Pine Telephone Company

Request for Proposal

Generator/Transfer switch

Posted 02/25/2011

Proposals are due by COB

03/11/2011

 

Electrical Emergency/Standby Power Systems Diesel Generator Sets

Part 1.   GENERAL

1.01        Scope

A.      Provide complete factory assembled outdoor self enclosed generator set equipment with digital (microprocessor-based) electronic generator set controls, digital governor, and digital voltage regulator. The generator housing shall be rodent proofed.

B.      Provide factory test, startup by a supplier authorized by the equipment manufacturer(s).

C.      The generator set manufacturer shall warrant all equipment provided under this section, whether or not is manufactured by the generator set manufacturer, so that there is one source for warranty and product service.   Technicians specifically trained and certified by the manufacturer to support the product and employed by the generator set supplier shall service the generator sets.

D.      The generator set supplier shall be responsible for complete compliance to all specification requirements for both the generator set and the paralleling equipment.

E.      Prototype testing, factory testing.

F.       Quantities:  three separate contracts.

              1.    Contract 1     36 units

              2.    Contract 2     33 units

              3.    Contract 3     24 units

G.      RUS contract 398 will be utilized for all three contracts.

H.      The units will be scheduled for delivery evenly over the next 12 months.

 

1.02        Codes and Standards

A.      The generator set installation and on-site testing shall conform to the requirements of the following codes and standards, as applicable.  The generator set shall include necessary features to meet the requirements of these standards.

              1.    ANSI S1.13-1971—Measurement of Sound Pressure Levels in Air

              2.    CSA 282, 1989 Emergency Electrical Power Supply for Buildings

              3.    IEEE446 – Recommended Practice for Emergency and Standby Power Systems for Commercial and Industrial Applications

              4.    NFPA 30 – Flammable and Combustible Liquids

              5.    NFPA 37 – Standard For the Installation and Use of Stationary Combustion Engines and Gas Turbines

              6.    NFPA 70 – National Electrical Code.  Equipment shall be suitable for use in systems in compliance to Article 700, 701, and 702.

              7.    NFPA 99 – Essential Electrical Systems for Health Care Facilities

              8.    NFPA 110 – Emergency and Standby Power Systems.  The generator set shall meet all requirements for Level 1 systems.   Level 1prototype tests required by this standard shall have been performed on a complete and functional unit, component level type tests will not substitute for this requirement.

B.      The generator set and supplied accessories shall meet the requirements of the following standards:

              1.    NEMA MG1-1998 part 32.  Alternator shall comply with the requirements of this standard.

              2.    UL142 – Sub-base Tanks

              3.    UL1236 – Battery Chargers

              4.    UL2200. The generator set shall be listed to UL2200 or submit to an independent third party certification process to verify compliance as installed..

C.      The control system for the generator set shall comply with the following requirements.

              1.    CSA C22.2, No. 14 – M91 Industrial Control Equipment.

              2.    EN50082-2, Electromagnetic Compatibility – Generic Immunity Requirements, Part 2: Industrial.

              3.    EN55011, Limits and Methods of Measurement of Radio Interference Characteristics of Industrial, Scientific and Medical Equipment.

              4.    FCC Part 15, Subpart B.

              5.    IEC8528 part 4.  Control Systems for Generator Sets

              6.    IEC Std 801.2, 801.3, and 801.5 for susceptibility, conducted, and radiated electromagnetic emissions.

1.     The generator set manufacturer shall be certified to ISO 9001 International Quality Standard and shall have third party certification verifying quality assurance in design/development, production, installation, and service, in accordance with ISO 9001

1.03        Submittals

A.      Shop drawings:

              1.    Outline drawings of assembly.

              2.    One line diagrams and wiring diagrams for assembly and components.

              3.    Interconnection wiring diagrams

 

B.      Product data:

              1.    Technical data on all major components.  Technical data must include an alternator thermal damage curve, description and operating characteristics of the alternator protection device, and an alternator reactive capability curve.  Alternator data demonstrating compliance.

              2.    Certification of the emissions performance of the generator set engine by the engine manufacturer.

              3.    Seismic certification, as required.

C.      Project information:

              1.    Test reports and certifications.

              2.    Factory test procedures.

D.      Contract closeout information:

              1.    Operating and maintenance data.

1.04        Qualifications

A.      The generation set manufacturer shall be certified to ISO 9001 International Quality Standard and shall have third party certification verifying quality assurance in design/development, production, installation, and service, in accordance with ISO 9001.

B.      The manufacturer of this equipment shall have produced similar equipment for a minimum period of ten years. When requested by the Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement.

1.05        Regulatory Requirements

A.      The generator set shall be UL2200 listed and labeled

B.      The generator set overcurrent protection shall be UL listed as a utility grade protective device.

C.      The generator set engine shall comply with all applicable emissions standards at the date of installation.   

1.06        Warranty

A.      The manufacturer shall warrant the material and workmanship of the generator set for a minimum of five (5) year from registered commissioning and start-up, or from date of shipment.

