2.23_Uninterruptable_Power_Supply.pdf

2.23 UNINTERRUPTIBLE POWER SUPPLY

A. General This specification describes a continuous duty, three-phase, solid-state, static Uninterruptible Power

System (UPS) hereafter referred to as the UPS. The UPS shall contain a full rated input rectifier / boost converter (hereafter referred to as Input Converter), output inverter, and 10% battery charging circuit. The system shall also contain a continuous duty bypass static switch, internal mechanical bypass, removable hot swap battery plant, and LCD interface display. All of the above system components are housed in a single enclosure. Maintenance bypass and extended battery is required to meet this specification shall be contained in matching enclosures with all interconnecting cabling included. All programming and miscellaneous components for a fully operational system as described in this specification shall be provided as part of the UPS.

B. Standards The UPS shall meet the requirements of the following standards:

IEEE 587-1980/ANSI C62.41 1980 Standards for Surge Withstand Ability.

FCC rules and regulations of Part 15, Subpart J, Class A.

UL listed under 1778, Standards for Uninterruptible Power Supply Equipment.

UL Canada (cUL).

NEMA PE 1 (National Electrical Manufacturers Association) - Uninterruptible Power Systems.

NEMA 250 (National Electrical Manufacturers Association) – Enclosures for Electrical Equipment (1000 Volts Maximum).

IEEE 519-1992 Standard Practices and Requirements for Harmonic Control in Electrical Power Systems NFPA 70 – National Electrical Code.

ISO 9001.

ISO 14001

Occupational Safety & Health Administration (OSHA).

C. Submittals Submittals shall contain the following documentation:

1. Installation Drawings: Indicate electrical characteristics and connection requirements. Provide cabinet dimensions; battery type, size, dimensions, and weight; detailed equipment outlines, weight, and dimensions; location of conduit entry and exit; single-line diagram, control, and external wiring requirements; heat rejection, full and part load efficiencies and air flow requirements.

2. Product Data: Provide catalog sheets and technical data sheets to indicate physical data and electrical performance, electrical characteristics, and connection requirements.

D. Warranty

1. UPS Module: The UPS shall be covered by a full parts and labor warranty from the manufacturer for a period of twelve (12) months from date of acceptance by customer.

2. Battery: The battery manufacturer’s warranty shall be passed through to the final customer and shall have a minimum period of one year.

E. Maintenance, Accessibility and Self Diagnostics

All UPS subassemblies, as well as the battery, shall be accessible from the front. UPS design shall provide maximum reliability and minimum MTTR (mean time to repair). To that end, the UPS shall be equipped with a self-test function to verify correct system operation. The self-test function shall identify the subassembly-requiring repair in the event of a fault. The electronic UPS control and monitoring assembly shall therefore be fully microprocessor based, thus doing away with all potentiometer settings. This shall allow:

Auto-compensation of component drift;

Self-adjustment of replaced subassemblies;

Extensive acquisition of information vital for computer-aided diagnostics (local or remote);

A socket for connection to a computer-aided diagnostics system.

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ELECTRICAL

260000

The UPS shall be repairable by replacing standard subassemblies requiring no adjustments or settings.

Communication with a remote maintenance system shall be possible.

F. System Description and Operation

1. Approved Manufacturer(s): The specified equipment shall be manufactured by American Power

Conversion (APC) or approved manufacturer in compliance with specifications. Liebert or Mitsubishi are approved equals.

2. UPS Design Requirements.

a. Output Power Continuous Rating: The continuous output power rating of the UPS shall be shall be 8KW, 10KVA at a 0.8 lagging power factor.

b. Input Voltage: 208 VAC – 25% / +15%, 3 phase, 4 wire plus ground.

c. Output voltage: 208 VAC 3 phase, 4 wire plus ground.

d. Battery Autonomy: The UPS shall have battery strings such that it shall be capable of operating at full load for 8 minutes at 0.8 PF output at a temperature of 25°C on battery power.

e. Battery Type: Hot swappable valve regulated sealed lead acid (VRLA).

