Mega POWER+ 250KW - Gamatronicgap.gamatronic.com/distributors/GamaWebSite/Downloads/Mega/... · Gamatronic Electronic Industries Ltd. 2 Mega Power+ Tender Specifications Gamatronic

Har Hotzvim Industrial Park, 14 Hartom St., PO Box 45029, Jerusalem 97774, Israel

Tel: +972-2-588-8222 Fax: +972-2-582-8875 Email: [email protected] web: www.gamatronic.com

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Release 1.1, February 2012

Gamatronic Electronic Industries Ltd.

2 Mega Power+ Tender Specifications


Har Hotzvim Industrial Park 14 Hartom St., PO Box 45029, Jerusalem 91450 Israel Tel: +972-2-588-8222 Fax: +972-2-582-8875 Email: [email protected] Website: www.gamatronic.com

The equipment described in this document is not intended to be used in connection with any application requiring fail-safe performance, unless the application design includes appropriate redundancy. This exclusion includes, but is not limited to, the direct operation of any life support system or any other system whose failure could lead to serious injury, death, environmental damage or mass destruction.

Copyright 2012 by Gamatronic Electronic Industries Ltd. All rights reserved worldwide.

Any representations in this document concerning the performance of Gamatronic's product(s) are for informational purposes only and are not warranties of future performance, either express or implied. Gamatronic's standard limited warranty, stated in its sales contract or order confirmation form, is the only warranty offered by Gamatronic Electronic Industries Ltd. in relation thereto.

The information contained in this document is proprietary and is subject to all relevant copyright, patent and other laws protecting intellectual property, as well as any specific agreement protecting Gamatronic's rights in the aforesaid information. Neither this document nor the information contained herein may be published, reproduced or disclosed to third parties, in whole or in part, without the express, prior, written permission of Gamatronic. In addition, any use of this document or the information contained herein for any purposes other than those for which it was disclosed is strictly forbidden.

Gamatronic reserves the right, without prior notice or liability, to make changes in equipment design or specifications.

Information supplied by Gamatronic is believed to be accurate and reliable. However, no responsibility is assumed by Gamatronic for the use thereof nor for the rights of third parties which may be affected in any way by the use thereof.

This document may contain flaws, omissions or typesetting errors; no warranty is granted nor liability assumed in relation thereto unless specifically undertaken in Gamatronic Electronic Industries Ltd. sales contract or order confirmation. Information contained herein is periodically updated and changes will be incorporated into subsequent editions. If you have encountered an error, please notify Gamatronic Electronic Industries Ltd. All specifications are subject to change without prior notice.


Mega Power+ Tender Specifications 3

TABLE OF CONTENTS

1. SCOPE..................................................................................................................................4

2. GENERAL REQUIREMENTS ...............................................................................................5

3. STANDARDS ........................................................................................................................6

4. GENERAL VENDOR REQUIREMENTS...............................................................................6

5. ENVIRONMENTAL CONDITIONS........................................................................................6

6. SYSTEM OPERATION .........................................................................................................7

7. INPUT STAGE REQUIREMENTS ........................................................................................8

8. OUTPUT POWER REQUIREMENTS...................................................................................9

9. SYSTEM..............................................................................................................................10

10. THERMAL DESIGN ............................................................................................................11

11. MAINTAINABILITY..............................................................................................................11

12. QUALITY AND RELIABILITY..............................................................................................11

13. EQUIPMENT CONSTRUCTION.........................................................................................12

14. CONTROL, INDICATION AND ALARM..............................................................................13

15. EVENTS LOG .....................................................................................................................14

16. WEB INTERFACE...............................................................................................................14

17. INSTALLATION AND COMMISSIONING ...........................................................................14

18. PRODUCT WARRANTY.....................................................................................................15

19. MANUALS ...........................................................................................................................15

20. FAMILIARIZATION TRAINING. ..........................................................................................15

21. SYSTEM HAND-OVER AND ACCEPTANCE.....................................................................15



1. Scope

1.1 This document covers the requirements for the delivery to site, installation, commissioning and maintenance of the latest state-of-the-art patented modular Uninterruptible Power Supply (UPS) system. The UPS system shall be a single unit, complete with modular and parallel redundancy.

