Attach J.01 DC BUS Specification_Amend 00002.pdf

SIR 693KA8-20-R-00008 // Amendment 00002

Attachment J.1

DIRECT CURRENT BACK-UP SYSTEM SPECIFICATION (DC BUS

SPEC)

Performance Goals and

Operating Characteristics

05/14/2018

PART 1 GENERAL

1.0 DC BUS Definition:

The system shall continuously supply regulated Direct Current (DC) power to loads and shall be capable of providing power during loss or interruption of input Alternating Current (AC) by using energy stored in a battery bank. The DC Back-Up System (DC BUS) shall be capable of suppressing transient voltage conditions. Input power will be AC, single-phase 240 volt and/or 208 volt, supplied by the electric utility. The DC BUS system shall provide nominal 24 volt DC, using multiple rectifier modules (up to

100 amps each) that can be set up with one or more rectifiers configured to provide redundancy. The system shall be configurable with redundancy to support loads up to 200 DC amps. The DC BUS shall include: rectifier with internal automatic transfer capability; control circuitry; 1000 VA, 120 voltage AC inverter with bypass having dual receptacle outputs, 1000 VA, 120 voltage AC inverter with bypass having hardwired output, optional 2000VA, 120 voltage AC inverter with bypass having hardwired output; and optional DC converter(s).

1.1 Major Component List:

The DC BUS System provided under this contract shall consist of Commercial-off-the-Shelf/Non-

Developmental Item (COTS/NDI) equipment and must contain the following features.

a. Rectifiers, minimum 2, each powered from separate AC circuits

b. Optional PV capability, which could be either

a. Optional Multimode inverter designed to operate independent of DC BUS

b. Optional PV Converter designed to operate with Rectifiers

c. Optional Fuel Cell Converter designed to operate with Rectifiers

d. Distribution Cabinet

e. Distribution Panel(s) with circuit breakers.

f. Inverter, 2ea.

g. Remote monitoring capability

h. Control panel,

i. AC wireway/Cabinet

j. DC wireway/Cabinet

k. Battery shunt

l. Main system bus

m. Battery disconnect

n. Low Voltage Disconnect Contactor

o. Battery. Valve Regulated Lead Acid (VRLA) battery, capacity 104 – 2100 Amp hours.

1.2 Optional Lowest Replaceable Unit (LRU) Component List

1. Rectifier

2. Inverter

3. Converter(s), three voltage types

4. Distribution panel

5. Circuit Breakers

6. PV Converter

7. Fuel Cell Converter

8. Multimode Inverter

9. Automated Battery Monitor

1.3 Applicable Documents

The Specifications Standards and Publications referenced are part of this document to the extent specified. In the event there are conflicts between FAA documents and industry standards, the FAA documentation shall take precedence.

Federal Aviation Administration

-FAA-G-2100H FAA Electronic Equipment, General Requirements

Department of Defense Standard

-MIL-HDBK 217 Reliability Prediction of Electronic Equipment

American National Standards Institute (ANSI)/ Institute of Electrical and Electronics Engineers (IEEE)

-ANSI/IEEE C62.41 IEEE Recommended Practice of Surge Voltages in Low-Voltage AC Power

Circuits

International Electro technical Commission (IEC)

IEC 801-2 Electrostatic Discharge Requirements

1.4 Environmental requirements:

1.4.1 Storage ambient temperature: -20°C (-4°F) to 70°C (158°F)

1.4.2 Operating ambient temperature DC BUS unit: 0°C (32°F) to 40°C (104°F)

1.4.3 Operating ambient temperature batteries: 15°C (59°F) to 27°C (80°F)

1.4.4 Relative humidity: 5 to 95%, non-condensing.

1.4.5 Altitude: The DC BUS shall operate at all altitudes between 0 and 3,300 feet without de-rating performance. The contractor shall provide de-rating data for operation between 3,300 and 10,000 feet in 1000-foot increments.

1.5 Maintenance and Safety Procedures:

1.5.1 The vendor shall identify and recommend system maintenance procedures.

1.5.2 The vendor shall identify and recommend effective protection from thermal, chemical, biological, toxicological, radiological, mechanical, electrical, electromagnetic, pyrotechnic, optical, and other hazards.

1.5.3 The vendor shall recommend personnel protective equipment where potential hazards to life or health necessitate protection.

PART 2 EQUIPMENT CHARACTERISTICS AND PERFORMANCE

2.0 General: DC BUS, a 24-volt DC system, shall have dual redundant rectifier modules of on-line technology that meets the stated performance requirements. The DC BUS system control shall provide synchronization control circuits, connection control circuits, disconnection control circuits, system instrumentation, system status indicators, system alarms and system diagnostic for Remote

Maintenance Monitoring and battery monitoring. The DC BUS must have a 15-year service life with published documentation that demonstrates obsolescence horizon for all components as well as reliability calculations.

