Guideform Specification Rotary Uninterruptible Power Supply

GUIDEFORM SPECIFICATION FOR AN "ONLINE INVERTER" 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.

UNINTERRUPTIBLE POWER SUPPLY (UPS) SYSTEM

A. General Requirements

The bidder shall furnish a complete uninterruptible power supply system, as specified herein, and hereafter referred to as the "UPS", to provide continuous, regulated AC power to critical loads under normal and abnormal conditions, including loss of utility AC power.
The UPS shall be an "online" inverter/rotary type with rotary regenerated true sinusoidal, phase or voltage relationship output.
There shall be no electrical connections between the utility AC input and the regenerated output to the critical loads.
The UPS shall include a synchronized electromechanical automatic bypass contactor to switch the critical load without interruption from the UPS to the alternate AC source in the case of a fault condition.

B. The following shall be furnished along with the equipment

Factory Test Report
Protective Packing
Installation Drawings
Operators Manual

C. Applicable Documents - The following documents apply to the specified equipment to the extent defined herein

National Electrical Code, NFPA 70-1993
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

D. Related Work - The UPS shall be installed in accordance with the manufacturer's recommendations

E. System Description

The UPS 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 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 DC bus of the online inverter through a battery disconnect switch. The utility AC power shall be connected to the normal source AC input of the online inverter. Also, utility power shall be connected to the automatic bypass contactor to provide power to the critical loads during maintenance. The alternate AC input of the maintenance bypass switch shall match the UPS output in voltage, phasing and ampacity. All circuit functions shall be controlled by a programmable microprocessor system. Inrush current on starting the system shall not exceed the full load operating current. No pony motor starting shall be accepted.
Definitions
1. Online Inverter - The portion of the UPS system, which contains the rectifier/charger, inverter shall be online at all time during normal operation.
2. Rectifier/Charger - The portion of the UPS system that converts the normal source AC input power to DC power for the inverter input and for charging the storage battery.
3. Inverter - The portion of the UPS system that converts DC power from either the rectifier/charger or storage battery, to AC regulated power, which is supplied to the AC motor.
4. Induction Synchronous Motor-Generator (M-G) - The portion of the UPS system that shall be powered by the inverter output and shall generate new, clean AC true sinusoidal, phase or voltage relationship, regulated power to be supplied to the critical loads. The winding of the motor and generator shall be at least 23 cm (9") apart giving total isolation of input to output.
5. Automatic Bypass Contactor - The portion of the UPS 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 UPS performance. The automatic bypass shall be electromechanical type for complete isolation of power paths.
6. Maintenance Bypass Switch (Optional) - The portion of the UPS system that provides AC power to the load when it is required to completely isolate the UPS and Battery from the rest of the building power grid. Although not required, this makes maintaining of the system as close to safe as possible.
7. Battery Disconnect Switch - The device used to electrically isolate the storage battery from the rectifier/charger, inverter for maintenance purposes and which provides over current protection at the storage battery output.
8. Critical Loads - Those loads that require regulated, clean AC power continuously and which are connected to the UPS system.
9. The UPS system configuration shall be a single UPS system rated to supply the full load as specified herein.

F. System Operation

Normal - The inverter shall supply AC power continuously to the induction M-G. 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 source 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.
Loss of Normal AC Input Source - 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 induction synchronous M-G or critical loads whenever the normal AC input power source of the UPS deviates from the specified tolerances or fails completely. The battery shall continue to supply power to the inverter for the specified protection time.
Return of Normal AC Power Source - The rectifier/charger shall start to assume the DC load from the storage battery when the normal AC power source 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.
Transfer to Alternate Source - If the UPS 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, then the transfer shall be inhibited and the UPS will shut down.
Re-transfer to the Online Inverter - The automatic bypass contactor shall be capable of automatically re-transferring the critical load back to the synchronous generator output after the online inverter has returned to normal voltage and stabilized for a period of time. Re-transfer shall not occur if the two sources are not in-phase.
Downgrade - If the storage battery is taken out of service for maintenance purposes, it shall be disconnected from the rectifier/charger and inverter by the battery disconnect switch. The UPS system shall be capable of continued function and meet all the performance criteria specified herein except for the battery reserve time capability.

G. Quality Assurance - The manufacturer shall have a quality assurance program with inspection of incoming parts, modular assemblies, and final products. 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.

