Appendix_Bolt_On_UPS_Cabinet_Assembly_with_Inverter_Charger_and_Battery_Bank.pdf

DDOT bolt on UPS cabinet assembly Specification 6/19/14 Page 1 of 12

District of Columbia Department of Transportation

BOLT ON UPS CABINET ASSEMBLY

WITH INVERTER CHARGER AND BATTERY BANK

GENERAL

This specification establishes the minimum requirements for a complete emergency battery backup system for use with Light Emitting Diode (LED) Traffic Signal Modules. The Battery Backup System (BBS) shall include, but not be limited to the following: Inverter/Charger, batteries, combination power transfer relay and manual bypass switch and all necessary hardware and interconnect wiring. The BBS shall provide reliable emergency power to a traffic signal system (Vehicle and Pedestrian Traffic) in the event of a power failure or interruption.

The BBS shall be capable of providing power for full run-time operation for an “LED-only” intersection (all colors: red, yellow, green and pedestrian heads), an intersection with only yellow and/or pedestrian incandescent bulbs or flashing mode operation for an intersection using Red LED’s.

1. The contractor shall supply UPS systems that meet the following performance specifications:

UPS system shall be DDOT version of The Dimensions brand model 24M11-WBE bolt on unit, offered by Sensata Technologies, or approved equal.

UPS shall include the DDOT approved version of :

Dimensions brand independent power panel and transfer switch.

2. OPERATION

1.1.1.1.1. Compatibility

BBS shall be compatible with The District Department of Transportation's 336S and 336 Super stretch traffic controller cabinet, Model 170E Controllers, Model 2070 Controllers and cabinet components for full time operation.

1.1.1.1.2. Run-Time

The BBS shall provide a minimum six (6) hours of full run-time operation for an “LED-only” intersection (minimum 700W/1000VA active output capacity, with 80% minimum inverter efficiency).

1.1.1.1.3. Output Capacity

The BBS shall be able to provide a minimum of 1100W @ +25ºC, continuous active output capacity, with 80% minimum inverter efficiency while running in Backup Mode (on batteries). The BBS shall be able to provide 850W @ +74ºC, continuous active output capacity.

1.1.1.1.4. Output Voltage

When utilizing battery power, the BBS output voltage shall be between 110 VAC and 125 VAC, pure sine wave output, ≤ 3% THD, 60Hz ± 0.05Hz.

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1.1.1.1.5. DC System Voltage

The BBS DC system voltage shall be 24 Vdc.

1.1.1.1.6. Transfer Time

The maximum transfer time allowed, from disruption of normal utility line voltage to stabilized inverter line voltage from batteries shall be 40 milliseconds.

The same maximum allowable transfer time shall also apply when switching from inverter line voltage to utility line voltage.

1.1.1.1.7. Operating Temperature

Operating temperature for the inverter/charger, and power transfer relay and manual bypass switch shall be –40 °C to +74 °C.

1.1.1.1.8. AC Feedback

BBS shall be equipped to prevent a malfunction feedback to the cabinet or from feeding back to the utility service.

1.1.1.1.9. Surge Protection

The BBS shall have lightning surge protection compliant with IEEE/ANSI C.62.41.

1.1.1.1.10. Power & Control Connections

The BBS shall be easily replaced by having easily removable AC input and output cables. The DC input connection shall be a one piece Anderson type connector. The external transfer relay control and battery temperature compensation cables shall be a quick release connector. The AC, DC, external transfer relay, and battery temperature compensation cables shall be removable without the use of a screwdriver.

1.1.1.1.11. AC Connection

The AC input and output shall be separate panel mounted plug / receptacles that allow no possibility of accidental exposure to dangerous voltages (male receptacle for AC Input and female receptacle for AC Output). The receptacles shall utilize some form of locking mechanism or hold down clamps in order to prevent accidental disconnects.

1.1.1.1.12. DC Connection

The DC connection shall be a recessed one piece Red Anderson style receptacle.

