STR-1416 GENERAL SPECIFICATION FOR BATTERY CHARGERS - iec… · 2017-10-24 · STR-1416 GENERAL...

THE ISRAEL ELECTRIC CORPORATION LTD. Engineering Projects & Business Development SPEC: STR-1416 Engineering Division Substation Planning Sector

STR-1416

GENERAL SPECIFICATION FOR BATTERY CHARGERS

ANNEXURE “B”

February 2017


2017/SPECS/STR-1416 B - 2

STR-1416

GENERAL SPECIFICATION FOR BATTERY CHARGERS

ANNEXURE “B”

DRAFT FINAL DRAFT CONTRACT

Name Date Sig Name Date Sig Name Date Sig

Prepared S. Bar Oz 02/16 Prepared S. Bar Oz 02/17 Prepared

Checked Z. NIR 02/16 Checked Z. NIR 02/17 Checked

Approved Z. NIR 02/16 Approved Z. NIR 02/17 Approved


2017/SPECS/STR-1416 B - 3

TABLE OF CONTENTS

ANNEXURE “B” 1. Purchaser……………………………………………………………………. B – 6 2. Scope of Work………………………………………………………………. B – 6 3. Delivery, Shipment, Storage………………………………………………. B – 8 4. Standards and Specifications……………………………………………… B – 10 5. Tender Documents…………………………………………………………. B – 12 6. General Approval of Technical Documentation…………………………. B – 13 7. Quality Assurance and Quality Control…………………………………… B – 16 8. Tests…………………………………………………………………………. B – 18 9. Name Plates………………………………………………………………… B – 22 10. Spare and Renewal Parts…………………………………………………. B – 22 11. Detailed Specification………………………………………………………. B – 27 11.1 Service ....................................................................................... B – 27 11.2 AC System Data ........................................................................ B – 27 11.3 Charger Ratings ........................................................................ B – 27 11.4 Environmental Conditions ..........................................................

11.5 EMC Compatibility Requirements………………………………… B – 27 B – 28

11.6 Operating Characteristics .......................................................... B – 30 11.6.1 Normal Service ............................................................ B – 30 11.6.2 Equalizing Charge ....................................................... B – 32 11.6.3 Boost Charge……………………………………………... B – 33 11.6.4 Transient Behavior of the Charger ...............................

11.6.5 Start-Up Behavior ........................................................ B – 34 B – 34

11.7 Mechanical Design Requirements ............................................ B – 35 11.8 Electrical Design Requirements ................................................ B – 38 11.9 Charger Components ............................................................... B – 40 11.9.1 Insulating Transformers and Reactor .......................... B – 40 11.9.2 Rectifier Bridge ........................................................... B – 40 11.9.3 Capacitors for Filter .................................................... B – 40 11.9.4 M.C.B.’s and C.B.'s ..................................................... B – 41 11.9.5 Control Circuits ........................................................... B – 42 11.9.6 Measuring Instruments ............................................... B – 42 11.9.7 Control ........................................................................ B – 43


2017/SPECS/STR-1416 B - 4

TABLE OF CONTENTS cont.

11.9.8 Communication……………………………………………. B – 44 11.9.9 Programmable Controller………………………………… B – 45 11.10 Alarms .................................................................................... B – 46 11.11 Labeling .................................................................................... B – 47 ANNEXURE "C" 1. For Summary of Prices of Battery Chargers 220VDC, 30A. See

Annexure "C; in Specification,STR-1416

2. For Summary of Prices of Battery Chargers 220VDC, 100A

see Annexure "C" in Specification STR-1416

APPENDIXES Appendix 1 - Painting requirements:

1A - specification No. 1400: Specification for Electrostatic Painting of aluminum plates.

1B - Specification No. 1500: Specification for Electrostatic Painting of electrical cabinets or other equipment constructed from mild steel.

Appendix 2 - Electrical Standard Specification Control Cubicles Wiring Requirements – IEC NO. EPD-A.03

Dated 09/2004. Appendix 3 - General Specification for Testing Industrial Rectifiers IEC No. S-83/04/1.80 Dated 02/2004 . Appendix 4 - Procurement Quality Requirements Q-APP-02 Rev. 4

Dated 03/2011.

Appendix 5 - Reliability, Maintainability and Safety Requirements for Battery Chargers 220V,30A and 220V 100A.

Appendix 6 - Nameplates Specification Dated 08/2015


2017/SPECS/STR-1416 B - 5

TABLE OF CONTENTS cont. DRAWINGS Charger characteristic IU according to DIN 41773 – EVK-6375. Principle diagram of a double DC system in a switching station – EVK-7212. Principle diagram of a single DC system in a substation – EVK-6374


2017/SPECS/STR-1416 B - 6

SPECIFICATION FOR

BATTERY CHARGERS

1. PURCHASER:

The Israel Electric Corporation Limited.

2. SCOPE OF WORK:

This Specification deals with technical requirements for two types of battery

chargers with nominal currents: 30 A and 100 A, intended for use in substation

auxiliary DC system with nominal voltage 250 V and main 3 phase AC

nominal voltage 230/400V.

2.1 GENERAL REQUIREMENTS

Design, develop, manufacture, test, preserve, pack and furnish

with adequate packing to Purchaser Battery Chargers with all

accessories as per this Specification detailed hereunder

including a communication adaptor (SNMP – Simple Network

Management Protocol) as specified in Clause No. 11.9.8. and a

Programmable Controller as specified in Clause No. 11.9.9.