3. AC Input Characteristics.

a. Input Frequency: 60 Hz (- 25% to + 15%)

b. Maximum Input Current at Low Line Voltage: 35 A with 125% continuous overload.

c. Input Power Factor: > .98 lagging for loads greater than 50% and > .95 for loads greater than

15%.

d. Harmonic Distortion of Input Current Wave Form: less than 5% at full load.

e. Power walk-in: Linear 0 to 100% over a 15-second period.

f. Magnetizing Inrush Current: Less than nominal input current for less than one cycle.

4. AC Output Characteristics.

a. Voltage Regulation: + 1.0% for balanced load; + 1.75 for 50% unbalanced load; + 2.5% for

100% unbalanced load

b. Frequency: 60 Hz +1% (or selectable up to 4%). 60 Hz + 0.1% when free running.

c. Voltage Distortion: Maximum 2% total (THD) and 1% any single harmonic on 100% linear loads.

d. Voltage Transient (Step Load) Response:

+ 3% for 50% step load change + 5% for 100% step load change + 1% for loss or return of AC input power or manual transfer at full load.

e. Voltage Recovery Time: Return to within 1% of nominal value within 50 milliseconds.

f. Phase Angle Displacement: 120° + 1° degrees for balanced load; 120° + .3° degrees for 100% unbalanced load

g. Non-Linear Load Capability: Output voltage total harmonic distortion shall be less than 3% when connected to a 100% non-linear load with a crest factor not to exceed 3.0.

h. Slew Rate: 1 Hz/second maximum (or selectable up to 2.0 Hz/sec).

i. Power Factor: 0.8 at the rated volt-amperes (VA)

j. Inverter Overload Capability:

120% of rated load for 1 minute 145% of rated load for 30 seconds

k. Bypass Overload Capability: > 800% for 500 milliseconds, 125% continuous.

l. Overall AC to AC efficiency with fully charged battery 93.5% at full load and 92.5% at 50% load.

5. DC Bus.

a. Normal DC voltage 192VDC.

b. Maximum DC current at cutoff voltage will be 29 A.

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6. Modes of Operation.

The UPS module shall be designed to operate as a double conversion, on-line reverse transfer system in the following modes.

a. Normal: The input converter and output inverter shall operate in an on-line manner to continuously regulate power to the critical load. The input and output converters shall be capable of full battery recharge while simultaneously providing regulated power to the load for all line and load conditions within the range of the UPS specifications.

b. Battery: Upon failure of the AC input source, the critical load shall continue being supplied by the output inverter, which shall derive its power from the battery system. There shall be no interruption in power to the critical load during both transfers to battery operation and retransfers from battery to normal operation.

c. Recharge: Upon restoration of the AC input source, the input converter and output inverter shall simultaneously recharge the battery and provide regulated power to the critical load.

d. Static Bypass: The static bypass shall be used to provide transfer of critical load from the Inverter output to the bypass source. This transfer, along with its retransfer, shall take place with no power interruption to the critical load. In the event of an emergency, this transfer shall be an automatic function.

e. Internal Mechanical Bypass: As a standard feature, the UPS shall be equipped with an internal, make before break, bypass switch. This switch shall mechanically bypass the UPS for times where maintenance is required.

7. Component Description.

a. Rectifier / Battery Charger

The input power converters of the system shall constantly control the power imported from the mains input of the system, to provide the necessary UPS power for precise regulation of the DC bus voltage, battery charging, and Main Inverter regulated output power.:

1. Soft-Start Operation: As a standard feature, the UPS shall contain soft-start functionality, capable of limiting the input current from 0-100% of the nominal input over a default 15 second period, when returning to the AC utility source from battery operation. The change in current over the change in time shall take place in a linear manner throughout the entire operation. (di/dt= constant)

2. Input Current Total Harmonic Distortion: The input current THDI shall be held to 5% or less at full system, while providing conditioned power to the critical load bus, and charging the batteries under steady-state operating conditions. This shall be true while supporting loads of both a linear or non-linear type. This shall be accomplished with no additional filters, magnetic devices, or other components.

