171-180000002112 - Attachment 8 - Maintenance Checklists - Current Equipment Solutions.docx

STATE OF MICHIGAN

Request For Proposal No. 171-180000002112 Power, Environmental Monitoring and HVAC for State Hosting Centers and Switch Rooms

ATTACHMENT 8 – MAINTENANCE CHECKLISTS

(Current Equipment Solutions)

Checklist 01: Attachment 8 - Maintenance Checklist UPS (Vertiv) All 3-Phase Models Module 1 – Power and Monitoring

SERVICE PERFORMED

UPS Full Preventive Maintenance Service

Semi-Annual Service

1. Perform temperature check on all breakers, connections, and associated controls. Repair and/or report all high temperature areas.

2. Perform a complete visual inspection of the equipment including subassemblies, wiring harnesses, contacts, cables, and major components.

3. Check air filters for cleanliness. (if applicable)

4. Check rectifier and inverter snubber boards for discoloration.

5. Record all voltage and current meter readings on the module control cabinet or the system control cabinet.

Annual Service (includes the above, plus)

1. Check for DC capacitor vent caps that have extruded more than 1/8" (if applicable).

2. Measure and record harmonic trap filter currents (if applicable).

3. Check the inverter and rectifier snubbers for burned or broken wires.

4. Check all nuts, bolts, screws, and connectors for tightness and heat discoloration.

5. Check fuses on the DC capacitor deck for continuity (if applicable).

6. With customer approval, perform operational test of the system, including unit transfer and battery discharge.

7. Calibrate and record all electronics to system specifications.

8. Check or perform Engineering Field Change Notices (FCN) as necessary.

9. Measure and record all low-voltage power supply levels.

10. Record phase-to-phase input voltage and currents.

11. Review system performance with customer to address any questions and to schedule any repairs.

Battery Inspection Service - Performed During the UPS Annual PM Service

1. Check integrity of battery cabinet (if applicable).

2. Visual inspection of the battery cabinet and/or room to include: Check for NO-OX grease or oil on all connections (if applicable).

Check battery jars for proper liquid level (if flooded cells).

· Check for corrosion on all the terminals and cables.

· Examine the physical cleanliness of the battery room and jars.

3. Measure and record DC bus ripple voltage (if applicable).

4. Measure and record total battery float voltage.

Checklist 02: Attachment 8 - Maintenance Checklist UPS (Non-Vertiv) All 3-Phase Models Module 1 – Power and Monitoring

SERVICE PERFORMED

UPS Preventive Maintenance Service

Semi-Annual Service

1. Perform temperature check on all breakers, connections, and associated controls. Repair and/or report all high temperature areas.

2. Perform a complete visual inspection of the equipment including subassemblies, wiring harnesses, contacts, cables, and major components.

3. Check rectifier and inverter snubber boards for discoloration.

4. Check power capacitors for swelling or leaking oil. (if applicable)

5. Check for DC capacitor vent caps that have extruded more than 1/8". (if applicable)

6. Record all voltage and current meter readings on the module control cabinet or the system control cabinet.

7. Measure and record harmonic trap filter currents. (if applicable)

Annual Service (includes the above, plus)

1. Check the inverter and rectifier snubbers for burned or broken wires.

2. Check all nuts, bolts, screws, and connectors for tightness and heat discoloration.

3. Check fuses on the DC capacitor deck for continuity (if applicable).

4. With customer approval, perform operational test of the system including unit transfer and battery discharge.

5. Calibrate and record all electronics to system specifications.

6. Measure and record all low-voltage power supply levels.

7. Record phase-to-phase input voltage and currents.

8. Review system performance with customer to address any questions and to schedule any repairs.

Battery Inspection Service

1. Check integrity of battery cabinet (if applicable).

2. Visual inspection of the battery cabinet and/or room to include:

1. Check for NO-OX grease or oil on all connections (if applicable).

2. Check battery jars for proper liquid level (if flooded cells).

3. Check for corrosion on all the terminals and cables.

4. Examine the physical cleanliness of the battery room and jars.

3. Measure and record DC bus ripple voltage (if applicable).

4. Measure and record total battery float voltage.

Checklist 03: Attachment 8 - Maintenance Checklist UPS (Nfinity and APS) Module 1 – Power and Monitoring

SERVICE PERFORMED

1. Record the phase to phase input voltages.

2. Perform a temperature check on all breakers, connections, and associated controls. Repair and/or report all high temperature areas.