B.      The warranty shall be comprehensive.  No deductibles shall be allowed for travel time, service hours, repair parts cost, etc. shall be allowed during the minimum noted warranty period described in paragraph A above.

Part 2.   PRODUCTS

2.01        Generator set

A.      Ratings

              1.    The generator set shall operate at 1800 rpm and at a voltage of: 120/240 Volts AC, Single phase, 3‑wire, 60 hertz. 

              2.    The complete generator set shall be rated per ISO8528 at 20kW at 1.0 PF[1], Standby rating, based on site conditions of: Altitude 304 meters, ambient temperatures of 50 degrees C, based on temperature measured at the control for indoor installations, and measured at the air inlet closest to the alternator for outdoor equipment.   

              3.    The generator set rating shall be based on emergency/standby service and marked as such per NFPA110.

B.      Performance

              1.    Voltage regulation shall not exceed one percent for any constant load between no load and rated load for both parallel and non-parallel applications.  Random voltage variation with any steady load from no load to full load shall not exceed plus or minus 1 percent.

              2.    Frequency regulation shall be isochronous from steady state no load to steady state rated load.  Random frequency variation with any steady load from no load to full load shall not exceed plus or minus 0.25%.

              3.    The diesel engine‑generator set shall be capable of single step load pick up of 100% nameplate kW and power factor, less applicable derating factors, with the engine‑generator set at operating temperature. 

              4.    Motor starting capability shall be a minimum of 87kVA.   The generator set shall be capable of sustaining a minimum of 90% of rated no load voltage with the specified kVA load at near zero power factor applied to the generator set. 

              5.    The alternator shall produce a clean AC voltage waveform, with not more than 7% total harmonic distortion at full linear load, when measured from line to neutral, and with not more than 3% in any single harmonic, and no 3rd order harmonics or their multiples.  Telephone influence factor shall be less than 40.

              6.    The generator set shall be certified by the engine manufacturer to be suitable for use at the installed location and rating, and shall meet all applicable exhaust emission requirements at the time of commissioning.

              7.    The generator set, complete with sound attenuated enclosure, shall be tested by the generator set manufacturer per ANSI S1.13.  Data documenting performance shall be provided with submittal documentation.

C.      Construction

              1.    The engine‑generator set shall be mounted on a heavy-duty steel base to maintain alignment between components.  The base shall incorporate a battery tray with hold-down clamps within the rails.

              2.    All switches, lamps, and meters in the control system shall be oil‑tight and dust‑tight.  There shall be no exposed points in the control (with the door open) that operate in excess of 50 volts.

              3.    All outdoor equipment shall be enclosed with corrosion-protected materials. Enclosure shall be rodent proofed. Steel components used in enclosures shall be powder coated and baked, and shall provide fade and corrosion resistance in compliance to  Dry film thickness shall be shd3363 of  2H+all a minimum of 1.8 Mils, gloss at 60degrees per ASTMD523 of 80+/- 10, pencil hardness per ASTM D3363

D.      Connections

              1.    The generator set load connections shall be composed of silver or tin plated copper bus bars, drilled to accept mechanical or compression terminations of the number and type as shown on the drawings.  Sufficient lug space shall be provided for use with cables of the number and size as shown on the drawings.

              2.    Power connections to auxiliary devices shall be made at the devices, with required protection located at a wall-mounted common distribution panel.

              3.    Generator set control interfaces to other system components shall be made on a common, permanently labeled terminal block assembly. 

2.02        Engine and Engine Equipment

A.      The engine shall be diesel, 4 cycle, radiator and fan cooled. Minimum displacement shall be 2.2 liters, with 4 cylinders. The horsepower rating of the engine at its minimum tolerance level shall be sufficient to drive the alternator and all connected accessories.  Two cycle engines are not acceptable.  

B.      An electronic governor system shall provide automatic isochronous frequency regulation.  The governing system dynamic capabilities shall be controlled as a function of engine coolant temperature to provide fast, stable operation at varying engine operating temperature conditions. The control system shall actively control the fuel rate and excitation as appropriate to the state of the generator set.  Fuel rate shall be regulated as a function of starting, accelerating to start disconnect speed, accelerating to rated speed, and operating in various isochronous or parallel states.

C.      Skid‑mounted radiator and cooling system rated for full load operation in 55 degrees C ambient as measured at the generator air inlet, based on 0.5 in H2O external static head. Radiator shall be sized based on a core temperature which is 10C higher than the rated operation temperature, or prototype tested to verify cooling performance of the engine/radiator/fan operation in a controlled environment.  Radiator shall be provided with a duct adapter flange.  The cooling system shall be filled with a 50/50-ethylene glycol/water mixture by the equipment manufacturer.  Rotating parts shall be guarded against accidental contact. 