3. The input converter shall control and limit the input current draw from utility to 150% of the UPS output. During conditions where input current limit is active, the UPS shall be able to support 100% load, charge batteries at 10% of the UPS output rating, and provide voltage regulation with mains deviation of up to +/-15% of the nominal input voltage

4. Modular Assembly: The rectifier/battery charger assembly shall be constructed of modular design to facilitate rapid maintenance.

5. Charging Levels: The battery charging shall keep the DC bus float voltage of +/- 220v, +/- 1%

6. Battery Charge Current Limit: The UPS shall be capable of limiting the energy sourced from the mains for purposes of battery charging. As a default setting, the battery charge energy will be set to 100% of its nominal value. When signaled by a dry contact, (such as from an emergency generator) the UPS shall be capable of limiting the battery charge energy taken from the mains. This shall take place in user selectable increments of 75%, 50%, 25%, 10% and 0% of the nominal charge power. The selection shall be made from the UPS front panel display/control unit.

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7. Temperature Compensated Charging: The battery charger shall be equipped with a temperature probe to enable temperature compensated charging and adjust the battery float voltage to compensate for the ambient temperature using a negative temperature coefficient of 3 mV per cell per degree Celsius at a nominal temperature of 25°C.

8. Capacity: The rectifier/battery charger shall have sufficient capacity to support a fully loaded inverter and fully recharge the battery to 95% of its full capacity within 6-8 hours.

b. Inverter.

The UPS output shall be derived from a Pulse Width Modulated (PWM) IGBT inverter design.

The inverter shall be capable of providing the specified precise output power characteristics (specified in section 2.2.C) while operating over the battery voltage range. The inverter assembly shall be constructed as a modular assembly to facilitate rapid maintenance.

c. Static Bypass.

As part of the UPS, a system static bypass switch shall be provided. The system static bypass shall provide no break transfer of the critical load from the Inverter output to the static bypass input source during times where maintenance is required, or the inverter can not support the critical bus. Such times may be due to prolonged or severe overloads, or UPS failure.

8. Uninterrupted Transfer: The static bypass transfer switch shall automatically cause the bypass source to assume the critical load without interruption after the logic senses one of the following conditions:

a. Inverter overload exceeds unit's rating.

b. Battery protection period expired and bypass current is available.

c. Inverter failure.

9. Interrupted Transfer: If the bypass source is beyond the conditions stated below, the UPS will make an interrupted transfer (not less than 500 msec. in duration).

a. Bypass voltage greater than + 10%, -10% from the UPS rated output voltage.

b. Bypass frequency greater than + 2 Hz from the UPS rated output frequency.

10. Automatic Uninterrupted Forward Transfer: The static bypass transfer switch shall automatically forward transfer power from the bypass to the rectifier / inverter, without interruption, after the UPS inverter is turned "ON", after an instantaneous overload-induced reverse transfer has occurred and the load current returns the UPSs nominal rating or less.

11. Manual Transfer: A manual static transfer shall be initiated from the UPS Control Panel by turning the UPS inverter off.

12. Overload Ratings: The static bypass transfer switch shall have the following overload characteristics after which time a thermal protection device will engage to protect the static bypass.

a. 800% of UPS output rating for 0.5 seconds (one cycle).

b. 150% for 30 seconds.

c. 125% of UPS output rating continuous.

13. Microprocessor Controlled Logic.

The full UPS operation shall be provided through the use of microprocessor controlled logic. All operation and parameters are firmware controlled, thus eliminating the need for manual adjustments or potentiometers. The logic shall include a self-test and diagnostic circuitry such that a fault can be isolated down to the printed circuit assembly or plug-in power assembly level. Every printed circuit assembly or plug-in power assembly shall be monitored. Diagnostics shall be performed via a PC through the local diagnostics port on the UPS.

14. Standard Communication Panel.

The UPS will include a standard easy to use communication panel. Included will be a backlit, color graphic animated LCD display, LED’s and audible indicators for UPS On line, UPS fault, UPS on battery and UPS off line. The UPS communication panel will include UPS “ON” and UPS “OFF” pushbuttons that will permit the user to safely command the UPS on or off without risk of load loss.

