Power Systems & Controls, Inc.

GUIDEFORM SPECIFICATION FOR A NO BREAK UPS SYSTEM

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.

No-Break UPS System - Single Module System

A. General Requirements

1. It is the intent of this specification to define the equipment and performance of a complete Hybrid™ Rotary No-Break UPS system to condition normal electrical power and to furnish a conditioned alternate source of electrical power during total failures of the normal source.
2. The equipment specified shall be capable of providing and monitoring regulated AC power to designated computer or other critical loads during utility power outages. The system shall include all components required to properly interface the building's AC power source, solid-state inverter, rectifier/charger, system bypass switchgear, storage DC device, a motor-generator (M-G) set if rotary, and an engine generator as described in the following specification.

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

1. National Electrical Code, NFPA 70-1993
2. American National Standards Institute (ANSI)
3. NEMA Publications Number PB-1 and MG-1
4. IEEE Standards 45
5. Occupational Safety & Health Act (OSHA)
6. Local Codes & Authorities having jurisdiction for this installation

C. Design - Functional Description:

1. The basic operation of the system will fulfill the functions of both an Uninterruptible Power System and a Standby Engine generator, forming a complete No-Break power system that will condition normal power to computer grade power and provide alternate power for a minimum of twelve hours without refueling the engine generators based mounted fuel tank.
2. The Engine generator described in this specification is Caterpillar diesel powered. However, alternate fuels may be specified based on customer preference. Under normal conditions, utility power is supplied to the input of the UPS system. The UPS system converts the three-phase AC power to DC via a phase-controlled rectifier.
3. The rectifier output is connected to the energy storage system and the system inverter. The energy storage system may include a flywheel, battery system or both. The Flywheel will be allow sufficient time for starting the system engine generator. The Series EPM is a patented motor/generator who's rotor mass provides energy storage in it's rotational inertia. During normal operation, the Flywheel system will maintain the flywheel at 2,250 rpm by drawing power from the UPS rectifier via a DC chopper power supply. In case of a power failure, the UPS DC voltage will decrease in direct proportion to the drop in AC voltage on the system input. The Series EPM senses this decreasing voltage and foes into action. The AC voltage is rectified to a regulated DC that is furnished to the UPS inverter, maintaining continuous uninterrupted operation of the critical load. In the event that normal utility power has not returned after 2 seconds, the UPS control logic will command the engine generator to start. The unloaded engine generator will start, come up to speed, and produce AC voltage in 10 seconds. On detection of AC voltage on the engine generator output the UPS control will open the normal input source circuit breaker and close the engine generator output circuit breaker.
4. When the engine generator output is sensed by the UPS rectifier logic it will gate the rectifier SCRs to produce regulated DC voltage at the level needed to drive the UPS inverter, maintaining continuous uninterrupted operation. On return of the normal utility power source the UPS control logic will open the engine generator output circuit breaker and close the normal source input circuit breaker, allow the engine to run in a cool down mode until shutdown, and return to normal operation. This approach is superior to other topologies due to the ability of the UPS to operate during continuously low voltages (sags to 80% of nominal voltage) while maintaining 0.5% regulated output voltage. In the event of very poor Utility power with a high number of short power outages the optional system battery may be added extending the tolerance of power outages without engine starting to 5, 10, or 15 minutes without modification to the system. In this configuration the Flywheel energy storage system will furnish the energy need for over 99% of all expected power outages, reducing the number of discharge cycles on the battery and extending the battery life by as much as four times that of battery only system.
5. The operation of the UPS shall be based on an inverter design. The inverter shall remain fully "on" during normal operation and provide 100% of the required load through the rectifier, inverter and to the load.
6. The system shall be comprised of four major sections that provide electrical isolation, a DC energy storage system and Diesel Engine while conditioning raw input power from a utility or engine generator system.
1. The electronics console will consist of a system rectifier/battery charger, battery/flywheel interface-filter and load commutated inverter.
2. The M-G section shall consist of a two bearing synchronous motor shaft coupled to a two bearing synchronous generator for complete electromagnetic isolation from input to output.
3. The Flywheel Energy Storage System will consist of a totally enclosed motor/generator/bi-directional power interface to simulate a battery system.
4. The diesel generator will be a self-contained engine generator complete with engine control panel, fuel system, exhaust silencer and all normal accessories.
7. Under normal operation the rectifier will convert the system inputs' AC power to DC. The DC will then be applied to the [system battery and/or] [Flywheel Energy Storage System] to maintain it in a float/ready condition. The rectifier output is also supplied to the naturally commutated inverter. The inverter converts the DC to an AC source to drive the M-G, which acts as a rotary filter for the critical load.
8. Flywheel Energy Storage System (Optional)During an input power failure the system rectifier will shut down while the inverter draws power from the flywheel energy storage system. During normal operation, the flywheel will draw DC current from the UPS rectifier to maintain the rotational speed need to support the UPS system during engine starting.
9. Battery Operation (Optional)During an input power failure the system rectifier will shut down while the inverter draws power from the battery system. No switching of the battery system will be permitted. The battery must be online at all times. No interruption or transfer of M-G input power will be permitted at this critical time to assure a continuous steady power source for the M-G. The battery will be sized for 10 minutes full load operation.