1.2 The UPS shall be composed of multiple 25 kVA/kW power modules. The capacity of the UPS shall be scalable by simply plugging in additional 25 kVA/kW power modules to increase the capacity up to a maximum of 250 kVA/kW.

1.3 Each power module has its own, built-in controller, rectifier and inverter. For an N+1 system the UPS shall have N+1 controllers, rectifiers and inverters.

1.4 Electrical configuration / topology for UPS unit shall be double-conversion, on-line, including Bypass, as described by IEC 62040-3, Annex A:

1.4.1 "Single UPS with a common rectifier, inverter and Battery" see section A.1.2 ,figure A.1 and A.4.

1.4.2 In regular mode, the rectifier charges the batteries and feeds the inverter. The load is powered from the inverter.

1.4.3 The load gets power from the Bypass in situations of main path fault or overload.

1.5 UPS units are classified as VFI – SS – 111 by IEC 62040-3.

1.6 The batteries are connected directly to the main dc bus without any switch, boost inverter, etc.

1.7 In the event of a mains failure, the UPS output shall be fed by a single conversion of the dc to ac inverter.



2. General Requirements

2.1 The UPS system shall be designed to supply continuous regulated ac power to critical loads, regardless of voltage variations and transient peaks, frequency variations, short or long power cuts within the limits of the scope of supply specified, 24 hours a day and 365 days a year.

2.2 Most of the maintenance can be carried out live without any interruption to customer critical loads. To achieve this, the power modules shall be hot swappable at anytime without having to switch the UPS into maintenance bypass mode.

2.3 The UPS system shall consist of the following: -

2.3.1 True online battery double conversion UPS topology.

2.3.2 True sinusoidal wave output.

2.3.3 Each power module shall contain its own, built-in controller, rectifier and inverter.

2.3.4 Each power module shall be able operate independently with out any need for external controller.

2.3.5 The power modules shall be hot-swappable and while the system is running live, changing modules or controller shall have no impact on the load.

2.3.6 A power module shall not be restricted to any specific slot. Power modules can be installed without having to pre-configure. Configuration shall be entirely automated.

2.3.7 The 25 kVA/kW Power Module shall reduce the total harmonics distortion to 5% by implementing power factor correction techniques, operating in continuous current mode and an input power factor of 0.99

2.3.8 The system shall consist of 10 power modules, 25 kVA/kW each.

2.3.9 The system shall have only one main controller, which shall be hot-swappable. In the event that the controller fails or is removed for maintenance, the system shall continue to supply the load without transferring the load to maintenance bypass.

2.3.10 The system output power shall be synchronized within the power modules and shall not require external synchronization.

2.3.11 When the power modules are hot-swapped, the entire system load will be shared equally by all modules on the system. This process shall be done in zero time and without disturbance to the critical load.

2.3.12 The UPS system shall be upwardly scaleable by simply adding UPS power modules, with no need of any additional parts.

2.3.13 Each power module’s weight should be no more than 35 kg.

2.3.14 UPS system footprint shall be 67 (D) x 65.5 (W) cm.

2.3.15 UPS system height shall be 197 cm.

2.3.16 UPS system weight shall vary from 192 kg for 25 kVA/kW system to 510 kg for 250 kVA/kW system.

2.3.17 The system shall contain one centralized hybrid 250 kVA static switch.

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Battery

Ac input Ac output Dc link

Inverter Rectifier / Charger



3. Standards

• IEC 62040 part 1: Uninterruptible power systems (UPS) - Part 1: General and safety requirements for UPS.

• IEC 62040 part 2: Uninterruptible power systems (UPS) - Part 2: Electromagnetic compatibility (EMC) requirements.

• IEC 62040-3: Method of specifying the performance and test requirements. UPS classification as VFI – SS – 111

• ISO 9001: Quality Standard Assurance System of the UPS manufacturer.

4. General Vendor Requirements

4.1 The principal shall have proven track records with existing installations successfully undertaken by the principal themselves for the installation of the modular UPS system.

