SUGGESTED SPECIFICATION
For GE Zenith ZDEC 2020
Low Voltage (600V) Modular Paralleling Switchgear
Section 16 – Electrical Standby Power Generation Systems
Note to Specifier:
Items bracketed [ ] are optional features and functionality.
Items bracketed < >, have multiple choices.
PART 1 GENERAL
1.01 WORK INCLUDED
A. Provide a complete Digital Power control system to automatically start and parallel ____ <2, 3, 4, 5, or 6> engine generator sets, rated ______kW ____ VAC, at 0.8 PF for three phase, _____ <3 or 4> wire, ______<50 or 60> Hz.
B. The control cabinets shall be freestanding and shall be based on a modular, and rack able design principle. A generator module must be capable of field installation in less than one hour.
C. The electrical contractor shall be responsible for supplying a complete system short circuit analysis and coordination study for all protective devices. The contractor must also supply and coordinate the duties of an independent testing firm to perform on-site physical inspection and testing of all protective devices and ensure the devices have been calibrated and set to the settings determined in the coordination study. This work must be performed prior to energizing the equipment and field start-up will not be allowed until verification is provided. Each protective device shall bear the testing firm certification label to verify appropriate testing has been performed.
1.02 REFERENCE STANDARDS
A. The control equipment covered by these specifications shall be designed, tested and assembled by a manufacturer that is ISO 9001:2000 registered and in accordance with the latest applicable standards of ANSI, IEEE, and NEMA.
B. The certification labels shall be for the entire equipment and shall be affixed by the final manufacturer, who certifies and is responsible for the total finished control assembly. Certification labels of sub-suppliers (e.g. enclosure/breaker/bus assembler) are not acceptable.
NOTE TO SPECIFER: USE THIS PARAGRAPH FOR UL891 SWITCHBOARD CONSTRUCTION.
C. [The low voltage switchboards and protection devices in this specification shall be designed, manufactured, and tested according to the latest revision of the following standards:
1. NEMA PB-2, Dead front Distribution Switchboards
2. UL 891, Dead front Switchboards
3. UL 489, Molded Case Circuit Breakers and Circuit Breaker Enclosures
4. NEMA AB-1, Molded Case Circuit Breakers and Molded Case Switches
5. NFPA 70, National Electrical Code
NOTE TO SPECIFER: USE THIS PARAGRAPH FOR UL1558 LOW VOLTAGE SWITCHGEAR CONSTRUCTION.
C. [The low voltage switchgear and protection devices in this specification shall be designed, manufactured, and tested according to the latest revision of the following standards:
1. UL1558 Metal Enclosed Switchgear
2. UL 1066, Low Voltage AC and DC Power Circuit Breakers Used in Enclosures
3. NFPA 70, National Electrical Code
4. ANSI C37.13, Low Voltage AC Power Circuit Breakers Used in Enclosures
5. ANSI C37.16, Preferred Ratings, Related Requirements, and Application Recommendations for Low Voltage Power Circuit Breakers and AC Power Circuit Protectors
6. ANSI C37.17, Trip Devices for AC and General Purpose DC Low Voltage Power Circuit Breakers
7. ANSI C37.50, Testing Procedures for Low Voltage AC Power Circuit Breakers Used in Enclosures
1.03 SUBMITTALS
A. Electronic copy of Submittal documents shall be provided within Fifteen (15) Business days after written notice of customer purchase order and shall include the following documents:
1. General arrangement (outline/dimensional) drawings, showing dimensions, weights, shipping sections, anchoring location(s), leveling channels and cable conduit entrance location(s).
2. Sequence of operation.
3. Major bill of materials.
4. Complete point-to-point field interconnect wiring diagrams showing connections between paralleling controls and Engine Generators and other external equipment requiring control-wiring connections.
5. A specification clarification and deviation statement.
PART 2 PRODUCTS
2.01 GENERAL REQUIREMENTS
A. The equipment described is a GE Zenith ZDEC 2020 Modular Paralleling Switchgear system as manufactured and assembled by GE Zenith Controls, Inc. and is the basis for the system design. Any alternates to this bid shall only be considered if a complete written description of the proposed system along with any variances from the specification, are received Five (5) business days prior to bid due date. Any variances not specifically enumerated prior to bidding shall be considered non-responsive. Costs incurred to modify the building and/or interfacing equipment, which is affected as a result of an alternate, shall be the responsibility of the contractor.
