61386390 SPEC Solid State Converter 400 Hz.pdf

Solid-State Converter | Output: 90 kVA, 115 VAC (Delta), 3 Ph

1. SCOPE

1.1. Scope. The purchase description set forth below describes the minimum requirements of the Government for a Solid-State Converter. It is the Government’s intent that a single primary contractor be awarded this contract and be responsible for the provision of equipment, and the accomplishment of all work detailed by this specification.

2. REQUIREMENTS

2.1. Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold, or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

2.2. Construction. The Solid-State Converter shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the Solid-State Converter to its maximum rating and capacity without distortion.

2.2.1. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

2.2.2. Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

2.2.3. Corrosion Control. All system components shall be protected against corrosion, deterioration by appropriate material selection, and application of coatings/sealants. The system and its parts shall be painted on all sides, prior to assembly, except mating surfaces such as mounting flanges and motor shafts. Painting shall result in a highly wear-resistant finish, which guarantees continued protection to the surfaces covered against the specified environment under all service conditions. Exposed ferrous parts such as screws, bolts, nuts, washers shall be treated to resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable. Stainless steel parts shall be passivated. Aluminum parts shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint. Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion. All paint shall be lead and chromate free.

2.2.4. Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

2.2.5. Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

2.2.6. Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's workstation(s). An emergency stop button shall be installed and accessible to the operator. When depressed, the emergency stop button shall eliminate energy to the system.

2.2.7. OSHA Compliance. The equipment installation and its component parts shall be IAW 29 CFR 1910, NFPA 70 and NFPA 79. Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399.

2.2.8. Safety Signs and Labels. Safety signs and labels IAW NEMA Z535.4 shall be securely attached to the equipment in visible locations, at the point of hazard(s), with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs.

2.2.9. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

2.2.10. Interchangeability. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

2.2.11. Measuring and Indicating Device Graduations. All measuring and indicating devices on the Solid-State Converter shall be graduated in the inch/pound or both inch/pound and metric.

2.3. Components. The Solid-State Converter shall consist of not less than the following components.

2.3.1. Electrical System. The machine shall conform to NFPA 79. The existing electrical power source available at the installation site is 480 VAC, 3 Phase, 60 Hz. The machine’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. The electrical system shall be complete, including transformers required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device, controlling all electrical power to the equipment, shall be utilized on the machine with means of lockout in the off position only.

2.3.2. Solid-State Components. Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Solid-state components shall not be adversely affected when subjected to power line transients and surges typically experienced in industrial environments. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Solid-state devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability.

2.3.3. Electrical Enclosures. Electrical components of the equipment shall be contained in enclosures of drip-proof construction and of minimum size consistent with good design practice and ventilation of components, meeting the requirements of NEMA 250, Type 3SX.

2.3.4. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the component being isolated and locked out. The devices shall be designed and manufactured such that they can be padlocked in the OFF position. This includes both mechanical and electrical devices. An energy isolation device shall be installed as the first energy control device on all major components of the system such that the component can be isolated at the component level.

2.4. Facility Electrical Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

2.5. Size and Capacity. The size and capacity of the Solid-State Converter shall be not less than specified in Table I.

Table 1 Input

Input Voltage 480 VAC (+/- 10%), 3 Phase Input Frequency 60 Hz Input Full Load Current 93 Amps

Protection Over/undervoltage, loss of phase, overcurrent, short circuit.

Inrush Current No greater than 100% of full load current Input Current Distortion Less than or equal to 5% Automatic Line Drop Compensation 5%

Output Output Power Rating 90 kVA Output Voltage 115 V (Line-to-Line), Delta, 3 Phase Output Frequency 400 Hz Power Factor Range 0.5 lagging to 0.8 leading

Overload

100% continuous 110% for 60 minutes 125% for 10 minutes 150% for 2 minutes

Voltage Adjust +/- 15% Crest Factor 1.415 +/- 3%

Voltage Regulation +/- 1.0% under all conditions of line, balanced loads and temperature

Voltage Transients IAW MIL-STD-704F

Frequency Regulation 400 Hz +/- 0.01% under all conditions of line, load and temperature