Each Battery Charger shall be supplied complete with all the

appurtenances and accessories as specified herein to form a

complete unit which will achieve and assure safe and reliable

operation of the system with the best overall performance. All

components supplied shall be of proven design.

2.2 Contractor's Firm Price will include all required components,

parts, accessories and instructions as they are necessary to


2017/SPECS/STR-1416 B - 7

achieve high reliability and good performance, in accordance

with the requirements of present specification and as they will be

delivered to the Purchaser. All the service prices, spare and

renewal parts price, as manufacturer's option prices, shall be

included in " Annexure C ".

IEC shall have the right to change the quantities of the items in

the second stage of the tender.

2.3 CONTRACTOR SERVICES

Contractor shall furnish, if requested by the Purchaser the

following services at the per diem rates per day as stated in the

proposal. The field personnel provided by the Contractor shall

be capable, qualified and able to perform the duties required to

the satisfaction of the Purchaser and shall be vested with

authority to make decisions binding on the Contractor.

2.3.1 Training – ITEM 3

Upon Purchaser's request, a Contractor's personnel shall assist

Purchaser's personnel, by conducting a thorough training,

including but not necessarily limited to correct start-up, safe

operation, safe shut-down and maintenance for all equipment

provided under this Specification. Contractor shall verify that the

operators are completely familiar with all phases of such

procedures and are capable of successfully operating the

equipment.

The training course shall be carried out over a period of five (5)

days for fifteen (15) persons from the Purchasers personnel. The

course shall take place in the Israel Electric company's training

school.


2017/SPECS/STR-1416 B - 8

In the first section of two day period, with the syllabus:

- General review of the battery charger.

- Start-up, safe operation, safe shut-down.

- Maintenance.

In the second section of three days period, with the syllabus:

- Internal setting, aiming and repairing.

- Software

- Calibration

- Maintenance of electronic boards level including practice.

3. DELIVERY, SHIPMENT, STORAGE

3.1 Contractor shall furnish the equipment free of expense, or charge, to the

Purchaser’s store of sites.

3.2 Contractor shall supply, free of charge, all packing material and transport

facilities to ensure safe transfers and storage.

3.3 The equipment package for shipment shall be so designed and carried out as

to prevent any damage to equipment during shipment and during prolonged

storage under the following climatic and environmental conditions:

3.3.1 Altitude not exceeding 1000m.

3.3.2 Ambient temperatures -5C to + 55C.

3.3.3 Severe atmospheric and industrial air pollution.


2017/SPECS/STR-1416 B - 9

3.3.4 Salt spray and/or sand dust.

3.3.5 Long dry periods.

3.3.6 Long periods of high humidity and rain.

3.4 Contractor shall state his own requirements for the storage of equipment for a

prolonged period under the climatic and environmental conditions described

under Clause 3.3.

3.5 Each shipping container shall have a packing list and in addition shall be

marked with the following information:

3.5.1 Descriptive name(s) of equipment or supplies contained.

3.5.2 Quantity packed in container.

3.5.3 Serial number.

3.5.4 Contract number.

3.5.5 Contractor’s name and address (city, state and country).

3.5.6 Gross weight of container.

3.5.7 Cubic volume of container.

3.5.8 Complete destination marking.


2017/SPECS/STR-1416 B - 10

4. STANDARDS AND SPECIFICATIONS

4.1 This specification is a general frame specification. The chargers shall comply

with an additional specification (“Charger Specification”) containing all the

required ratings and performances data.

4.2 The charger and charger components shall be manufactured and tested

according to the following standards (the latest edition):

- IEC-60146-1-1.

- IEC-61204, IEC-61000-3, IEC-60076-2, IEC-60981.

- EN-60529, EN-50272, EN-60898.

- DIN 41772, 41773, 41774.

- NEMA PE5.

- Standards Institution of Israel (SII) 165/1175

In any case of contradiction the requirements of this specification and charger

specification shall be binding.

4.3 The following standards/prescriptions of Israel Electric Co. are an integral part

of this specification:

- Painting requirements:

Specification No. 1400: Specification for electrostatic

painting of aluminum plates.

Specification No. 1500: Specification for electrostatic

painting of electrical cabinets or other equipment

constructed from mild steel.

- Control Cubicles Wiring Standard Specification: IEC NO. EPD-A.03

DATED 09/2004.


2017/SPECS/STR-1416 B - 11

- Quality system requirements for suppliers – ISO-9001:2008.

- General Specification for Industrial Rectifiers – IEC No. S-83/04/1.80

Dated 02.2004.

- Procurement Quality Requirements Q-APP-02 Rev. 4.

- Reliability, Maintainability and Safety Requirements.

- Name Plate Specification

4.4 In case the Contractor cannot meet one or more requirements of the above-

mentioned standards, he shall specify this in the tender.

4.5 Evaluation of Contractor's Technical Proposal

4.5.1 Contractor's offered data and parameters as well as definite answers or

comments will be evaluated from a technical point of view using an expert

computer program for decision making. The decision making process consists

of identifying all relevant criteria and attaching to each criterion an appropriate

weight for technical evaluation. All proposals (alternatives) made by different

contactors will be evaluated taking into account the same relevant criteria. The

computer program uses a pair wise comparison technique based on statistical

analysis to evaluate criteria importance and to rank alternatives (proposals).