D.      Electric starters capable of three complete cranking cycles without overheating.      

E.      Positive displacement, mechanical, full pressure, lubrication oil pump. 

F.       Full flow lubrication oil filters with replaceable spin‑on canister elements and dipstick oil level indicator. 

G.      An engine driven, mechanical, positive displacement fuel pump. Fuel filter with replaceable spin‑on canister element. Fuel cooler, suitable for operation of the generator set at full rated load in the ambient temperature specified shall be provided if required for operation due to the design of the engine and the installation.    

H.      Replaceable dry element air cleaner with restriction indicator.         

I.        Flexible supply and return fuel lines. 

J.       Engine mounted battery charging alternator, 40-ampere minimum, and solid‑state voltage regulator.

K.      Coolant heater

              1.    Engine mounted, thermostatically controlled, coolant heater(s) for each engine. Heater voltage shall be as shown on the project drawings. The coolant heater shall be UL499 listed and labeled.

              2.    The coolant heater shall be installed on the engine with SAEJ20 compliant materials.  Steel tubing shall be used for connections into the engine coolant system wherever the length of pipe run exceeds 12 inches.  The coolant heater installation shall be specifically designed to provide proper venting of the system.  The coolant heaters shall be installed using isolation valves to isolate the heater for replacement of the heater element.  The design shall allow the heater element to be replaced without draining the engine cooling system or significant coolant loss. 

              3.    The coolant heater shall be provided with a 12VDC thermostat, installed at the engine thermostat housing.  An AC power connection shall be provided for a single AC power connection to the coolant heater system.

              4.    The coolant heater(s) shall be sized as recommended by the engine manufacturer to warm the engine to a minimum of 40C in a 15C ambient, in compliance with NFPA110 requirements, as a minimum, or the temperature required for starting and load pickup requirements of this specification.

L.       Provide vibration isolators, spring/pad type, quantity as recommended by the generator set manufacturer.   Isolators shall include seismic restraints if required by site location.               

M.     Starting and Control Batteries shall be lead acid type, 12 volt DC, sized as recommended by the engine manufacturer for compliance to NFPA110 starting requirements, complete with battery cables and connectors.            

N.      Provide exhaust silencer(s) for each engine of size and type as recommended by the generator set manufacturer and approved by the engine manufacturer.  The mufflers shall be critical grade.  Exhaust system shall be installed according to the engine manufacturer’s recommendations and applicable codes and standards.    

O.      Provide a dual wall sub‑base fuel storage tank with 100 gallons capacity.  The tank shall be constructed of corrosion resistant material and shall be UL listed.  The equipment, as installed, shall meet all local and regional requirements for above ground tanks.

Outdoor Weather-Protective Enclosure

P.      Generator set housing shall be provided factory‑assembled to generator set base and radiator cowling. Housing shall provide ample airflow for generator set operation at rated load in the ambient conditions previously specified. Enclosure shall be rodent proofed. The housing shall have hinged side‑access doors and rear control door.  All doors shall be lockable.  All sheetmetal shall be primed for corrosion protection and finish painted with the manufacturers standard color using a two step electrocoating paint process, or equal meeting the performance requirements specified below. All surfaces of all metal parts shall be primed and painted.  The painting process shall result in a coating which meets the following requirements:

Primer thickness, 0.5-2.0 mils.  Top coat thickness, 0.8-1.2 mils.

Gloss, per ASTM D523-89, 80% plus or minus 5%.  Gloss retention after one year shall exceed 50%.

Crosshatch adhesion, per ASTM D3359-93,  4B-5B.

Impact resistance, per ASTM D2794-93, 120-160 inch-pounds.

Salt Spray, per ASTM B117-90, 1000+ hours.

Humidity, per ASTM D2247-92, 1000+ hours.

Water Soak, per ASTM D2247-92, 1000+ hours.

Q.      Painting of hoses, clamps, wiring harnesses, and other non-metallic service parts shall not be acceptable.   Fasteners used shall be corrosion resistant, and designed to minimize marring of the painted surface when removed for normal installation or service work.

R.      The generator set shall be provided with a 125A mounted main line circuit breaker, sized to carry the rated output current of the generator set.  The circuit breaker shall incorporate a thermal-magnetic trip with other overcurrent protection devices that positively protect the alternator under overcurrent conditions.  The supplier shall submit time overcurrent characteristic curves and thermal damage curve for the alternator, demonstrating the effectiveness of the protection provided.

2.03        Low Voltage AC Alternator

A.      The AC alternator shall be; synchronous, four pole, 2/3 pitch, brushless, revolving field, drip-proof construction, single prelubricated sealed bearing, air cooled by a direct drive centrifugal blower fan, and directly connected to the engine with flexible drive disc.  The alternator design shall prevent shaft current from flowing and eliminate the need for insulated bearings.  All insulation system components shall meet NEMA MG1 requirements for Class H insulation systems.  Actual temperature rise measured by resistance method at full load shall not exceed 808C[2] in a 408C ambient. 

