Cat UPS 900
900 kVA Battery-Free UPS System
Three-Phase Uninterruptible Power Supply
60 Hz 480 V
Technical Specifications
Cat UPS 900
900 kVA / 720 kW BATTERY-FREE UPS SYSTEM
PART 1 – GENERAL
1.01
1.02
SCOPE
A.
Supply a single-conversion battery-free uninterruptible power
supply system (UPS) as described herein that provides
uninterruptible power within specified tolerances during failure or
deterioration of the normal power supply.
B.
Include start-up services for all Equipment.
C.
Rigging, installation labor and installation materials (including all
interconnections between detached pieces of equipment) shall be
the responsibility of others.
SYSTEM DESCRIPTION
A.
The Equipment shall include a single-conversion battery-free UPS
Module (UPS) comprised of the following major elements integrated
into a single unit:
1. One or more 300 kVA / 240 kW multi-module power stages
(MMU) as needed to provide the required capacity, each
containing input fuses, input contactor, static disconnect switch,
integral flywheel energy storage subsystem (FES), bi-directional
AC-to-AC converter (BDC), isolating choke and output
contactor;
2. A system cabinet containing an automatic non-interruptive static
bypass switch with wrap-around bypass breaker. System
cabinet components shall be rated for a 900 kVA load. The
system cabinet shall have disconnect switches to individually
isolate the MMU inputs and outputs.
3. All controls and accessories necessary for the Equipment to
function properly as specified.
B. The UPS Module shall provide at least 14 seconds ride-through time at
rated load without using chemical batteries.
C. The UPS shall be rated 900 kVA / 720 kW.
D. An optional internal maintenance bypass (MBP) shall be available and
shall be included when specified.
1.03
QUALITY ASSURANCE
A.
The UPS shall be tested at the factory for proper operation. The
UPS module shall be functionally tested, and the MMU shall be
burned in for a minimum of 48 hours. Copies of the factory test
report and quality control program documentation shall be provided
on request.
B.
The UPS module shall be listed and labeled by UL in accordance
with the requirements of UL 1778. All other Equipment shall be
listed and labeled in accordance with the applicable UL
requirements.
C.
UPS shall design and construction shall conform to the following
standards as applicable:
1. UL1778, Standards for Uninterruptible Power Supply
Equipment.
2. UL1004, Electric Motors.
3. FCC Rules and Regulations 47, Part 15, Subpart J, Class A.
4. NEMA PE 1-1983 UPS Standard.
5. IEEE 587-1980/ANSI C62.41 1980, Category A &B
Recommended practice on surge voltages in low power circuits.
6. NEC.
7. OSHA safety standards for electrical equipment and service of
electrical equipment.
8. CSA C22.2 No.107.1 Commercial and Industrial Power
Supplies.
9. Industry Canada ICE-003, Canadian EMC.
All Equipment shall be new and of current design and manufacture.
1.04
PROPOSAL
1.05
A.
Provide firm price and delivery lead-time measured from the date of
order receipt for the Equipment and services in accordance with the
requirements of this specification.
B.
Provide a paragraph-by-paragraph specification compliance that
clearly identifies whether the proposed Equipment and services
comply with the specification (Comply), comply with the intent of the
paragraph and provide the performance specified but deviate in
minor detail (Deviation), or do not comply, do not provide the
specified performance or substantially deviate from the
specification requirements (Exception). If the proposal complies
fully with the requirements of a paragraph, the notation “Comply”
shall be applied to the paragraph and no notations associated with
that paragraph shall relieve the supplier from complying with the
requirements of the paragraph. Any Deviation or Exception must be
marked with the legend “Deviation” or “Exception”, respectively,
and explained sufficiently to allow the purchaser or its agents to
clearly evaluate the effect and consequences of the Deviation or
Exception.
C.
Include all other information required by this specification to be part
of the proposal.
SUBMITTALS
A.
Provide general arrangement drawings showing all exterior
dimensions, cable access, shipping splits, and clearances. Show
sizes, weights, and relationships between individual shipping units,
the location and designation of all field wiring termination areas,
and the maximum number and permissible size range of power
conductors which can be accommodated for each power
termination, heat rejection, air flow, and location of air inlets and
outlets.
B.
Provide assembly and mounting details for all Equipment and
shipping splits.
C.
Provide electrical, mechanical, and environmental specifications for
the proposed equipment. Also include this information in the bid.
D.
Provide the same paragraph-by-paragraph response to these
specifications in sufficient detail to clearly show all deviations.
Clearly identify any changes in this compliance compared to the
compliance supplied with the proposal. The submittal may be
rejected if it contains any deviations or exceptions not included in
the proposal.