4.5.2 The main criteria used for the technical evaluation are according to the main

paragraphs in this Specification as follows:

Electrical Data, Design and Construction, Tests Requirements, Maintenance

Requirements, Operating Experience (in the world and in Israel), Technical

support from Contractor. All sub clauses for which different contractors offer

different technical data will form the sub-criteria of the relevant main criteria.


2017/SPECS/STR-1416 B - 12

4.5.3 All sub clauses in this Specification indicated by the symbol © are compulsory

requirements. In case Contractor's proposal will not comply with one of the

compulsory requirements his offer will be disqualified.

5. TENDER DOCUMENTS

The Contractor shall present to the tender all the documents and

data required in Annexure “B” of Charger Specification, in four

(4) copies.

The Purchaser reserves for himself the right to reject an

incomplete quotation.

The following quality related documentations shall be submitted:

- A full description of Contractor's Quality Assurance Program.

- Certification of Approval of the Quality Assurance System

according to the ISO 9001:2008 Standard given by Israel

Standardization Institute or International Standards Institute.

- Design control Procedures.

- Qualification of Subcontractor's Procedure.

- List of qualified suppliers of the most important part and

Components.

- A general front view of the proposed Battery Charger.

- Prospects, leaflets, catalogues.

- All data of reliability (R.A.M)


2017/SPECS/STR-1416 B - 13

- A basic electrical diagram for the Battery Charger.

- Calculation of the life cycle (20 years) of the proposed capacitors, including

catalogs and graphs.

6. GENERAL APPROVAL OF TECHNICAL DOCUMENTATION

6.1 After notification of award, Contractor shall submit to the Purchaser for

approval, within 60 days of the date of award, four (4) sets of prints covering

the following information:

6.1.1 Mechanical drawings of the charger comprising outlines, front view of charger

with instruments location, front (and rear if necessary) view of charger with

open doors (covers) showing the component location, terminals and cable

entrances.

The distances required from the surrounding objects (equipment, walls) shall

be specified on the above-mentioned drawings in order to assure the correct

operation and maintenance of the charger.

6.1.2 Full set of detailed circuit diagrams, comprising all the charger internal circuits

(including printed circuit boards – PCB) and location of typical test points

6.1.3 A complete list of materials/items comprising all the electronic components,

transformers, chokes, capacitors, switches, instruments, terminals wiring, etc.

The list shall specify the type of the components, manufacturer and catalogue

number or drawings. Wiring insulation and canal shall be halogen free.

6.1.4 A general block diagram of the charger showing the main circuits and the

topical interconnection between the different parts.

6.1.5 Nameplates with all required data.


2017/SPECS/STR-1416 B - 14

All items shall be identified by the same notations used in both the electrical

diagrams and mechanical drawings.

6.1.6 Test report certification according to Appendix 3:

"I.E.C. Specification S-83/04/1.80"

6.2 The above-mentioned documents will be modified, if necessary, according to

Purchaser’s requirements. After the final approval, the Contractor shall submit

a C.D. (compact disk) of the approved drawings and documents.

6.3 One month before delivery of the first Battery Charger or disks, the Contractor

shall submit for Purchaser’s approval three (3) Instruction Manuals comprising

all the information as may be required for erecting, commissioning, operating,

testing and maintaining the charger.

Periodic test instructions shall indicate the measuring points and the

permissible range of the measured values.

The contractor will submit complete adjustment instruction.

The instruction manuals shall comprise all the approved drawings, as well as

the relevant catalogue leaflets (prospects) of the components recommended

spare parts list. After approval eight (8) instruction manuals shall be

submitted.

Each Battery Charger will be supplied with his own Instruction Manual and

Drawings during delivery.

6.4 Quality Assurance documentation

Quality Assurance manual (4 copies) including a full description of

Contractor's Quality Assurance program:


2017/SPECS/STR-1416 B - 15

- Certification of Approval of the Quality Assurance System according to

the ISO 9001:2008 Standard given by Israel Standardization Institute or

International Standards Institute.

- Design control Procedures.

- Qualification of Subcontractor's Procedure.

- List of qualified suppliers of the most important part and Components

6.5 Quality Control Documentation

6.5.1 Inspection and Tests plan according to Appendix 4 Procurement Quality

Requirement Q-APP-02 REV.4.

6.5.2 Quality Control Procedures.

6.5.3 The following documentation:

- Electrical Testing Procedures as per applicable Standards.

- Non Conformance's and Deviation Control Procedures.

- Certificates of Electrical Tests, according to this Specification.

- Inspection and Test Report.

6.6 The Purchaser reserves himself the right to reject equipment not

manufactured according to approved drawings.

6.7 All data and descriptive material in the above drawings and instructions books

shall be in English. All dimensions shall be shown in international system of

units (S.I.).

6.8 Contractor shall complete engineering details immediately after award of

Contract, regardless of delivery date.


2017/SPECS/STR-1416 B - 16

6.9 The serial number of the equipment shall be clearly labeled on all items. In

addition, the packaging shall contain the serial numbers of all included

equipment in said package. The shipping documents shall contain the serial

numbers of all equipment in said shipment.

7. QUALITY ASSURANCE AND QUALITY CONTROL

7.1. The Contractor's quality Assurance Program shall meet the requirements

described in ISO Standard 9001:2008

7.2. The Purchaser shall have the right to audit and comment on Contractor's

Quality Assurance System regardless of whether it was previously audited by

a certifying agency or any other body.

