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SUGGESTED SPECIFICATIONFor 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

GE Digital Energy-Power Quality Page 1 GE ZDEC 2020 Modular Paralleling SwitchgearIssue Date: July 28, 2009 Publication # GS-2115

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:

6. UL1558 Metal Enclosed Switchgear

7. UL 1066, Low Voltage AC and DC Power Circuit Breakers Used in Enclosures

8. NFPA 70, National Electrical Code

9. ANSI C37.13, Low Voltage AC Power Circuit Breakers Used in Enclosures

10. ANSI C37.16, Preferred Ratings, Related Requirements, and Application Recommendations for Low Voltage Power Circuit Breakers and AC Power Circuit Protectors

11. ANSI C37.17, Trip Devices for AC and General Purpose DC Low Voltage Power Circuit Breakers

12. 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).

11. Start Signal Received, Status (green).

12. Low Coolant Level, Alarm (amber).

13. Generator Breaker Failed to Close, Alarm (amber).

14. Generator Breaker Failed to Open, Alarm (amber).


K. System shall be capable to synchronize, parallel and load share different manufacturer brands of generator sets, on a common bus. Systems capable of paralleling only one brand of generator set are not acceptable.

L. Dedicated hardwired controls for engine start/stop, synchronization, and breaker open/close shall be provided for each generator. Systems providing manual paralleling of generators via master touchscreen HMI only are not acceptable.

3.02 ENGINE-GENERATOR PROTECTION

A. The 24VDC generator set starting batteries shall power the engine-generator protective relay.

B. The engine-generator protection shall include the following functionality as a minimum:

1. 25 - Synch Check and synch-check with dead-bus.

2. 27/59 - Under voltage and over voltage.

3. 32R - Reverse power protection.

4. 40 - Reactive Power import (excitation loss).

5. 40 - Reactive Power export (over-excitation).

6. 46 - Current balance.

7. 50 - Peak current.

8. 60 - Voltage balance.

9. 81 O/U – Over/Under frequency.

3.03 ENGINE GENERATOR COMMUNICATIONS

A. ZDEC 2020 shall be capable of communicating with different engine generator set manufacturers via CAN network connection.

B. System shall include flexibility to communicate with multiple brands of generator set. Systems capable of communicating with only one type of set-mounted engine-control are not acceptable.

3.04 ENGINE-GENERATOR INTERFACE

A. The engine-generator manufacturer shall:

1. Provide network communications link for direct connection to the GE ZDEC 2020 Generator Controller for alarm & shutdown status; meeting the requirements of NFPA 110.

2. Provide a Woodward compatible electronic type isochronous governing system. The governor shall be capable of receiving a (Woodward-compatible) speed bias signal from the GE ZDEC 2020 Generator Controls for automatic synchronization control.


3. Provide an electronic voltage regulator, mounted on the alternator. The voltage regulator shall be equipped with VAR/PFC capability.

4. The engine generator supplier shall be responsible for ensuring the generators being supplied each have the same pitch <2/3> <4/5>.

5. If the generator is equipped with its own circuit breaker, a normally open breaker position dry contact shall be provided.

3.05 MASTER CONTROL

A. The Master control shall be capable of Emergency standby operations, non-emergency modes of operations, Generator optimization and Load controls.

B. Control power supply shall be 24VDC from the engine batteries.

C. The Master PLC shall be GE Fanuc Versa Max series or equal, included with back-up power supply for use during DC engine cranking shall be backed-up with auxiliary power source using the DC engine cranking battery.

D. The Master Control section shall be equipped with at minimum the following devices and any additional for providing a functional system. Digital (touch screen/HMI-based) representations of these devices are not acceptable.

1. Status Annunciator Panel (LED type) mounted on outer door of Master Control. Digital (touch screen/HMI-based) representations of these devices are not acceptable. All status, alarm and shutdown lights shall flash until acknowledged and/or reset. All alarm conditions shall be easily accessible in the master PLC for ease of interface with the BMS system.

a. System Not in Auto (red).

b. Any Engine Start Signal Received (green).

c. Summary Shutdown (red).

d. Summary Alarm (amber).

e. Non-Emergency Mode Activated (green).

f. Any Engine Communications Failure (red).

g. Any Engine Control Fuse Blown (red).

h. Control Power Fuse Blown (red).

i. Auxiliary Power Failure (red).