1.06
E.
Provide electrical one-line drawings showing all power and control
interconnect wiring. Include number of conductors, power wiring
amperages, arrangement and ratings of all protection devices, and
control wire size and type.
F.
Provide point-to-point interconnect drawing or wire lists detailing the
termination points and terminal designations for all field wiring
between equipment or shipping splits. This drawing will either
contain wiring requirements or shall be keyed to the one-line
drawing in a manner that clearly determines wiring requirements.
G.
Provide two copies of all drawings at least 30 days prior to
shipment. Ship user manuals with equipment.
MANUALS
Provide 2 sets of user manuals containing safety, handling, storage,
installation, operation and normal maintenance instructions. The manuals
should also contain specifications, requirements, descriptions, and
features for all Equipment.
1.07
WARRANTY AND MAINTENANCE CONTRACT
The manufacturer shall warrant the Equipment against defect in
workmanship and materials for one year from date of delivery to the initial
end user. An optional 5-year extended warranty shall be available.
PART 2 – PRODUCTS
2.01
ACCEPTABLE MANUFACTURERS
The approved manufacturer for the UPS is Caterpillar, Inc. No
substitutions are permitted.
2.02
CONSTRUCTION
A.
All materials used shall be new, of current manufacture, high
quality, free from defects and shall not have been in previous use
except as required for factory testing.
B.
All Equipment except for any remote annunciation panels, remote
EPO panels or computer monitoring equipment, shall be freestanding NEMA 1 construction or IEC equivalent. Remote
annunciation panels and remote EPO panels shall be wallmounted.
2.03
C.
Cable access shall be permitted from the top or bottom using
raceway or conduit without modification.
D.
Construction of Equipment shall facilitate lifting and rigging.
Clearance shall be provided in the base of Equipment to allow
lifting by forklift from the front or rear. Means shall be provided to lift
Equipment by crane without damage using slings and spreader
bars provided by the installing or rigging contractor.
E.
All wiring shall be in accordance with NFPA 70, OSHA, and EN. All
bus bar connections shall be properly coated with anti corrosion
compound and torqued.
F.
All control wiring interconnections between shipping splits of a
single piece of Equipment shall be supplied and fitted with
connectors or fanning strips constructed and identified to assure
correct connection. Connectors shall have appropriate restraints to
prevent loosening.
G.
All field control wiring terminations shall be made to terminal blocks
or appropriate receptacles for plug-in connections. Receptacles
shall have appropriate restraints to prevent plugs from loosening.
H.
All Power interconnections between shipping splits of a single piece
of Equipment shall be supplied and equipped with termination or
connection hardware.
I.
All components shall be marked at the field replacement level with
the part designations shown on Equipment drawings and parts lists.
Label all terminal blocks and other wiring termination means with a
designation for the termination location and individual termination
point within the location.
J.
PCBs shall not be used nor shall any components be used that
require toxic or hazardous materials documentation for
transportation.
UPS MODULE
A.
DESCRIPTION:
The UPS Module shall be single-conversion design. The input to
the UPS module shall be connected to the inputs of all of the MMUs
through isolation switches in the system cabinet. If the UPS module
contains more than one MMU, then the power trains of the MMUs
shall be identical. The input of each MMU shall be connected to a
phase-controlled static disconnect switch through an isolating
contactor and fuses. The output of the static switch shall be
connected to the input of an isolating inductor and the output of the
isolating inductor shall be connected to the load side of a BDC and
to the MMU output contactor. The other side of the BDC shall be
connected to a FES. The output contactors of the MMUs shall
connect to the output bus of the UPS module through isolation
switches in the system cabinet. An automatic bypass shall connect
the input of the UPS module to the output through an electrically
operated bypass circuit breaker.
B.
OPERATION:
1.
The UPS shall operate continuously while maintaining
specified output power quality whenever the AC input power
is within specified steady state limits. The UPS shall operate
properly from turbo-charged diesel generators equipped with
isochronous governors and three-phase sensing voltage
regulators when they are rated to support the critical load at
rated UPS power plus UPS losses and FES recharging
power. The UPS shall not require over-sizing of engine
generator sets to accommodate UPS input harmonics.
2.
In Normal Mode the MMU input contactor shall be closed
and the static disconnect switch shall be on. The input
source shall supply real power to the MMU to support the
load and to keep the FES unit fully charged through its
associated BDC. The BDC shall exchange reactive current
with the input through the isolating inductor to regulate the
output voltage. The BDC shall also supply the reactive and
harmonic currents required by the load so that the UPS input
source is not required to supply these currents. The static
disconnect switch shall be phase-controlled to block reverse
power flow from the BDCs to the input. UPS output voltage
shall remain within 10 degrees of the input voltage during
steady state operation at all load levels from no load to full
load.