3. Perform a complete visual inspection of the equipment, including sub-assemblies, wiring harnesses, contacts, cables and major components.

4. Check all nuts, bolts, screws, and connectors for tightness and heat discoloration.

5. Inspect for broken, brittle, damaged, or heat stressed components and cables.

6. Clean any foreign material and dust from internal compartments.

7. Perform a status check of alarm circuits.

8. Perform an operational test of the system including unit transfer to and from bypass.

9. Perform an operational test of the system including unit transfer to and from battery.

10. Install or perform Engineering Field Modifications including firmware revisions as necessary.

11. Return the system to normal load and verify the output voltage.

12. Review system performance with customer to address any system questions.

Checklist 04: Attachment 8 - Maintenance Checklist Battery Monitoring Services Module 1 – Power and Monitoring

SERVICE PERFORMED

1. Perform a complete visual inspection of the equipment, including sub-assemblies, wiring harnesses, contacts, cables and major components.

2. Check all nuts, bolts, screws, and connectors for tightness and heat discoloration.

3. Inspect for broken, brittle, damaged, or heat stressed components and cables.

4. Clean any foreign material and dust from internal compartments.

5. Calibrate Data Control Module (DCM).

6. Calibrate Load Module.

7. Clear memory in Controller.

8. Perform any necessary software / firmware upgrades to monitoring system, if applicable.

9. Maintain and archive battery diagnostic system database.

10. Synchronize database with system hardware.

11. Generate battery health inspection report.

Checklist 05: Attachment 8 - Maintenance Checklist Automatic Transfer Switches Module 1 – Power and Monitoring

SERVICE PERFORMED

1. De-energize the transfer switch & engine start signals.

2. Secure and lockout normal and emergency disconnects.

3. Remove the pole covers and arc chutes.

4. Verify and record all sensing and time delay functions in the switchgear.

5. Vacuum clean the accumulated dust from the switchgear and accessory panels.

6. Inspect for moisture or signs of previous wetness or dripping.

7. Remove dirt and grime with an approved solvent.

8. Clean and lubricate TS coil and operator linkage.

9. Inspect all insulating parts for cracks or discoloration due to excessive heat.

10. Inspect all main arcing contacts for excessive erosion.

11. Inspect all main current carrying contacts for pitting and discoloration due to excessive heat.

12. Perform contact resistance test on normal and emergency main contacts.

13. Inspect and clean all add-on panels and accessories.

14. Re-install arc chutes and pole covers.

15. Manually operate the main transfer movement to check proper contact alignment, deflection gap and wiping action and control contact operation.

16. Check all cable and control wire connections to the transfer switch control and sensing panel and other system components and tighten if necessary.

17. Reconnect Engine Start.

18. Re-energize the switchgear and conduct a test by simulating a normal source failure.

19. Perform millivolt drop readings across normal and emergency main contacts during transfer test.

20. Download event log and ATS Settings (Group 5 Controller only)

21. Prepare Computer Generated Report (a sample of this report is available upon request) of inspection for each piece of equipment and submit to customer.

Power Control System Scheduled Maintenance

1. Clean switchgear cabinets interior thoroughly.

2. Check all control wiring terminations and repair as necessary.

3. Clean and inspect bus detail.

4. Verify proper torque settings on bus detail and feeder cable terminations. (Generators must be locked out to perform this procedure).