B.      The alternator shall be capable of delivering rated output (kVA) at rated frequency and power factor, at any voltage up to 5 percent above or below rated voltage.          

C.      The subtransient reactance of the alternator shall not exceed 12 percent[3], based on the standby rating of the generator set.

D.      Provide an anti-condensation heater for the alternator for generator sets installed outdoors or in unheated environments[4]. 

2.04        Generator set Control. The generator set shall be provided with a microprocessor-based control system that is designed to provide automatic starting, monitoring, protection and control functions for the generator set.  The control system shall also be designed to allow local monitoring and control of the generator set, and remote monitoring and control as described in this specification.

The control shall be mounted on the generator set. The control shall be vibration isolated and prototype tested to verify the durability of all components in the system under the vibration conditions encountered.  

 

The generator set mounted control shall include the following features and functions: 

 

A.      Control Switches

              1.    Mode Select Switch.             The mode select switch shall initiate the following control modes.  When in the RUN or Manual position the generator set shall start, and accelerate to rated speed and voltage as directed by the operator.  In the OFF position the generator set shall immediately stop, bypassing all time delays.  In the AUTO position the generator set shall be ready to accept a signal from a remote device to start and accelerate to rated speed and voltage.

              2.    EMERGENCY STOP switch.             Switch shall be Red "mushroom‑head" push‑button.  Depressing the emergency stop switch shall cause the generator set to immediately shut down, and be locked out from automatic restarting.  The switch shall include a lockout provision for use in safely disabling the generator set for necessary service. 

              3.    RESET switch.   The RESET switch shall be used to clear a fault and allow restarting the generator set after it has shut down for any fault condition. 

              4.    PANEL LAMP switch.   Operating the panel lamp switch shall cause the entire panel to be lighted with DC control power.  The panel lamps shall automatically be switched off 10 minutes after the switch is operated, or after the switch is operated a second time.

              5.    Voltage and Frequency Adjustment.  The genset mounted control shall include digital raise/lower switches for adjustment of voltage and frequency. 

B.      Generator Set AC Output Metering.  The generator set shall be provided with a metering set including the following features and functions:

a)      Analog voltmeter, ammeter, frequency meter, and kilowatt (KW) meter[5].  Voltmeter and ammeter shall display all three phases.  Ammeter and KW meter scales shall be color coded in the following fashion: readings from 0‑90% of generator set standby rating: green; readings from 90‑100% of standby rating: amber; readings in excess of 100%: red.              
b)      Digital metering set, 0.5% accuracy, to indicate generator RMS voltage and current, frequency, output current, output KW, KW‑hours, and power factor.  Generator output voltage shall be available in line‑to‑line and line‑to‑neutral voltages, and shall display all three phase voltages (line to neutral or line to line) simultaneously. 
 

C.      Generator Set Alarm and Status Display. 

              1.    The generator set shall be provided with alarm and status indicating lamps to indicate non‑automatic generator status, and existing warning and shutdown conditions.  The lamps shall be high‑intensity LED type.  The lamp condition shall be clearly apparent under bright room lighting conditions.  The generator set control shall indicate the existence of all alarm, shutdown, and status conditions associated with the generator set, including all paralleling control functions and the engine ECM on an alphanumerical display on the genset.  The following alarm, shutdown, and status conditions are required, as a minimum: 

            low oil pressure (alarm)

            low oil pressure (shutdown)

            oil pressure sender failure (alarm)

            low coolant temperature (alarm)

            high coolant temperature (alarm)

            high coolant temperature (shutdown)

            engine temperature sender failure (alarm)

            low coolant level (alarm or shutdown‑‑selectable)

            fail to crank (shutdown)

            fail to start/overcrank (shutdown)

            overspeed (shutdown)

            low DC voltage (alarm)

            high DC voltage (alarm)

            weak battery (alarm)

            low fuel‑daytank (alarm)

            high AC voltage (shutdown)

            low AC voltage (shutdown)

            under frequency (shutdown)

            over current (warning)

            over current (shutdown)

            short circuit (shutdown)

            ground fault (alarm)

            over load (alarm)

            emergency stop (shutdown)

 

              2.    Provisions shall be made for indication of 8  customer‑specified alarm or shutdown conditions.  Labeling of the customer-specified alarm or shutdown conditions shall be of the same type and quality as the above specified conditions.  The non‑automatic indicating lamp shall be red, and shall flash to indicate that the generator set is not able to automatically respond to a command to start from a remote location. 

D.      Engine Status Monitoring. 

              1.    The following information shall be available from a digital status panel on  the generator set control :  

            engine oil pressure  (psi or kPA)

            engine coolant temperature (degrees F or C)

            engine speed (rpm)

            number of hours of operation (hours)

            number of start attempts

            battery voltage (DC volts)

 

              2.    The control system shall also incorporate a data logging and display provision to allow logging of a minimum of the last 20 warning or shutdown indications on the generator set, the time of the last fault of each type, and the number of faults of each type, and total time of operation at various loads as a percent of the standby rating of the generator set.   