D. Submittal Content:

1. As a minimum, the submittal shall include the following:
1. Description of the configuration and operation of the proposed UPS system.
2. Outline drawings of all equipment, including overall dimensions and weights.
3. A one-line electrical diagram showing internal and customer provided wiring.
4. Vendor must provide proof of existing rotary UPS sites, of similar size and complexity to this specification, that have been in operation for over five years.
5. Evidence that the vendor has at least five years experience in the manufacture, service and training of customer personnel for rotary UPS systems.
6. Maximum heat loss and noise level of the UPS set while operating at full load.
7. Description of preventive and emergency service and customer service training offered by the supplier.

E. Major System Components: The basic components of the system shall include an M-G set, rectifier/charger, static inverter, system, switchgear, system controls, storage battery, fused battery disconnect (or similar disconnect), system status and control panel, and (optional) a remote annunciator panel. The M-G section must be capable of separation from the electronics portion of the UPS system. This is required to allow outdoor installation of the M-G thereby reducing HVAC requirements for the UPS system. The complete system shall be fully assembled and tested as a system prior to shipment with the sole exception of the battery system.

1. Diesel Generator
2. The units will be rated at 1,000 kW, 1,250 kVA at 0.8 P.F., Standby rated, 1800 RPM, 3 phase, 60 cycle, 480 volt for operation in an ambient temperature of 110oF, at an altitude of 1500 feet above sea level. The sets will be capable of 10 percent overload for two hours out of twenty-four for standby duty. Ratings of the diesel electric set will be based on operation of the unit at rated generator RPM when equipped with all necessary operating accessories; i.e.: air cleaners, lubricating oil pump, fuel transfer pump, fuel injection pumps, jacket water pump, alternating current generator, and exciter.
3. Engine The engines will be water-cooled four-cycle compression ignition diesel, turbo charged and after cooled for maximum efficiency. Engine speed will not exceed 1800 RPM. It will meet specifications when operating on No. 2 domestic fuel oil. Diesel engines requiring, premium fuels will not be considered. The engine will be equipped with fuel, lube oil, and intake air filters, lube oil cooler, fuel transfer pump, and gear driven water pump.
4. Governor The engine will be equipped with an electronic isochronously operating governor providing 1% speed regulation from no load to full rated load. Steady state regulation will be +.25%. Governors will be load-sharing type equal to Woodward 2301A for paralleling with other like units. The governor controller will be mounted in the generator control panel.
5. Base-The engine-generator will be mounted on steel base rails. Vibration isolators will be provided between the generator set rails and the concrete pad. Isolators will be spring type, equal to ACE Mountings Series 120.
6. Exhaust and Silencer An exhaust silencer, critical type, side inlet, Maxim M-51, will be provided. A flexible stainless steel exhaust adapter will be furnished and mounted between the engine and silencer. Silencers will be side-inlet type mounted horizontally over the generator set. Provide condensation drain plug and ASA 125# companion flanges with hardware and gaskets to match silencer flanges.
7. Heater and Antifreeze The engine will be provided with antifreeze (a solution of 50% ethylene glycol) and two units mounted immersion type jacket water heaters incorporating a thermostatic switch to maintain engine jacket water at 90°F, in an ambient temperature of 0°F. The heaters will be 6,000 watt each, single phase, 60 hertz, 240/480 volts.
8. Fuel System Injection pumps and injection valves will not require adjustment in service. The engine will have an individual mechanical injection pump and injection valve for each cylinder, any one of which may be removed and replaced from parts stock. Fuel system will be equipped with replaceable fuel filter elements. Provide both primary and secondary fuel filters. All fuel filters will be conveniently located ahead of injection pumps so that fuel will have been thoroughly filtered before it reaches the pumps. No screens or filters requiring cleaning or replacement will be used in injection pump or injection valve assemblies. Engine will be equipped with a built-in gear-type engine-driven fuel transfer pump, capable of lifting fuel against a head of twelve feet, for supplying fuel through the filters to the injection pump at constant pressure.
