Power Systems & Controls, Inc.

GUIDEFORM SPECIFICATION FOR AN ROTARY HYBRIDT UPS SYSTEM, SINGLE MODULE 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.

UNINTERRUPTIBLE POWER SUPPLY (UPS) SYSTEM

A. General Requirements

1. Response to this request shall require submittal of a proposal of adequate depth to fully define the hybrid rotary UPS system offered.
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 battery, and motor-generator (M-G) set 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 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 the M-G set.
2. The system shall be comprised of two major sections that provide electrical isolation and battery backup while conditioning raw input power from a utility or engine generator system.
1. The electronics console shall consist of a system rectifier/battery charger, battery 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. Under normal operation, the rectifier shall convert the system input AC power to DC. The DC will then be applied to the system battery to maintain it in a float charge 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. The M-G shall store energy in its rotational mass so as not to require power from the system battery for power outages of 200 mSec. or less.
4. Battery Operation - 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 shall 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 shall be sized for [5, 10, 15 or 20] 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. 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.
4. 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
3. 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.
4. 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.
5. Storage Battery
1. Cell Description
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.
6. 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. 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. 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. Battery Circuit Breaker - Disconnect Open
3. High Battery (volts)
4. Low Battery (volts)
5. System On Battery
6. Fuse (open)
7. Transformer - Battery 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 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.