Attachment J.06 DC BUS Battery Test and Appendix.pdf
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- Attached to
- Direct Current Back-Up System (DC BUS) Power Supply Federal contract opportunity
- Solicitation number
- 693KA8-20-R-00008
About this file
This document includes technical specifications for testing direct current backup systems (DC BUS) and associated batteries as part of a federal contract opportunity. The Federal Aviation Administration is seeking life cycle support services for DC BUS power supplies to provide uninterruptible power to critical air traffic equipment. Offerors must comply with submission instructions by March 10, 2020. Questions are due by this date as well, with answers to be posted by March 18th. Proposals are due March 27th. The contract will have a two-year base period and four two-year option periods, for a potential ten-year term. The specifications describe required tests for DC BUS units, batteries, system operation, and load performance. Test procedures, equipment, recording parameters, and pass/fail criteria are defined.
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Text version
9/23/19
ATTACHMENT J.6 DC BUS INSTALLATION TEST
The DC BUS installation contractor shall perform all DC BUS system tests, including batteries, and disconnecting devices as needed to certify the proper operation of the system as a whole.
1. DC BUS start-up must be completed before beginning system test. See Section J, Attachment J.1 Paragraph 3.1.
2. The DC Bus installation Contractor shall provide all testing and monitoring equipment required to conduct site test.
3. The Installing Contractor shall provide electricians for site test, as needed.
4. Load banks and load bank cables as required for site testing shall be provided and operated by the Installing Contractor.
1.0 DC BUS Test
1.1 DC BUS Unit
a. DC BUS Data
1) Make: Model:
2) Serial #: kVA: kW:
b. Battery Data
1) Make: Model:
2) # of Strings: Jars/string: Cells/Jar: Float/Cell:
1.2 Heat Run.
Operate the entire system continuously for four (4) hours at full load. Record: rectifier output voltage, current; Inverter output voltage, current and frequency at one hour time intervals to verify stability of the DC BUS output. Also monitor and record the room temperature throughout the heat run. After 4-hours, perform an infrared scan of DC BUS module, DC BUS input and output breaker(s), and DC BUS battery connections. During the Heat Run verify that all operating controls, alarms, meters and mimic lights are functioning properly.
1.3 Steady-State Test
1. Connect the multi-functional Power Quality Meter (PQM) to the input of the DC BUS to be tested.
2. Record the input voltage, current, power, Power Factor, and Total Harmonic Distortion
(THD) (voltage and current distortion). Record, on the data sheets, the input voltage and current readings from the PQM recorder and from the DC BUS display panel at the following load levels:
a) 100% load.
b) 50% load.
c) No load (0% load).
3. Connect the PQM recorder to the 24 volt DC bus, output of the rectifier(s).
4. Record DC bus output voltage, current, power. Record, output voltage and current readings from the PQM recorder and from the DC BUS display panel at the following load levels:
a) 100% load.
b) 50% load.
c) No load (0% load).
1.4 Transient Load Tests
1. Connect the PQM waveform recorder to the 24 volt DC bus, output of the rectifier(s).
2. Recovery shall meet or exceed the vendor’s declared recovery time and steady state value.
SIR 693KA8-20-R-00008
ATTACHMENT J.6 DC BUS INSTALLATION TEST
3. Record the following load step transients with the waveform recorder:
a) 0% - 50% - 0%.
b) 0% - 100% - 0%.
2.0 System Battery Test: The objective of this test is to verify the compatibility of the batteries with the associated DC BUS and to verify the full load operation of each unit for the reserve time specified.
1. Prior to the start of the test, the battery shall be floated at the required voltage for the time specified by the battery vendor. Measure and record the resistance of all inter-cell and inter-tier connections using a micro-ohmmeter.
2. DC BUS is tested using Installation Contractor supplied loads and load bank(s). The 100% linear load is distributed as follows: One inverter connected without a load, second inverter output load at 800 Watts; remaining load is 24 volt DC from distribution panel.