H. Submittals

With Proposal - Catalog cuts and/or data sheets describing the proposed equipment shall be submitted with the proposal. A users listing shall be available giving company names locations and systems installed. All deviations from this specification shall be listed and included with the proposal.
After Receipt of Order - A minimum of two sets of installation drawings showing outline dimensions, weights, connections and a one-line diagram of the UPS shall be sent to the purchaser to be used in planning the installation of the system.
After Construction of Equipment
1. Two copies of drawings shall be furnished of the following.
  1. Equipment Installation Outline
  2. Connection Diagram for External Cabling
  3. Equipment Internal Wiring Diagram
2. Two instruction manuals shall be furnished and shall include, as a minimum, the following.
3. One copy of the final test report shall be furnished with the equipment.

I. Delivery, Storage & Handling - The equipment 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 cabinet during shipment and storage.

J. Site Conditions - The equipment shall be suitable for installation indoors (altitude 0 to 12,000 meters or 0 to 4,000 feet) with ambient temperatures from -20° to +40°C (-20°F 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.

K. Warranty - The manufacturer shall state his warranty of the equipment. In no case shall it be less than 12 months after start-up or 18 months after shipment, whichever occurs first.

PRODUCT
1. Electrical Characteristics
  1. UPS Normal Source Input
  2. Voltage Range: [208, 380, 480 or 600 VAC] 3-phase, 3 or 4 wire
  3. Voltage Range: +15 to -20% of Nominal
  4. Frequency: [50Hz or 60Hz]
  5. System Efficiency - 90%+ (varies with input volts & size of unit)
  6. Current Limit - not to exceed 125% of Full Rated Load
  7. Power Factor - 0.98 Lagging with THD Filter
  8. Input Current THD - Complies with IEEE 519
2. UPS Bypass Input (Must be same as 1.4)
  1. Voltage/Frequency: [208, 380, 480 or 600]vac 3-Phase, 3 Wire
  2. Frequency: [50Hz or 60Hz]
  3. Power Rating: [25 to 300]kVa
  4. Bypass Tolerance: ±5% Differential
  5. Bypass Angle: 10 Degrees Typical
3. UPS Output
  1. Voltage:[120/208, 220/380, 277/480, 346/600]VAC, 3 Phase, 3 or 4 Wire
  2. Frequency: [50 or 60]Hz
  3. Power Rating: [25 to 300]kVa @ 0.8 Power Factor
  4. Voltage Regulation: ±0.5% Nominal for any of the following conditions
Components
1. Storage Battery:
  1. Voltage - 567 volts DC, 252 cells
  2. Protection time: [5, 10, 15, 20, 30] minutes
  3. Enclosure - [NEMA 1, NEMA 3R ] Seismic Zone [ ]
2. Rectifier/Charger
  1. The rectifier/charger shall consist of a solid-state, three-phase rectifier with control circuitry to provide a ramping current walk-on on start-up of the rectifier and charger. Over current Protection
    1. An automatic protection circuit shall protect the input of the rectifier/charger.
    2. The output of the rectifier/charger shall be both fused and electronically current limited to protect the connectors to the inverter input and to prevent damage to the battery.
  2. Control Circuitry
    1. 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.
    2. The control circuitry shall automatically provide a battery float charge voltage after a power failure of the normal AC source.
  3. Inverter
    1. The inverter shall consist of DC filter capacitors, DC surge protection, a power transistorized pulse width modulated (PWM) inverter and control circuitry to provide AC voltage regulation, frequency control and electronically controlled current limiting.
    2. Over current Protection
      1. The inverter shall be protected by fast acting fusing to prevent damage to the solid-state devices in the inverter bridge.
      2. The inverter output shall be electronically current limited.
    3. DC Filter Capacitors - The input of the inverter shall have banks of filter capacitors.
    4. The inverter shall be a PWM type to minimize the number of power semiconductors for increased reliability and to provide improved transient response.
    5. Control Circuitry
  4. Uninterruptible Automatic Bypass Switching
    1. The uninterruptible automatic bypass system shall consist of solid-state and electromechanical devices that automatically transfers the critical load from the synchronous generator output to the bypass power source without disruption to the critical loads.
    2. Inverter Failure - If the inverter is out of normal limits, the control circuitry shall initiate transfer of the critical load from the synchronous generator output to the alternate AC power source via the automatic bypass contactors. The bypass contactor shall close before the generator circuit breaker opens so as not to disrupt the critical load. If the alternate power source is not within normal voltage limits, then transfer shall be inhibited.
    3. Transfer Conditions
    1. The automatic bypass transfer shall occur for the following conditions:
      1. Inverter Overload
      2. Inverter Over temperature
      3. Inverter DC Bus Over voltage
      4. Inverter DC Bus Under voltage