4.2 The principal shall have well trained technicians at service centers located throughout the country to provide support for the UPS.

4.3 The principal shall have sufficient UPS spare parts stocked at the nearest authorized service centers or it branches to provide fast and efficient after sales services.

4.4 The principal shall keep the spare parts in stock for 5 years after the UPS is declared obsolete.

4.5 The principal shall have all the required tools and testing and measuring equipment needed to provide professional service and support for the UPS during installation and throughout the warranty period.

4.6 The principal shall support the installation and maintenance of the UPS system by their own engineers and authorized service centers.

4.7 The principal shall provide catalogues with relevant technical data, includingt the dimensions and weight of the UPS and batteries.

5. Environmental Conditions

5.1 The UPS system shall operate satisfactorily under the following ambient and environmental conditions:

5.1.1 Operating Temperature: -10 °C to 40 °C during normal operation.

5.1.2 Storage Temperature: -20 °C to 60 °C.

5.1.3 Relative humidity: 95 % maximum without condensation.

5.1.4 Altitude: from sea level to 1500 m without derating.

5.1.5 UPS protection level: IP20.



6. System Operation

6.1 The UPS shall be designed to operate as a true online system in the following modes:

6.1.1 Normal: The ac mains supply shall be rectified by high frequency IGBT rectifier into regulated dc voltage for powering the dc/ac inverter and for charging the batteries. The dc/ac inverter shall be PWM 3 levels IGBT and the output voltage shall be a true sinusoidal wave.

6.1.2 Mains failure: In the event of fluctuations or total failure of main's voltage, the batteries shall be online with no transfer time to provide the power to the dc/ac inverter to power critical loads without any disruption.

6.1.3 Battery Bank: The battery bank function shall provide the backup time as specified in the tender specification.

6.1.4 During backup mode, the audible and continuous visual alarm shall be indicated on the front LCD panel. The alarm is also available through the SNMP port for interfacing to a computer or building control system. When ac mains return to normal, the UPS shall resume normal mode and continue to provide quality output to the load without disturbance while continuing to charge the battery at the same time.

6.1.5 Recharging: When the ac mains power supply is restored, the UPS shall automatically resume recharging the batteries after a short power walk-in period. This charging shall cause no interference or disruption to the critical load.

6.1.6 Bypass: The UPS system shall consist of multiples of 25 kVA/kW power module, and a bypass hybrid circuit for high availability. When a power module fails, the other modules are not affected and continue to provide the power output to the critical load as long as the load is less than remaining modules power capacity, otherwise the load will be transferred automatically to bypass.

6.2 Online Maintenance: The UPS centralized bypass system shall be designed as such that maintenance can be performed live, i.e. while the system is operating and without causing any disruption to the critical load. The N+1 UPS system shall have the hot- swap feature to provide the capability to add/remove/replace the power modules

6.3 Phase Synchronization: The output power to the load shall be synchronized within the power module, to power the critical load. The UPS shall be synchronized to the ac supply line.

6.4 Upgradeability: The UPS system shall be capable of being upgraded to a higher capacity by simply adding 25 kVA/kW power modules. Addition of these power modules shall be “hot- swap”, i.e., the power module is added to the system live with no disruption to the critical loads. Similarly, removing the power modules can downsize the UPS system. The power modules can be utilized with other UPS of the same or different capacity.

6.5 Spare or Redundant Power Modules (N+1 or N+x): If required the spare power modules are incorporated as part of the total system unit. The minimum (N+1) redundancy unit shall be 1 × 25 kVA/kW power module.

6.6 For higher redundancy (N+x), the user may choose to have 10%, 20% or higher capacity. These spare power modules can be utilized with other UPS system of different capacity in the same building or plant provided the power modules are rated at 25 kVA/kW.

6.7 These redundant power modules shall act as hot standby units to eliminate the need for “around-the-clock” emergency services.

6.8 Fault Tolerance: The combination of the modular UPS and the parallel redundant architecture shall confine the component or PCB failures to a single power module. The remainder of the system power modules shall not be affected and shall continue to provide protection to the critical load. With the N+1 parallel redundant architecture, the UPS faulty power module is isolated from the working units thus providing the system fault tolerance.