7.3. The Contractor shall be responsible for assuring that his subcontractor's

Quality Assurance/Quality Control Programs, including their organizations,

procedures, personnel qualification etc., are approved and are consistent with

the specific requirements imposed by the Purchaser in the Specification.

7.4. The Contractor shall submit with his proposal a preliminary Inspection and

Test Plan (I & T Plan).

7.5. A mutually agreed inspection point plan, including witness and points, shall be

agreed between the purchaser and the Contractor. Any subsequent

alternation to this program shall require the Purchaser's agreement, prior to

start of any work affected by these alterations.

7.6. Test and Inspection certificates as required in the Specification and the

applicable Standards, shall be submitted immediately following their

generation. The certificates shall be original, signed by the Contractor, and

contain actual measured values.


2017/SPECS/STR-1416 B - 17

The generation of certificates, including those generated by Subcontractors

and sub-suppliers, shall bear no extra cost to Purchaser.

7.7. Any equipment non-conformance to drawings, specifications or other

purchase order requirements which are considered by the Contractor as

"acceptable as is" or for "repair", shall be submitted to the Purchaser for

approval, with their recommended dispositions. All such non-conformances

shall be approved by the Purchaser, shall be documented, and a copy of the

approval shall accompany each shipment.

7.8. All materials used in the manufacture of the equipment shall conform to the

Specification, approved drawings and accepted Standards.


2017/SPECS/STR-1416 B - 18

8. TESTS

8.1 The Purchaser will have the right to demand acceptance tests at the

manufacturer's facility with a representative of the Purchaser being present.

The acceptance test results will be considered an integral part of the

equipment delivery.

8.2 Prior to the Contract signature, Contractor shall propose a meaningful set of

Factory Acceptance Tests as Field Acceptance Tests. The Purchaser and the

Contractor shall agree upon these sets of tests, which after the contract

signature, will become part of the contract requirements. These tests shall be

done for two first Battery Chargers. Any changes, after the Contract

signature shall be by written agreement only.

8.3 The stages for the test shall be as follows:

- The Contractor shall submit documents such as process procedures and

test procedures to the Purchaser for review, comment and approval.

- The Contractor shall perform the test after receiving from the Purchaser all

the comments and approval to the documents.

- The Contractor shall submit the test results to the Purchaser that the

Charger complies with the Specification requirements.

- The Purchaser shall check the charger in Contractor's site.

8.4 The test shall be performed as close as possible to real service

conditions.

The test shall be performed according (but not limited) to relevant Clauses of

IEC 60146-1-1, Section 7: Test for valves device assemblies and convertor

equipment and to Purchaser’s requirements mentioned in Clause: 4.3 and

according to I.E.C. Specification No. S-83/04/1.80


2017/SPECS/STR-1416 B - 19

The temperature and stability test will be performed for 24 hours.

The load test will be performed with the required rated voltage and the current.

The load will be of a resistance type.

The test will be performed continuously for a period of at least 24 hours.

The load test shall check the relevant points of the normal service and boost

charge operating characteristics (EVK-6375) including the short circuit

condition. The test shall be performed by Contractor and test certificate shall

be submitted for Purchaser approval.

The charger functions shall be tested with batteries 220V, 150AH for

220V/30A charger, with batteries 220V, 500AH for 220V/100A charger.

The Contractor shall prove that he has all the necessary equipment to perform

the test.

Only after the test is approved by Purchaser (this includes drawing approval,

quality control approval and test approval), Contractor may proceed to

manufacture the rest of the ordered chargers. The required test of the first unit

is not necessary if Contractor can submit a test certificate for a similar unit.

The tested unit shall have the same rated voltage and the same rated current

of the proposed charger.

All the components of the tested unit (rectifier bridge, main transformer,

capacitors, automatic control) shall be of the same type and same

manufacturer as for the proposed charger.

The Purchaser reserves the right to verify the compliance of the delivered

items with this specification. Delivery which will not pass acceptance test will

be rejected.


2017/SPECS/STR-1416 B - 20

8.5 The purpose of the above tests is two fold:

a. To demonstrate that the delivered equipment answers to the requirements

of the Specification.

b. To expose any design or manufacturing flaws.

At the factory, two complete Battery Chargers, shall be assembled and tested.

The first set of Battery Chargers tests is for steady-state performance; it shall

be conducted for variation of load, Line Voltage, D.C. voltage, power factor,

frequency and temperature.

The second set of tests is for dynamic performance, such as for tripping the

D.C. input power line, short circuiting the output terminals and fuse clearing.

Output voltage deviation will not be more than 3.6% of rated value even for

fast dynamic changes of the load in full range.

The final set of tests shall represent the reliability by operating the Battery

Charger without failure for a time and loading schedule to support the MTBF

predictions and the Gamma-Percentage Operating Time to Failure indicator.

At the site, the system shall be re-tested to check damage or failure due to

packing and/or shipping and for operation with the actual switchgear as

follows:

1. The factory steady-state performance test shall be repeated, using the two

AC power suppliers.

2. Part of the factory dynamic tests shall be repeated to check the switching

operation of the system.


2017/SPECS/STR-1416 B - 21

3. The system shall be run with a dummy load for an extended period (3

hours) as a final Acceptance Test.

8.6 Routine test:

Contractor shall perform and submit routine test reports for Battery Charger

specifying the relevant Standards, Norms, Recommendations, etc. to prove

that Battery Charger have the capability to meet all the ratings as specified,

after receiving from the Purchaser all the comments and approval to the

documents.