E.      Engine Control Functions.

              1.    The control system provided shall include a cycle cranking system, which allows for user selected crank time, rest time, and # of cycles.  Initial settings shall be for 3 cranking periods of 15 seconds each, with 15-second rest period between cranking periods. 

              2.    The control system shall include an engine governor control, which functions to provide steady state frequency regulation as noted elsewhere in this specification.  The governor control shall include adjustments for gain, damping, and a ramping function to control engine speed and limit exhaust smoke while the unit is starting.  The governor control shall be suitable for use in paralleling applications without component changes.

              3.    The control system shall include time delay start (adjustable 0‑300 seconds) and time delay stop (adjustable 0‑600 seconds) functions.  

              4.    The control system shall include sender failure monitoring logic for speed sensing, oil pressure, and engine temperature which is capable of discriminating between failed sender or wiring components, and an actual failure conditions.   

F.       Alternator Control Functions:

              1.    The generator set shall include an automatic microprocessor-based voltage regulation system that is matched and prototype tested by the engine manufacturer with the governing system provided.   It shall be immune from misoperation due to load‑induced voltage waveform distortion and provide a pulse width modulated output to the alternator exciter.  The voltage regulation system shall be equipped with three‑phase RMS sensing and shall control buildup of AC generator voltage to provide a linear rise and limit overshoot.  The voltage regulation system shall be based on a full wave rectified input, pulse-width modulated output design.  The system shall include a torque‑matching characteristic, which shall reduce output voltage in proportion to frequency below an adjustable frequency threshold.  The voltage regulator shall include adjustments for gain, damping, and frequency roll‑off.  Adjustments shall be broad range, and made via digital raise-lower switches, with an alphanumeric LED readout to indicate setting level.    Rotary potentiometers for system adjustments are not acceptable.

              2.    Controls shall be provided to monitor the output current of the generator set and initiate an alarm (over current warning) when load current exceeds 110% of the rated current of the generator set on any phase for more than 60 seconds.  The controls shall shut down and lock out the generator set when output current level approaches the thermal damage point of the alternator (over current shutdown). The protective functions provided shall be in compliance to the requirements of NFPA70 article 445.

              3.    Controls shall be provided to individually monitor all three phases of the output current for 1, 2, or 3-phase short circuit conditions. The control/protection system shall monitor the current level and voltage. The controls shall shut down and lock out the generator set when output current level approaches the thermal damage point of the alternator (short circuit shutdown).

              4.    Controls shall be provided to monitor the KW load on the generator set, and initiate an alarm condition (over load) when total load on the generator set exceeds the generator set rating for in excess of 5 seconds.   Controls shall include a load shed control, to operate a set of dry contacts (for use in shedding customer load devices) when the generator set is overloaded.

              5.    An AC over/under voltage monitoring system that responds only to true RMS voltage conditions shall be provided.  The system shall initiate shutdown of the generator set when alternator output voltage exceeds 110% of the operator-set voltage level for more than 10 seconds, or with no intentional delay when voltage exceeds 130%.  Under voltage shutdown shall occur when the output voltage of the alternator is less than 85% for more than 10 seconds.             

              6.    A battery monitoring system shall be provided which initiates alarms when the DC control and starting voltage is less than 25VDC or more than 32 VDC[6].  During engine cranking (starter engaged), the low voltage limit shall be disabled, and if DC voltage drops to less than 14.4 volts for more than two seconds a "weak battery" alarm shall be initiated. 

G.      Control Interfaces for Remote Monitoring:

              1.    No field connections for control devices shall be made in the AC power output enclosure.  Provide the following features in the control system:            

              2.    Form "C" dry contact set rated 2A @ 12VDC to indicate existence of any alarm or shutdown condition on the generator set.

              3.    One set of contacts rated 2A @ 12VDC to indicate generator set is ready to load.  The contacts shall operate when voltage and frequency are greater than 90% of rated condition.

              4.    A fused 10 amp switched 12VDC power supply circuit shall be provided for customer use.  DC power shall be available from this circuit whenever the generator set is running.

              5.    A fused 20 amp 12VDC power supply circuit shall be provided for customer use.  DC power shall be available from this circuit at all times from the engine starting/control batteries. 

Part 3.   OPERATION

3.01        Sequence of Operation

A.      Generator set shall start on receipt of a start signal from remote equipment.  The start signal shall be via hardwired connection to the generator set control and a redundant signal over the required network connection.

B.      The generator set shall complete a time delay start period as programmed into the control.

C.      The generator set control shall initiate the starting sequence for the generator set.  The starting sequence shall include the following functions:

              1.    The control system shall verify that the engine is rotating when the starter is signaled to operate.  If the engine does not rotate after two attempts, the control system shall shut down and lock out the generator set, and indicate “fail to crank” shutdown.