1.1.1.1.13. Relay / Temperature Probe Connection

The external power transfer relay control and battery temperature sense inputs shall be heavy duty panel mounted connectors. The temperature probe must have a lug for attaching the sensor to the battery.

1.1.1.1.14. General Connections

All connections shall provide mechanically and electrically secure connections without the use of a screwdriver. The only exception will be the 18-position Relay Terminal Block which shall require a small screwdriver for holding down the relay wires.

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1.1.1.1.15. Unit Failure

In the event of inverter/charger failure, battery failure or complete battery discharge, the power transfer relay shall revert to the NC (and de-energized) state, where utility line power is connected to the cabinet.

1.1.1.1.16. Overload

The Battery Backup System must be able to shutdown to protect against internal damage in the event of an overload at its’ output.

3. Functionality, Displays, and Controls

1.1.1.1.17. Standby Type System

There shall be two, user adjustable transfer point set types if the user wanted to use the BBS as a “Standby” type system instead of the default “Buck/Boost or Line Interactive” type system. The user will be able to select either “Normal” or “Generator” transfer points. The user will be able to set the low and the high cutoff transfer points which are adjustable between 89 and 135 AC volts. The BBS will automatically apply the 5 volt difference for the return transfer points.

1.1.1 If the BBS is configured to use these adjustable transfer points, the BBS shall bypass the utility line power whenever the utility line voltage is outside of the set transfer points (± 2VAC).

1.1.2 In cases of low (below the set low cutoff point) or absent utility line power, when the utility line power has been restored at or above 5 VAC ± 2 VAC of the set low cutoff point for more than 30 seconds (or the user configured line qualify time), the BBS shall transfer from battery backed inverter mode back to utility line mode.

1.1.3 In cases of high (above the set high cutoff point) utility line power, when the utility line power has been restored at or below 5 VAC ± 2 VAC of the set high cutoff point for more than 30 seconds (or the user configured line qualify time), the BBS shall transfer from battery backed inverter mode back to utility line mode.

1.1.1.1.18. Buck/Boost or Line Interactive Type System

The BBS shall be line interactive by default, and have a Buck/Boost function or mode of operation. The Buck/Boost shall have a range of 80-160Vac. There are not to be any user configurable transfer point settings for the Buck/Boost function. With Buck/Boost selected as the sense type, the output to the signal system will be regulated to voltages between 102-130 Vac.

1.1.1.1.19. Buck Boost Counters and Run Time

There will be a Buck and Boost event counter and run time meter accessible through the LCD and Ethernet. Buck and Boost events will be recorded separately from each other. The counter and run time meter will show the cumulated information since the last reset.

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1.1.1.1.20. Line Qualify Time

The BBS will have an adjustable line qualify time. The range will be from 1 to 60 seconds, in 1 second increments. The factory default setting will be 30 seconds.

1.1.1.1.21. LCD Display

The BBS shall have a 4 line by 20 character backlit LCD display. The main screen shall indicate information regarding; transfer points, transfer point type, time of day status, utility input voltage, charger on/off status, battery percent of charge, battery voltage, BBS Mode, a scrolling line of text (which automatically lists any faults, alarms and relay status information), inverter event counter and run time meter. The run time meter shall indicate run time in hours and minutes.

The display shall be temperature compensated and have a user selectable contrast adjustment by pressing “Enter” at the main screen.

1.1.1.1.22. Keypad

The BBS shall have a 4-way navigational keypad so that the user can navigate the menu system by using “↑”, “↓”, “←”, “→”, “Enter”, and “Esc” keys. There shall also be an “Inv” key to turn the inverter on or off.

1.1.1.1.23. Status LED’s

The BBS shall have three status LED’s.

1.1.4 Green LED “Output” – This is to be on any time the BBS is providing output for either backup, buck, or boost modes.