9. Lubrication gear-type lubricating oil pump will supply oil under pressure to main bearings, crank pin bearings, pistons, timing gears, camshaft bearings and valve rocker mechanism. Effective full flow lubricating oil filters will be provided and so located that lubricating oil is continuous filtered, except during periods when oil is bypassed to protect vital parts such as when filters are clogged. Replacement resin impregnated cellulose type filter elements will be accessible and easily removable. Filter system will be equipped with a spring-loaded bypass valve as an insurance against stoppage of lubricating oil circulation in event the filters become clogged. A suitable water-cooled, engine-mounted lubricating oil cooler will be furnished. The diesel oil sump drain will be fitted with a suitable valve and will be brought to the outside of the set for ease of changing oil.
10. Air Cleaners-One or more engine-mounted dry type air cleaners of sufficient capacity to protect working parts of the engine from dust and grit will be provided.
11. Cooling System The engine will be equipped with a remote horizontal core, vertical discharge radiator and fan of sufficient capacity for cooling the engine when the diesel electric set is delivering full rated standby load in an outside ambient temperature of 110°F, taking into consideration de-rating factors for antifreeze. Provide an expansion tank on the radiator with pressure regulating fill cap. The engine will have a thermostat integral with the jacket water circuit to maintain the water at the proper operating temperature. The engine will have an engine-driven centrifugal type water-circulating pump for circulating water through the cooling system.
12. Battery and Charger-The automatic start-stop system will be electrically operated through a 24-volt battery system. A lead-acid battery set of minimum 420-ampere hour capacity will be furnished with suitable battery rack and cables. Batteries will have the capacity to provide 90 seconds of cranking at an ambient room temperature of 40°F in accordance with the requirements of NFPA 99. A current limiting two-rate battery charger will be furnished to automatically recharge batteries. It will include automatic equalize timer, overload protection, silicon diode full wave rectifiers, voltage surge suppressors, DC voltmeter, DC ammeter, and fused AC input. AC input voltage will be 120 VAC, 1-phase. The battery charger will have a minimum output of 20 ampere. Charger will be wall mounted where shown on the plans. The battery charger will have contacts for annunciation of battery low DC voltage alarm. Starting Electric Starting System: The engine will be equipped with a dual motor electric starting system of sufficient capacity to crank at a speed that will start the engine under operating conditions. The starting pinion will disengage automatically when the engine starts.
13. Generator-The generator will be the brushless type rated at [ ] KW, Prime Power, [ ] kVA at 0.8 power factor, 3 phase, 60Hz, 480 volt, 4 wire, 1800 RPM. The generator will be of single bearing construction, six (6) lead, form wound, VPI treated, close coupling. Class F insulation will be utilized in both the rotor and stator. Temperature rise at 1250 KW will not exceed 80°C over 40°C ambient for continuous duty when producing full rated KVA load at 480 volts. The generator will incorporate a rotating permanent magnet type exciter, full wave rectifier bridge and static voltage regulator which will maintain voltage within +½% rated voltage. Voltage regulator will be of the three-phase sensing type with volts per hertz regulation. Voltage regulator will be mounted in generator control cubicle.
14. Controls-An automatic engine starting and control system will be furnished as a part of the generator control. Automatic starting equipment on the engine will consist of necessary controls and wiring to interface with the generator control switchboard. Field wiring will include the wiring between the terminal blocks of the engines and the generator control panel and UPS console. Provide contacts on the engine for the following functions:
1. Automatic low lube oil pressure pre-alarm, alarm and shutoff.
2. Automatic high water temperature pre-alarm, alarm and shutoff.
3. Automatics over-speed alarm and shutoff.
4. Automatic low water temperature alarm.
15. Fuel Tank The main fuel oil storage tank (12 hour fuel capacity, UL Listed) and fuel oil piping system will be as specified below.
1. (Optional) Each day tank will be a 100 gallon packaged unit, UL listed, complete with float controlled fuel valve, float switch, fuel level gauge, high fuel alarm relay, low fuel alarm relay for remote annunciation, leak detection relay, solenoid valve, tank drain valve, and threaded pipe connections for inlet, engine suction, engine return, overflow, vent, and drain.
2. Tanks will be heavy gauge steel with epoxy-coated interior and enamel painted exterior finish. All internal plumbing and wiring will be pre-connected. Top cover will be removable for inspection and/or service.
3. (Optional if needed) The fuel transfer pump package will be a duplex type for remote mounting.
16. Motor-Generator (M-G)
1. The M-G set shall consist of the following elements:
1. Brushless, two bearing synchronous motor with brushless exciter. Allowable temperature rise shall be 130°C.
2. Reduced current motor starter, pony motor type.
3. Motor controls.
4. Utility input circuit breaker.
5. Brushless, two bearing synchronous generator with voltage regulator and paralleling capability. Allowable temperature rise shall be 130°C.
6. Brushless direct connected AC exciter with rotating rectifiers.
7. Flexible gear type coupling between motor and generator, adjustable to match input and output phase angle.
8. Generator controls.
9. Generator output circuit breaker.
10. Common mounting steel base with spring type vibration isolators.
2. Rectifier-Charger
1. The rectifier/charger section shall consist of a voltage regulated, current limited, three phase SCR bridge rectifier. It shall provide power to the DC link and maintain the battery in a float condition. It must be regulated to avoid overcharging. The rectifier/charger shall have sufficient capacity to provide full load power to the inverter, with a reserve capacity of 25% for simultaneous battery recharging. This will allow recharge of a completely discharged battery system in 10 times the discharge period.
2. The rectifier/charger shall be designed for use with a [140, 240, or 260] cell (nominal) battery system.
1. The rectifier/charger shall limit currents from 1.1 to 1.25 times nominal full load (adjustable).
2. The battery voltage shall be regulated to provide a float voltage of 2.25 volts per cell (VPC). The float voltage can be field adjusted over the range of 2.23 to 2.35 VPC.
3. The rectifier/charger shall be contained within the UPS console. Separate battery chargers shall not be permitted.
3. The rectifier/charger shall have an IEEE 519.1992 compliant input filter.
3. Inverter
1. The inverter section of the system shall be all solid-state, capable of accepting the DC output of the battery, and delivering AC power within specified limits to the M-G set. The inverter shall have the necessary logic and controls to automatically start up and accept the M-G set load. It shall be rated for 100% continuous duty at 40°C ambient.
2. The inverter shall contain an internal oscillator capable of maintaining output frequency of the protected M-G set within specified limits (± 0.5 Hz).
3. The inverter shall be load commutated and shall not require commutation SCRs or circuits.
4. The inverter semiconductors shall be protected by fast acting current limiting fuses.
5. Inverter Input Characteristics - The inverter shall be capable of full load operation from any storage battery system with the following characteristics:
1. Float Voltage: 540VDC
2. Low Voltage Limit: 396VDC
6. Inverter Output Characteristics:
1. The output voltage and frequency characteristics of the system shall maintain the protected M-G set's output within the manufacturer's specification during operation on battery for the following steady state conditions:
1. M-G output voltage ±0.5%
2. M-G output frequency ±0.5Hz
2. Output Overload…The system shall be capable of accepting 110% load for two hours, 125% load for ten minutes, or 150% load for two minutes. The system shall support an overload until over-temperature or other preventative devices indicate an imminent problem. Overload transfers based on timers are not acceptable.