              2.    The engine shall fire and accelerate as quickly as practical to start disconnect speed.  If the engine does not start, it shall complete a cycle cranking process as described elsewhere in this specification.  If the engine has not started by the completion of the cycle cranking sequence, it shall be shut down and locked out, and the control system shall indicate “fail to start”.

              3.    The engine shall accelerate to rated speed and the alternator to rated voltage. Excitation shall be disabled until the engine has exceeded programmed idle speed, and regulated to prevent over voltage conditions and oscillation as the engine accelerates and the alternator builds to rated voltage.

D.      On reaching rated speed and voltage, the generator set shall operate as dictated by the control system in isochronous, synchronize, load share, load demand, or load govern state.

E.      When all start signals have been removed from the generator set, it shall complete a time delay stop sequence.  The duration of the time delay stop period shall be adjustable by the operator.

F.       On completion of the time delay stop period, the generator set control shall switch off the excitation system and shall shut down.

              1.    Any start signal received after the time stop sequence has begun shall immediately terminate the stopping sequence and return the generator set to isochronous operation.

Part 4.   OTHER REQUIREMENTS

4.01        Prototype Testing (submit evidence of prototype testing; manufacturer’s certificate etc.)

4.02        Submittals. Within 10 days after award of contract, provide six sets of the following information for review:

Š       Manufacturer’s product literature and performance data, sufficient to verify compliance to specification requirements.

Š       A paragraph by paragraph specification compliance statement, describing the differences between the specified and the proposed equipment.

Š       Manufacturer's certification of prototype testing.       

Š       Manufacturer's published warranty documents.      

Š       Shop drawings showing plan and elevation views with certified overall dimensions, as well as wiring interconnection details.      

Š       Interconnection wiring diagrams showing all external connections required; with field wiring terminals marked in a consistent point‑to‑point manner.

Š       Manufacturer's installation instructions.

4.03        Factory Testing. 

A.      The generator set manufacturer shall perform a complete operational test on the generator set prior to shipping from the factory.  A certified test report shall be provided.  All testing shall be performed with calibrated metering.    

B.      Generator set factory tests on the equipment shall be performed at rated load and rated power factor. Generator sets that have not been factory tested at rated power factor will not be acceptable. 

C.      Make these bullets: run at full load, maximum power, voltage regulation, transient and steady‑state governing, single step load pickup, and function of safety shutdowns.          

.   

 

4.04        Training

A.      The equipment supplier shall provide training for the facility operating personnel covering operation and maintenance of the equipment provided.  The training program shall be not less than 16 hours in duration and the class size shall be limited to 5 persons.  Training date shall be coordinated with the facility owner.  Training shall take place at the local distributor’s authorized service facility with an identical piece of equipment as supplied as part of this contract.

4.05        Service and support

A.      The generator set supplier shall maintain service parts inventory for the entire power system at a central location which is accessible to the service location 24 hours per day, 365 days per year.   The inventory shall have a commercial value of $3 million or more.  The manufacturer of the generator set shall maintain a central parts inventory to support the supplier, covering all the major components of the power system, including engines, alternators, control systems, paralleling electronics, and power transfer equipment.

B.      The generator set shall be serviced by a local service organization that is trained and factory certified in generator set service.  The supplier shall maintain an inventory of critical power system replacement parts in the local service location.  Service vehicles shall be stocked with critical replacement parts.  The service organization shall be on call 24 hours per day, 365 days per year.  The service organization shall be physically located within 250 miles of the site.

C.      The manufacturer shall maintain model and serial number records of each generator set provided for at least 20 years.

 

Part 5.   GENERAL

5.01        Scope

A.      Provide complete factory assembled power transfer equipment with electronic microprocessor-based controls designed for fully automatic operation and including: surge voltage isolation, voltage sensors on all phases of the normal source and one phase of the emergency source, positive mechanical and electrical interlocking, and mechanically held contacts for both sources.

B.      The generator set manufacturer shall warrant transfer switches to provide a single source of responsibility for all the products provided.   Technicians specifically trained to support the product and employed by the generator set supplier shall service the transfer switches.  Technicians shall have passed qualification examinations on the product, and be certified by the manufacturer as capable of effectively servicing the equipment provided.

5.02        Codes and Standards

A.      The automatic transfer switch shall conform to the requirements of the following codes and standards:

              1.    UL1008.  The transfer switch shall be UL listed and labeled.

              2.    CSA C22.2, No. 14 – M91 Industrial Control Equipment.

              3.    CSA 282, Emergency Electrical Power Supply for Buildings

              4.    IEEE Standard C62.41 and C62.45.

              5.    NFPA70 – National Electrical Code.  Equipment shall be suitable for use in systems in compliance to Article 700, 701, and 702.

              6.    NFPA99 – Essential Electrical Systems for Health Care Facilities

              7.    NFPA110 – Emergency and Standby Power Systems.  The transfer switch shall meet all requirements for Level 1 systems.