5. Manually parallel each generator.

6. Verify all meters for accuracy.

7. Verify all indications lights and alarms operate properly.

8. Ensure all circuit breakers function properly.

9. Annotate all trip settings of circuit breakers.

10. Perform secondary circuit breaker injection testing (if the additional service option is selected).

11. Verify all fused disconnect switches operate (if applicable).

12. Dynamically check all generator pre-alarms and shutdowns.

13. Verify all backup PLC power supplies are operating correctly (if applicable).

14. Check PLC fault tables and clear if needed (if applicable).

15. Check for CPU battery expiration date (if applicable).

16. Check all station batteries for proper voltage.

17. Ensure system operates in automatic mode by initiating engine start.

18. Ensure generators share load properly and there is no cross current under no load.

19. Check load control, bus optimization and load demand (if applicable).

20. Ensure engines run through cool-down and shut-down accordingly.

Checklist 06: Attachment 8 - Maintenance Checklist Stationary Battery Systems (Sealed Battery) Module 1 – Power and Monitoring

SERVICE PERFORMED

Semi-Annual Service

1. Inspect the appearance and cleanliness of the battery and the battery room. Clean normal jar top dirt accumulation (to be done only with battery off line).

2. Measure and record the total battery float voltage and charging current.

3. Measure and record the overall AC ripple voltage.

4. Measure and record the overall AC ripple current.

5. Visually inspect the jars and covers for cracks and leakage.

6. Visually inspect for evidence of corrosion.

7. Measure and record the ambient temperature.

8. Verify the integrity of the battery rack/cabinet.

9. Measure and record 100% of the jar temperatures.

10. Measure and record the float voltage of all cells.

11. Measure and record all internal ohmic readings.

12. Provide a detailed written report noting any deficiencies and corrective action needed, taken and/or planned.

Annual Service (includes the above, plus)

1. Re-tighten all battery connections to the battery manufacturer's specifications, if required. Refer to the manufacturer’s literature to determine if re-tightening is required.

2. Measure and record all battery connection resistances in micro-ohms, when applicable

Checklist 07: Attachment 8 - Maintenance Checklist Sealed Batteries (Non-Vertiv) Module 1 – Power and Monitoring

SERVICE PERFORMED

Semi-Annual Service

1. Inspect the appearance and cleanliness of the battery and the battery room. Clean normal jar top dirt accumulation (to be done only with battery off line).

2. Measure and record the total battery float voltage and charging current.

3. Measure and record the overall AC ripple voltage.

4. Measure and record the overall AC ripple current.

5. Visually inspect the jars and covers for cracks and leakage.

6. Visually inspect for evidence of corrosion.

7. Measure and record the ambient temperature.

8. Verify the integrity of the battery rack/cabinet.

9. Measure and record 100% of the jar temperatures.

10. Measure and record the float voltage of all cells.

11. Measure and record all internal ohmic readings.

12. Provide a detailed written report noting any deficiencies and corrective action needed, taken and/or planned.

13. Verify approval for Battery Life program.

Annual Service (includes the above, plus)

1. Re-tighten all battery connections to the battery manufacturer's specifications, if required. Refer to the manufacturer’s literature to determine if re-tightening is required.

2. Measure and record all battery connection resistances in micro-ohms, when applicable.

Checklist 08: Attachment 8 - Maintenance Checklist DC Power Distribution Services (DC Battery) Module 1 – Power and Monitoring

SERVICE PERFORMED

Batteries

1. Measure and record individual cell voltages.

2. Record the float and equalize voltage.

3. Record battery temperature and pilot cell temperature.

4. Re-torque up to 20% of the battery cells based on inter-cell resistance measurements; additional quantities of cells requiring retorque will be documented as a recommended corrective action.

5. Document battery casings, inter-cell straps, and links requiring cleaning.

6. Measure and record individual cell impedance and inter-cell resistance.

7. For flooded cells only record individual cell specific gravity.

a. Fill low cells, utilizing customer provided distilled water, up to 2 gallons per string.

b. Document as a recommended corrective action flooded cells requiring additional distilled water.

8. Battery load testing (Optional, contact Vertiv for pricing information.

Checklist 9: Attachment 8 - Maintenance Checklist DC Power Distribution Services (Rectifiers, Inverters, Converters) Module 1 – Power and Monitoring

SERVICE PERFORMED

Rectifiers

1. Cable Connections: Check connections for tightness, heat, and discoloration utilizing thermal laser gun. Tighten connections as required.