2.1 DC BUS System Performance Ratings: The DC BUS shall supply fully conditioned and continuous power during normal operations. The DC BUS shall also be capable of providing continuous rated power during loss or interruption of input AC power by using DC power stored in the battery bank. And, automatically transfer back to utility power when the AC source is within the system’s rating or limits. Under specified conditions, external or internal failures and normal switching, the DC BUS shall: automatically, within 10 ms or less, transfer the load from one rectified module to the other; and, automatic bypass from DC BUS input distribution cabinet to inverter output, that switches

AC load within 8 ms.

2.2 DC BUS continuous output capacity rating: The vendor shall offer a DC BUS system capable of 24-volt DC 200 300 amp output minimum.

2.3 DC BUS Battery Capacity: The vendor shall offer multiple options of batteries rated

104 to 2100-amp hour, 24 volts.

2.4 Electrical Input Requirements.

2.4.1 Rectifier/Charger. Redundant units, minimum two per DC BUS, with automatic switching of load from one rectifier to the other rectifier, within 10 ms, in event of rectifier failure.

Rectifiers may automatically share the load during normal operation. The DC BUS shall have separate

AC power input feeds for each rectifier/charger.

2.4.2 Rectifier/Charger electrical input requirements input voltage: Single-phase: 208 volt, line-to-line, and 240 volt Line-to-Line, without adjustments.

2.4.2.1 Input voltage range: +10%, -15% steady state.

2.4.2.2 Input frequency: 60 hz +/-5%.

2.4.2.3 Input Power Factor (PF): (ratio of kW to kVA) Power Factor values, between 30% load and 80% load, shall remain between 0.90 lagging and unity. Load is full rated capacity of the DC

BUS.

2.4.2.4 Input Total Harmonic Distortion (THD), Current: THD values between 30% and

80% load shall not exceed 10%. Load is full rated capacity of the DC BUS.

2.4.2.5 Inrush current: Inrush current values shall not exceed these values at these specific times:

1. At 0.01 second, 8-times the steady state rating of the unit. Peak current measurement.

2. At 0.1 second, 3-times the steady state rating of the unit. RMS current measurement

3. And at 1 second, steady state. RMS current measurement.

Vender shall provide actual inrush current values of DC BUS units proposed under this contract.

2.5 Electrical Output Requirements.

2.5.1 Rectifier/Charger Bus Output Requirements.

2.5.1.1 Output voltage: 24 volts DC. Manual adjustable system output voltage between 23.5 and 28.5 volts DC, 0.1V increments. Steady state output voltage limits ±0.5%. If range, increments, or limits are different, explain the deviation and implications.

2.5.1.2 Output Bus Current: 50 - 200 amp minimum.

2.5.1.3 Output Voltage Transient Recovery: Maximum Voltage Transient shall not exceed

a. +/- 3% nominal voltage for a 50% load step.

b. +/- 5% nominal voltage for a 100% load step.

Output voltage shall fully recover to nominal voltage limits within 16.7 milliseconds or less.

2.5.1.4 Output Overload Current at Full Output Voltage Capability:

a. 125% for 10 minutes in normal operation, +/- 7% of set voltage.

b. 150% for 60 seconds in normal operation, +/- 10% of set voltage.

c. 167% of full load current for 3-seconds, +/- 10% of set voltage.

2.5.1.5 Current Limit: 100A, at 24 voltage, indefinitely, unit has 100% duty cycle.

2.5.1.6 AC to DC Efficiency: The minimum DC BUS AC to DC rectification efficiency at rated input and output voltage is 88%, at 100% linear load, nominal input voltage, with batteries fully charged.

2.5.1.7 DC ripple voltage (AC ripple riding on DC output). System noise is limited to requirements listed in paragraph 2.7.3.2 of this specification. This DC ripple is measured with batteries connected and disconnected.

2.5.1.8 Battery Charging

2.5.1.8.1 Temperature compensated battery charging. The DC BUS must have automatic temperature compensation so float voltage can be adjusted, up or down depending on the ambient air temperature surrounding the batteries. Need temperature sensor on batteries. The actual adjustment of float voltage, up or down, based on battery ambient air temperature, will vary depending on each battery manufactures requirements.

Example: For temperatures above 25o C (77o F), the voltages will be lowered 5.04 mV (2.8 mV) per cell per degree above 25o C (77o F). For temperatures below 25o C (77o F), the voltages per cell should be increased by 5.04 mV (2.8 mV) per cell per degree below 25o C (77o F).

In this example 25o C (77o F) is taken as the upper operating temperature of the batteries. This could be different for other battery manufactures but the voltage adjustment will operate the same.