              8.    IEEE446 – Recommended Practice for Emergency and Standby Power Systems for Commercial and Industrial Applications.

              9.    NEMA ICS10-1993 – AC Automatic Transfer Switches. 

B.      The transfer switch manufacturer shall be certified to ISO 9001 International Quality Standard and shall have third party certification verifying quality assurance in design/development, production, installation, and service, in accordance with ISO 9001.

a)       

Part 6.   PRODUCTS

6.01        Power Transfer Switch

A.      Ratings

              1.    Refer to the project drawings for specifications on the sizes and types of transfer switch equipment, withstand and closing ratings, number of poles, voltage and ampere ratings, enclosure type, and accessories.

              2.    Main contacts shall be rated for the operation voltage as installed. 

              3.    Transfer switches shall be rated to carry 100 percent of rated current continuously in the enclosure supplied, in ambient temperatures of ‑30 to +60 degrees C, relative humidity up to 95% (non‑condensing), and altitudes up to 10,000 feet (3000M).

              4.    Transfer switch equipment shall have withstand and closing ratings (WCR) in RMS symmetrical amperes greater than the available fault currents shown on the drawings.  The transfer switch and its upstream protection shall be coordinated.  The transfer switch shall be third party listed and labeled for use with the specific protective device(s) installed in the application.

B.      Construction

              1.    Transfer switches shall be double‑throw, electrically and mechanically interlocked, and mechanically held in the source 1 and source 2 positions.

              2.    Transfer switch internal wiring shall be composed of pre-manufactured harnesses that are permanently marked for source and destination.   Harnesses shall be connected to the control system by means of locking disconnect plug(s), to allow the control system to be easily disconnected and serviced without disconnecting power from the transfer switch mechanism.

              3.    Transfer switch shall be provided with flame retardant transparent covers to allow viewing of switch contact operation but prevent direct contact with line voltage components. 

              4.    Transfer switches shall be 3-pole or 4-pole as shown on the drawings.  3-Pole equipment shall be provided with a neutral bus and lugs.  The neutral bus shall be sized to carry 100% of the current designated on the switch rating.  4-Pole equipment shall include a neutral contact mechanism that is sized and designed exactly like the phase contacts, and connected on a common operating bar so that the neutral and phase contacts all operate at the same time.

              5.    Enclosures shall be UL tested and NEMA 1 type rated.  The enclosure shall provide NEC wire bend space when both sources and the load are all connected from either the top or bottom of the transfer switch.  The cabinet door shall be key‑locking.

C.      Connections

              1.    Field control connections shall be made on terminal blocks that are clearly and permanently labeled.

              2.    Transfer switch shall be provided with AL/CU mechanical lugs sized to accept the full output rating of the transfer switch.

6.02        Transfer Switch Control

A.      Solid‑state under voltage sensors shall simultaneously monitor both sources. Pick‑up and drop‑out settings shall be adjustable.

B.      Automatic controls shall signal the engine‑generator set to start upon signal from normal source sensor.  Solid‑state time delay start, adjustable from 0 to 10 seconds (factory set at 3 seconds) shall avoid nuisance start‑ups.  Battery voltage starting contacts shall be gold-flashed dry type contacts, factory wired to a field wiring terminal block.

C.      The switch shall transfer when the emergency source reaches the set point.  Provide a solid‑state time delay on transfer, adjustable from 0 to 300 seconds, factory set at 5 seconds.

D.      The switch shall retransfer the load to the normal source after a time delay retransfer, adjustable from 0 to 30 minutes, factory set at 10 minutes.  Retransfer time delay shall be immediately bypassed if the emergency power source fails.

E.      Controls shall signal the engine‑generator set to stop after a time delay, adjustable from 0 to 10 minutes, and factory set at 5 minutes, beginning on return to the normal source.

F.       The control system shall include field adjustable provisions to control the speed of operation of the transfer switch power contacts.  In addition, the control shall include a field-configurable in-phase monitor function that causes the transfer to be initiated only when the sources are in phase.  When in-phase transfer is enabled and transfer does not occur within 120 seconds, the control shall automatically transfer the load using delayed transfer.

G.      Provide a field-configurable exerciser clock with provisions for operating the generator set for a test period at 7, 14, 21, or 28-day intervals in either with-load or without-load configuration.  Operation time of the generator set shall be field configurable.  Exerciser clock functions that require setting the test time by pressing an exercise button at the desired time of exercise (only) shall not be acceptable.

H.      Power for the transfer switch operation shall be derived from the source to which the load is being transferred.

I.        The transfer switch shall be provided with a battery charger for the generator set starting batteries.  The battery charger shall be a float type charger rated 15 amps.  The battery charger shall include an ammeter for display of charging current and shall have fused AC inputs and DC outputs.  The charger shall also include fault indications for high and low dc voltage, and supply power failed, and dry contacts for external indication of these fault conditions. 

6.03        Front Panel Devices:

Provide control switches mounted on cabinet front for:

A.      Test ‑ Simulates normal power loss to control for testing of generator set.  Controls shall provide for a test with or without load transfer.