Frequency Transients None

Phase Angle Regulation +/- 1° for balanced loads +/- 2° for unbalanced loads

Harmonic Distortion 2.0% maximum

Protection Overload, short circuit, over/undervoltage and safety disconnect

Automatic Line Drop Compensation 5% Environment

Acoustic Noise < 65 dBA maximum at 5 feet Temperature Range - 104℉ to 131℉ Relative Humidity 10 – 95%, non-condensing Ingress of Water Type 3SX, IP55

Energy Factors

Efficiency 94% typical of full load 92% typical of half load

Installation Space Max Allowable Installation Space 48” W x 36” D x 96” H

2.6. Standard Features.

2.6.1. Built-in maintenance diagnostic system

2.6.2. Touch screen digital control panel (English language)

2.6.3. External communications port access, front panel USB and Ethernet

2.6.4. Event log / diagnostics

2.6.5. AC input and output contactors “connect/disconnect” device

2.6.6. Input surge protection IAW IEEE C62.41, Category B

2.6.7. 5% max AC input current distortion, IGBT active front end

2.6.8. Automatic input line monitoring

2.6.9. Forklift pockets/tubes

2.6.10. Convection cooling

2.6.11. Enclosure, NEMA 250, Type 3SX

2.6.12. 15% automatic line drop compensation

2.6.13. Emergency power OFF switch

2.6.14. Voltage, current and frequency monitoring

2.6.15. Elapsed time meter

2.6.16. Front panel voltage adjustment

2.6.17. Front panel summary fault indicators

2.6.18. Input high voltage transient protection

2.7. Required Accessories.

2.7.1. Output cable, 30 feet in length

2.8. Marking on Instruments, Control Panels, and Plates. All words on instruments, control panels, and plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

2.8.1. Nameplate. A nameplate shall be permanently and securely attached to each machine.

The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer's name

Manufacturer's model designation Manufacturer's serial number Power input (volts, total amps, phase, and frequency) Contract Number or Order Number Date of manufacture

2.8.2. Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text.

2.9. Operating and Maintenance (O&M) Manuals. Three (3) hard copies and one (1) electronic copy(s) of the O&M Manuals shall be provided with the machine. O&M Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical Data shall contain at a minimum:

a. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment.

b. Complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories.

c. Operating instructions including programming requirements, pre-operational checks, start up, shut down and emergency shutdown procedures.

d. Maintenance and service instructions, including all preventive maintenance schedules, and lubrication charts.

e. Trouble-shooting guides.

f. Parts list containing illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts, including quantities.

g. Energy control procedure, in accordance with 29 CFR 1910.147, to bring equipment to a zero-energy state for maintenance.

h. All mechanical and electrical schematics with a table of contents showing discrete components, block diagrams, wiring diagrams with inputs and outputs identified, system electrical interface documents, and drawings for the specific model of all machine equipment/drives/controls supplied.

2.10. NRTL Certification. The equipment and its installation specified herein shall be inspected and labeled by a Nationally Recognized Testing Laboratory (NRTL) as defined in 29 CFR 1910.7 and approved as defined in section 2.2.7 of this statement of work, OSHA

Compliance. A satisfactory NRTL Field Evaluation Report shall be provided to the receiving activity after equipment delivery, and prior to destination testing.

2.11. Test Data Results Used for Evaluation of Equipment to Meet Specification Requirements. The Contractor shall submit a written test report of all tests conducted at origin and destination. The test report shall be submitted within 10 working days after the tests are performed.

2.12. Warranty. Supplies and services furnished shall be covered by warranty from defects in design, materials and workmanship. The warranty shall be the manufacturer’s standard commercial warranty which shall conform to all the requirements of the contract. Acceptance of the manufacturer’s standard commercial warranty shall not minimize the rights of the Government under clauses in the contract, and in any conflict that arises between the terms and conditions of the contract and manufacturer’s warranty, the terms and conditions of the contract shall take precedence. The warranty period shall commence when final acceptance has been achieved as determined when all contract line-item numbers have been processed.