B. Systems using paralleling controls mounted on the engine generator are not acceptable.
C. Systems that do not have hardwired (non-touchscreen HMI based) controls for manual start/stop, synchronizing, and breaker open/close are not acceptable.
D. Any request for substitution(s) must be submitted Ten (10) business days before the scheduled bid date, and must include a technical proposal of adequate detail to fully define the system offered.
2.02 CONTROL SECTION CONSTRUCTION
A. Control enclosures shall be freestanding, floor supported, with front access required only after installation and commissioning. Removable lifting eyes shall be supplied for shipping and lifting purposes.
B. Control enclosure finish shall be RAL 9003 (White); electro statically charged polyester powder paint, minimum 1.5 mils in density. Finish shall be suitable for indoor and outdoor environments.
C. Control section(s) shall contain a maximum voltage of 120VAC, with finger-safe components to minimize shock hazards being initiated by accidental contact.
D. Door(s) shall be provided with sufficient hinges and stiffeners to support the door and components for minimum deflection and wobbling when opening or closing. Doors must swing more than 95 degrees, and be supplied with a lockable handle.
E. Control section shall include a 2¼” x ¼” (57.2mm x 6.4mm) ground bar.
F. Control equipment shall be freestanding with two sections (Main and Extension) for one (1) Master and up to six (6) Generator controls. The Main section shall be equipped with controls for one (1) master, three (3) generators and up to eight (8) load controls. The Extension section shall be equipped with controls for three (3) additional generators and up to (24) additional load controls.
G. A dedicated controller for each generator shall be provided with integrated generator start/stop control, alarm/shutdown functions, and loading controls that are separate from a Master PLC.
H. Generator controls shall be modular, draw-out type. The draw-out mechanism shall permit the generator controls to remain active/online when the draw-out mechanism is in the withdrawn position for testing or maintenance.
I. The generator controls shall be capable of being completely removed from the control enclosure and replaced online with a new module without requiring shutdown of the Master Control or any other generator set controls.
J. Master control logic shall be imbedded in a PLC. A failure of the Master PLC shall not compromise the ability of the control system to automatically start, synchronize, and parallel engine generators to the paralleling bus upon receipt of a start signal from downstream transfer switch(es) or breaker transfer pair(s).
K. Field wiring connections shall be from top or bottom.
L. Control wiring 600 volt, UL1015 or SIS bare wire solder less type connectors shall be used for terminating all wires. Current transformer circuit terminations shall be ring tongue compression type. PLC circuits shall be bare wire type. Control wires shall be numbered at each end with circuit number and visible next to the terminals.
M. Communication wires shall be provided with shielded wire to minimize electromagnetic interference. Shielded wire grounded at one point.
N. Current transformer circuits are connected through shorting terminal blocks.
O. DC Best battery Control Power Selector for the system logic shall be derived from the engine starting batteries. Control logic shall be powered through a suitable means, which shall permit continuity of power until the last battery is no longer available. The controls shall be powered from any battery or combination of batteries and prevent feedback to any failing battery. The transition of control logic power from any battery combination to any other battery combination shall be accomplished without disruption in power flow.
2.03 POWER SECTION CONSTRUCTION
A. Supply continuous current rating and short circuit bracing AIC as indicated on contract single line diagram drawings.
B. The equipment shall be furnished with an <indoor NEMA 1 enclosure> <indoor drip-proof enclosure> <outdoor NEMA 3R non-walk-in enclosure> <outdoor NEMA 3R walk-in enclosure with protected aisle>. The equipment shall be a completely self-supporting structure of the required number of vertical sections bolted together to form one metal-enclosed structure. Sides, top and rear covers shall be code gauge steel, bolted to the equipment structure. The frame structure members shall be die-formed 11-gauge steel bolted together and reinforced at all corners. Sides, front and rear covers shall be 13-gauge steel. Equipment shall be painted ANSI 61 gray, electro statically charged polyester powder paint, and minimum 1.5 mils in density.
C. The equipment shall be furnished with individually mounted circuit breakers. Access to the circuit breaker load terminations shall be from the rear of the equipment. The equipment cable and bus compartment shall be isolated from the front-accessible protective device compartments by rigid glass-reinforced polyester barriers.
D. All bus bars shall be <fully tin-plated> <fully silver-plated>. All vertical riser bus used in molded case breaker sections shall be fully silver-plated. All draw out breaker primary connections shall be fully silver-plated. Breaker primary connections for stationary-mounted breakers shall have the same plating as the main bus.