2. Fusing and Distribution: Check all distribution fuses and circuit breakers for heating utilizing thermal laser gun.

3. Output Currents and Voltages: Record through the MCA panel.

4. High and Low Voltage Settings: Verify set points through the MCA panel.

5. Fusing and Distribution: Visual inspection of connections for tightness heat and discoloration.

6. Alarms: Verify alarms to ensure proper operation. Check all fuses for alarms, both audible and visual. Check whether alarms are tied into office alarms.

Power Boards

1. Record plant capacity and plant load; measure voltage at the battery and power board.

2. Measure noise level at the battery with all rectifiers operating.

3. Insure proper operation of low voltage disconnect (LVD), if equipped.

4. Alarms: Verify alarms to ensure proper operation. Check all fuses for alarms, both audible and visual.

5. Inspect fusing, distribution, and connections.

Inverters, Converters

1. Measure input and output voltages, currents and frequency, as applicable.

2. Check input and output cable connections.

3. For inverters, check line sync and measure voltage from inverter line to bypass line.

4. Check alarms for visual and audible indications.

5. Inspect AC tank and DC filter capacitors, as applicable.

6. Calibrate meters.

7. Transfer the inverter to standby and back, verify circuit operates correctly.

Checklist 10: Attachment 8 - Maintenance Checklist Flywheel Module 1 – Power and Monitoring

SERVICE PERFORMED

1. Verify equipment is running normally at maximum speed.

2. Visually inspect interior and exterior for any damaged, broken or overheated components.

3. Check for any coolant leaks.

4. Check the bubble indicator and adjust leveling feet (if necessary) to ensure equipment is level.

5. Conduct a thermal scan of all components and assemblies.

6. Verify proper operation of all cooling fans and coolant pump.

7. Check coolant level (add coolant as necessary).

8. Verify tightness of all nuts, bolts, and connectors.

9. Verify all ribbon cables, cable harnesses, power connections and circuit boards are fully seated and secure.

10. Check continuity of all fuses.

11. Clean interior and exterior of equipment.

12. Clean air filter and replace if damaged.

13. Verify equipment parameters are correct per LOL documentation and/or Operations Manual.

14. Check power supplies and ensure all values are within specifications.

15. Record power, temperature, and vital readings via the LCD display. Ensure vacuum (Drag Power) is within specification.

16. Review and download Event History for any abnormalities or recurring events.

17. Conduct discharge test to verify proper operation (if permitted).

18. Verify operation of installed options.

19. Verify all FCN’s have been installed.

Checklist 11: Attachment 8 - Maintenance Checklist UPS (Non-Vertiv) Single-Phase Models Module 1 – Power and Monitoring

SERVICE PERFORMED

UPS Preventive Maintenance Service

1. Record the phase to phase and phase to neutral input voltages.

2. Perform a temperature check on all breakers, connections, and associated controls. Repair and/or report all high temperature areas.

3. Perform a complete visual inspection of the equipment, including sub-assemblies, wiring harnesses, contacts, cables and major components.

4. Check all nuts, bolts, screws, and connectors for tightness and heat discoloration.

5. Inspect for broken, brittle, damaged, or heat stressed components and cables.

6. Clean any foreign material and dust from internal compartments.

7. Perform a status check of alarm circuits.

8. Perform an operational test of the system including unit transfer and battery discharge.

9. Return the system to normal load and verify the output voltage. Calibrate as necessary.

10. Review system performance with customer to address any system questions.

Battery Preventive Maintenance Service

1. Check integrity of battery cabinet.

2. Visually inspect battery system for: Swelling, leaks, loose foreign objects, overheated or corroded cables and connectors, loose connections on batteries, and appropriate product labels related to safety and warning hazards.

3. Clean and neutralize cell tops as required.

4. Tighten all battery terminal connections to their proper specifications.

5. Measure and record DC bus ripple voltage.

6. Measure and record total battery float voltage.

7. Record room ambient temperature.

Checklist 12: Attachment 8 - Maintenance Checklist UPS Peripherals Maintenance Bypass Cabinet Module Battery Disconnect, Load Bus Sync, Power Tie, System Control Cabinet, Slim Line Distribution Cabinet Module 1 – Power and Monitoring

SERVICE PERFORMED

1. Perform a complete visual inspection of the equipment, including sub-assemblies, wiring harnesses, contacts, cables and major components.

