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,
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 manufacturerÕs
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
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,
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.
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. 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. 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
Òfail to crankÓ 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 Òfail to startÓ.
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; manufacturerÕs certificate etc.)
4.02
Submittals.
Within 10 days after award of contract, provide six sets of the following
information for review:
á
ManufacturerÕs product literature and
performance data, sufficient to verify compliance to specification
requirements.
á
A paragraph by paragraph specification
compliance statement, describing the differences between the specified and the
proposed equipment.
á
Manufacturer's certification of prototype
testing.
á
Manufacturer's published warranty
documents.
á
Shop drawings showing plan and elevation views
with certified overall dimensions, as well as wiring interconnection
details.
á
Interconnection wiring diagrams showing all
external connections required; with field wiring terminals marked in a
consistent point‑to‑point manner.
á
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 distributorÕs
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.