2. Light Test pushbutton.

3. Reset pushbutton.

4. Audible Horn and Horn silence pushbutton.

5. System AUTO/MAN selector switch.

6. Synch panel:


a. Two (2) synchro-lights (white LED).

b. Digital SynchroScope, 4.5” (114mm) switchboard meter with 1% accuracy (red LED).

c. Sync switch, with provisions for up to Six (6) Generators.

d. Sync check relay.

E. The following additional conditions shall be annunciated on the touchscreen Human-Machine Interface Panel (HMI). All alarm conditions shall be easily accessible in the master PLC for ease of interface with the BMS system.

1. System Gen. Bus Under Frequency, Alarm (red).

2. System Gen. Bus Over Frequency, Alarm (red).

3. Load add/shed, one per priority, Load Add (green), Load Shed (red).

4. Load Demand Mode is Active, Status (green).

5. Building Exerciser is Active, Status (green).

6. Emergency Power Available, Status (green).

7. System Gen. Bus Overload, Alarm (red).

8. Standby mode is Active, Status (green).

3.06 TOUCHSCREEN OPERATOR INTERFACE (HMI)

A. HARDWARE1. Touschscreen shall be GE Fanuc Quick View Panel - 15” <17”> color-

TFT touch screen monitor with 1024 x 768 pixel resolution.

2. Integrated 64 MB Compact Flash type 2 memory <expandable up to 96> or <128MB>, capable of storing screen captures as *.bmp file format.

3. Communication to Master PLC via Modbus Serial RS-485.

4. All information including transfer switches, engine points and parameters shall be made available to the BMS via a single point network connection, operating on Ethernet TCP/IP, Modbus protocol with 10/100Mbps capacity.

5. 24VDC input voltage.

6. Microsoft CE Operating system (PC operating systems not allowed), with flash (solid-state) hard drive.

7. HMI shall be capable of hosting a Java website where all screens can be viewed and controlled remotely on the Local Area Network via a standard web browser.

a. The need for the installation of any software other than an operating system and an Internet browser on the remote computer is not acceptable.

b. Accessing the HMI from additional computers will not require any additional software licenses.

c. Accessing the HMI from remote computers (on the LAN) should be similar to accessing a web page on the World Wide Web Internet.


8. No control or metering screen should be more than 3 clicks away from any other screen.

B. The Touch screen shall consist of the following screens: 1. Generator Summary Screen

2. Generator Bus Summary Screen

3. Generator and Generator Bus Trend Screen

4. ATS Summary Screen

5. System Single Line/Mimic Screen

6. System Control Screen

7. Load Control Screen

8. Generator Optimization Screen

9. System Alarm Screen

10. Plant Exerciser Screen

C. Generator Summary Screen 1. Capable of monitoring each engine-generator and it’s associated circuit

breaker.

2. Power metering to include: Watts, VArs, power factor, frequency, amperes, and voltage (3 and 4 wire measurements, as applicable) with accuracy of 1%.

3. Engine run hours.

4. Engine status (Off, Run, Cooldown).

5. Number of generator breaker operations.

6. Generator Priority.

7. Cool-down time.

8. Alarm and Shut down status.

9. Engine Data to include: Engine RPM, Battery Voltage, No of Engine starts, Oil pressure, Coolant Temperature, Left and Right Exhaust Temperatures.

D. Generator Bus Summary Screen

1. Combined metering for output of all generator sets, including: Watts, VArs, power factor, frequency, amperes, and voltage (3 and 4 wire measurements, as applicable) with accuracy of 1%.


E. Generator and Generator Bus Trend Screens1. Generator Summary and Generator Bus Summary Screens shall have

quick link icon to navigate to the trending screens.

2. System shall be capable of trending the following parameters for each generator, or combined output/generator bus: Voltage (L-L, L-N), Average Volts (L-L, L-N), Current (A, B, C, Average), kVA, kW, kVAR, Frequency) with accuracy of 1%.

3. System shall be capable of trending and logging data at a resolution of one (1) second.

4. The system shall be setup trend and log the following values until the designated space on the flash drive is full at which time the information will be overwritten in a FIFO procedure.

F. ATS Summary Screen1. Position (connected to normal, connected to emergency) indication of

each transfer switch.

2. Source availability (normal and emergency).

3. Operator controls for: Test with Load, Test no Load, Bypass Time delay on transfer to Normal or emergency sources.

4. Display of Source Voltages (L-L), and Frequency.

G. System Single Line/Mimic Screen1. Single screen showing status of each generator set (running, off,

cooldown).