      5. Blown Fuse in the Inverter
      6. Synchronous Generator Under or Over voltage
      7. Over temperature On Magnetics
      8. PLC Fault
      9. Communications Fault
      10. Control Power Supply Fault
      11. Bearing Over temperature
      12. High Battery
      13. Excitation Loss
    2. The Automatic Bypass Transfer shall not occur for the following conditions: Alternate source out of voltage or frequency tolerance.
  5. Maintenance Bypass Switch (Optional)
Controls: The following controls shall be included on, or inside of, the UPS console:
1. Rectifier/Charger
2. Utility AC Power Circuit Breaker (Automatic)
3. DC Float Voltage Adjustment
4. Touch Screen Controls & Interface
5. Status Display Screen
6. UPS Control Screen
7. Input Monitor Screen
8. Output V&I Monitor Screen
9. Battery Status Screen
10. Alarm Window
11. Power Monitor Screen
12. Clock Control Panel
13. Control & Monitoring of all UPS functions shall be by means of touch zones on the touch screen display
Indicators: The following status and alarm functions shall be monitored and displayed on the front of the UPS cabinet by a touch screen display:
1. Status Indications
2. Utility Source Available
3. Battery Source Available
4. UPS Online
5. UPS Fault
6. Status of All Circuit Breakers in power paths
7. Alarm Indication
8. All faults shall be clearly identified with the time of their occurrence.
Remote Alarm Panel (Optional) - A wall mounted alarm panel shall be furnished. It shall have an audible alarm, alarm silencing switch and lamps for the following conditions:
1. Utility Source Available
2. Battery Source Available
3. UPS On Bypass
4. UPS Fault Alarm w/Silencing Switch
Other Standard Equipment Available - The following equipment shall be a functional part of the UPS system:
1. Remote Emergency Power Off
2. Remote Emergency Power Off (push-button UPS)
3. Remote Emergency Power Off (remote alarm panel)
Design
1. Life - 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 carried out.
2. Maintenance - Provision shall be provided for testing the control circuits while the critical loads are bypassed to the alternate source. All adjustments and tests shall be possible with the use of a standard volt-ohm-ammeter and oscilloscope.
Construction
1. Enclosure - The UPS electronics and electromechanical components shall be housed in a steel, NEMA 1 type enclosure with front access. Access shall be through hinged doors with locks and latch handle. The enclosure shall be primed and painted inside and outside with a suitable semi-gloss enamel. The enclosure shall be a freestanding floor mount design with removable side and back panels to provide flexibility of installation configuration.
2. Layout - Modules and subassemblies shall be mounted in open construction design so that each may be easily replaced. The equipment shall be constructed so that each component can be replaced without special tools.
3. Materials & Workmanship
  1. Workmanship shall be of the highest quality in every respect.
  2. All materials shall be new and of best commercial grade.
  3. Brackets and securing hardware shall be electroplated with corrosion resistant material.
  4. Internal wiring conductors shall be combined into cables, or bundles and shall be tied securely together.
Cooling - Cooling shall be natural convection or forced air.
Storage Battery
1. The storage battery shall have sufficient capacity to maintain the UPS output at full rated load for the time specified herein. The battery shall be designed for use with UPS systems and shall be equipped with safety vents on the containers. The battery shall be lead-calcium type with an electrolyte specific gravity of 1.215 ± .005 at 25°C.
2. Voltage
  1. Floating: 2.25 volts per cell adjustable ± .05 v/cell
  2. Final Discharge: 1.70 volts per cell; equalize of 106% of fault
3. The storage battery shall be furnished with cabinets and connecting hardware. The battery shall be delivered charged and filled, ready for service.
Battery Disconnect Switch - A safety switch rated for the proper DC voltage and final discharge ampacity shall be furnished with the UPS. This switch shall be placed at the output of the storage battery. Battery disconnect switch shall be safety interlocked by UPS logic to prevent closure to UPS bus when the UPS does not have utility power applied.

EXECUTION

Manufacturing
1. The manufacturer shall design, build, test and arrange for shipment of the UPS.
2. The manufacturer shall prepare and deliver the required drawings and instruction manuals with the equipment.
Site Preparation - The owner shall prepare the site for installation of the equipment.
Installation
1. The owner shall arrange for local electricians to install the equipment.
2. The equipment shall be installed in accordance with local codes and the manufacturer's recommendations.
Field Start-up and Inspection - The equipment is to be checked out and started by the field service representative from the equipment manufacturer.
Spares - A list of manufacturer's recommended spare parts shall be submitted with the manuals.

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