Occupational Safety & Health Act (OSHA)
Local Codes & Authorities having jurisdiction for this installation.
1.4 System Description
1.4.1 The RUPS system shall consist of an online static inverter with power transistors and pulse width modulation (PWM), induction motor, synchronous generator, storage battery, battery disconnect switch, and an automatic bypass contactor. The AC output of the synchronous generator shall be connected to the critical loads. The storage battery shall be connected to the normal source AC input of the online inverter. Also utility power shall be connected to the alternate AC input of the maintenance bypass switch shall match the RUPS output in voltage, phasing, and ampacity. All circuit functions shall be controlled by a programmable microprocessor. Inrush current on starting the system shall not exceed the full load operating current. No pony motor shall be accepted.
1.4.2 Online Inverter: The power electronics portion of the RUPS system, which contains the rectifier/charger and the inverter shall be online at all time during normal operation.
1.4.3 Rectifier/Charger: The portion of the RUPS system that converters the normal source alternating current (AC) input power to direct current (DC) power for the inverter input and for charging the storage battery.
1.4.4 Inverter: The portion of the RUPS system that converts direct current (DC) power from either the rectifier/charger or storage battery, to alternating current (AC) regulated power, which is supplied to the AC motor.
1.4.5 Induction Motor – Synchronous Generator (M-G): The portion of the RUPS system that shall be powered by the inverter output and shall generate new and clean AC sinusoidal waveform with the voltage regulated to be supplied to the critical loads. The winding of the motor and generator shall be at least 23 cm (9″) apart giving total electrical isolation of the input to output.
1.4.6 Automatic Bypass Contactor: The portion of the RUPS system that shall automatically transfer the critical loads from the synchronous generator output to the AC input source without interruption in the event of degradation of the RUPS performance. The automatic bypass shall be electro-mechanical type for complete isolation of the power paths.
1.4.7 Maintenance Bypass Switch (Optional): The portion of the RUPS system that provides AC power to the load when it is required to completely isolate the RUPS and battery from the rest of the building power grid. Although not required, this process is the safest and fastest way to maintain that RUPS system.
1.4.8 Battery Disconnect Switch: The device used to electrically isolate the storage battery from the ractifer/charger, inverter for maintenance purposes, and which provides over current protection at the storage battery output.
1.4.9 The RUPS system shall be a single module rated to supply the full load as specified herein. A (N+X) paralleled RUPS system shall be utilized for accomplishing redundancy. A redundant RUPS shall have each module rated to supply the full load as specified.
1.5 System Operation:
1.5.1 Normal: The inverter shall supply AC power continuously to the induction motor and synchronous generator. The synchronous generator output shall be connected to the critical load. The synchronous generator output shall also be synchronized with the alternate AC power source provided that the alternate AC power supply is within the specified voltage and frequency range. The rectifier/charger shall convert the normal AC input power to DC power for the inverter and for float charging the storage battery.
1.5.2 Input Power Disturbance: The storage battery shall supply DC power to the inverter at all times after initial start-up so that there is no interruption of AC power to the motor generator or critical loads whenever the normal AC input power source of the RUPS deviates from the specified tolerances or fails completely. The battery shall continue to supply power to the inverter for the specified protection time.
1.5.3 Return of Input Power: The rectifier/charger shall start to assume the load from the storage battery when the normal AC power supply returns. The rectifier/charger shall thereafter supply the inverter with full DC power and recharge the storage battery. This shall be an automatic function and shall cause no disturbance to the critical loads.
1.5.4 Transfer to Alternate Source: If the RUPS system senses a fault or out-of-tolerance condition, an inverter shut down signal shall automatically transfer the critical loads from the synchronous generator output to the alternate AC power source without an interruption of power. If the alternate AC power source is outside normal limits, than the transfer shall be inhibited and the RUPS will automatically shut down.
1.6 Quality Assurance
1.6.1 The manufacturer shall have a Quality Assurance (QA) program in place with inspection of incoming parts, modular assemblies, and final products. The manufacturer shall have a designated QA manager who is responsible for overseeing the overall QA process, as well as Quality Control (QC) representatives responsible for actively overseeing the manufacturing process.
1.6.2 A final test procedure for the product shall include a check of all performance specifications and a minimum “burn in” period. An on-site test procedure shall include a check of controls and indicators after installation of the equipment.