3.
When input frequency or voltage deviates outside of
predetermined limits, the static disconnect switch shall turn
off and the MMU input contactor shall open. At the same
time the bi-directional converter shall draw power from its
associated FES unit to maintain power to the load without
interruption and within specified tolerance. The FES shall
continue to supply power to the load unit until it is fully
discharged or until the input returns within specified
tolerance and the UPS resynchronizes and reconnects.
UPS shall resynchronize in the direction of the smaller
angular difference and the maximum frequency slew rate
shall be adjustable to accomplish resynchronization from
180 degrees out of phase at a slew rate that can be set at
between 0.3 and 3.0 Hz per second. The default slew rate
shall be 1 Hz per second. When the UPS module
reconnects to the input the power walk-in shall be linear and
without steps. After reconnecting to input power the UPS
shall ramp the load from FES power to the input source.
The ramping rate shall be adjustable from 240kW per
second to 10kW per second per MMU. The ramping
function shall be linear and shall not have any step functions.
4.
If the input does not return within specified steady-state
limits in time to allow the UPS to re-synchronize and reconnect before the FES is fully discharged, one of the
following shall occur as determined by field-selectable
parameters:
a. The UPS shall shut down without damage or clearing of
fuses, and the output voltage shall cleanly transition to
zero without spikes or surges. This shall be the default
selection.
b. If the input power is available, whether or not within
specified bypass tolerances, but synchronization has not
been achieved when the FES unit is fully discharged, the
UPS shall transfer to bypass in a break-before-make
fashion. The duration of the break shall be
programmable.
5.
Except as noted in the preceding paragraph, transfers to and
from bypass shall be synchronized and without interruption
of load voltage or current. The UPS shall automatically
transfer to bypass if it is overloaded, or the output voltage
deviates outside specified limits. In Normal Mode operation,
the UPS shall transfer to bypass immediately if the load
reaches 200% of rated load. In Discharge Mode, automatic
transfers to bypass shall be immediately initiated if the load
reaches 135% of rated load. Bypass transfers shall also
occur for less severe overloads if the duration of the
overload exceeds specified overload capability. Transfers to
bypass shall be inhibited if the bypass is not within +/-10% of
nominal voltage when bypass range checking is turned on.
The default state of Bypass range checking shall be on and
the state shall be selectable using a field programmable
firmware setting.
C.
6.
The UPS Module shall be capable of fully recharging the
FES units from a maximum discharge in less than 2.5
minutes at the default rate. The recharge rate shall be
adjustable to slower rates via field programmable firmware
setting.
7.
The UPS shall accept an input from a normally open external
potential-free contact to signal operation from a diesel
generator or other alternate source. The UPS shall permit
programming of a second set of operating parameters that
are activated by the contact closure. These parameters
shall include walk-in rate, and FES recharge rate.
8.
The UPS controls shall be programmable for either
automatic or manual starting. When the key switch on the
system cabinet is in the Online position, automatic start shall
cause the UPS to initially energize the output through the
bypass when power is applied to the input in either a black
start condition or when restarting after the flywheel has fully
discharged. Once the flywheel has been charged to at least
4000 rpm, the UPS shall transfer to Normal Mode and
provide UPS protection to the load. If manual starting is
programmed, then it shall be necessary to momentarily turn
the key switch on the system cabinet to the Reset position
and then turn it to the Online position to restart the system
and place it in Normal operating mode.
UPS MODULE CONSTRUCTION:
1.
The UPS Module shall not require side or rear access or
clearance for service or ventilation. All components shall be
removable from the front and all normal service and
adjustment shall also be from the front.
2.
Equipment shall be constructed to fit through a normal
doorway having clear dimensions of at least 35 inches wide
by 79 inches high.
3.
The UPS shall have modular, field-replaceable power
electronic sub-assemblies for ease of maintenance in the
field.
4.
Proper forced-air ventilation shall be provided to ensure that
all components operate within their specified temperature
ratings. Fans shall be redundant so that any single fan
failure in any cabinet shall not cause any component
temperature to increase beyond acceptable limits, and shall
not cause the UPS to shut down or operate at reduced
capacity. All fans shall be equipped with fan failure sensors
connected to an alarm on the UPS control panel.
5.
Temperature sensors shall be provided to monitor internal
UPS temperatures. Upon detection of temperatures that
exceed the manufacturer’s recommendations, a Notice
Condition shall be indicated on the UPS control panel. If
temperatures reach a level that is potentially harmful to the
UPS module, it shall transfer to bypass, shut down
immediately and indicate an alarm condition. Ambient air
inlet temperature shall also be monitored, and a notice event
shall be logged if the temperature exceeds the specified
maximum value.