2..5.1.8.2 Nominal Float voltage and Equalized voltage adjustable within rectifier limits.

2.5.2 Inverter (24 volts DC to 120 volts AC) Output Requirements.

2.5.2.1 Output voltage: Single-phase - 120 volt two wire plus equipment ground.

2.5.2.2 Output Power: normally 1000VA, optionally 2000VA.

2.5.2.3 Output voltage regulation Steady State: 5%.

2.5.2.4 Output Frequency: Frequency 60 Hz +/- .1 Hz

2.5.2.5 Output Voltage Waveshape: Quasi-sine wave or Stepped approximation to sine wave, Crest Factor between 1.35 and 1.45.

2.5.2.6 Output Voltage Transient Recovery: Maximum Voltage Transient shall not exceed

Output voltage shall recover to nominal voltage regulation limits within 16.7 milliseconds or less.

2.5.2.7 Output Overload Current at Full Output Voltage Capability:

a. 105% for 10 minutes in normal operation, +/- 7% of set voltage..

b. 125% for 60 seconds in normal operation, +/- 10% of set voltage.

c. 150% of full load current for 3-seconds, +/- 10% of set voltage.

2.5.2.7.1 Current Limit: 100%, at 120 volts, indefinitely, unit has 100% duty cycle.

2.5.2.8 Bypass. The DC BUS shall be equipped with a bypass around the inverter connected to the AC loads that will automatically switch in 8ms or less when the inverter fails or DC BUS voltage reaches discharge limit of the battery string.

2.5.2.9 AC Noise reflected by Inverter. (AC noise or ripple reflected back on 24 volt DC bus by the inverter). System noise is limited to requirements listed in paragraph 2.7.3.2 of this specification.

This DC ripple is measured with batteries connected and batteries disconnected, and two inverters in DC

BUS system.

2.5.2.10 AC Noise on inverter(s) AC output. System noise is limited to requirements listed in paragraph 2.7.3.2 of this specification.

2.5.3 Converter output (DC to DC) Requirements.

2.5.3.1 Input/output voltage.

a. 24V to –48V

b. +24V to 12V

c. +24V to –24V

2.5.3.2 Output Current – 5 amps.

2.5.3.3 Output Voltage Transient Recovery: Maximum Voltage Transient shall not exceed

2.5.3.4 Noise reflected by converter(s). (AC noise or ripple reflected back on 24 volt DC bus by the converter(s). System noise is limited to requirements listed in paragraph 2.7.3.2 of this specification. This DC ripple is measured with batteries connected and disconnected and three converters: +24V to -48V; +24 to 12V; and +24V to -24V.

2.5.3.5 Noise on inverter(s) AC output. System noise is limited to requirements listed in paragraph 2.7.3.2 of this specification.

2.5.4 Optional PV Converter Requirements

2.5.4.1 Input Voltage: Must accept 120VDC – 400VDC but a wider range is preferred.

2.5.4.2 Output Voltage Transient Recovery: Maximum Voltage Transient shall not exceed

2.5.4.3 Noise reflected by converter(s). (AC noise or ripple reflected back on 24 volt DC bus

2.5.4.4 Dimensions: Converter must fit in rectifier rack.

2.5.5 Optional Fuel Cell Converter Requirements

2.5.5.1 Output Voltage Transient Recovery: Maximum Voltage Transient shall not exceed

2.5.5.2 Noise reflected by converter(s). (AC noise or ripple reflected back on 24 volt DC bus

2.5.5.3 Dimensions: Converter must fit in rectifier rack.

2.5.6 Optional Multimode Inverter Requirements

Unit should have enough capacity (continuous kVA) to supply input power to DC BUS.

Inverter should meet or exceed specifications of Schneider Conext XW6048 except for DC voltage requirements and must include all accessories necessary to accept PV module voltages from 100 –

400VDC.

2.6 System Operation, Normal System Operation: The battery unit shall not be required to assume any portion of a step load in normal operation. The DC BUS shall continue to function in the normal mode of operation with or without a DC source.

2.6.1 Normal Mode: During normal operation, the DC BUS shall be used to provide precise regulated and transient free power to the electronic equipment load. The primary AC source shall be used to supply power to the rectifier charger. The rectifier charger shall provide regulated DC power to support the load, inverter(s), converter(s) and simultaneously maintain the battery in a fully charged condition.

2.6.2 Emergency Mode: Upon failure of the primary AC power, input power for the load, inverter, or converter shall automatically be supplied from the battery. When normal power is restored, input power for the loads and for recharging the battery shall automatically be supplied from the rectifier charger. If the input AC power does not return, the DC BUS shall automatically shut down in an orderly manner when the discharge limit of the battery is reached.