1.6.3 Storage, Handling & Delivery: The RUPS shall be shipped on a wooden pallet suitable for forklift handling. The equipment shall be covered with clear plastic sheeting to prevent dust and dirt from entering the unit during shipment. For international shipment, the wooden pallet will be constructed of treated wood and shall meet all other specifications required for international freight.
1.7.1 Proposal: Catalog cut sheets and/or data sheets describing the proposed equipment shall be submitted with the proposal. A users listing shall be available upon request giving company names, locations, and systems installed. All deviations from this specification shall be listed and included with the proposal.
1.7.2 Receipt of Order: A minimum of two sets of installation drawings showing outline dimensions, weights, connections, and a one-line diagram of the RUPS shall be sent to the purchaser to be used in planning the installation of the system.
1.7.3 Formal Approval: If a formal submittal approval is required for the project then the following should be requested, submitted, and approved before design/construction of the RUPS commences:
- Equipment Installation outline
- External Cabling Connection Diagram
- Equipment One-Line Power Diagram
- Equipment Elevation Drawing
- “Other” Site Evaluation Diagrams
1.7.4 Delivery of Equipment: As a minimum, the following shall be provided with the equipment upon its arrival to the final destination:
- Operation & Maintenance Manual
- System Installation Procedures
- System Operation Procedures
- System Troubleshooting Instructions
- System Maintenance Milestones
- Recommended Spare Parts List
- Final Test Report Copy
1.8.1 The manufacturer shall state his warranty of the equipment, and in no case shall it be less than 12 months after start-up or 18 months after shipment, whichever occurs first. A warranty statement will be provided with the equipment and included as part of the over overall O&M manual.
2.1 System Size
2.1.1 The RUPS will be sized to handle any application ranging from 25kVA to 300kVA.
2.2 RUPS Input
2.2.1 Input Voltage: 208, 440, 460, 480, or 600 Volts at 60Hz and 208, 380, 400, 415, or 600 Volts at 50Hz. These three phase input voltages are available in 3-wire (DELTA) or 4-wire (WYE) configurations.
2.2.2 Voltage Range: +15% to -20% of Nominal.
2.2.3 Frequency: [50Hz or 60Hz]
2.2.4 Power Factor: 0.98 Lagging with THD filter.
2.2.5 Current Limit: Not to exceed 125% of full rated load.
2.2.6 Input Current THD: Complies with IEEE 519.
2.2.7 Bypass Angle: 10 Degrees.
2.3 RUPS Output
2.3.1 Output Voltage: 208, 440, 460, 480, or 600 Volts at 60Hz and 208, 380, 400, 415, or 600 Volts at 50Hz. These three phase input voltages are available in 3-wire (DELTA) or 4-wire (WYE) configurations.
2.3.2 Frequency: [50Hz or 60Hz]
2.3.3 Voltage Regulation: +/- 0.5% Nominal (Steady State, No Load, Full Load)
2.3.4 Power Factor: 1.0 to 0.8 Lagging power factor.
2.3.5 Voltage Transient Response: 8% Maximum deviation with recovery within 0.5% within 500 milliseconds for 50% load application or removal. (+/- 12%) For 100% load step; less than 0.1% for loss of or return of AC power.
2.3.6 Voltage Adjustment: +/-10% of Nominal.
2.3.7 Phase Separation: 120° +/-1° (Balanced Load). 120° +/- 3° (Unbalanced Load).
2.3.8 Voltage Harmonic Distortion: 3% RMS maximum, 2% an component.
2.3.9 Frequency Stability: +/-0.1% (Free Running).
2.3.10 Overload Capacity: 110% (2 Hours), 125% (10 Minutes), and 150% (1 minute).
2.4.1 The equipment shall be suitable for installation indoors (altitude 0 to 12,000 meters or 0 to 4,000 feet) with ambient temperatures ranging from 0° to +40°C (32° to +104°F) with 1% de-rating for each 1°C above 40°C up to 50°C, and relative humidity from 0% – 95% non-condensing.
2.4.2 Site Conditions
- Ambient: 0° to 40°C (32° to 104°F) with 50° and 55° (Optional).
- Humidity: 0% to 95% Non-condensing.
- Audible Noise: 90dB Open Frame. Lower noise levels (Optional).
- Construction: Suitable for indoor application. Outdoor enclosures (Optional).
- Bearings: Grease lubricated, Anti-friction type.
- Service Factor: Continuous duty, 24-hour service.