Routine tests shall be performed according to relevant clauses of I.E.C. 60146

PT1-1 section 7.1.3 table 13 "Routine tests" and Purchaser’s requirements

mentioned in Clause 4.3

The routine test shall be performed at Contractor's laboratory in presence of

the Purchaser's staff.

8.7 Contractor shall submit a list of all tests to be performed on site, after

mounting of the Battery Charger to the approval of the Purchaser.


2017/SPECS/STR-1416 B - 22

9. NAME PLATES & MARKING

All the equipment items are to be provided with name plates. The name plates

content and installation mode should be according to Appendix No. 6.

In addition Each internal modules of the charger will be marked with a serial

number.

10. SPARE AND RENEWAL PARTS

10.1 The Contractor shall include in its technical proposal a catalogue

containing all relevant potential Spare Parts for the proposed

Equipment as well as propose a detailed list of Spare Spares

recommended for:

10.2 The catalogue and the lists shall include:

- Description and designation for blocks and printed cards.

- Name of supplier and manufacturer.

- Necessary catalogue data for separate order.

- Optimal stocking level of PC boards.

- If the supply is from stock or by manufacturing after order.

- Lead time before supply (including transport time to Israel).

See columns below.


2017/SPECS/STR-1416 B - 23

PROVISION OF THE CATALOGUE AND THE LISTS, AS

WELL AS ANY AMENDMENTS THERETO AS MAY BE

REQUIRED BY PURCHASER, IS A CONDITION TO THE

EVALUATION OF THE TECHNICAL PROPOSAL. FAILURE

TO PROVIDE SAME SHALL ENTITLE PURCHASER, AT

ITS SOLE DISCRETION, TO DISQUALIFY THE

PARTICIPANTS.

10.3 The Contractor shall identify the materials and items which have

critical effects on the System’s reliability and items that required

special maintenance treatments.

10.4 Purchaser shall review the catalogue and the lists of

recommended Spare Parts during the technical clarifications.

10.5 Upon Purchaser’s demand, each participant shall be required to

provide to Purchaser amended lists and catalogue, as part of its

final technical offer.

10.6 After Contract execution and during the drawing approval

process, the Contractor shall provide Purchaser with the

following details regarding each item in the catalogue:

a. Identity of manufacturer (if not previously known);

b. Supplier’s part number;

c. Manufacturer’s part number;

d. Name of recommended alternate supplier and part number;


2017/SPECS/STR-1416 B - 24

e. Detailed description of each item as required for ordering (if not previously

provided);

f. Whether the part is repairable or not;

g. Storage instructions for spare parts.

h. MTBF - meantime between failure.

i. Gamma-Percentage Operating Time to Failure.

j. MTTR - meantime to repair.

The above information shall be transmitted to Purchaser as a

computer data base allowing for easy searches.

10.7 All Spare Parts shall be new and unused in all cases.

10.8 The Purchaser reserves the right to purchase said parts directly

from the manufacturer or from another sub-supplier.

10.9 The Contractor warrants that spare and renewal parts shall be

available for at least twenty (20) years for the equipment

supplied under this Contract.

10.10 The Contractor guarantees that all the Spare Parts features will

be according to its catalogue and that the catalogue is

periodically updated to stay current.


2017/SPECS/STR-1416 B - 25

10.11 SPARE PARTS

Bidder shall give here, a list of recommended spare parts according to clause

10 for one Battery Charger with price quotation.

The part number and technical description shall be specified for each quoted

item.


2017/SPECS/STR-1416 B - 26

Name of Bidder_______________

Table No. 1: Spare Part List until end of warranty.

Spare Part

Name & No.

Producer’s

Name

Spare Part

Purpose

Probability

of Failure

Technical

Data

Is it in

stock (Y/N)

Supply time

after ordering


2017/SPECS/STR-1416 B - 27

11. DETAILED SPECIFICATION

11.1 Service

The charger will be connected to the D.C. system of an unattended substation

or switching station, and operate continuously (24 hours per day) according to

diagram EVK-6374 & EVK-7212. During the service the charger shall meet

the operating requirements mentioned in clause 11.6 of this specification.

11.2 AC System Data

The charger will be supplied from the main AC distribution of the substation.

The supply voltages are either:

3 x 400V 10% (three phase)

Total Harmonic Distortion (THD) in main voltage up to 5 %.

Frequency may vary between 48.5 – 50.5 Hz. The AC short circuit current at

chargers supply terminals is 10KA.

11.3 Charger Ratings

Charger main ratings and the AC system data will be mentioned in charger

nameplate.

11.4 Environmental Conditions

The charger will be installed in ventilated rooms of a switching station or

substation.


2017/SPECS/STR-1416 B - 28

Ambient temperature range: -5 to +40C. The average relative humidity is

equal to or less than 75% and for 30 days the relative humidity can reach

95%. Altitude not exceeding 1000m above sea level.

11.5 EMC Compatibility Requirements

11.5.1 Insulation Resistance

>100 MOhm at 500 V, during 5 sec minimum:

- between all terminals (except earth terminal) connected together and the

case (earth terminal).

- between terminals of independent circuits including contact circuits.

- across the open contacts of the all circuit breakers and output (signaling)

relays.

11.5.2 Dielectric withstand

According to IEC 60664-1:

- 2kV r.m.s., 50 Hz, 1 minute between all input and output terminals (except

earth terminal) connected together and the case (earth terminal).