2. Check all mechanical connections for tightness and heat discoloration, making corrections where necessary.

3. Clean any foreign material and dust from internal compartments.

4. Perform a status check of alarm circuits. (If Applicable).

5. Calibration of the equipment to meet manufacturer's specifications (if applicable).

6. Operational checkout of the system to include transfers and proper status indications.

7. Check or perform Engineering Field Change Notices (FCN) as necessary.

8. Return unit to operational service with normal load then measure and verify display indications.

Checklist 13: Attachment 8 - Maintenance Checklist Static Transfer Switch (STS1 and STS2) Module 1 – Power and Monitoring

SERVICE PERFORMED

1. Perform a complete visual inspection of the equipment, including sub-assemblies, wiring harnesses, contacts, cables and major components.

2. Check air filters for cleanliness (if applicable).

3. Check all mechanical connections for tightness and heat discoloration, making corrections where necessary.

4. Clean any foreign material and dust from internal compartments.

5. Perform a status check of all alarm circuits. (Applicable to STS1 Only).

6. Calibration of the equipment to meet manufacturer’s specifications. (Applicable to STS1 Only).

7. Operational checkout of the system to include transfers and proper status indications.

8. Check or perform Engineering Field Change Notices (FCN) as necessary.

9. Return unit to operational service with normal load then measure and verify display indications.

Checklist 14: Attachment 8 - Maintenance Checklist Water Detection System (Floor-mount, Ceiling, Wall-mount) Module 1 – Power and Monitoring

SERVICE PERFORMED

Water Detection Cables

1. Check for dirty cables.

2. Replace Cables as needed.

3. Examine Cable connectors.

4. Wipe entire cable system clean if dusty or dirty.

Electric Panel, Controls, and Cable System and connections:

1. Check fuses.

2. Check electrical connections.

3. Check contactors for pitting.

4. Using microprocessor controls, ensure proper operation of the unit components.

5. Inspect leak detection cabling and proper communication to Liebert Site Scan Monitoring System

6. Check Alarm function and verify alarm transaction data to Liebert Site San System

Checklist 15: Attachment 8 - Maintenance Checklist SiteScan Module 1 – Power and Monitoring

SERVICE PERFORMED

Checklist 16: Attachment 8 - Maintenance Checklist Precision Cooling Services Xtreme Density (XD) Systems (XDC, XDP, XDP-W, XDF) System Includes the associated XDV’s, XDO’s, XDH’s, XDK’s, XDR’s Module 1 – Power and Monitoring

SERVICE PERFORMED

XDO's, XDV's, XDF's

1. Check all electrical connections.

2. Check incoming voltage at power block.

3. Check main fan amps.

4. Check all piping connections for refrigerant leaks.

5. Make sure all isolation or shut off valves are open. 6. Check operation of water detection. (If applicable)

7. Check air temperatures at return and discharge of coils. Record temperature differences.

8. Check ionization system for proper static controls.

XDC & XDP

1. Check electrical connections on all fuse blocks, contactors, pumps and compressors.

2. Check and record voltages at disconnect.

3. Check compressor amperages, 1A, 1B, 2A, 2B.

4. Check compressor head and suction pressures, both tandems.

5. Check superheat on both circuits.

6. Check pump amperages, both pumps.

7. Check pump pressures, suction and discharge.

8. Check refrigerant level in receiver, middle site glass should be full.

9. Check operation of hot gas bypass valves.

10. Check refrigerant level in condenser receivers.

11. Check ionization system for proper static control.

Air Cooled Condenser (If Applicable)

1. Check if condenser coil clean, brush clean if necessary.

2. Fan motor mounts secure.

3. Motor fan blades turn freely, (no bearing restriction).

4. Refrigerant lines properly supported no metal to metal contact.

5. Check all electrical connections for loose wires.

Glycol Pump Package (If Applicable)