2.6.3 Downgrade Mode: If the battery must be taken out of service for any reason, it shall be disconnected from the rectifier charger and inverter by means of a circuit breaker. The DC BUS shall continue to function and meet the performance criteria specified except for the battery protection time specified.

2.7 DC BUS Module Design

2.7.1 Reliability: The documented reliability of each DC BUS, defined as input to the rectifier and output of rectifier, shall not be less than 150,000 hours (battery MTBF not included) mean time between failures (MTBF). The above figure should be substantiated by documented analysis and calculated based on MIL-HDBK 217.

2.7.2 Routine Maintenance: Modular sub-assembles: for ease of maintenance and service, the DC BUS must have field replaceable modular sub-assemblies serviceable from the cabinet front panel. The DC BUS system shall not require periodic maintenance or inspections more than four times each year. No visit for routine or periodic maintenance shall require more than 4 staff-hours for the quarterly visit.

2.7.2.1 Mean Time to Repair (MTTR):

The DC BUS shall be configured so that system restoration, following a failure, can be accomplished by the replacement of a LRU(s). Mean time to repair the DC BUS by replacement of an LRU following a failure shall not exceed 30-minutes, assuming spare components, subassemblies and experienced technician are available on site. MTTR is the mean time to repair all of the removable items in a system for corrective maintenance. MTTR is defined as beginning when the trained technician arrives at the

DC BUS location. It includes the total time required to isolate and replace the defective LRU and return the DC BUS to normal operation.

2.7.3 Grounding, Bonding, Shielding, and Surge Protection.

2.7.3.1 Input Surge Protection: DC BUS systems shall meet ANSI/IEEE Standard C62.41, Categories A & B (6kV).

2.7.3.2 Electromagnetic Interference (EMI): Radiated and conducted EMI shall be suppressed to ensure that computer systems, or other similar electronic systems shall neither adversely affect the

DC BUS system nor be adversely affected by the DC BUS system.

2.7.3.2.1 DC BUS system shall meet FCC regulation Title 47 CFR PART 12 Class B. DC BUS test configuration (not pricing configuration), electrical/electronic components, for testing purposes, comprises: control panel; two (2) rectifiers, minimum (depending on number of rectifiers needed to meet

24 volt, 100A normal, 50A – 200A optional, single rectifier redundancy); two (2) inverters; and three

(3) converters.

2.7.3.2.2 System shall neither interfere with nor have an adverse effect on Amplitude Modulation

(AM) radio equipment operating in the following frequency ranges: VHF, 115 to 130 MHz; and UHF, 320 to 370 MHz.

2.7.3.3 Electrostatic Discharge (ESD): DC BUS system shall not incur damage or malfunction when ESD voltages of severity level 4, as specified by IEC801-2, are applied to exposed parts of the power system.

2.7.4 Low battery voltage protection: To prevent total discharge of the battery, the DC BUS shall automatically shut down when the battery voltage reaches a programmable minimum voltage level.

If the shut-down was caused by loss of AC input, then when power is restored normal system operation automatically resumes.

2.8 Display and Controls

2.8.1 DC BUS Control Panel: The term DC BUS control panel denotes that portion of the DC BUS containing the display panel and control functions. Each DC BUS Unit shall be provided with a control section to provide complete monitoring and control through the use of menu-prompted commands. The monitor controller shall be:

1. Windows-based software

2. Open systems interface

3. RS232 and RS 485 Local communication ports

4. Remote monitoring capability

5. Password protection for security

2.8.2 Manual Procedures: Start-up and shutdown procedures shall be detailed on the display panel in text and graphic form.

2.8.3 Metered Values: A microprocessor shall control the display and memory functions of the monitoring system. All voltage and current parameters shall be monitored using true RMS measurements for accurate (+/- 1%) representation of non-sinusoidal wave forms typical of computers and other sensitive loads. The following parameters shall be monitored and displayed:

1. DC BUS Rectifier:

a. Input voltage.

b. Input current.

c. Output voltage.

d. Output current.

2. Battery

a. Battery voltage.

b. Battery charging/discharging current.

c. Battery Temperature

2.8.4 Alarms

Alarm conditions shall be reported at the DC BUS Module. The control panel shall report the alarms listed below. Each alarm shall be visually displayed in text form and an audible alarm will sound for each alarm. These are adjustable set points.