- 2kV r.m.s., 50 Hz, 1 minute between all input and output terminals of

independent circuits.

- 1kV r.m.s., 50 Hz, 1 minute across the open contacts of the circuit breakers

and signaling relays.

11.5.3 High voltage impulse

According to IEC 61439-1 and IEC 61180-1, III overvoltage category

Three positive and three negative impulses at interval of 5 sec: 4.8 kV peak,

1.2/50µs, 0.5J .

- between all input and output terminals of independent circuits (except output

relay contacts).

- between all input and output terminals of independent circuits and case (earth

terminal).

11.5.4 Overvoltage

According to IEC 60664-1 basic and supplementary insulation in charger shall

withstand:

- short-term (during 5 sec) temporary overvoltage of UN + 1200V . - long-term (longer than 5 sec) temporary overvoltage of UN + 250V .


2017/SPECS/STR-1416 B - 29

11.5.5 Power supply (dips) interruption

According to IEC 61000-4-11, class 3, criteria acceptance B

The charger must withstand interruption (U= 0% UN) and dips (U= 40% UN ; U=

70% UN) in the auxiliary supply, under normal operating conditions, without

change of operating state, de-energizing and losses of data during the test, but

degradation of performance is allowed:

U= 0% UN – during 20 ms;

U= 40% UN – during 200 ms;

U= 70% UN – during 500 ms.

11.5.6 High frequency burst disturbance

According to IEC 61000-4-12, level 3, criteria acceptance A:

- 2.5kV (peak), 1 MHz for common-mode test between independent circuits and case (earth). - 1.25 kV (peak), 1 MHz for differential (transverse) test across terminals of the same circuit (except metallic contacts and communication port). - 1.25 kV (peak), 1 MHz for common mode for communication port.

Test duration 2 s, 6-10 bursts per period of power supply frequency.

11.5.7 Fast transient/burst immunity

According to IEC 61000-4-4, level 4, criteria acceptance A

Common-mode test between each independent circuits and case (earth):

- 4 kV (peak) for input/output circuits and internal auxiliary power supply. - 2 kV (peak) for communication ports.

Repetition rate during burst 5 kHz; Burst period 300 ms, Burst duration 15 ms.

Test duration 1 min, each polarity.

11.5.8 Surge immunity test


- 4 kV (peak) for common-mode test between each independent circuits and case (except communication port). - 2 kV (peak) for differential (transverse) test across terminals of the same circuit (except communication port).

The test wave shape: 1.2/50 µs voltage pulse.

11.5.9 Immunity to radiated electromagnetic energy


The frequency range is swept from 80 MHz to 800 MHZ with the signal 80%

amplitude-modulated with 1 kHz sine wave, field strength 20V/m

Spot frequencies: 80, 160, 450 and 800 MHz

11.5.10 Immunity to conducted radio frequency interferences



2017/SPECS/STR-1416 B - 30

- 10 V (r.m.s) for frequency 150 kHz to 80 MHz with amplitude modulated by frequency 1 kHz at 80% sine wave. 11.5.11 Power frequency magnetic field immunity


- 100 A/m applied continuously.

- 1000 A/m applied during 3 s.

11.5.12 Pulse magnetic field immunity

According to IEC 61000-4-9, Class V, criteria acceptance A

1000A/m, waveform 8/20 µs, 5 positive and 5 negative pulses every 10 s.

11.5.13 Damped oscillatory magnetic field immunity

According to IEC61000-4-10, Class V, criteria acceptance A

100A/m for frequency 100kHz and 1MHz with a burst duration of 2 s, applied in

all planes.

11.5.14 Radiated immunity from digital communications


Test field strength 30 V/m at frequency band 800 to 960 MHz and 1.4 to 2.0

GHz with the 80% amplitude-modulated signal, 1 kHz.

11.5.15 Electrostatic discharge test (ESD)

According to IEC 61000-4-2, Class 4, criteria acceptance A:

- 8 kV – contact discharge

- 15 kV discharge in air to user interface, display and exposed metalwork

Class 3, criteria acceptance A :

- 6 kV discharge in air to all communication ports;

11.6 Operating Characteristics

The operating characteristics of the charger shall be IU-type according to

standard DIN 41773.

11.6.1 Normal Service – (Floating charge)

The charger is connected in a floating (trickle) charge mode. It supplies the

load current and charges the battery simultaneously with the maintenance

charging current, thus maintaining its full capacity available. The voltage is

maintained constant ( 1%).


2017/SPECS/STR-1416 B - 31

The current limitation must be 30A and 100A respectively.

On AC supply failure, the battery takes over the supply of the load without

break. On restoration of the AC supply, the charger takes over the load and

charges the battery with the difference between charger rated current and

load current. The current supplied by the charger to the load and battery shall

be limited to the rated current of the charger ( 2%), regardless of the

discharging degree of the battery.

The transients occurring upon the AC supply restoration (inrush currents,

current spikes etc.) shall by no means affect the charger operation, even in

the case of an extremely short supply interruption.

When the charger reaches the preset floating voltage, it starts to operate with

the constant voltage characteristics. The current will decrease until the full

capacity of the battery is restored.

The required operating characteristic appears in drawing EVK-6375.

Means of inrush current limitation will be provided.

The charger shall be stable at any point of the operating characteristic.


2017/SPECS/STR-1416 B - 32

11.6.2 Equalizing Charge

An internally mounted manual selector switch shall permit change over to the

equalizing charge mode of operation.