E. The main bus and riser bus shall be fully isolated from the circuit breaker, instrument, and auxiliary compartments. The vertical bus shall be mounted on supports of high impact, non-tracking, flame-retardant, molded, glass-reinforced polyester.
F. <An insulated and isolated bus system that fully insulates the horizontal main bus and isolates each phase of the vertical riser bus shall be provided. A fluidized epoxy coating shall insulate Main bus bars. Replaceable covers shall provide accessibility to main bus joints. No live connections shall be accessible from the rear except the breaker load side terminals. (Not applicable to bus work rated 4000 and greater). Vertical and horizontal busses shall be isolated from the cable compartment by glass-reinforced polyester barriers. No live connections shall be accessible form the rear except the breaker load side terminations.>
G. Low voltage power circuit breakers shall contain a true, two-step stored energy operating mechanism and shall provide a quick-make, quick-break operation.
H. Each circuit breaker shall be equipped with a digital, true RMS sensing trip unit to protect against fault conditions. The trip unit system shall be integral to the circuit breaker frame and consist of a combination of the following: trip unit, rating plug, trip actuator, and current sensors. The trip unit shall be housed in a metallic enclosure providing protection against magnetic interference, dust, and other foreign materials.
I. Provide adjustable trips for each trip unit as indicated on the contract drawings. <Provide trip units with power monitoring capabilities for interface to building monitoring system.>
J. Low voltage power circuit breakers shall be draw out construction and shall permit the breaker to be withdrawn from a connected position to a test position and to a disconnected position. The draw out mechanism shall be mechanically interlocked with the circuit breaker’s operating mechanism to prevent racking the breaker (in either direction) when the main contacts are closed.
PART 3 MODULAR DIGITAL PARALLELING CONTROLS
3.01 ENGINE-GENERATOR CONTROL
Each engine-generator control system shall be equipped with at minimum the following hardwired components and any additional for providing a functional system. Digital (touch screen/HMI-based) representations of these devices are not acceptable:
A. Dedicated engine generator controller for each generator set, with dedicated processor performing the following functions: Start/stop, synchronizing, load sharing, VAR/PF sharing.
1. Each generator controller shall operate independently, without dependence on the master controller or any other generator controllers.
2. In the event of a Master PLC failure, the engine-generator controller shall be capable of starting the generators and dead close/synchronize onto the generator bus.
3. The engine-generator controller shall be capable of communicating with Master PLC via Modbus RTU interface.
B. Generator Breaker Open / Close Selector switch (52s)
C. Breaker status lights:
1. Open (Green)
2. Closed (Red)
3. Breaker Tripped/Locked out (White)
D. Three position Engine control Switch (Off-Auto-Man)
1. Off – In this position, the engine shall shutdown after a cool-down period.
2. Auto – In this position, the engine control shall be ready for full automatic operation upon receipt of a start signal.
3. Manual – In this position, it shall be possible to start an engine in manual mode. The speed and voltage can be controlled manually for synchronizing and Generator breaker can be closed manually.
E. Speed manual control device (65s), if engine is capable of remote speed biasing.
F. Voltage manual control device (90s), if engine is capable of remote voltage biasing.
G. Reset pushbutton
H. Emergency Stop Pushbutton with integrated protective cover to prevent against inadvertent operation.
I. Status Annunciator (LED type) mounted on door of Generator Control. Digital (touch screen/HMI-based) representations of these devices are not acceptable. All alarm and shutdown lights shall flash until acknowledged or reset:
1. System Not in Auto (red).
2. Any Engine Start Signal Received (green).
3. Summary Shutdown (red).
4. Summary Alarm (amber).
5. Non-Emergency Mode Activated (green).
6. Any Engine Communications Failure (red).
7. Any Engine Control Fuse Blown (red).
8. Control Power Fuse Blown (red).
9. Auxiliary Power Failure (red).
J. The following alarm conditional shall be annunciated on the touch screen Human Machine Interface (HMI) Panel:
1. Low Oil Pressure, Alarm (amber), Shutdown (red).
2. High Water Temperature, Alarm (amber), Shutdown (red).
3. Engine Over crank, Shutdown (red).
4. Engine Over speed, Shutdown (red).
5. Fail to Synchronize, Shutdown (red).
6. Battery Charger Failure, Alarm (amber).
7. Generator Controller Not in AUTO, Status (red).
8. Auxiliary Power Failure, Alarm (amber).
9. Low Water Temperature, Alarm (amber).
10. Emergency Stop Activated, Shutdown (red).