1. DC BUS System Voltage

2. DC BUS System Current

3. AC Fail

4. High Voltage

5. Low Voltage.

6. Extra Low Voltage

7. Current limit

8. Rectifier fail

9. Inverter fail

10. Converter fail

11. Breaker fail

12. Fuse fail

13. Low Voltage Disconnect status

14. Battery Discharge Time

15. Battery Charge Current. Open/battery disconnected

16. Circuit breakers throughout the DC BUS System shall be monitored.

2.8.5 Controls

Control functions shall be:

1. Rectifier DC output voltage, adjust.

2. Battery circuit breaker trip.

3. Audible alarm off.

4. Control Enable.

5. Display control.

6. Alarm Reset.

7. Reset system rectifiers.

8. Volt ADJ.

9. Alarm Thresholds.

10. Rectifier on/off.

2.8.6 Self-Diagnostics

1. History Status File: A history status file shall contain all of the information in the present status screens. The control system shall maintain this information in discreet 4 millisecond frames updating memory on a First-In/First-Out basis. This shall provide status recall of a period of at least 252 milliseconds (63 frames); 156 milliseconds before the malfunction fault (30 frames), the fault frame, and 92 milliseconds after the malfunction (23 frames). Each frame shall display four 1 millisecond time period slices with 1 millisecond resolution for output voltage and current.

2. Event History File: The control system shall maintain an event history of the alarm conditions that have occurred during system operation. System memory shall be capable of storing at least 128 events for recall.

2.8.7 Monitoring Capability

DC BUS control circuits shall be capable of interfacing with third party monitoring software.

2.8.7.1 FAA’s Environmental Remote Monitoring (ERMS) via the RS232 port in an open protocol environment. Interface via communication ports shall be built into the DC BUS or included with the DC BUS unit. Ethernet monitoring and direct connect laptop/PC monitoring may use different communications ports, therefore the DC BUS unit shall have both communication ports. The site-monitoring signal processing module shall be built into the system logic. The following shall be available for external monitoring:

1. Metered Values, in paragraph 2.8.3, above.

2. Alarms, in paragraph 2.8.4, above.

2.8.7.2 Vertiv’s UXTM battery monitor will be connected on DC BUS batteries by the DC BUS installer.

2.8.7.2.1 The DC BUS shall be capable of relaying at least two battery alarm conditions remotely from the UXTM via ERMS, which is already installed. The battery conditions include high temperature alarm and high resistance alarm.

2.8.7.2.2 When required by the FAA, the DC BUS installer shall install a communication device, such as the RICI-5000 Gateway, to the UXTM, which will allow the FAA to remotely monitor all UXTM battery measurements.

2.9 DC BUS Rack/Cabinet

Indoor enclosure standard. Optional Outdoor NEMA 3 rated enclosure.

2.9.1 Physical Characteristics.

1. Height - 7ft (84 inches) (optional outdoor enclosure may exceed this)

2. Width (optional outdoor enclosure may exceed this)

a. Inside diameter – 23 inches – mounting hole centerline to centerline

b. Outside diameter 2 ft. sq. footprint excluding battery

3. Material - Steel (optional outdoor enclosure may differ)

4. Channel Rack or Cabinet

5. Designed for Seismic using the latest IBC requirements.

6. All equipment listed in paragraphs 2.9.2 through 2.9.7.4 must fit in one 23 inch rack.

(optional outdoor enclosure must house all equipment but not necessarily in a single 23 inch rack)

7. Underwriters Laboratory (UL) listing for components

2.9.2 AC Wireway, Or enclosed Cabinet.

1. Lugless wiring terminal strip.

2. Terminal strip must accommodate #10 wire or larger as specified by the manufacturer.

3. All interconnect wiring between AC wireway and system components shall be performed by manufacturer.

4. Pre-wire for 4 rectifiers and 2 inverters.

5. All interconnecting system wiring must be properly sized IAW NEC standards.

2.9.3 DC Wire way, Or enclosed Cabinet.

1. Must meet same specifications as AC wireway.

2. Must have an insulated bus bar to accommodate all DC power returns. This bus bar must be insulated from the chassis and include a properly sized bonding jumper up that shall be connected to the designated ground within the cabinet. Must have an isolated ground return bus to accommodate all DC returns.

3. Pre-wire according to # of breakers on distribution panel(s).

4. All interconnecting wiring must be stranded.

5. Must have a ground bus, not a ground stud, to accommodate all returns.

2.9.4 Main System Bus.

1. Isolated 200A rated positive bus

2. Isolated 200A rated negative bus

2.9.5 Distribution Panel(s). Output of rectifier to radios and other DC loads.

1. Rack mounted.

2. Minimum 60 circuit breakers.

a. Forty (40) 10 amp single pole circuit breakers.

b. Two (2) 70 amp circuit breaker(s) for 1000VA inverter(s) – Optional 2000VA inverter will use 120 amp circuit breaker instead.

c. Eighteen (18) additional 10 amp circuit breaker spaces.

3. All breakers

a. Single pole, DC-rated for radios.

b. No instantaneous trip

c. Hydraulic-Magnetic

d. Altitude compensated

e. Temperature compensated

f. Alarming capability

g. Circuit breaker identification card.