7. Input Stage Requirements

The UPS is designed to operate with the following input characteristics:

7.1 Input Voltage: 3 phase 400 +15% and -20%, 4 wire system

7.2 Frequency: 47 - 63 Hz

7.3 Power Factor: > 0.99 Without external correction filters

7.4 Power Walk-In: > 60 second

7.5 Transients - Complies with: IEC801-5: Immunity to Surge IEC801-4: Immunity to Fast Transient (Without the use of isolation transformer)

7.6 Rectifier components: IGBTs

7.7 Input current: 3 x 42 A protected per power module per phase

7.8 THDI: 5% at nominal load



8. Output Power Requirements

The UPS system shall continuously provide high-quality output power to the load with the following characteristics:

8.1 Output voltage: 3 phase, 4 wire 380 Vac, 400 Vac or 415 Vac with ± 1 % range

8.2 Frequency: 50, 60 Hz ± 0.1%

8.3 Output frequency: synchronized to the ac power line, 47 -53 Hz, 57-63Hz.

8.4 Power Factor : 1

8.5 Inverter efficiency (dc-ac): 98% at full load

8.6 System efficiency (ac-ac): 96 %

8.7 Dynamic response to 100% load step: 2%

8.8 Phase Displacement: At balanced load: 120 ° ± 1 ° At 100% unbalanced load: 120 ° ± 1 °

8.9 Output total harmonic voltage distortion (THDv) With linear load: < 2% With non-linear load (Crest factor): < 5 %

8.10 Inverter:

8.10.1 Inverter nominal power per module: 25 kVA/kW

8.10.2 Input dc voltage range: ±320 – ±460 Vdc

8.10.3 Inverter dc current at minimum dc voltage: 40 Amps per power module

8.10.4 Inverter switching/regulation technology: Pulse Width Modulation (PWM)

8.10.5 Inverter power switching components: IGBT

8.10.6 Inverter current limit: 37 A /module

8.10.7 Inverter efficiency (dc-ac): At 50% load: >97 % At 75% load: >97.5 % At 100% load: >98 %

8.11 Parallel redundant architecture, transfer time: 0 second

8.12 Dc characteristics

8.12.1 Dc voltage: ± 384 - ± 432 Volts under normal operation

8.12.2 Dc ripple: 1 %

8.12.3 Nominal float charge voltage: 13.5 Vdc per battery

8.12.4 Dc over-voltage: 14.8 Vdc per battery , configurable

8.12.5 PFC charger

8.13 Cooling:

8.13.1 Forced, fan speed is microprocessor-controlled

8.13.2 Fan fault alarm shall be triggered when any fan fail in any power module

8.13.3 Maximum power module capacity shall be reduced to 20 kW when a fault occur on that particular module



9. System

The UPS system shall include:

• housings to contain sufficient power modules to provide a minimum of N+1 redundant configuration,

• main touch screen controller, and

• hybrid static switch.

The user can choose the redundancy of 1 or more modules as required. The system shall be scalable to 250 kVA/kW in a single UPS system.

The operation is described below:

9.1 Rectifier

9.1.1 The rectifier shall be located in the power module.

9.1.2 The rectifier shall be rated to provide full load current to the inverter, simultaneously providing required charge current to charge the battery blocks.

9.1.3 The rectifier is also rated to restore the battery to 90 % of its full-charge condition period not exceeding 5 hour following a maximum allowable discharge cycle for batteries, to provide 15 minutes backup time.

9.1.4 The rectifier shall have protection built-in so as to eliminate the possibility of battery being overcharge and rectifier damage.

9.1.5 The rectifier shall have built-in protection to eliminate battery overcharging and rectifier damage.

9.1.6 In the event of failure, the rectifier and it’s associated components in the UPS power module shall automatically shut itself down, further isolating itself without leading to an entire UPS system shutdown

9.2 Inverter

9.2.1 Inverter failure, in particular module shall not affect the entire system. The faulty module will shutdown and isolate itself to allow all the remaining modules in the UPS system continue provide output AC power without affecting the critical load.