G. System Controls and Indicators

1. Display Unit: A microprocessor controlled display unit shall be located on the front of the system.

The display shall consist of an alphanumeric display with backlight, an alarm LED, and a keypad consisting of pushbutton switches. The following metered data, shall be available on the alphanumeric display:

Measurements, status indications and events.

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Bar-graphs and waveforms of the measured values.

Personalization menu protected by a password, used to make specific settings.

Event log with time stamping.

Access to all measurements.

System Parameters Monitored (data displayed): The visual display will display the following system parameters based on true RMS metering:

Measurements:

Year, Month, Day, Hour, Minute, Second of occurring events.

Source Input Voltage Input Frequency Output AC voltage Output AC current

Status indications and events:

Static bypass switch on EPO Active Mechanical bypass activated External bypass switch (Q3) activated Battery discharged Return from low battery Low battery Load not powered from UPS UPS in bypass Runtime calibration aborted Runtime calibration started Runtime calibration complete Battery self test aborted Battery self test started Battery self test completed Number of battery modules decreased Number of battery modules increased Fan fault SBS fault System not in sync.

Bypass not available, frequency/voltage out of range Mains voltage/frequency out of range Site wiring fault Low battery voltage shut down Defective battery detected Runtime is below alarm threshold Load is above alarm threshold Battery over-voltage warning Battery over-temperature warning Emergency power supply fault Output overloaded

Display of operating curves: The graphical display shall be capable of displaying curves and bar graphs of the above-mentioned measured values for significant periods.

Time-stamped historical events: This function shall time-stamp and store all important status changes, anomalies and faults and make this information available for automatic or user-requested consultation; it shall interpret the events and indicate remedial measures if applicable.

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2. Controls: The following controls or programming functions shall be accomplished by use of the display unit. Pushbutton membrane switches shall facilitate these operations.

Silence audible Alarm Set the alphanumeric display language Display or set the date and time Enable or disable the automatic restart feature Transfer critical load to and from static bypass Test battery condition on demand Set intervals for automatic battery tests Adjust set points for different alarms Program the parameters for remote shutdown.

3. Front Panel Interface: The following shall make up the UPS front panel user interface.

Load On When Green, this LED indicates the load is being supported by the UPS output

On Battery When Yellow, this LED indicates the UPS is running from Battery power

Bypass When Yellow, this LED indicates the load is being supported by static bypass/mechanical bypass Bypass When Yellow, this LED indicates the load is being supported by static bypass/mechanical bypass

4. Push Button User Controls

Up Arrow Down Arrow Help Key Escape Key Enter Key

5. Emergency Power Off (EPO): The UPS shall be equipped with a local emergency power off button and dry contact input that can be used to command UPS shut down remotely. Activation of this command shall lead to the following actions:

inverter shutdown opening of the static bypass switch and the battery circuit breaker opening of an isolated dry contact on the programmable relay board

6. RJ-45 Interface port for remote communications with a network via web browser or SNMP, or APC InfraStruXure Manager.

7. Dry Contacts: The UPS shall be provided standard with a programmable input/output relay board.

This board shall have 8 dry contacts, i.e. 6 for input signals and 2 for output signals. Contacts shall be programmed as:

Low battery Load on battery power Load on automatic bypass Load on UPS Common Fault UPS Off

The contacts will be programmable normally open or normally off and will change state to indicate the operating status. The contacts will be rated at 2.0 A (250 VDC / 30 VDC).

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H. Mechanical Design and Ventilation

1. Enclosure: The UPS shall be housed in a freestanding enclosure with dead front construction. The mechanical structure of the UPS shall be sufficiently strong and rigid to withstand handling and installation operations without risk. Access to UPS subassemblies shall be through the front or top.

The sheet-metal elements in the structure shall be protected against corrosion by a suitable treatment, such as zinc electroplating, bichromating, epoxy paint or an equivalent.