17. Automatic Bypass Switch Systems…The UPS system shall contain two electromechanical switching devices to automatically transfer the critical load from normal operation to bypass in the event of a component failure. The bypass operation must have no effect on the critical load. Use of a solid-state static switch is not acceptable.
1. Inverter Bypass…The inverter bypass switch shall automatically transfer the M-G set from inverter to utility power under the following conditions:
1. Inverter output fails for any reason.
2. Manual command.
1. Critical load continues to be powered by the M-G set. The M-G set shall provide total electrical isolation, voltage and frequency regulation as long as the input voltage source is with in ±20% steady state and during sags of -40%.
2. When a solid-state static switch is used in the inverter bypass circuit, an electromechanical switch must be provided in parallel with the static switch as an alternate power source for the motor input.
3. System Bypass…The system bypass switch shall automatically transfer the critical load from M-G power to utility power under the following conditions:
1. M-G set Over voltage/Under voltage.
2. Winding Over temperature.
3. Motor or generator bearing over temperature.
18. Storage Battery(Optional)
1. Cell Description (if used)
1. Batteries shall be used as a stored energy source for the inverter. The ampere-hour rating of the battery shall be sufficient to support the inverter for [5, 10 15 or 20] minutes with the system operating at rated load.
2. The battery parameters shall be in accordance with the input voltage requirements of the inverter section. The battery shall be [flooded, or sealed] [lead-calcium, or antimony] construction, with a [1 or 2] year pro-rated warranty.
3. The batteries shall be float charged to 2.25VDC required by the particular cell.
2. Battery Circuit
1. The system shall be provided with a switching device to disconnect the DC circuit between the battery and the inverter input. The switch shall provide a positive visible means to isolate the battery from the rest of the system for maintenance, or when the battery is fully depleted.
2. The switch shall be equipped with a shunt trip to be used to open the breaker upon activation of the emergency power off system or low DC shutdown of the inverter.
3. Battery Mounting:
1. Battery Racks, if used, shall be [_____] tier, seismic zone [_____] construction.
2. Fully enclosed cabinets shall be used to house batteries.
19. System Status & Control Panel shall include the following:
1. Instruments - digital 1% for the following:
1. AC Input & Output Volts
2. AC Input & Output Frequency
3. AC Input & Output Current
4. DC Link – Volts
5. Rectifier Output – Current
6. Flywheel - Battery Charge/Discharge – Current
7. Input kW Motor Volts
8. Output kW
9. Percentage Capacity
2. Mimic Display shall indicate the following:
1. Primary Source - (on/off)
2. Auxiliary Source - (on/off)
3. Input Breaker - (open/closed)
4. Rectifier/Charger - (on/off)
5. Inverter Bypass - (open/closed)
6. Flywheel - Battery Disconnect - (open/closed)
7. Inverter - (on/off)
8. M-G Set - (run/off)
9. System Bypass - (open/closed)
10. Output Breaker - (open/closed)
3. Fault Indicators - Separate indicators shall be provided for:
1. Input Over/Under voltage
2. Flywheel/Battery Circuit Breaker - Disconnect Open
3. Flywheel/High Battery (volts)
4. Flywheel/Low Battery (volts)
5. System On Flywheel/Battery
6. Fuse (open)
7. Transformer - DC Choke Over temperature
8. Bearing-Winding Over temperature
9. Inverter Over temperature - Motor Overload
10. Generator Over/Under voltage
11. Output Under Frequency
12. Not In-Phase
4. The following start sequence lighted switches shall be provided:
1. M-G Start
2. System Bypass
3. Inverter Bypass
4. UPS (On-UPS)
5. Stop or Module Shutdown
5. The following indicators - controls shall be provided:
1. Alarm (Audible Horn)
2. Alarm Silence/Lamp Test
3. Saves Counter
4. Fault Reset
5. System Reset
6. Emergency Stop (EPO)
6. Remote Monitor (Optional) - A separate alarm panel shall be provided and include at least the following monitoring and alarm functions:
1. System On Utility (Primary Source)
2. System On Auxiliary Source
3. System On Flywheel/Battery
4. System Bypassed
5. System Fault
6. Generator CB Closed
7. Out-Of-Phase
8. Audible Alarm (sounds when any fault condition occurs)
9. Alarm Silence Push-button
10. Lamp Test