4. Interrupting rating:

a. 65V b.5000A

5. System shunt

a. 300 Amp

b. 50mV

2.9.6 Low Voltage Disconnect (LVD)

1. User settable voltage range between 18-24VDC, in 0.1V increments

2. Monitor controlled

2.9.7 DC BUS Rectifiers, Inverters, Converters, and Monitoring/Control panel.

2.9.7.1 Rectifier. At least two for redundancy and ability to supply required output, Rack mounted. Input AC 240 or 208 volt, line-to-line, single phase.

2.9.7.2 Inverter. At least two per system both rack mounted, input 24 volts DC, output 120 volts

AC. One 1000VA with dual receptacle output, the other normally 1000VA with hardwired output.

Optionally the other will be 2000VA with hardwired output

2.9.7.3 Converters. Three each per system. Rack mounted, output 5 amps.

a. 24V to –48V

b. +24V to 12V

c. +24V to –24V

2.9.7.4 Monitoring and Control panel. Rack mounted.

2.9.8 Labeling.

1. Label wires feeding rectifier(s), inverter(s), converter(s), and other LRU items.

2. Label rectifier(s), inverter(s), converter(s), and other LRU items.

3. Voltage hazard warn label, on access doors/panels, where 24, 120, 240, or 208 volts are present; indicate type voltage AC or DC.

4. Conductors, connectors, insulated wires, positive/negative bus bars, and circuit breakers shall be permanently labeled in accordance with paragraphs 3.3.1.4.10.2 and 3.3.3 of

Section J, Attachment J.13, FAA-G-2100H, FAA Electronic Equipment, General

Requirements.

5. Hazardous warning labels shall be adequately posted on the equipment to identify potential risk of electrical shock.

6. Weight warning labels shall be posted on all equipment in excess of 30 lbs.

2.10 Battery String.

2.10.1 Battery Type. Valve Regulated Lead Acid (VRLA) with capacity range from 104 to

2100 Amp-Hours, 24 volt, mounting design that meets the latest IBC requirements, with 20-year design life, front access terminal design; from one of the following battery manufacturers.

1. Exide/GNB, ABSOLYTE GP;

2. Deka, Unigy II;

3. C&D Technologies, msEndur;

4. Power Battery, CV Series

5. Enersys, Powersafe OPzV

6. SBS, VRZ Series

2.10.2 Physical Description

a. Single battery string of twelve (12) 2V VRLA cells (nominal). User shall have access to each cell for inspection and testing.

b. Rack mounted in accordance with battery manufacturer and latest IBC requirements.

c. At the FAA’s option, battery may be substituted with other battery types (flooded, or

NiCd), multiple strings, or multi-cell modules.

2.10.3. Batteries shall conform to the following criteria:

1. Battery Runtime – 4hrs, 24 hrs, 36 hrs, and 72 hrs. Provide a table indicating cabinet/rack model number and runtime in hours for each DC BUS unit at 100% load.

2. Constant Current Discharge Ratings – Each battery model shall have a chart indicating

Amps to 1.75 Final Volts per cell @ 77°F for 4, 24, 36 and 72 hours.

3. Warranty: 7-year full warranty.

4. Case and Cover: Standard.

5. Operating Temperature: Between 600 F and 900 F.

6. Following shall be furnished with the battery string:

a. Batteries.

b. Battery rack.

c. Inter-battery cables/connectors.

d. Tier-to-tier battery cables/connectors.

e. Battery to disconnect breaker cables/connectors.

f. Battery numbering.

g. Battery weight labels for modules and individual removable cells. Weight warning labels shall be posted on all equipment in excess of 30 lbs

h. Steel case construction.

i. Transparent shield, easily removed, covering battery terminals. Transparent shield shall protect against accidental contact on side, top and front of battery terminals, tie bars, and/or connecting cables.

j. Plastic guards of sufficient strength shall be installed over battery terminals and energized bus bars to ensure protection against impact against tool carts, moving equipment, etc.

2.11 Ancillary Equipment.

2.11.1 Test and Maintenance Equipment

1. Vertiv Universal Xplorer Telecom Monitor (UXTM) Battery Monitor. Features as specified in published manufacturer literature and including Laptop for review, setup, real-time data collection, and history (at least 1 year).

2. Cannon 350 Amp Load Bank (L-42-350), with a battery quick disconnect comprised of one male and one female connector appropriately sized for the battery cable. Use

Anderson Power Products SB350 Series connectors, or equivalent. Features as specified in published manufacturer literature.