2. Cable Access: The standard UPS shall accommodate top or bottom entry cables.

3. Cabinet Weights and Dimensions: The width of the UPS System is 32.8 (in Inches) and has an approximate weight of 1050 lbs.

4. Ventilation and Heat Rejection: The UPS shall be designed for forced air-cooling. Air inlets shall be provided from the front bottom of the UPS enclosure. Air exhaust shall be from the top rear portion of the unit. Full load heat rejection is 4777 BTU /hour.

I. Battery

1. The UPS battery shall be of modular construction made up of user replaceable, hot swappable, fused, battery modules. Each battery module shall be monitored to determine the highest battery unit temperature for use by the UPS battery diagnostic, and temperature compensated charger circuitry.

2. The battery jars housed within each removable battery module shall be of the Valve Regulated Lead Acid (VRLA) type.

3. The UPS shall incorporate a battery management system to continuously monitor the health of each removable battery module. This system shall notify the user in the event that a failed or weak battery module is found.

J. Accessories

1. External Control and Communications Devices

The following control and communications devices shall be provided in the UPS module.

2. Network Adaptor:

The Ethernet Web/SNMP Adaptor shall allow one or more network management systems (NMS) to monitor and manage the UPS in TCP/IP network environments. The management information base (MIB) shall be provided in DOS and UNIX "tar" formats. The SNMP interface adaptor shall be connected to the UPS via the RS232 serial port on the standard communication interface board.

The UPS, in conjunction with a network interface card, shall be capable of gracefully shutting down one or more operating systems during when the UPS is on reserve mode.

The UPS shall also be capable of using an RS232 port to communicate by means of serial communications to gracefully shut down one or more operating systems during an on battery situation.

3. Remote UPS Monitoring

The following three methods of remote UPS monitoring shall be available:

Web Monitoring: Remote monitoring shall be available via a web browser such as Internet Explorer.

RS232 Monitoring: Remote UPS monitoring shall be possible via either RS232 or contact closure signals from the UPS.

Simple Network Management Protocol (SNMP): Remote UPS Monitoring shall be possible through a standard MIB II compliant platform.

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K. Factory Assisted Start-Up

Factory trained service personnel shall perform the following inspections, test procedures, and on-site training:

1. Visual Inspection:

Inspect equipment for signs of damage.

Verify installation per manufacturer’s instructions.

Inspect cabinets for foreign objects.

Inspect Battery Units.

Inspect Power Module(s).

2. Mechanical Inspection:

Check all UPS and external maintenance bypass cabinet internal power wiring connections.

Check all UPS and external maintenance bypass cabinet terminal screws, nuts, and/or spade lugs for tightness.

3. Electrical Inspection:

Verify correct input and bypass voltage.

Verify correct phase rotation of all mains connections.

Verify correct UPS control wiring and terminations.

Verify voltage of all battery modules.

Verify neutral and ground conductors are properly landed.

4. Site Testing:

Ensure proper system start-up.

Verify proper firmware control functions.

Verify proper firmware bypass operation.

Verify proper maintenance bypass switch operation.

Verify system set points.

Verify proper inverter operation and regulation circuits.

Simulate utility power failure.

Verify proper charger operation.

Document, sign, and date all test results.

5. On-Site Operational Training: During the factory assisted start-up, operational training for site personnel shall include key pad operation, LED indicators, start-up and shutdown procedures, maintenance bypass and AC disconnect operation and alarm information.

L. Field Quality Control & Service Organization

1. Field Service Engineer Qualifications

The manufacturer must employ a 7 X 24 nation wide field service organization with rapid access to all regions of the nation. The responding service professionals must be factory-trained engineers with an accredited and proven competence to service three phase UPS systems.

2. Spare Parts

Field Engineers must have immediate access to recommended spare parts with additional parts storage located in regional depots. Additional spare parts shall be accessible on a 7 x 24 basis from the national depot and must be expedited on a next available flight basis or via direct courier (whichever mode is quickest).

3. Maintenance Training

The manufacturer shall make available to the customer various levels of training ranging from basic

UPS operation to UPS maintenance.

M. Owner Training: Provide four (4) hours of Owner training after system start up.

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