2. Generator metering summary (Volts, kW, pF, Freq) with accuracy of 1%.

3. 3-Position Engine Control Switch position (Off, Auto, Manual).

4. Generator Bus metering summary (Volts, kW, pF, Freq) with accuracy of 1%.

5. Generator Bus feeder breaker position.

6. System Status Display (Auto, E-Start received, Load Demand Mode, System Under test).

7. Display of active alarms with date/time stamp and reason.

H. System Control Screen


1. System Mode of Operation select (Test with Load, Test no Load, Load Bank Test).

2. Light Test.

3. Horn Silence.

4. Fault reset pushbutton.

5. Cooldown timer setting.

6. Minimum number Generators online setting.

7. Minimum engine runtime setting.

I. Load Control Screen1. The loads shall be divided into blocks (as determined by the number of

generators) as well as operator-assigned priorities levels for each load.

2. Load adding and shedding shall be performed based on available generator capacity and assigned size of each load.

3. Block and priority settings shall be user assignable for each load.

4. Block shedding shall be included for generator failures with automatic re-adding based on generator capacity.

5. Under-frequency conditions shall require manual user intervention for identifying and re-setting load add operations Auto/Manual Load Shed setting.

6. Screen shall include control switch for enable/disable selection of Block Loading control.

7. Status of Load Shed/Add for each block.

8. Manual Load Shed/Add control for each block.

9. Manual enable/inhibit kW shed for each block.

J. Generator optimization Screen1. Manual assignment of Generator set capacity (kW) and priority.

2. Enable/disable selection of generator priority based on engine run hours, with setting for maximum hours difference set-set.

3. Minimum number generators online setting.

4. Upper and Lower Load (kW%) limits for optimization.

5. Minimum and Maximum settings for reserve capacity (kW).

6. Start and stop delay timers for optimization.

7. Real-time indication of generator reserve capacity.


K. System Alarm Screen1. The system shall record all alarm events with date/time stamp.

2. The alarm events can be acknowledged individually or all at once.

3. The system shall be capable of storing the latest 20,000 alarms (Over 1-year of storage.).

4. The ACS shall be capable of delivering e-mail messages when any alarm or shutdown occurs. The message must contain the time, date and reason of the alarm.

5. The HMI shall be capable of monitoring the number of operations and the suggested maintenance period for each of the following pieces of equipment:

a. Each generator (run hours).

b. Each controlled breaker (# of operations).

6. Based on either the number of operations or the time lapse since the last maintenance for each type of device, the HMI shall calculate and display the next expected maintenance date.

7. The ACS shall be capable of notifying alarm, shutdown and maintenance schedule to persons specified by user via e-mail message.

8. The software shall include a communications screen that identifies all Ethernet devices and ModBus devices supplied with the control system and their communication status (Green = Online, Red = Offline).

L. Plant Exerciser Screen1. Plant Exerciser shall be provided to exercise the system in different non-

emergency modes of operations based on the user’s configuration. The Plant Exerciser can be programmed 24 hours – 7 days a week schedule. It shall also include automatic day light savings and leap year adjustment.

2. Start and ending times for one event per day, 7 day plant exerciser.

3. Selection of Test with Load, or Test no Load for each event.

4. Manual exercise inhibit selection for each event.


3.07 SECURITY

A. Security code required for access shall protect against configuration changes and alarm clearing by unauthorized personnel. There are two (2) levels of access to the configuration menus. They are listed below. Each successive level has access to all of the levels above. A user defined four-digit (4) security code is required for access to the configuration menus.

B. Levels of Access:1. Monitor only (no security code) - Access to all Status Screens, view

Alarm / Event Log Display, and ability to commit (acknowledge) an Audible Alarm.

2. Operator level (Level one) – Access to most common operational set point and control functions.

3. Supervisor level (Level two) – Full access to all set points and controls - including configuration settings.

3.08 DESCRIPTION OF OPERATION

The GE ZDEC 2020 Digital Energy Commander is designed to start and parallel all engine generator sets, upon receipt of a start signal from an automatic transfer switch(es), or other device that emergency power is required. The system has controls provided for all the following modes of operation:

A. Emergency Standby Mode of Operation

1. Upon notification of a loss of normal power to any part of the system load, the ZDEC 2020 controls will automatically:a. Send shed signals to the appropriate ATS’s or its downstream

load devices (except for the Priority #1 ATS).