2.13. Workmanship. Workmanship of the Solid-State Converter shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

2.14. Installation. Contractor shall be responsible for tasks as outlined in Section 4, Table 2.

The Contractor shall adhere to Attachment A for site specific facility requirements.

Installation shall comply with EM 385-1-1 and UFC 3-301-01.

2.15. Electrical Installation. The Contractor shall furnish all labor, wiring, cabling, and associated hardware required to perform a comprehensive electrical installation from the government-designated installation location. The scope of work includes the installation of all power, control, and interconnecting wiring within the appropriate conduit. Primary power shall be sourced from a Government provided disconnect, which will be located within 10’ from the installation location.

2.16. Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is a United States citizen proficient in the English language, shall be provided for specialized training to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. The training shall be for number of operators and be performed at customer facility and shall not be less than one (1), eight (8) hour workday, between 0720 – 1602 HRS, excluding any federal holidays. The course shall utilize manuals provided under this contract and shall hands-on training. All printed training aids shall be supplied at no additional cost to the government and be in the English language.

3. QUALITY ASSURANCE

3.1. Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. Except as otherwise specified in the contract or purchase order, the contractor may use his own facility or any other facility suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. Only supplies that totally conform to the specifications shall be offered for inspection and test. The contractor's test schedule shall allow consecutive inspection and test of the supplies offered. The Government reserves the right to charge the contractor for any Government re-inspection cost when supplies are not ready at the time requested by the contractor or when necessitated by prior rejection. The Government reserves the right to perform any inspections set forth in the purchase description where such inspections are deemed necessary to ensure supplies and services conform to prescribed requirements.

3.2. Responsibility for Compliance. All items must meet all requirements of Section 3.

3.3. Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient conditions of 55℉ to 100℉ and 10% to 95% relative humidity.

3.4. Contract Quality Assurance Inspection (Origin). Contract quality assurance inspection shall be applied at the contractor’s facility prior to being offered for acceptance under the contract. Quality assurance inspection shall consist of the examination in 3.6. The machine shall pass the examination, all tests, and the contract quality assurance inspection to be acceptable. At the option of the Government, tests may be witnessed by technical representatives of the receiving activity. The Contractor shall notify the Government Point of Contact of the scheduled date, time, and location of the tests.

3.5. Final Inspection/Acceptance Test (Destination). Final inspection and acceptance test shall be performed on the Solid-State Converter to ensure conformance with this purchase description. The acceptance test shall be performed only after the Solid-State Converter is installed at its final location. The acceptance test shall consist of the examination in 3.6 and test in 3.7. The machine shall pass the examination, all tests, and the final inspection to be accepted.

3.6. Examination. The Solid-State Converter shall be examined to determine compliance with all requirements of this purchase description.

3.7. Operational Test. The Solid-State Converter shall be operated while coupled to a resistive/reactive load bank with the following specifications: 100 kW, 120 VAC, 400 Hz, 0.7 Power Factor. The load bank will be run up to 80% max capacity, with load bank input power provided by the Solid-State Converter’s output power. Proper operation of all controls, motors, adjusting mechanisms, and accessories shall be verified during the trial period.

3.8. Verification. The meaning of verification for the purpose of this contract is to assure that the items installed and/or connected by Government personnel are correct.

4. TASKS

TABLE 2

Tasks Government

Responsibility Contractor

Responsibility

RIGGING: Furnish labor and material handling equipment for off-loading and placing machine at installation location.

X

MECHANICAL: Level and align machine.

Provide and install anchor bolts/nuts. X

ELECTRICAL: Connect solid-state converter to junction box, located downstream of Government supplied electrical disconnect.

Junction box located within 10 feet of installation site. Source and install output cable (cable length: 30’).

X

COMMISSIONING: Verify and certify the machine is correctly installed. Verification of installation shall be included within the warranty.

X

OPERATIONAL TEST: Provide all necessary tools, gages, instrumentation, and materials to perform onsite operational test. Operational test shall include connection between solid-state converter and Government furnished load bank.

X

OPERATIONAL TEST SUPPORT:

Government shall help connect solid-state converter to the load bank and operate the load bank.

X

TRAINING: Provide at customer facility.

Training shall not be less than one (1), eight

(8) hour workday.

X