1.1.5 Red LED “Fault” – This is to be on any time there are any faults in the system.

1.1.6 Yellow LED “Alarm” – This is to be on anytime there are alarms on the system.

1.1.1.1.24. Charger

The BBS shall have an integral charger. The charger shall be a 4 step charger (zero-volt start, bulk, accept, and float).

1.1.7 The charger shall have the capability of providing the charge current required by the battery up to 20 amps DC.

1.1.8 The user shall be able to select either “gel” or “AGM” type batteries. The default setting is for AGM.

1.1.9 The BBS shall use a temperature-compensated battery charging system. The charging system shall compensate over a range of 2.5 – 4.0 mV/ °C per cell.

1.1.10 The temperature sensor shall be external to the inverter/charger unit. The temperature sensor shall come with 2 meters (6’6”) of wire and have a lug at the end for termination to the negative post of a battery for the best temperature measurement.

1.1.11 Batteries shall not be recharged when battery temperature exceeds 50 °C ± 3 °C.

1.1.12 Recharge time for the battery, from “protective low-cutoff” to 80% or more of full battery charge capacity, shall not exceed ten (10) hours.

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1.1.1.1.25. Backup Counter and Run time

The BBS shall include a front-panel event counter display to indicate the number of times the BBS was in Backup, Buck, and Boost modes; and a front-panel hour meter to display the total number of hours and/or minutes the unit has operated in those modes since last reset. The run time shall be displayed in HHH:MM format. All meters shall be re-settable. The information displayed shall be cumulative since last reset.

1.1.1.1.26. Event Log

There shall be an event log that is 256 lines in length. Data shall be recorded in a FIFO format so that the oldest record is purged as the newest is entered. The event log shall date and time stamp all events. Each event that is recorded will also show the operating mode of the BBS before the event (Standby, Backup, Buck, and Boost).

1.1.1.1.27. Dry Relay Contacts

The BBS shall provide the user with 6 programmable dry relay contacts. These dry relay contacts shall be rated for 3 amps @ 125 Vac. Each relay can be programmed to trigger by more than one condition simultaneously. If any relay is energized, it will show up on the main screen of the LCD, Ethernet web browser, and the RS-232 menu. The programming options are as follows:

4. On Battery

5. Low Battery

6. Timer

7. Time of Day

8. Alarm

9. Fault

10. BBS Failure

11. Off

1.1.13 The relay contact terminal blocks shall conform to On-Shore Technology, type ED2200/22, or Phoenix Contact type FRONT 2,5-H/SA 5, or WECO type 180- A-111, or equivalent. The spacing between each terminal shall be 0.197” (5mm), with the hold-down screw and wire entrance both on the same face, facing forward and in the horizontal axis.

1.1.1.1.28. Timer Relay Contacts

The BBS shall have a timer that will energize the dry contact relays (that are configured for “Timer”) after the user configured time has elapsed. This timer is started when the BBS is in Backup mode. The user can configure the timer from 0 to 480 minutes, in 1 minute increments. The factory default setting is at 120 minutes.

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1.1.1.1.29. Low Battery Relay Contacts

The BBS shall have an adjustable low battery relay setting. This setting shall be adjustable so that the user can set the point at which the low battery relay energizes. This setting applies to any dry contact relay that is configured for “Low Battery”. This setting is adjustable from 0 to 100% of remaining usable battery capacity in 5% increments. This setting must be in percent. The factory default setting is 40%.

1.1.1.1.30. Battery Voltage Test Points

The BBS shall include a LCD display to indicate battery voltage and standard meter probe input jacks (+) and (-) to read the battery voltage externally.

1.1.1.1.31. Circuit Breakers

The BBS shall be equipped with Input and Output AC circuit breakers. The BBS shall also have a DC input circuit breaker.

1.1.1.1.32. Time of Day Program

The BBS shall be equipped with a Time Of Day (TOD) program. The user can set the beginning and the end time of the TOD program. The user can also “Enable” and “Disable” the program. Operation is such that if the program is enabled and the BBS goes to Backup mode, the TOD program will energize any dry contact relays that are programmed for TOD. If the BBS is still in Backup mode and the TOD program has expired, any relay that was energized by the TOD program will de-energize when the TOD program expires.