The operating characteristic of the equalizing charge will be IU characteristic,

as in float mode but with different voltage.

The Contractor is to take this into effect and supply the necessary control

circuit and connection terminals.

In case of AC failure the charger shall return to float charge mode.

In case of load changes all M.C.B. and C.B. will not be affected by the

transformer inrush current.

All the operating characteristic shall be according to DIN 41773.

The required equalizing charge characteristic, as well as its parameters will be

mentioned in charger specification and the list of compulsory requirements.

Equalizing charge (2.4V per cell) intended to bring all the cells to equally

charged condition. Equalizing charge requires low current limit value (5-7 A

per every 100 Ah of a battery).


2017/SPECS/STR-1416 B - 33

11.6.3 Boost Charge

An internally mounted manual selector switch shall permit change over to the

boost charge mode of operation.

1. The operating characteristic of the boost charge will be

IU characteristic, as in normal service, but with different parameters.

2. A boost charge mode operation requires the operation of the exhaust fans

in the battery room.

When the exhaust fans power supply circuit will interrupt, the charger will pass

automatically to the floating charge mode with the last adjusted values.

Change-over will be initiated by the boost charge blocking relay connected in

the exhaust fan circuit. Return to boost mode may only be carried normally by

an operator.

The Contractor is to take this into effect and supply the necessary control

circuit and connection terminals.

In case of AC failure the charger shall return to float charge mode.

In case of load changes all M.C.B. and C.B. will not be affected by the

transformer inrush current.

All the operating characteristic shall be accordin/g to DIN 41773.

The required boost charge characteristic, as well as its parameters will be

mentioned in charger specification and the list of compulsory requirements.

The charger will include a timer that can be set ahead to switch from boost

charge to float charge.


2017/SPECS/STR-1416 B - 34

Current limitation in a BOOST mode will be half of float mode value.

11.6.4 Transient Behavior of the Charger

The speed at which the charger reacts to sudden load changes is very

important to the correct behavior of the charger in the DC system. After a

sudden load change including short circuits, the current and voltage shall

return to the values of the operating characteristics within 200ms, and within

the range of 94% to 106% of voltage setting.

11.6.5 Start-up behavior

In all working modes the output voltage shall not exceed 106%.

Start-up amplitude of AC current shall not exceed the value of 2 x In nominal

current.


2017/SPECS/STR-1416 B - 35

11.7 Mechanical Design Requirements

11.7.1 General

11.7.1.1 The charger shall be designed as a steel cubicle, mounted over cable

channels, 30 to 40cm wide, or on floating floors. Similar cubicles may

be mounted on both sides.

11.7.1.2 All the ventilation openings shall be front located. The cable will enter

the charger from below through cable glands. The quantity and cross

sectional area of cables will be mentioned in charger specification. The

cubicle shall be provided with profile to attach the ingoing and outgoing

cables.

11.7.1.3 The Battery Chargers, delivered under this Contract shall consist of free

standing, floor mounted Cabinet, made of welded steel frame work,

steel frontal doors and panels, heavy duty industrial constructed. Doors and

panels shall be of at least 2 mm steel; frame work shall be of at least 3 mm,

steel. Plates smaller than 600 x 600mm may be manufactured from

1.5mm steel plates.

11.7.1.4 No ventilation openings shall be located on cubicle top unless protected by an

additional cover (roof).

The ventilation of the unit will be by natural ventilation only.

11.7.1.5 Control switches shall be located on the front panel, not higher than 1800 mm

or lower than 600 mm. For measuring instruments the mounting heights shall

be between 800/1200-1800 mm.

11.7.1.6 The cubicle shall be protected against splash water, 600mm from the floor.

The cubicle shall be provided with appropriate lifting hooks for transport. The


2017/SPECS/STR-1416 B - 36

cubicles shall be cleaned and painted according to Purchaser’s standard No.

1400, No. 1500 as specified in Annexure 1.

11.7.1.7 The charger shall be IP23 degree of protection according to IEC60529.

11.7.1.8 The Battery Charger and control systems shall be in modular construction for

ease of maintenance and to minimize downtime. They will be reinforced in

such a manner that they will provide adequate rigidity and strength to

withstand all stresses which can occur during transportation, installation,

testing and operation, without any distortion or damage of the cabinets or

components mounted inside the cabinets.

11.7.1.9 All chargers modules shall be of the draw-out type, removable from the front

of the Battery Charger.

11.7.1.10 The Battery Charger shall permit easy access to modules and assemblies for

control and maintenance. They will permit easy checking, adjustment or

maintenance without the removal of any adjacent module or assembly.

The Battery Charger Cabinet shall have all instruments, status indicators, and

controls placed easily visible to the operator. All warning labels shall be

clearly visible when any of the cabinet doors are open.

Easy access to terminal blocks shall be provided. Separating plate between

terminals for different voltages or functions shall be provided.

11.7.1.11 Cable entrances into the Battery Charger cabinet shall be done on the bottom

side of the cabinet, through removable plate, with cable glands supplied by

the Purchaser.

Necessary framework and brackets for fixing the cables into the cabinets will

be supplied by the Manufacturer.

All the wiring and cables shall be installed in cable ducts.

11.7.1.12 Copper ground bus, of at least 50mm² shall be installed in each power line


2017/SPECS/STR-1416 B - 37

bounded or bolted to the structure. All metallic parts of electrical components,

normally not under voltage, but which can assign voltage as result of a trouble

should be grounded to this ground bus. The ground bus shall have two bolts

for Purchaser's ground cables' connections, each at least 50mm².