b. Start all available engine-generators.

c. The first Generator to reach its rated voltage and frequency shall close the gen-breaker on dead gen-bus. Subsequent generators after reaching their rated voltage and frequency shall subsequently synchronize and onto the generator bus by closing associated gen-breakers.

d. Once enough generators are online, loads shall be transferred in the order of load priority to the engine-generators that are online. A dedicated ‘Load Add’ and ‘Load Shed’ control relays shall control each load.

e. As additional engine-generators come online, additional loads shall be transferred to the engine-generators.

f. After an adjustable period of time, the system shall allow the generators to optimize down to only the required number to be online to minimize generator wet stacking. The stopping and starting sequences shall be settable thru the touchscreen HMI and shall be based on the based on manual priorities or by engine run time.

g. If the engine-generators become overloaded, the system shall start shedding the load until the engine-generators are no longer overloaded. Loads are shed in order of lowest to highest priority.


2. Once the normal sources have returned and the load has been transferred back to the normal source by the remote ATS devices, the emergency start signal shall be removed and the generators will cool-down and then shutdown.

B. Test no Load1. The system shall be notified to start a Test-no-Load sequence by one of

the following: Building exerciser or operator initiated from touchscreen HMI.

2. The generators shall be started and the generator breaker closed to the bus. Load control and load demand shall be disabled during this mode of operation.

3. The Generator(s) shall continue to run until the exerciser timer has elapsed or the Operator has removed the test signal from the touchscreen HMI.

4. After the Test-no-Load signal is removed or the exerciser time has elapsed, the Generators breakers shall open and generator shall be stopped without initiating cool-down mode.

5. Once normal power sources have returned and the load has been transferred back to the normal source by the remote ATS devices, the emergency start signal shall be removed and the generators shall cool-down and then shutdown.

C. Test with Load (Open or Closed Transition)1. Test-with-Load sequence shall be initiated by one of the following:

Exerciser or operator initiated from touchscreen HMI.

2. A signal will be sent to all available transfer switches to initiate test with load, subsequently ATS’s shall send start signal to the ZDEC 2020 master Controls.

3. The generators shall be started and closed to the Generator bus.

4. Once the engine-generators are online, the system shall enable the appropriate ATS devices to transfer onto the generator system.

5. After the ‘Test with Load’ or the exerciser time has elapsed, the ATS devices shall transfer the loads back to the normal source. The emergency start signal shall be removed and the generators shall cool-down and then shutdown.

6. When the normal power has returned for a specified period of time the system will transfer back to the utility source via the ATS devices.

7. Once the normal sources have returned and the load has been transferred back to the normal source by the remote ATS devices, the emergency start signal shall be removed and the generators shall cool-down and then shutdown.

D. Load Bank Test1. The system shall be notified to start a Load bank test by the Operator

from the touchscreen HMI.

2. Generators that are selected for Load bank test shall be started and its breaker shall be closed to the bus. Load control and load demand shall be disabled during this mode of operation.


3. Once the required engine-generators are online, the operator shall close the load bank breaker upon initiating the ‘Push to Close Load Bank breaker’ button provided on the touchscreen HMI. To abort the load test, the operator shall select the same button on the touchscreen HMI.

4. After the operator removes the Load Bank Test signal, the ‘Load bank cool down relay’ shall be energized for the cooling the Load bank and the Load bank cool down status shall be displayed on the touchscreen HMI.

5. After the load bank cool down timer is elapsed (adjustable from touchscreen HMI), the Load bank cool down relay shall be de-energized and Generator Breaker(s) shall open and shall be stopped after cool down.

6. When the normal power has returned for a specified period of time the system shall transfer back to the normal source via the ATS devices.

7. Once the normal sources have returned and the load has been transferred back to the normal source by the remote ATS devices, the emergency start signal shall be removed and the generators shall cool-down and then shutdown.

E. Generator Optimization1. Generator optimization controls shall be provided to start/stop the

generator(s) in response to the changes in load demand.

2. Generator(s) shall be started or stopped based on their user assigned priority number. Each generator can be assigned a priority number between 1 and maximum number of generators in the system. Priorities shall be capable of being manually user set via the touchscreen HMI, or automatically set based on engine running hours.

3. Minimum Number of Generators Online: The minimum number of Generators Online can be selected from the password protected Preset Screen on the touchscreen HMI. (Example: If the minimum number of generators is set to 2, there will always be at least two generators running.)