3. Fluke 189 Digital Volt-Ohm Meter. Features as specified in published manufacturer literature.

4. Fluke 66 Infrared Thermometer, w/NIST/DKD. Features as specified in published manufacturer literature.

2.11.2 Tool Kit. DC BUS and Battery Maintenance tool kit. Insulated tool kit recommended by the vendor for maintenance of the DC BUS and DC BUS batteries. An example of the type tool kit needed is the Cementex, TCK-101 M/S, with metric sockets. The tool kit should contain tools of the non-sparking type equipped with handles listed as insulated for the maximum working voltage; battery venting tool; and non-metallic flashlight for use in explosive gas environments.

2.11.3 Battery Maintenance Lift. Foot operated hydraulic pump platform lift. Steel construction, two lift capacities.

1. Light-Duty Lift. Two wheeled lift with: minimum lift height of 54-inches; platform dimensions approximately 20-inches by 22-inches; lift capacity appropriate to the installed battery; unit weight approximately 69 pounds. WESCO model number MPL-

54-2022 or equivalent.

2. Medium-Duty Lift. Four wheeled lift with: minimum lift height of 54-inches; platform dimensions approximately 22-inches by 22-inches; lift capacity appropriate to the installed battery; unit weight approximately 162 pounds. WESCO model number DPL-

54-2222 or equivalent.

2.11.4 Portable Eyewash Station. An example of the approved portable eyewash station is

Fendall AQ100 with Cartridges model AQ120.

PART 3 EQUIPMENT

3.1 DC BUS Start-Up Service. The DC BUS vendor provides start-up service. The installation contractor is responsible for providing all labor and material to commission the DC BUS system. The start-up service, at a minimum, shall do the following tasks.

1. Record DC BUS unit make/model and serial number for factory warranty documentation.

2. Validate the installation integrity of the DC BUS unit and battery electrical connections.

a. Check facility panel DC BUS circuit breakers;

b. Check Distribution panel main breaker;

c. Check Load bank connections; and

d. Check DC BUS input and output power connections.

3. Perform a full mechanical inspection of the unit.

4. Start DC BUS unit.

5. Configure DC BUS unit’s programmable settings.

a. Reset or verify correct factory programmed settings;

b. Set proper battery charge and float voltages; and

c. Record all DC BUS parameter settings and give this document to FAA.

6. Verify that all operating and monitoring parameters are functioning.

7. Provide at least two (2) hours of DC BUS operator training. Instruct on use of DC BUS control panel and laptop/PC connection and screen menu. Also, provide at least one (1) hour of battery monitor operation training.

8. Remove AC input to DC BUS, simulating a commercial power failure, and then validate the DC BUS and Batteries are operating within their prescribed parameters.

9. Complete DC BUS Start-Up Checklist located in Section J, Attachment J.8.

3.2 Battery Testing

3.2.1 Equipment Requirements. The Contractor shall deliver all equipment and support items necessary to support battery testing.

3.2.2 Test Implementation. The contractor will be responsible for coordinating test implementation activities, perform test procedures, test personnel, briefings, contractor personnel oversight and Contractor Acceptance Inspections (CAI). All contractor personnel shall be trained and experienced in battery system installation, integration, and testing of a battery system. The project shall be under the oversight of an FAA representative (Site POC) designated by the SSC. Air traffic control activity shall have priority over all contractor activities. The project shall not inhibit air traffic operational control or alter the status of the facility’s power system.

3.2.3 Testing. After replacing each battery string, the contractor shall conduct battery tests to verify battery performance in accordance with Original Equipment Manufacturer (OEM) and Institute of Electrical and Electronics Engineers (IEEE) requirements.

After installing the new batteries:

1. Place the battery back in the power system circuit and a float charge overnight at the voltage level required by the OEM. If the OEM requires the battery to be equalized, equalize in accordance with OEM requirements.

2. After the float charge, measure and record the following baseline parameters using calibrated test equipment other than the battery monitor: Evaluate each battery/cell against the calculated average to determine if the cell is within the manufacturers limits.

a. Float Voltage (full charge)

b. Equalize Voltage, if recommended by battery manufacturer

c. Cell internal resistances (reference section 3.2.4)

d. Interconnection resistances (reference section 3.2.4)

e. Intercell connection torque

f. String (open cell) Voltage

g. Individual Cell Voltages (under float)

h. String Current (under float)

i. AC Ripple Voltage

j. AC Ripple Current

k. Temperature of Pilot Cell

l. Ambient Temperature

m. Ground Faults

n. Specific Gravity (flooded cells only), if required

3. Replace any cells that exceed the battery manufacturer’s recommendations. Replace any connections that are out of tolerance (greater than manufacturer’s recommended limits).

Where the battery manufacturer’s recommendations are not available, replace a cell when its internal resistance value exceeds 120% of the average, and clean torque or replace connections that exceed 110% of the average.

4. If flooded cells are replaced, the specific gravity of each cell shall be provided in lieu of the internal resistance of each cell. Replace any cell whose specific gravity is out of tolerance (outside the battery manufacturer’s recommended limits).