6.
Front service clearance shall not exceed 36 inches. This
maximum does not include additional front clearance that
may be required by construction codes or regulations. The
UPS Module shall be constructed so that no code
clearances are needed at the rear or sides.
7.
The UPS module shall allow sufficient conduit landing and
power cable attachment in the range of 350 MCM 750 MCM
to accommodate rated currents. Cable access shall be from
top or bottom without modification of the equipment.
8.
UPS module footprint shall not exceed 51 square feet and
the floor loading shall not exceed 250 pounds per square
foot, based upon the equipment footprint and one-half of the
minimum required front service clearance area.
9.
The UPS Module shall have built-in surge suppression.
Surge suppressors shall have built-in failure indication.
10.
The UPS Module shall be protected against overloads and
short-circuits on its output. All power semiconductor devices
shall be properly fused and shall have appropriate current
limiting means to prevent cascading failures. Extensive
internal monitoring and diagnostics shall be included to
minimize UPS damage from internal failures.
11. Control power shall be internally derived from redundant
sources. Control power from external sources shall not be
required during operation.
12. The UPS Module shall have a withstand rating of at least
65,000 amps
D.
ELECTRICAL REQUIREMENTS:
1.
2.
Input:
a.
Nominal voltage
Connection
b.
Voltage range
c.
d.
Nominal frequency
Frequency range
e.
Input current
f.
g.
Magnetizing current
Power factor
h.
Harmonic current
distortion
480V
3-phase, 3-wire + ground
from grounded wye
source
+/- 10% default
+10% - 15% Maximum;
Programmable within
maximum range
60 Hz
Programmable within +/10% maximum +/- 3%
default factory setting
898 A nominal at full load
1260 A maximum
including recharge and
low line
None
≥0.99 at rated load and
nominal voltage
<3% of full load current
with linear load; less than
8% with maximum nonlinear load per EN 500913
Output:
a.
b.
c.
d.
e.
Rating
Current
Nominal voltage
Connection
Voltage Regulation Steady state
900 kVA/ 720 kW
1084 A RMS
Same as input
3-phase, 3-wire + ground
+/1% for +/- 10% input,
f.
E.
F.
G.
Transient
Recovery time
Frequency regulation
balanced or unbalanced
loads
+/- 5% for 100% step load,
<50 msec.
Input synchronized in
Normal Mode
0.2% free running
3% THD at rated linear
load; 5% for rated nonlinear load
g.
Harmonic voltage
distortion
h.
Overload capability –
Normal mode
125% - 10 minutes
150% - 2 minutes
1000% - 10 milliseconds
i.
Ride-through time
14 seconds at rated load
EFFICIENCY:
1.
The UPS Module efficiency shall be at least 97.0 percent.
2.
Efficiency is defined as the total output kW divided by the
input kW under the following operating conditions: Normal
Mode operation that provides full UPS protection without
operator intervention, rated 0.8 power factor balanced load,
nominal input voltage, FES connected and fully charged, and
ambient temperature between 150C and 300C.
ENVIRONMENTAL REQUIREMENTS:
1.
Operating ambient temperature range for cold start shall be
at least 320F to 1040F (00C to 400C).
2.
Ambient storage temperature range shall be at least -130F to
1580F (-250C to 700C).
4.
Relative humidity limits shall be 5% to 95%, non-condensing.
5.
Operating elevation limit shall be at least 3000 feet without
de-rating. For operation above 3000 feet the ambient
operating temperature shall be reduced by no more than
1.2°C for each 1000 feet up to an elevation of 7000 feet.
STATIC DISCONNECT SWITCH:
H.
1.
The static disconnect switch in each MMU shall be a
continuous duty rated, phase-controlled, full wave, threephase, line-commutated electronic switch using SCRs as
switching devices. It shall turn off within one-half cycle of
detecting an input voltage or frequency outside of preset
limits as specified. Phasing of the switch during normal
operation shall also inhibit reverse power flow from the
output of the switch to the input. Connection to the AC input
through the switch shall be initiated when the phase
difference between the input and output is less than one-half
degree to reduce inrush currents when reconnecting to input
power after a discharge.
2.
Each phase of the static disconnect switch shall be protected
by fast-acting fuses.
3.
The static switch shall be isolated from the input by a
contactor. The contactor shall be opened when an out of
tolerance input is detected to disconnect the static switch
from the input.
FLYWHEEL ENERGY STORAGE SUBSYSTEM (FES):
1.