9.2.2 The output of the inverter of all the power modules shall be phase synchronized without any need of external controller resulting in the output having an identical and matched input and output power supply voltage.

9.2.3 The inverter shall be able to restart automatically on the availability of a power source even after prolonged power failure, which may cause the battery to discharge to minimum.

9.3 Parallel Architecture Circuit

9.3.1 In the event that one power module is faulty the UPS shall not be required to switch over to mains or generator supply.

9.3.2 The parallel architecture shall allow the power module to isolate itself. the load is automatically transferred and shared equally among the remaining modules and the UPS continues to operate normally with no disrupting the load.

9.4 Battery

9.4.1 The batteries shall be rechargeable valve regulated, sealed, lead acid, maintenance free and the construction shall be such that no maintenance is required during operation.

9.4.2 The batteries shall have a minimum designed life of 5 years and operate at a temperature and humidity as recommended by the manufacturer specifications.

9.4.3 The batteries shall be able to withstand rapid charging without damage. The battery shall recover 90% of its full capacity in less than 5 hour on recharging after full discharge (for 15 minutes battery back-up).

9.4.4 Manufacturer’s catalogue, technical data, performance curve and etc. shall be submitted to prove the adequacy of needed capacity.



9.4.5 Batteries safety: at least Category HB, according to UL-94 standard.

9.5 The overall system efficiency (ac-ac) on double conversion mode shall exceed 96 % at full load.

10. Thermal Design

10.1 Airflow from the front side to back side of the UPS shall be unrestricted.

10.2 The UPS shall not require additional forced cooling.

10.3 The module includes built-in thermal protection.

10.4 The UPS heat dissipate shall not be more than 4% of its maximum output load (in Watts).

11. Maintainability

Easy maintainability of the UPS system shall be regarded as important feature in the design and shall embody safety and simplicity.

11.1 Maintenance may performed at any time without a need to shut down the UPS or isolate the batteries. During maintenance the UPS shall be able to provide the full protection to the system without any disruption to the critical loads using the N+1 configuration.

11.2 The power modules shall be easily accessible from the front by pulling out the modules while the system is still running. No special equipment or tools are required for the dismantling of modules. The modules shall be removable by sliding out of the respective slot.

11.3 After the inspection and cleaning, the modules shall be easily reinserted into the system without having to carry out any manual phase synchronization. Each power module should not weigh more than 35 kg.

11.4 The principal shall be able to support the system for 5 years after the system has been declared obsolete by the principal.

11.5 The principal shall demonstrate that the Mean-Time-To-Repair or replace the power modules shall be less than 15 minutes by either trained or untrained staff.

12. Quality and Reliability

12.1 The UPS shall be manufactured under recognized international standards of quality assurance such as ISO9001, CE (or equivalent) compliance.

12.2 To ensure a high reliability for the continuous operation, the components used in the UPS shall be source from suppliers certified of ISO9001 standards.

12.3 The UPS shall be required to pass full factory acceptance test.

12.4 If required, the UPS will undergo a 24-hour full load test.

12.5 The UPS shall be tested in accordance to the IEC 62040-3 Standard and shall comply with standards specified in section 3.



13. Equipment Construction

13.1 The main parts of the UPS system, namely the power modules and controller, are hot-swappable.

13.2 The UPS system shall comprise of 1 to 10 UPS modules of 25 kVA/kW each, system controller, centralized static switch and distribution block.

13.3 The battery bank is common to all the modules and can include more than one branches to gain battery redundancy if desired.

13.4 The system is fully functional without the system controller, or in the event that the monitor display is inhibited. The system controller is not mandatory for the operation of the UPS.