B.      Override ‑ Momentary position to override retransfer time delay and cause immediate return to normal source, if available.

C.      Provide LED-type switch position and source available indicator lamps on the front of the transfer switch cabinet.

6.04        Control Interface

A.      The transfer switch will provide an isolated relay contact for starting of a generator set.   The relay shall be normally held open, and close to start the generator set. 

B.      Provide one set Form C auxiliary contacts, operated by transfer switch position, for remote indication of transfer switch position.  Contacts shall be rated 10 amps at 250 VAC.

6.05        Enclosure

A.      The cabinet door shall be key‑locking.

B.      Transfer switch equipment shall be provided in a NEMA 1 or better enclosure, as indicated on the drawings or by the installation location.

C.      The cabinet shall provide code-required wire bend space at point of entry as shown on the drawings.  Manual operating handles shall be accessible to authorized personnel only by opening the key‑locking cabinet door.  Transfer switches with manual operating handles located on outside of cabinet do not meet this specification and are not acceptable.

Part 7.   OPERATION

7.01        Open Transition Sequence of Operation

A.      Transfer switch normally connects an energized utility power source (source 1) to loads and a generator set (source 2) to the loads when normal source fails.  The normal position of the transfer switch is source 1 (connected to the utility), and no start signal is supplied to the genset.

B.      Generator Set Exercise (Test) With Load Mode. The control system shall be configurable to test the generator set under load.  In this mode, the transfer switch shall control the generator set in the following sequence:

              1.    Transfer switch control shall initiate the exercise sequence at a time indicated in the exercise timer program, or when manually initiated by the operator (test).

              2.    When the control systems senses the generator set at rated voltage and frequency, it shall operate to connect the loads to the generator set by opening the normal source contacts, and closing the alternate source contacts a predetermined time period later.  The timing sequence for the contact operation shall be programmable in the controller.

              3.    The generator set shall operate connected to the load for the duration of the exercise period.  If the generator set fails during this period, the transfer switch shall automatically reconnect the generator set to the normal service.

              4.    On completion of the exercise period, the transfer switch control shall operate to connect the loads to the normal source by opening the alternate source contacts, and closing the normal source contacts a predetermined time period later.  The timing sequence for the contact operation shall be programmable in the controller.

              5.    The transfer switch shall operate the generator set unloaded for a cooldown period, and then remove the start signal from the generator set.  If the normal power fails at any time when the generator set is running, the transfer switch shall immediately connect the system loads to the generator set.

C.      Generator Set Exercise (Test) Without Load Mode. The control system shall be configurable to test the generator set without transfer switch load connected.  In this mode, the transfer switch shall control the generator set in the following sequence:

              1.    Transfer switch control shall initiate the exercise sequence at a time indicated in the exercise timer program, or when manually initiated by the operator.

              2.    The control system shall operate the generator set unloaded for the duration of the exercise period.

              3.    At the completion of the exercise period, the transfer switch control shall remove the start signal from the generator set.  If the normal power fails at any time when the generator set is running, the transfer switch shall immediately connect the system loads to the generator set.

Part 8.   OTHER REQUIREMENTS

8.01        Factory Testing.  The transfer switch supplier shall perform a complete operational test on the transfer switch prior to shipping from the factory.  A certified test report shall be available on request.  Test process shall include calibration of voltage sensors.

8.02        Service and support

A.      The manufacturer of the transfer switch shall maintain service parts inventory at a central location which is accessible to the service location 24 hours per day, 365 days per year.

B.      The transfer switch shall be serviced by a local service organization that is trained and factory certified in both generator set and transfer switch service.  The supplier shall maintain an inventory of critical replacement parts at the local service organization, and in service vehicles.  The service organization shall be on call 24 hours per day, 365 days per year.

C.      The manufacturer shall maintain model and serial number records of each transfer switch provided for at least 20 years.

 



[1] The power factor used for single phase generator sets is 1.0.

[2] 105C rise results in best practical motor starting and short circuit performance, as well as resulting in best equipment life. Use of alternators with up to 150C temperature rise can make surface temperatures high enough to be dangerous.   

[3] Subtransient reactance is the most important parameter in defining alternator performance.  With higher subtransient reactance, motor starting, voltage dip and short circuit performance is compromised.

[4] Anti-condensation heaters should be included for all generator sets mounted in outdoor enclosures, located in coastal or tropical environments, and for all medium and high voltage alternators.  Maintaining alternator temperature at temperatures higher than ambient prevents condensation that can result in premature alternator failure.

[5] An acceptable alternate to the specified bargraph displays would be conventional needle-type instruments, with the color coding required located on the display of the meter.  Needle type instruments are susceptible to misoperation due to non-linear distortion, but provide needed indication of trends and stability.

[6] For 12VDC nominal voltage systems, use Undervoltage at 8VDC and overvoltage at 16VDC.