1.1.1.1.33. Keypad Password Protection

The BBS Configuration and System menus (on LCD) shall be password protected with a 6 digit alphanumeric password. The password feature can be disabled by the user in the System menu. This feature by default is disabled.

1.1.1.1.34. Web Browser Password Protection

The web browser shall be password protected and require a user ID and a password. This feature by default is disabled.

1.1.1.1.35. Bypass Switch

The manual bypass switch module and power transfer relay shall be rated at 240VAC/30 amps.

12. Communications

1.1.1.1.36. The UPS must be the capability to provide Ethernet and IP addressing communications for inclusion in systems with the capability for remote monitoring and programming. This capability must be provided internal to the unit. As an interim solution; UPS system must also be capable of serial communications via DDOT existing 170 controllers through available spare hardware port.

1.1.14 UPS supplier must comply with communications protocols currently used by DDOT QUICNET© system.

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1.1.1.1.37. User Configuration, System, and Status Menus

All BBS Configuration, System, and Status menus shall be accessible and programmable from the RS-232 port and from the Ethernet port. Additionally, all log files shall be available through these ports.

1.1.1.1.38. RS-232

The BBS shall have RS-232 communications. The communications port shall be an EIA-232 (DB9-Female) connector.

1.1.15 The data transmission rate shall be user adjustable between 300 and 115200 baud.

1.1.1.1.39. Ethernet

The BBS shall have an Ethernet port as standard. The Ethernet port shall be an RJ45, EIA 568B pin out type connector. The data rate shall be 100mbps.

1.1.16 The BBS shall have an embedded web server.

1.1.17 The Ethernet port shall have user configurable IP, subnet mask, and gateway.

1.1.18 The firmware and web pages for the BBS shall be upgradeable through the Ethernet port using a Java applet. The applet shall have:

12.1.1.1.1. User input box for the IP address of the system that is to be upgraded.

12.1.1.2. “Connect” button to initiate communication to the BBS which reports current Model Number, Serial Number, MAC Address, System DC Voltage, and Firmware & Web page version levels.

12.1.1.3. “Update” button that when clicked automatically updates the BBS firmware and web pages on the BBS without the user having to select files for uploading.

12.1.1.4. Two progress bars that show that the web pages file and firmware file are being uploaded. At the end of the update the applet shall state to the user “All Operations Complete.”

1.1.1.1.40. Web Pages

12.1.2. Shall have a header area that shows location, date, time, firmware version, BBS Mode, quick status updates of alarms –faults –and relay status. This header is to be on every web page.

12.1.3. Shall have a Configuration page that allows for configuration of; sense type, transfer points (normal and generator), line qualify time, Time of Day program, self test, low battery relay in percent, timer relay, and dry relay contacts

12.1.4. Shall have a Status page that shows the current settings of; sense type, transfer points, line qualify time, Time of Day program, self test, and dry relay contacts

12.1.5. Shall have a System page to configure; location, date, time, password, user ID, IP address, sub-net mask, and gateway address

12.1.6. Shall have an email page to configure which events trigger an email. It also shall allow input of up to 6 email addresses

12.1.7. Shall have a 256 line event log (FIFO). The event log shall be able to be printed from the web browser. The event log shall be able to be saved as an htm file. The event log shall also be able to be copied and pasted into an excel spreadsheet.

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13.

14.

C.5.1.6.23 Power: The AC power interface must be an independent panel design meeting the following minimum requirements.