5. After recording baseline data on test data sheet provided in Sec-J Attachment J.6 and verifying that baseline data is in accordance with OEM requirements, contractor shall setup test equipment and coordinate with the FAA POC to configure the battery system for either a service test or a full capacity load test (reference section 3.2.5).

6. When performing service tests or load tests, as directed by the program office, the contractor shall utilize the manufacturer constant current discharge sheet and appropriate load bank setup to ensure the battery is not overloaded. Please contact the program office immediately where you suspect service test runtime and load values are too high for the battery model based on battery capacity, site load, charging or other factors.

7. Accomplish the Service Test or the Full Capacity Load Test. Refer to J.6. The Vendor is responsible for reading the procedures and adapting them to each specific install such that the integrity of the safety, the data, and the contract requirements are retained.

Attachment J.15, Excerpt from JO 6980.31A paragraph 5-19 5-18, shall be used for a full capacity load test. JO 6980.31 paragraph 5-54 shall be used for service test. Where the referenced procedure conflicts with contract requirements, the contract requirements shall take precedence.

a. Upon completion of the test, the contractor shall coordinate with the local

FAA to place the battery back into the power system.

b. The battery string will require a recharge period before it will reach 100% capacity.

c. The FAA will ensure that float and equalize charge voltages from the rectifier/charger are adjusted to match the battery manufacturer’s specifications.

3.2.4 Battery Cell Resistance Readings. Resistance measurements shall meet the requirements identified by the battery manufacturer using both a Vertiv (Alber) Cellcorder and a battery monitor (if installed).

3.2.4.1 Vertiv (Alber) Cellcorder. To ensure accuracy of future measurements (as compared to baseline measurement), the contractor shall identify the connection method used in the cellcorder manual

(ex: 3-probe connection, 2-probe connection) associated with each set of resistance measurements taken so that future measurements can be made using the same method. Identify the connection method in the

“Notes” section of the cellcorder report. The contractor shall use the 3-probe method to obtain separate internal and connection readings where connections are readily accessible. Where connections are not readily accessible, the contractor may utilize the 2-probe method. Utilizing the methods outlined in the

OEM instruction manual, take and record the measurements for the internal resistance of all cells within the battery configuration. The Cellcorder readings shall be taken after the battery string has been charge overnight but prior to the discharge (capacity) test.

When taking the battery strap resistance measurements, there will be four data columns. Depending upon the cell number, not all data columns will be filled in. The columns are dependent upon the Strap

Type utilized to make the specific connection.

1. Horizontal Straps

2. Inter-row Vertical Straps

3. Inter-row Angled Vertical Straps

Any strap resistance 20% above the average shall be re-cleaned and re-measured.

The internal resistances of the individual cells may also vary. The variations could be due to:

1. The internal resistance of the individual cells,

2. If the resistance includes the strap resistance,

3. If the resistance includes the inter-tier cable resistance.

All readings should be within +/- 20% of the average internal baseline resistance readings. Readings outside of +/- 20% indicate one of the following:

1. Shorted plates (minus readings),

2. Mismatched interior cables,

3. Improper torque applied to the connections,

4. Bad chemical reaction within the battery.

3.2.4.2 Vertiv UXTM. All monitored readings (including but not limited to charge current, ambient temperature, cell temperature, string voltage, cell voltage, ripple, internal resistance, and strap resistance) shall be taken after the battery string has been charge overnight and immediately prior to the discharge (capacity) test.

3.2.5 Capacity Load Testing, New Battery String. When performing load tests the contractor must utilize the manufacturer constant current discharge sheet and appropriate load bank setup to ensure the battery is not overloaded. Please contact the program office immediately where you suspect load values are too high for the battery model based on battery capacity, site load, charging or other factors.

3.2.5.1 Accomplishing the Full Capacity Load Test. Refer to Attachment J.15, Excerpt from

JO 6980.31A, FAA Load Test Procedure, paragraph 5-19 starting in sub-step b (10) and ending in sub-step b (23) must be used for a full capacity load test. Other portions of JO 6980.31A are not a requirement. Where the referenced procedure conflicts with contract requirements, the contract requirements shall take precedence. Load test may not be designed to run for less than 4 hours and shall be run longer when required by the size of the load bank. References to Appendix O, PPE throughout the procedure shall be disregarded and instead PPE shall be determined and continuously updated using the latest NFPA and industry requirements.

3.2.6 Baseline Readings and Load Testing Data. Upon successful completion of all Baseline and Load Tests, the contractor shall provide soft copies of all manufacturer documents for the DC BUS, the test equipment, and the monitor as well as the CAI Checklist, baseline battery and load test data to the site Environmental Service Unit (ESU) Personnel (1 ea.) and Battery Program Office (1 ea.).