Ride-through energy for the UPS system shall be supplied
by a flywheel energy storage module (FES) in the MMU that
stores energy in the inertia of a rotating mass. The energy
shall be immediately accessible to support the critical load
without interruption.
2.
The FES shall be a fully integrated device in which the
motor, generator, and flywheel energy storage functions are
performed by one brushless rotating machine composed of a
single rotor and a single stator. The rotor shall be forged
from a single piece of 4340 steel and shall have no coils or
permanent magnets.
3.
The rotor and stator shall be contained in a single evacuated
housing and shall have a vertical shaft orientation.
4.
When in normal operation, at least 75 percent of the FES
rotor weight shall be supported by magnetic suspension
provided by field coils mounted inside the FES housing.
5.
The field coils and stator windings shall be cast coil type
using vacuum impregnation techniques for encapsulation.
6.
The flywheel rotor shall be rated for 7,700 RPM and have a
plastic yield strength of at least 2.5 times the peak Mises
stress resulting from the rated operating speed. Each rotor
shall undergo ultrasonic and magnetic particle inspection.
The complete FES shall be type-tested to withstand the
following fault conditions and copies of the test results shall
be available:
a.
b.
c.
d.
e.
I.
J.
Sudden loss of vacuum.
AC short-circuits.
DC short-circuits.
Catastrophic bearing failure.
Over speed testing to 120% of rated speed.
BI-DIRECTIONAL CONVERTERS (BDC):
1.
The FES shall be charged and discharged using an AC-toAC BDC. The BDC shall be composed of two PWM AC-toDC, four quadrant converters configured in a back-to-back
arrangement.
2.
Each AC-DC converter shall use three-phase full wave PWM
conversion techniques utilizing three IGBT converter stages.
All stages in each AC-DC converter shall be identical and
interchangeable and shall have built-in short-circuit and
overload protection.
3.
Failure or over temperature of the converters shall be
monitored and alarmed. A sudden failure of a converter shall
not cause the UPS to transfer to bypass if the remaining
MMUs have capacity at least equal to the connected load. If
the load exceeds the capacity of the remaining MMUs, the
system shall transfer to bypass as required elsewhere in this
specification.
STATIC BYPASS:
1.
A static bypass switch shall be included, consisting of two
SCRs per phase arranged in a back-to-back configuration.
Fuses suitable for protection of semiconductor devices shall
protect each phase of the static switch. An isolating
contactor shall be connected upstream of the static switch to
provide back feed isolation whenever the bypass source is
out of tolerance.
K.
2.
A bypass breaker connected in parallel with the static
bypass switch shall be commanded to turn on at the same
time as the static bypass. The bypass breaker shall be sized
for the rated output of the UPS.
3.
The UPS shall monitor the static bypass fuses and alarm if a
fuse is cleared. Additionally, the position and status of the
isolating contactor shall be monitored and alarmed.
4.
Except as noted in the next paragraph, transfers to and from
bypass shall be synchronized and without interruption of
load voltage or current. The UPS Module shall automatically
transfer to bypass under the conditions specified in the
Operation section above. Transfers to bypass shall be
inhibited if the phase difference between the bypass and
output is greater than 15 degrees; the frequency difference
is greater than 0.1 Hz or the bypass voltage deviates from
nominal by more than 10%. A field-programmable setting
shall allow transfer to a bypass source that deviates from
nominal by more than 10%.
5.
If Input power is available but synchronization has not been
achieved when the FES becomes fully discharged, the UPS
may transfer in a break-before-make fashion as stated in the
Operation section above.
6.
Manual Transfers to bypass shall be initiated from the UPS
Module control panel by turning the key switch to the Bypass
position. Turning the key switch from the Bypass position to
the online position will manually return the UPS from bypass
to normal operation.
CONTROLS AND INSTRUMENTATION:
1.
UPS Control Panel:
a. A digital control panel shall be located on the System
Cabinet. It shall have a LCD alphanumeric display, a
“Bypass-Online-Reset” key switch, an EPO button, a
horn and a horn silence button.
b. The Bypass-Online-Reset key switch shall have 3
positions. The “Online” position of key switch shall
place the UPS on-line if sufficient MMU capacity is
available to support the connected load. If not, the
command shall be ignored until sufficient MMU
capacity is available. The “Bypass” position shall
c.
d.
e.
f.
2.
manually transfer the UPS to bypass provided the
bypass is available and within specified tolerances. If
the bypass is not within specified tolerances when the
key switch is placed in this position, the command
shall be ignored and the UPS shall remain on-line.
The “Reset” position shall be a momentary contact
operation used to reset the system after complete
discharge when auto-restart is not enabled or after
the system has been shut down using the EPO.