C.5.1.6.24 The Independent Panel Design must be used primarily for existing cabinets being retrofitted with UPS systems. This panel must be mounted in close proximity to the existing power interface and must provide the following: a 50A 120VAC single phase electrical service interface must be required at the direction of the engineer to support relocation of incoming utility service wiring to the new panel power-in terminal strip with a properly rated circuit breaker to control the utility power state, a surge suppressor to protect the UPS, the wiring to the Manual Bypass Switch must be integrated into this panel for incoming AC Power such that all wires are accessible within this panel on identified terminal stripes that will allow for the maintenance of the equipment using only standard hand tools.

The output AC power from the Manual Bypass Switch shall be terminated on the original incoming utility power service terminals. The panel shall be covered with plexi-glass or other approved material to minimize the risk of electrical hazards.

C.5.1.6.25 Status/Alarms: The Status/Alarms outputs of the UPS must be interfaced into the traffic controller through appropriately defined status inputs to report the conditions required above. Logic Common from the traffic controller must be provided to the common side of the status/alarm terminations and the status/alarm output must be returned to the controller.

C.5.1.6.25.1 UPS assembly must include appropriate terminations and relays to facilitate connection of existing PHOTO ENFORCEMENT EQUIPMENT.

C.5.1.6.25.2 Photo enforcement equipment must be connected in a matter that will not provide power from the UPS system when UPS system is in operation and in standby mode (photo enforcement equipment must be connected to always draw from PEPCO feed, and must not operate when intersection is on battery power).

C.5.1.6.25.3 Procedures: When installing UPS at an existing traffic signal controller cabinet location, the Contractor shall notify the Agency Engineer a minimum of five days prior to beginning work. The traffic signal must not be disconnected from utility unless a representative of the DDOT representative is present and then only during the time of day and day of week designated by the DDOT representative .

C.5.1.6.25.4 Warranty: The UPS, in its entirety, must be warranted for two years from the date of installation against defective material and workmanship. Batteries warranty must be a minimum of 3 years and must not be prorated during the warranty period.

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C.5.1.6.25.5 The Contractor shall provide three blue and white prints of the control circuit diagram. The blue and white prints shall be produced from the original diagram and must be clear and legible. The Contractor shall install two copies of the circuit diagram inside the traffic signal controller cabinet or in the UPS cabinet in the ready accessible water resistant enclosure and must furnish one additional copy to the Engineer. The Contractor shall provide one set of the following to the Engineer: equipment list, operation and maintenance manuals, board level schematic diagram and wiring diagrams of the UPS and battery data sheets.

C.5.1.7 Documentation

C.5.1.7.1 An additional copy of the UPS software on CD or Jump drive must be provided to the Engineer at no additional cost.

C.5.2 INSTALLATION

C.5.2.1 Procedures: The contractor shall deliver each UPS cabinet to the targeted intersection as a pre-configured, tested package; ready to be bolted onto the existing controller cabinet.

C.5.2.1.1 Contractor shall follow all DDOT construction standards and permitting regulations.

C.5.2.1.2 UPS assembly must be delivered to location fully charged and load tested.

C.5.2.1.3 Contractor shall schedule a pre-installation field visit to each targeted location.

The pre-installation visit shall include a designated representative from DDOT.

The pre-installation visit shall determine the actual side of the controller cabinet that the UPS cabinet will be attached.

C.5.2.1.4 Contractor shall take digital photograph of the targeted cabinet, and shall illustrate on the photograph, the actual mounting location of the UPS assembly.

C.5.2.1.5 DDOT shall approve or disapprove the proposed mounting location based on the

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PDF submittal.

C.5.2.1.6 Contractor shall notify the DDOT, representative a minimum of five days prior to beginning work. The traffic signal must not be disconnected from utility power unless a representative of the DDOT representative is present.

C.5.2.1.7 Contractor shall be responsible for all scheduling and coordination with PEPCO and MPD.

C.5.2.1.8 Contractor shall securely attach UPS assembly to the approved side of the existing traffic controller cabinet.

C.5.2.1.9 UPS assembly must be attached with no less than 4 of the appropriately sized bolts and fenders washers.

C.5.2.1.10 All cable feed thru holes must be standard conduit sized and include feed chase nipples with appropriate bushings.