14. Control, Indication and Alarm

The UPS system shall include the following control, indication and alarm system as a minimum requirement in addition to the control equipment as specified above;

14.1 Local Control Panel 7” TFT color, touch LCD power flow diagram indications

14.1.1 Ac line status and measurements.

14.1.2 Bypass line status and measurements.

14.1.3 Inverter line status and measurements.

14.1.4 Output line status and measurements.

14.1.5 Battery and battery test status.

14.1.6 Load on bypass.

14.1.7 Load on inverter.

14.1.8 Load level.

14.1.9 Battery mode.

14.1.10 Double conversion mode.

14.1.11 Communications status with modules and static switch.

14.1.12 Synchronization status.

14.1.13 UPS ON .

14.2 The local LCD indicator shall be located on the system cabinet. The following information shall be available on the LCD panel:

14.2.1 System output power bar graph showing watts (W) and voltampere (VA).

14.2.2 System ac input and output voltages.

14.2.3 System ac input and output current.

14.2.4 System ac input and output frequency.

14.2.5 System output power factor (PF).

14.2.6 Input and output voltages and currents for per module.

14.2.7 UPS total capacity.

14.2.8 Dc voltage levels.

14.2.9 Power module status.

14.2.10 Event log.

14.2.11 Static switch status.

14.2.12 Additional monitor and control information.

14.3 Power Module Indicators:

14.3.1 Module fault indicator.

14.3.2 Input OK LED.

14.3.3 Output OK LED.



15. Events log

15.1 The UPS shall be able to record up to 500 events

15.2 For each event the log system shall capture all system measurements, modules input, output and dc voltages, static switch's inverter, bypass and output voltages, status of each module, etc.

16. Web Interface

The system shall include a browser-based Inter/Intranet interface enabling the user to monitor the UPS and shall have the following monitoring capabilities such as:

16.1 UPS input parameters, i.e. voltage, frequency.

16.2 UPS output parameters, i.e. voltage, frequency, load current.

16.3 UPS battery status.

16.4 Events log and fault alarm indication.

16.5 Status and parameters of each power module.

17. Installation and Commissioning

17.1 Preparation of the installation site:

The purchaser shall prepare all infrastructure needed in order to allow UPS installation and operation.

The manufacturer’s representative shall follow the manufacturer’s installation recommendations.

17.2 Installation Prior of installation UPS system, the manufacturer’s representative shall carry out a joint inspection of all items of equipment. Defective components shall be replaced at no additional cost to the purchaser. Installation plans, schedule and list of personnel (complete with credentials) shall also be submitted.

17.3 Commissioning

17.3.1 Site Acceptance Tests (SAT) On the completion of all installation works, a final test shall be conducted and shall include performance and function tests.

17.3.2 The UPS testing shall be in accordance to IEC 62040-3, which includes tests of mains failure, mains return, transfer, backup time, recharge time, etc.

17.3.3 The manufacturer’s representative shall prepare a testing schedule for the mentioned tests and shall submit it to the purchaser for approval and certification.

17.3.4 The purchaser reserves the right to include additional tests or modify the test schedule. The test schedule shall include tests to determine UPS system functionality, efficiency, overload capability, short-circuit, etc.



18. Product Warranty

18.1 Warranty of the UPS expires 12 months after the successful commissioning of the UPS, or 18 months after delivery if manufacturer's engineer test and confirm the installation. A Certificate of Completion shall be issued after the successful SAT.

18.2 During the warranty period he UPS shall function without failure.

18.3 The normal warranty period under the sales terms and condition shall apply during this period.

18.4 If the customer desires, an extended warranty can be obtained, at extra cost.

19. Manuals

Each UPS system shall be provided with a set of connection diagrams showing the terminals and connections. All wiring, schematic and layout drawings shall be submitted for the approval of the representative. Instruction manuals for the installation, operation and maintenance of the UPS system shall be in accordance with the general requirements of the specification.

20. Familiarization Training

Familiarization testing will take place during or following the system acceptance test (as appropriate to the situation). The training shall include the following elements:

20.1 UPS familiarization training

20.2 Training schedule and agenda

20.3 Operation and instruction manuals

20.4 Certificate of attendance

21. System Hand-Over and Acceptance

Hand-over and acceptance of the system shall occur after system installation has been completed, and shall include:

21.1 Endorsement of defect list.

21.2 Endorsement of test results.

21.3 Certificate of acceptance.

Documents

Mega POWER+ 250KW - Gamatronicgap.gamatronic.com/distributors/GamaWebSite/Downloads/Mega/... · Gamatronic Electronic Industries Ltd. 2 Mega Power+ Tender Specifications Gamatronic