The LCD shall indicate data in real time on the system
cabinet. Summary data from all MMUs shall be
obtained from this LCD display.
The Red “Emergency Power Off” (EPO) button on the
control panel shall completely shut down the UPS,
and open its input and output contactors. It shall also
turn off the static switch bypass and open the wraparound breaker. The EPO shall not turn off the
maintenance bypass.
The LCD shall have screens to show the following:
1)
UPS module summary screen showing
metering and status data for the UPS module
in total.
2)
Input and output voltage, current kVA & kW.
3)
Detailed telemetry data for electrical, thermal
and mechanical diagnostic parameters
measured for each MMU.
4)
MMU set point screen to show MMU settings.
5)
Display & communications settings.
6)
Configuration and Identification data to
facilitate remote communications and service
identification of the MMU.
7)
An alarm screen showing only MMU alarm
events.
8)
A notice screen showing MMU notice events
and alarm events.
9)
An event screen that shows all events
including alarms, notice and status events.
The default screen viewed on the control panel LCD
shall be the UPS module summary.
MMU Control Panel
a. The Control panel shall include an emergency MMU off
button and a three position key switch. A horn shall
also be included to annunciate notice and alarm
conditions audibly. The controls on an individual MMU
shall apply only to that MMU.
b.
The key switch shall permit an operator to control the
MMU without risk of load loss. The key switch shall
have “Bypass”, “Online”, and “Reset” positions. The
Online position shall be the normal operating position
of the key switch to provide UPS protection. Placing
the key switch in the Bypass position shall turn off the
output of the associated MMU and transfer the load to
bypass only if the remaining MMUs do not have
sufficient capacity to continuously support the
connected load. If the bypass is not available and the
remaining MMUs do not have sufficient capacity, the
key switch command shall be ignored and the MMU
shall remain on-line. The Reset position shall be a
momentary key switch position that shall be used to
reset the MMU.
3.
Status Events:
Status events shall indicate normal events and shall not
indicate a problem or failure. A status event indicating that a
MMU is off-line or that there is insufficient flywheel energy to
support the load shall cause the “Normal” LED on the control
panel to flash. Status messages shall be written to the event
memory and displayed on the message screen.
4.
Notice Events:
Notice events shall indicate a problem that is not serious
enough to shut down the UPS but requires service or
attention from a technician. A Notice event shall illuminate
the “Notice” LED on the control panel and the system shall
emit an audible alarm. Notice messages shall be written to
the event memory and displayed on the notice and message
screens.
5.
Alarm Events:
Alarm events shall indicate a serious problem with the UPS
and will cause it to shut down and transfer the load to
bypass without interruption, provided bypass power is
available. An alarm event shall illuminate the “Alarm” LED on
the control panel and the system shall emit an audible alarm.
Alarm messages shall be written to the event memory and
displayed on the alarm, notice and message screens.
6.
Event Memory:
All event messages shall be stored in an event memory that
shall be capable of storing at least 1000 messages. When
the event memory is full, it shall continue to store messages
by overwriting previous messages starting with the oldest
messages first.
7.
Viewing the Event Memory:
Event messages shall be accessed from the control panel
and viewed on the LCD display. Separate views shall be
available that show the following:
a. Message screen - all events (status, notice and alarm).
b. Notice screen - notice plus alarm events only.
c. Alarm screen - alarm events only.
8.
Monitored System Variables:
a. The following variables shall be monitored and
displayed in real time on the UPS control panel.
1)
Input variables:
♦ 3-phase AC phase-to-neutral voltage.
♦ 3-phase AC phase-to-phase voltage.
♦ 3-phase current.
♦ Frequency.
♦ Total power (kW).
♦ Total kVA.
♦ Input power factor.
2)
Output variables:
♦ 3-phase AC phase-to-phase voltage.
♦ 3-phase currents.
♦ Frequency.
♦ Total power (kW).
♦ Total kVA.
♦ Output power factor.
3)
Sensors shall also be provided that will report
internal operating system variables listed
below.
♦ Cabinet air temperature.
♦ Air inlet temperature.
♦ Static Switch temperature.
♦ Positive DC bus voltage.
♦ Negative DC bus voltage.
♦ Flywheel tachometer (RPM).
♦ Percent energy available.
♦ Vacuum level.
♦ Top field coil current.
♦ Bottom field coil current.
♦ Bearing Loading.
♦ Lower bearing unloading force.
♦ Lateral vibration.
♦
♦
♦
♦
♦
♦
♦
♦
♦
Axial vibration.
Top field coil temperature.
Bottom field coil temperature.
Armature temperature.
Top field coil IGBT temperature.