1. Inspect water regulator valves for refrigerant or glycol leaks.

2. Check percentage of glycol solution for freeze protection.

3. Inspect all water union joints for leaks.

4. Dry cooler coil clean.

5. Check glycol pumps for seal leaks.

6. Check glycol pump amperage.

7. Check all electrical connections for loose wires.

8. Fan motor mounts secure.

9. Fan blade spin freely.

Wall Controllers

1. Check wire screw terminals from main unit.

2. Check and record dip switch settings.

3. Go through entire program and check all temperature and alarm set points.

4. Go through the alarm history program and make sure there are not several of the same alarms.

Checklist 17: Attachment 8 - Maintenance Checklist Precision Cooling Services (Floor-mount, Ceiling, Wall-mount & Heat Rejection) Module 2 – HVAC

SERVICE PERFORMED

Filters

1. Check for restricted airflow.

2. Replace air filters as needed.

3. Examine filter switch.

4. Wipe entire section clean.

Blower Section

1. Verify that impellers are free of debris and move freely.

2. Check belt for condition and proper tension.

3. Replace belts as needed.

4. Verify that the bearings are in good condition.

5. Check the fan safety switch for proper operation.

6. Check the pulleys and motor mounts for tightness and proper alignment.

Air Cooled Condenser (If Applicable)

1. Verify condenser coil cleanliness.

2. Brush clean and spray using hose and nozzle connected to local water source (if local water source is available).

3. Chemical cleaning of outdoor condensing unit is excluded from normal scheduled maintenance and can be performed on a time and material basis.

4. Examine motor mounts for tightness. Tighten if necessary.

5. Verify that the bearings are in good working order.

6. Confirm that the refrigerant lines are properly supported.

Water/Glycol Condenser (If Applicable)

1. Check cleanliness of copper tubing.

2. Confirm that the water regulating valves are functioning properly.

3. Check the glycol solution level.

4. Check glycol freeze protection level.

5. Check for water/glycol leaks.

Glycol Pump

1. Examine for any glycol leaks.

2. Determine proper pump operation.

Steam Generating Humidifier (If Applicable)

1. Check the canister for any deposits.

2. Check the condition of all steam hoses.

3. Examine the water make-up valve for any leaks.

4. Check and adjust potentiometers for optimal performance.

Infrared Humidifier (If Applicable)

1. Check the pan drain for any type of blockage.

2. Examine the humidifier lamps for proper operation.

3. Check the pan for any type of mineral deposits.

Refrigerant Cycle/Section[footnoteRef:1] [1: ]

1. Examine refrigerant lines for leaks or damage.

2. Using the sight glass, check lines for moisture.

3. Monitor suction pressure.

4. Monitor head pressure.

5. Monitor discharge pressure.

6. Check superheat.

Electric Panel, Controls, and Ancillary Items

1. Check fuses.

2. Check electrical connections.

3. Check contactors for pitting.

4. Using microprocessor controls, ensure proper operation of the unit components.

5. Inspect leak detection cabling (if connected to unit).

6. Check Ionization system for proper static control.

Chilled water units - additional checks (if Applicable):

1. Inspect chilled water valve and actuator for proper operation.

2. Adjust/ tighten linkage if necessary.

3. Inspect internal chilled water piping and coil for leaks.

Checklist 18: Attachment 8 - Maintenance Checklist Dual Cool AC Systems – Primary Water Source Rotate Module 2 – HVAC

SERVICE PERFORMED

Rotate Units to Alternate Source Supply

1. Check AC units to make sure source supply is as indicated on unit name tag data.

2. Rotate each unit to the alternate source and verify proper Operation

3. Verify unit operation and communication to Site Scan.

4. Wipe entire system clean if dusty or dirty.

Electric Panel, Controls, and Cable System and connections:

1. Check fuses.

2. Check electrical connections.

3. Check pump pressure for each source before and after rotation

4. Using microprocessor controls, ensure proper operation of the unit components.

5. Inspect piping connections and water valves and leak detection cabling and proper communication to Liebert Site Scan Monitoring System image1.png image2.png