2.5 Storage Battery
2.5.1 Voltage: 567 VDC, 252 Cells.
2.5.2 Final Discharge: 1.70 Volts per cell; equalize of 106% of float.
2.5.3 Protection Time: [5, 10, 15, 20, 30, 60, __] Minutes.
2.5.4 The storage battery shall have sufficient capacity to maintain the RUPS output at full rated load for time specified herein. The battery shall be designed for use with RUPS systems and shall be equipped with safety vents. The battery shall be lead-calcium type.
2.5.5 The storage battery shall be furnished with cabinets and connecting hardware. The battery shall be delivered charged and ready for service.
2.5.6 Battery Disconnect Switch: A safety switch rated for the proper DC voltage and final discharge ampacity shall be furnished with the RUPS. This switch shall be placed at the output of the storage battery. The battery disconnect switch shall be safety interlocked by RUPS logic to prevent closure to the bus when the RUPS does not have utility power applied.
2.6.1 The rectifier/charger shall consist of a solid-state, three-phase rectifier with control circuitry to provide a ramping current walk-on and start-up of the rectifier and charger. Over current protection.
- Fuses shall protect the input of the rectifier/charger.
- The output of the rectifier/charger shall be electronically current limited to protect the connectors to the inverter input and to prevent damage to the charger.
2.6.2 Whenever AC power is applied to the rectifier/charger, the control circuitry shall gradually ramp up the output current to allow gradual loading of the nominal input AC power source. The control circuitry shall automatically provide a battery float charge voltage after a power failure of the normal AC source.
2.7.1 The inverter shall consist of DC filter capacitors, DC surge protection, a power transistorized pulse width modulation (PWM) invrter and controls to provide AC voltage regulation, frequency control, and electronically current limiting.
2.7.2 Over Current Protection: The inverter shall be protected by the fast acting over current detection to prevent damage to the solid-state devices in the inverter bridge. The inverter output shall be electronically current limited.
2.7.3 DC Filters Capacitors: The input of the inverter shall have a bank of filter capacitors.
2.7.4 The inverter shall be a PWM type to minimize the number of power semiconductors for increased reliability and to provide improved transient response.
2.7.5 Controls: The inverter shall be provided with controls to provide constant AC voltage and frequency regulation. The control circuitry shall electronically current limit the output of the inverter. The circuitry shall provide a low voltage initial start-up of the inverter and ramp up to full voltage in less than 20 seconds. The control circuitry shall interface with a DC low voltage sensor and turn off the inverter at the 1.70 volts per cell level to prevent damage to the battery.
2.8 Automatic Bypass Switch
2.8.1 The uninterruptible automatic bypass system shall consist of electromechanical devices that automatically transfer the critical load from the synchronous generator output to the bypass power source without disruption to the critical loads.
2.8.2 Inverter Failure: If the synchronous generator is out of normal limits, the controls circuitry shall initiate transfer of the critical load from the synchronous generator output to the alternate AC power source via the automatic bypass contactor. The bypass contactor shall close before the generator circuit breaker open so as not to disrupt the critical load. If the alternate power source is not within normal voltage limits, then transfer shall be inhibited.
2.8.3 Transfer Conditions:
- Inverter Overload
- Inverter Over Temperature
- Inverter DC Bus Over Voltage
- Inverter DC Bus Under Voltage
- Synchronous Generator Under/Over Voltge
- Magnetics Over Temperature
- Low/High Battery
- Bearing Over Temperature
- Excitation Level
2.8.4 The automatic bypass transfer shall not occur for the following conditions:
- Alternate source out of voltage or frequency tolerance.
- UPS output under frequency condition.
- Emergency stop command.
2.9 UPS Color Touch Screen Controls
2.9.1 The following controls shall be included:
- Generator AC Power Circuit Breaker
- DC Float Voltage Adjustment
- Touch Screen Controls & Interface
- Status Display Screen
- UPS Control Screen
- Input Monitor Screen
- Output V&I Monitor Screen
- Battery Status Screen
- Alarm Window
- Power Monitor Screen
- Clock Control Panel
2.9.2 Control and monitoring of all RUPS functions shall be by the means of touch zones on the touch screen display.
2.9.3 The following status and alarm functions shall be monitored and displayed on the front of the RUPS by a touch screen display:
- Status Indications
- Utility Source Available
- Battery Source Available
- UPS Online
- UPS Fault
- Circuit Breakers Status
- Alarm Indication
- All faults shall be clearly identified with time/date of their occurrence
2.10.1 Quality: All materials, parts, and components used will be new and of the highest grade. Brackets and securing hardware shall be electroplated with corrosion resistant material. Internal wiring conductors shall be combined into cables, or bundles and shall be tied securely together.