F. Electrical Characteristics:

1. Input
1. Voltage: [600, 480, 415, 380, 220 or 208] ±10%, 3F, [3 or 4] wire, grounded [wye or delta]
2. Frequency: [50 or 60] Hz, ±5%
3. Power Factor: Unity to 0.9 lagging at full load.
4. Voltage Impulses: To 1500 volts for not more than 1 millisecond.
5. Brownout: 15% continuously low input voltage without use of battery.
2. Output
1. Power: [250, 313, 375, 438, 500, 625, 750, 857, 1000, 1250 or 1400] kVA at 0.8 lagging Power Factor, continuous duty.
2. Voltage: [600, 480, 415, 380, 220 or 208] ±10%, 3F, [3 or 4] wire, grounded wye.
3. Frequency: [50 or 60] Hz ±0.5%
4. Voltage Regulation, Steady State, ±0.5%
5. Drift…Less than ±1% for 90°F (50°C) temperature change.
6. Transient Regulation…50% load step: +8%, -10% for 30 cycles maximum.
7. Loss or return of AC input…±0.5% for zero cycles maximum (stays within steady state band)
8. Phase Displacement (Voltage): 120° ±1° balanced load, 120° ±3° for an 25% imbalance.
9. Overload: 10% of nominal for 2 hours, 125% of nominal for 10 minutes, 150% of nominal for 2 minutes.
10. Inrush Current: The system shall be capable of withstanding the inrush current of any motor whose peak current inrush does not exceed 50% of the full load current rating of the generator.

G. Environmental Characteristics

1. Ambient temperature
1. Electronics section: 0° to 40°C (32° to104°F
2. M-G and Switchgear: 0° to 40°C (32° to104°F
3. Batteries: 25°C (77°F) nominal, per manufacturers specifications
2. Relative Humidity: 0% to 95% (non-condensing)
3. Altitude: 0 to 1000 meters (0 to 3300 feet)
4. Construction Installation: Suitable for interior or protected area.
5. Bearings: Grease lubricated, anti-friction, ball bearing with a 10-year expected life when proper maintenance is performed. Sealed bearings may not be used!
6. Service Factor: Continuous duty, 24-hours per day use.
7. Speed: [1800rpm for 60Hz or 1200rpm for 50Hz]

H. Quality:

All materials, parts and components shall be new and be of highest grade.

I. Testing:

Each subassembly shall undergo a thorough test prior to installation in the system. The total system (less battery) shall be assembled and undergo a functional and load test and shall be subject to a factory full load test prior to shipment.

J. Maintainability:

1. All maintenance operations shall be fully described along with a recommended maintenance schedule and rates for vendor supplied maintenance contracts.
2. No regular maintenance service operations will be required at less than one-year intervals except for the following:
1. Bearings to be greased at six-month intervals (no shutdown required).
2. Batteries to be maintained per manufacturer's specifications. Note: At installations where unusual concentrations of moisture, vapors, dust, or other particles may impinge upon windings and other electrical components, periodic cleaning may be required at more frequent intervals.

K. Execution:

1. 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.
2. Site Preparation - The owner shall prepare the site for installation of the equipment.
3. 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.
4. Field Start-up and Inspection - The equipment is to be checked out and started by the field service representative from the equipment manufacturer.
5. Spares - A list of manufacturer's recommended spare parts shall be submitted with the manuals.

L. Warranty:

The system, exclusive of batteries, shall be warranted against defects for a period of one (1) year from date of start-up or 18 months from date of shipment, whichever comes first.