4. N+1 Feature: This feature can be enabled or disabled from the touchscreen HMI. If this feature is enabled then the number of generators running at any given time will be one more than required number of generators.

F. Load Add/Shed Controls

1. The system shall be capable of controlling <8> <16> <32> downstream transfer devices (ATS or breaker transfer pairs).

2. The system shall include Automatic Load Add controls:

a. System will check available capacity and add loads in accordance with the assigned priority.

3. The system shall include Manual Load Add controls:

a. Capability shall be provided for the operator to manually add loads if an under frequency signal does not exists in the system.


b. If too much load to the Generator Bus and an under frequency condition occurs, the automatic load shed sequence shall be re-initiated.

4. Block Load Shed

a. When a Block load control is enabled, and a generator is removed from the generator bus due to an overload condition or under frequency, all the loads corresponding to common block shall be shed at the same time.

b. If block load control is disabled, the loads are shed sequentially based on the assigned priority number of the load.

G. Plant Exerciser (PE)

a. Plant Exerciser shall be provided to exercise the system in different non-emergency modes of operation based on the user’s configuration. The Plant Exerciser can be programmed in a 24 hours – 7 day a week schedule. PE shall also include automatic day light savings and leap year enable/disable adjustment.

PART 4 EXECUTION

4.01 FACTORY TESTS

A. The following production tests shall be performed prior to shipment:

1. Ring-out all AC and DC circuits.

2. Check operation of all metering devices using secondary current and/or voltage injection.

3. Factory simulates the utility and generator sources for ensuring proper automatic and manual operations for the paralleling system.

4. [Provide factory [inspection only / full procedure] witness test.]

4.02 EXAMINATIONA. Verify that switchgear is ready to install.

B. Verify field measurements are as shown on manufacturer’s drawings.

C. Verify that required utilities are available, in proper location and ready for use.

D. Beginning of installation means installer accepts conditions.

4.03 PREPARATION FOR SHIPMENT

A. Provide suitable packaging and supports to enable the equipment to withstand shocks and vibrations from normal shipping and handling.

4.04 INSTALLATION

A. Contractor shall furnish and completely install all switchgear as show on drawings and per manufacturer's instructions manual(s).

4.05 FIELD QUALITY CONTROL


A. Refer to manufacturer's instruction manual(s) for details.

4.06 ADJUSTING

A. Refer to manufacturer's instruction book to make adjustments to circuit breakers and switchgear, controls, etc. as required.

B. Set adjustable protective devices per [Engineer's recommendations] [recommended settings of coordination study (performed by others)].

4.07 START-UP SERVICE A. Provide a qualified service engineer to assist in the following:

1. Pre-installation meeting with the contractor, engineer and other related personnel to coordinate the installation, interconnection of all related equipment and start-up requirements.

2. Start-up of the system with complete testing.

4.08 CLEANINGA. Clean switchgear interiors to remove construction debris, dirt, and shipping

materials.

B. Repaint scratched or marred exterior surfaces to match original finish.

4.09 TRAINING

A. Provide services of factory trained Field Engineer for four (4) hours of training at owner's job site immediately following testing and start-up services. Training shall include instructions on adjusting, servicing, and maintaining switchgear assemblies.

4.10 WARRANTYA. Standard equipment warranty shall be as follows:

1. The warranty period shall be twelve (12) months after commissioning or eighteen (18) months after shipment, whichever occurs first.

B. For these purposes, date of start-up is defined as the date when the manufacturer's authorized service engineer starts the equipment and certifies that it is in proper working order per contract.

C. All warranty and liability claims shall be subject to manufacturer's standard terms and conditions.

D. [Provide extended warranty <1, 2, 3 4, or 5> years and include with operation and maintenance manuals recommended preventative maintenance procedures and Service contact information.]

4.11 OPERATING AND MAINTENANCE MANUAL

A. Within five (5) business days after shipment, submit four (4) copies of the operating and maintenance manual.


B. The operating and maintenance manual shall include the following:

1. General arrangement (outline/dimensional) drawings, showing dimensions, weights, shipping sections, anchor bolts, leveling channels and cable conduit entrance locations.

2. Sequence of operations.

3. Detailed 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. Indication of replaceable parts and assemblies.

6. [Factory Test Reports]

7. [Factory Witness Test Reports]

8. [Preventative Maintenance Schedule]

9. [Recommended Spare Parts list]

---END OF SECTION---


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