Bottom field coil IGBT temperature.
Top bearing temperature.
Bottom bearing temperature.
RPS advance setting
9.
The UPS Module shall have 6 programmable external
customer inputs designed to interface to normally open,
potential-free contacts. Each of these inputs shall be
programmable to any of the following functions: On
Generator, Generator set Breaker Open, Remote Switch to
Bypass, Remote Switch to On-line, On-Line Inhibit, Remote
Horn Silence, Abnormal Room Temperature, Fire Alarm,
Building Alarm 1, Building Alarm 2, Building Alarm 3,
Building Alarm 4, User 1 (user defined input 1), and User 2
(user defined input 2). The inputs are logged to the event
memory and can be used to activate the programmable
output contacts. The remote switching inputs switch the UPS
between on-line and bypass operation. The On Generator
input is used to initiate alternate UPS operational settings as
specified in section 2.03 B.
10.
The UPS Module shall have 6 programmable form-C,
potential-free output contacts. Each output contact can be
programmed to indicate any of the following functions: Online, On-Bypass, Flywheel Discharging, Notice Event or
Alarm Event, Alarm Event only, Overload, UPS cabinet over
temperature, Genset Start unavailable, Overload bypass, DC
fuse failure, fan failure, Run Generator set (continuous
contact), Start Generator set (Momentary Contact), Stop
generator set (momentary contact), Transfer ATS to
emergency source, and a summary indication that a building
alarm input or the fire alarm input is on.
11.
The UPS shall have remote communications capability via
Ethernet hardware. The factory installed modem shall
provide remote notification via modem to a pager and/or a
computer equipped with monitoring software.
L. REMOTE COMMUNICATIONS:
M.
1.
Remote notification via Modem shall be included to provide
dial-out notification to multiple pagers or computers when an
Alarm or Notice condition occurs. In North America and EC
countries where a special modem license is not required, an
internal modem shall be provided. For other parts of the
world, an interface to an external modem shall be provided,
including a UPS-protected power receptacle installed in the
UPS to supply the modem. The installing contractor shall
provide any cabling between the UPS and the external
modem.
2.
A modem shall be incorporated to allow remote monitoring of
UPS status, events, telemetry and event memory.
3.
Remote monitoring shall also be provided via Ethernet using
the UPSView monitoring software or the optional Modbus
interface. Monitoring via Ethernet shall also include the
ability to transmit Notice and Alarm conditions via e-mail
over a LAN and Internet, if internet access is provided.
UPSVIEW™:
UPSView™ graphical, real-time monitoring and display software
shall be included that runs on PCs equipped with Windows Vista,
XP, 2000, ME, 98 or NT4.0 for monitoring Cat UPS modules. All
metered values and scalar diagnostic parameters displays shall be
selectable between numerical, bar graph and value vs. time graph
formats. Digital diagnostic parameter status shall also be displayed.
Colors shall be used to indicate normal (green), Notice (yellow) and
alarm (red) conditions. Scalar graphical displays shall indicate
notice and alarm levels. UPSView shall also display events in
streaming mode and shall be able to store them to a file on the PC.
2.04. OPTIONS
The following options shall be available for the UPS and shall be included
when specified.
A.
DUAL INPUT OPTION:
1.
An option shall be available to supply the UPS with 2 inputs,
one to supply the UPS and the other to supply the static
switch bypass with wrap around breaker.
2.
B.
C.
The feeders for the two inputs shall be from a common
source and each input shall be sized for operation at rated
UPS load.
INTERNAL MAINTENANCE BYPASS:
1.
An internal maintenance bypass shall be available as an
option. The bypass shall allow the load to be maintained online while the UPS is being serviced. The maintenance
bypass shall be physically isolated from the MMU to allow it
to be safely maintained, including the automatic bypass.
2.
Operation of the maintenance bypass shall be completely
manual.
3.
Bypass components shall have a withstand rating of at least
65,000 amps.
EXTERNAL SYNCH OPTION:
1.
The external synch option shall cause the UPS to
synchronize to a source other than its input source while the
flywheel is discharging. The external synch function shall
engage when all of the following conditions are satisfied.
a.
b.
c.
2.
D.
The input source is outside specified tolerances.
The UPS is discharging.
The external synch function is enabled by an external
contact closure.
When engaged, the external synch option shall synchronize
the UPS to a three-phase voltage signal supplied from an
external source to a sensing input in the UPS.