3. After successfully battery load test, recharge batteries of system to 95% capacity, after which time perform full load test or service test as specified by the FAA using the appropriate procedure located in Attachment J.1, Section 3.2.
4. Close DC BUS AC input circuit breaker. Upon successful completion of the battery tests and after the batteries have a chance to reach their normal charge and temperature, take a full set of cell voltage readings.
5. After completion of discharge testing, torque connections varying by more than ±10% of average voltage.
6. Compare the battery discharge test data with the battery manufactures battery charts. Note any differences.
3.0 Complete battery data and checklist, Sheets 1 and 2, found in Appendix 1 to Section J, Attachment J.6.
APPENDIX TO ATTACHMENT J.6 DC BUS INSTALLATION TEST
Note & Record All battery Manufacturer Data on Battery Load Test Data Sheet (next tab)
Check for Cell Cracks or Electrolyte Leakage on Flooded Cells.
Check for Corrosion & Post Seal Integrity.
Check integrity of Battery Racks.
Check and Record Ambient Temperature and Ventilation.
Obtain initial Cell Corder data of battery string(s).
Measure and record total battery system (string) voltage.
Measure and record individual cell voltages.
Perform Internal Cell Resistance and Intercell Resistance Tests.
Provide hard copy of Cell Corder data.
Disconnect battery string to be tested using installed disconnect device or by disconnecting the negative cable connection and insulating.
Connect Load Bank to Battery Quick Disconnect
Initiate Load (Capacity) Test for 4 hours of testing, at the Battery
Manufacturer's recommended Load to 1.75 VPC. For battery designs with loads exceeding the 4-hour test value, a 6-hour test must be performed.
Record discharge data on Battery Load Test Data Sheet Record measured capacity (in %) on Battery Load Test Data Sheet
After at least 12-hours of recharge, initiate off-line recharge of tested string.
Upon completion of charge, place string back on-line. Record any battery problems in "Notes" section of Battery Load Test Data Sheet.
Battery Load Test and Baseline ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments ok See Comments
ATTACHMENT J.6 APPENDIX 1 - DC BUS INSTALLATION TEST
Customer :
Site :
City: State:
Contact: On Site Date:
Battery Manufacturer Battery Model Battery AH Battery String Site Reserve Time
Installers 1).
2).
3).
4).
SERIAL
AS
RECEIVED
CELL
VOLTAGE
(OPEN
CIRCUIT)
CELL
VOLTAGE
UNDER
LOAD
(START
OF TEST)
CELL
VOLTAGE
AFTER
RECHARGE
CELL TEMP.
(NEG. POST
OF CELL)
BATTERY ON DISCHARGE (MINUTES)
CELL
NO. 0
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
Cell 1
Pa ge
Y es o r N o
Cell 2 Cell 3 Cell 4 Cell 5 Cell 6 Cell 7 Cell 8 Cell 9
Cell 10 Cell 11 Cell 12
C on tin ue d N ex t
Total Batt Voltage
Amb. Temp
Test Amps
% Capacity (Tested)
NOTES:
ATTACHMENT J.6 APPENDIX 1 - DC BUS INSTALLATION TEST
SERIAL
AS
RECEIVED
CELL
VOLTAGE
(OPEN
CIRCUIT)
CELL
VOLTAGE
UNDER
LOAD
(START
OF TEST)
CELL
VOLTAGE
AFTER
RECHARGE
CELL TEMP.
(NEG. POST
OF CELL)
BATTERY ON DISCHARGE (MINUTES)
CELL
NO. __
Cell __
Pa ge
Y es o r N o
Cell __ Cell __ Cell __ Cell __ Cell __ Cell __ Cell __ Cell __ Cell __ Cell __ Cell __
C on tin ue d N ex t
Total Batt Voltage
Amb. Temp
Test Amps
% Capacity (Tested)
NOTES:
| Attachment J.6 |
| Battery Test Appendix 1 Attachment J.6 |
| Attachment J.6 Appendix 1 |
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