C.5.2.1.11 UPS system must include mating connector to facilitate interface with DDOT

Traffic signal emergency generator.

UPS system must be connected to allow any existing generator ports to provide charging voltage to the battery banks during long term outages.

C.5.2.1.12 UPS system must be tested under full intersection load prior to PEPCO power being restored and while intersection is still under manual police control to insure proper operation.

C.5.1.6.11 Wiring for the UPS within the traffic signal controller cabinet and within the UPS cabinet (when required) must be sized in accordance with the NEC and must conform to the requirements the Agency Specifications. Wiring panels and terminal blocks must be neatly finished and clearly and permanently marked.

Conductors must be neatly arranged and bundled in groups with cable ties. The bundled conductors shall not obstruct access to other circuits and terminals in the cabinet. A listing, indicating terminal numbers with a description of their use, shall be attached to the cabinet door and overlaid with a clear, plastic covering.

Edges of the plastic overlay shall be sealed with a clear waterproofing compound.

Unless cable is passing through the cabinet uninterrupted, incoming and outgoing conductors must have each wire connected to terminal post positions.

C.5.1.6.12 The UPS cabinet assembly shall be side mounted on existing traffic controller cabinet.

C.5.1.6.13 Cabinet for UPS must be weatherproof and constructed of welded sheet anodized aluminum, 0.125-inch minimum. Cabinet finish must include graffiti resistant coating. Cabinet mounting attachments must be durable, corrosion resistant, DDOT bolt on UPS cabinet assembly Specification 6/19/14 Page 11 of 12 compatible with the aluminum of the cabinet or isolated from it and of heavy-duty construction. Cabinets shall be no larger than 40 inches in height, 15 inches in width, and 10 inches in depth.

C.5.1.6.14 Doors: Cabinet doors shall provide full access to the cabinet interior and must have gaskets to ensure weatherproofing. The door must be equipped with the Agency’s standard tumbler lock. Two keys for each cabinet shall be provided to the Engineer. Hinges must be stainless steel and continuous. Doors must have a doorstop arrangement that will allow it to be firmly positioned at 90 and 135 degrees, ± 10 degrees. The locking system for cabinets must be a three-point draw roller system. Rollers must be fabricated from nylon with a diameter of at least 8/10 inch. The door opening shall be double flanged on all four sides.

C.5.1.6.15 The door must have a screened and louvered vent design to prevent rain entry, with a standard size furnace vent filter. The filter tray shall be sized to house and secure the filter in place. The screen shall be constructed from at least 0.031-inch aluminum with 1/8-inch diameter openings positioned on 3/16 inch staggered centers. The screen must be placed on the inlet side of the filter and held in place by the filter or silicone adhesive.

15.

16. QUALITY ASSURANCE

1.1.1.1.41. Each BBS shall be manufactured by an ISO 9001:2008 certified company in accordance with a manufacturer Quality Assurance (QA) program.

1.1.1.1.42. QA process and test results documentation shall be kept on file for a minimum period of seven years.

1.1.1.1.43. Each system shall be visually inspected for any exterior physical damage or assembly anomalies. Any defects shall be cause for rejection.

17. WARRANTY

1.1.1.1.44. Manufacturers shall provide a five (5) year warranty. The first three years will be with the Advanced Replacement Program. Under the Advanced Replacement Program, the manufacturer will send out a replacement unit within two business days of the call notifying them of an issue. The manufacturer will send out either a new unit or a re-manufactured unit that is fully tested and is up to the latest revision. The manufacturer is responsible for all shipping charges to

DDOT bolt on UPS cabinet assembly Specification 6/19/14 Page 12 of 12 the customer. The last two years of the warranty will be factory-repair warranty for parts and labor on the BBS.

1.1.1.1.45. Batteries shall be warranted for full replacement for two (2) years from date of purchase.

1.1.1.1.46. The warranty shall be included in the total bid price of the BBS.