N+1 REDUNDANCY:
1. An option shall be available for units rated 900 kVA / 720 kW or
less to include a redundant MMU in the UPS. The redundant
MMU shall be of equal capacity and shall be interchangeable
with any primary MMU. The BDC of the redundant MMU shall
be operating at all times and the FES shall be maintained in the
same state of charge as the primary flywheels. The redundant
MMU shall be able to seamlessly assume the load supported by
any primary MMU at any time. It shall also share load with the
other MMUs during a discharge whether or not all primary
MMUs are operational.
2. If all primary MMUs are operational, the redundant MMU shall
proportionally increase the ride-through time of the UPS.
3. The redundant MMU shall not increase losses under the
conditions described in section 2.03.E.2 by more than 6 kW.
E.
Gen Set Start Power:
Gen Set Start Power shall provide 1725 Cold Cranking Amps at 24
volts for generator starting. It shall be rated for 10 cranking cycles
in succession at 50°C.
F.
REMOTE STATUS PANEL:
A remote monitoring panel shall be available containing 8 LEDs a
horn and horn silence to provide remote indication of UPS module
status. The remote monitoring panel shall connect to the UPS via a
serial link.
G.
REMOTE EPO:
A Remote EPO option shall be available. This option shall provide
an EPO button in mounted in an enclosure. The button shall be a
press-to-operate and shall be latched in the depressed position.
The button shall have a normally open and a normally closed
contact each capable of handling the required voltage and current
to interface with the remote EPO input of the UPS.
H.
SEISMIC KIT:
An option shall be available to allow the UPS module to be
seismically anchored. When equipped with the seismic kit the UPS
shall be pre-certified by the California OSHPD for seismic
installations and be approved and stamped by an engineer
specializing in seismic evaluation, as meeting UBC zone 4
requirements when installed in accordance with the manufacturers
recommended procedures for seismic locations.
I.
4-WIRE:
1.
An option for a 4-wire input and out configuration shall be
available. This configuration shall be designed to operate
with line-to-neutral and/or line-to-line loads.
2.
J.
This option shall have a 200% rated neutral and shall be
designed to work with loads having high harmonic currents.
Impedance grounded source:
1.
An option for the UPS to be connected to an impedance
grounded source shall be available.
PART 3 – EXECUTION
3.01
3.02
SCOPE
A.
Provide on-site quality control and commissioning services as
specified.
B.
Technicians performing all specified services shall be trained,
certified and authorized by the manufacturer. They shall be
primarily employed to service the manufacturer’s equipment.
ON-SITE QUALITY CONTROL
A.
The following general and visual inspections shall be performed onsite at the time the equipment is commissioned:
1.
Inspect equipment for signs of damage.
2.
Inspect equipment for cleanliness & foreign objects. Advise
installing contractor if condition is not satisfactory.
3.
Verify sizing and connection of neutral and ground
conductors.
4
Verify proper termination of all control wiring.
5.
Verify that the equipment is level and properly anchored.
6
Verify that all circuit boards are configured and mounted
correctly.
7.
Verify the installation conforms to manufacturer’s drawings
and installation requirements.
8.
Verify that all optional hardware is installed.
B.
C.
D.
3.03
Perform the following mechanical inspections:
1.
Check all control wiring connections for tightness.
2.
Check all power wiring connections for tightness.
3.
Check all terminal screws and/or lugs for tightness.
The following electrical inspections and tests shall be performed on
site at the time of commissioning:
1.
Verify all fuse continuity.
2.
Verify input voltages and bypass voltages correspond to the
Equipment rating.
3.
Verify phase rotation of inputs and bypass.
4.
Verify connection of Current transformers, and control power
transformers.
5.
Perform DVMM test on UPS to verify correct resistance on
phase-phase and phase-ground for both input and output
connections.
These services are on a “best effort” basis and shall not absolve
the installing contractor’s responsibility for properly installing the
Equipment.
START-UP
A.
Perform the following checks as part of system start-up:
1.
Energize control power circuits and verify all control
voltages.
2.
Verify correct firmware revision.
3.
Check operation of control logic and verify correct software
set-ups.
4.
Start the Module.
5.
Verify FES starts and charges properly.
B.
C.
6.
Energize the module output. Verify BDC operation correct
output voltage regulation and proper phase rotation.
7.
Verify that no alarm conditions exist.
8.
Verify all indications, Notices, Alarms, and metering
functions operate properly and are calibrated.
9.
Verify operation of all options. In particular, verify that if a
modem is installed it is connected to telephone lines and
communicates correctly. Set modem telephone numbers and
parameters in UPS software.
Perform the following tests and simulations:
1.
Simulate input power failure and verify FES discharge and
recharge. Verify that operation alarms & indications are
correct.
2.
Manually transfer the system to bypass and return. Verify
correct transfer and operation of all indications and alarms.
Complete and sign and date all start up documentation and test
results.