2.10.2 Design: The system shall use components of adequate rating to provide an expected service life of twenty (20) years continuous duty and ten (10) years without component replacement, provided that routine maintenance procedures are conducted.
2.10.3 Experience: The manufacturer should have at least (10) years experience designing, constructing, and servicing RUPS systems. Previous experience with other rotational power quality systems will not be accepted.
2.10.4 Enclosure: The RUPS electronics and electromchanical components shall be housed in a steel, NEMA 1 enclosure with front access. Access shall be through hinged doors with locks and latched handles. The enclosure shall be primed and painted inside and outside with a suitable semi-gloss enamel. The enclosure shall be freestanding floor mounted design with removable side and back panels to provide flexibility for installation and maintenance.
2.10.5 Maintainability: No regular maintenance service operations are required except for a yearly preventative maintenance (PM) review. A (N+X) paralleled other other unique “project specific” modifications may require a more rigorous maintenance approach in order to ensure longevity of operation and end of life (EOL). Maintenance may be done at more frequent intervals if desired.
2.10.6 System Layout: Modules and subassemblies shall be mounted in an open construction design so that each may be easily replaced. The equipment shall be constructed so that each component can be replaced without the need for specialized tools.
2.10.7 Installation: Installations where unusual concentrations of moisture, vapors, dust, and other particles may impinge upon windings. Rotating mechanical systems require clean inlet air. Contaminants such as magnetic, metallic, conductive, abrasive, or chemically active materials must be avoided in the airflow by effective filtering. Materials such as dust or lint, which can accumulate over time and block ventilation passages, must also be filtered.
2.11 Optional Features
2.11.1 Remote Monitoring System: There are many methods that can be utilized to allow the user to interface with the RUPS system giving them a wide range of monitoring and control options –
- Modbus: Modbus over serial line with RTU protocol. A Modbus serial port is provided to remotely access the RUPS Modbus registers and status bits. All the RUPS analg metering information, operational status information, and messaging will be provided via Modbus protocol. Modbus over TCP is also available. A Ethernet is provided to remotely access the modbus registers and status bits the same as RTS but with a TCP interface that runs on Ethernet. Please contact factory for additional information.
- Web Based: The web based remote monitoring/control feature puts the user at the control screen of the RUPS, anywhere in the world, via the World Wide Web (www). The web interface can be programmed to give limited access based on responsibility or full access of the whole user interface. Please contact factory for additional information.
- Remote Color Touch Scree Panel: All RUPS analog metering and operational status are displayed on a remote screen that can be installed in secure or remote locations. All real-time data is displayed with a dedicated communications ink. Link via Profibus DP or Profinet Industrial Ethernet. Please contact the factory for additional information.
2.11.2 Sound Attenuated Enclosure: The RUPS will be built into a sound attenuation enclosure to reduce the noise emission to less than 75 dB when measured at industry standards. The attenuated enclosure will enclose the RUPS, and shall be equipped with noise absorbing material which won’t restrict air flow. It also allows an extra level of protection against dust and other particulates.
2.11.3 Outdoor Rated Enclosure: The RUPS will be built to endure the harshest outdoor environments – sand, snow, rain, salt, etc. The enclosures will be built to NEMA 3, 3R, 4, 4X, 12…standards. For large systems (300kVA+) or “turn-key” applications that RUPS can be built into an ISO container allowing for easy transportation, installation, and maintenance.
3.1.1 The manufacturer shall design, build, and fully test the RUPS system. If requested by the customer, the manufacturer shall arrange shipment of the RUPS the the customer’s requested destination.
3.1.2 The manufacturer shall prepare and deliver the required drawings and manuals with the RUPS.
3.2 Site Preparation
3.2.1 The owner shall prepare their site for installation of the RUPS.
3.2.2 The owner shall arrange for local electricians to install the RUPS.
3.2.3 The RUPS shall be installed in accordance with local codes and the OEM’s recommendations.
3.3 Field Service Start-up & Installation
3.3.1 The RUPS is to be checked and inspected by the field service representative from the OEM to confirm proper installation.
3.3.2 The RUPS is to be started-up by the field service representative from the OEM to confirm proper operation. The OEM representative should provide commissioning, training, etc. if requested by the customer.