11.7.1.13 Access to the electrical equipment mounted in the cabinets shall be made, on

front side, through 3 points latched doors, made with stainless steel hinges,

easily removable from their mounting places, lockable with two sets of keys.

Purchaser prefers cabinets which need only front access, with the conditions

that the Battery Charger unit overall dimensions will be indicated by

Purchaser during approval of the drawings.

11.7.1.14 All screws and mounting devices used for fastening equipment and

nameplates, inside/outside the cabinets shall be of rustproof type.

Screws shall not penetrate outside faces of the cabinet/s.

11.7.1.15 Indicators LEDs denoting abnormal conditions shall be readily observable by

operator without removing panels or opening cabinet/s doors. Power circuit

breakers shall be actuated preferable from front side without opening

cabinet's doors.

11.7.1.16 All status, alarm and instrumentation displays shall be arranged on a single or

more frontal panels, easily visible and accessible to a person standing on the

floor. All factory adjustments or non-operator controls should be located

behind the lockable cabinet/s doors. All alarms and signals shall be remotely

indicated by Potential Free contacts of output relays.

11.7.1.17 The Battery Charger shall have a modular construction, permitting easy and

fast maintenance. Replacement of the faulty module will be possible only

operating connectors and screws, without use of soldering. The

replacement shall be done only through the frontal door/s of the cabinet.

11.7.1.18 Painting of the furnished equipment shall be done in accordance with the


2017/SPECS/STR-1416 B - 38

Purchaser's Standard attached to this specification (appendix No. 1).

11.7.1.19 The enclosure of the Battery Charger shall be grounded.

11.7.1.20 In general internal wiring shall be performed in accordance with enclosed

EPD-A.03-Standard (see Appendix No. 2).

11.7.2 Mechanical Requirements to Internal Control and Protection Circuits and

Modules of Charger:

11.7.2.1 Vibration

IEC 60255-21-1, class 2

- Vibration response (energized): sinusoidal; frequency 60 to 150 Hz;

acceleration 1g; sweep rate 1 octave/min; 1 cycle in 3 orthogonal directions.

- Vibration withstand (de-energized): sinusoidal; frequency 60 to 150 Hz;

constant acceleration 2g; 40 cycle in 3 orthogonal directions.

- Vibration during transportation: 2 g in each of three mutually perpendicular

axes swept over range of 10 to 500 Hz for a total of six sweeps, 15 min each

sweep, without structural damage or degradation of performance.

11.7.2.2 Seismic

IEC 60255-21-3, level 2, criteria acceptance A

- X- and Y-axes: 3g, 11 mm, 1 – 50 Hz

- Z-axis: 2g, 7.5 mm, 1 - 50 Hz

11.8 Electrical Design Requirements

11.8.1 The charger will be based on a full wave, thyristor controlled rectifier,

connected through an isolating transformer, to the AC supply.

A solid state control system shall provide the rectifier with the required

characteristic. The rectifier shall be protected by automatic circuit breaker with

appropriate characteristics.


2017/SPECS/STR-1416 B - 39

11.8.2 A filtering and smoothing system shall assure that the ripple of the output

voltage measure at the output terminals will be:

a. 0.2% of the output r.m.s voltage with battery connected.

b. 1% of the output r.m.s voltage without battery connected.

11.8.3 Appropriate filtering or other means shall prevent voltage disturbances being

fed by the charger to the AC system.

11.8.4 Interference suppression devices and filters shall be provided in order to limit

the electromagnetic interference voltage levels from charger to power system

and from power system to charger.

11.8.5 Acoustical Requirements:

The maximum noise level at 1m distance shall be no more than 55dBA.

The noise test will be performed with the rated voltage and current, at full load.

11.8.6 The charger shall be natural air-cooled. The temperature rise of any

component shall be a maximum of 55 C above ambient temperature,

according to Clause 11.4 (-5 to +40 C).

Exceptions will not be permitted even if the components have an insulation

class which permits higher temperatures.

If the heat dissipater of the thyristor controlled rectifier bridge reaches the

temperature of 95ºC, the Battery Charger's main switch shall be tripped and

an alarm shall be provided by a N.O. dry contact in addition to indicator lamp

(led) in the front panel.


2017/SPECS/STR-1416 B - 40

11.9 Charger Components

The charger shall include (but not be limited to) the following components:

11.9.1 Insulating Transformers and Reactors

The transformer shall comply with the requirements of IEC 60146 PT 1-3. The

transformer core shall be of low losses steel sheets.

The transformer winding must be made with Class "F" wiring insulation (at

least, or better).

The Insulating Transformer's external maximum temperature T=85ºC. The

measuring can also be done with Infrared Thermometer.

The electronic parts maximum temperature T=70 ºC.

11.9.2 Rectifier Bridge

Max. voltage of SCR must be not less than 1200 Volt.

Rectifier Bridge must be equipped with overvoltage protected elements.

The rectifier bridge shall be of full wave type, thyristor controlled, for three

phase supply. The heat sink of the bridge shall be of the cast or rolled

aluminum type, as originally supplied with the bridge. Maximum allowable

temperature of the heat sink is 85ºC.

Heat sink must be protected from over temperature by thermo switch

connected to control circuit.

11.9.3 Electrolytic capacitors for DC filters

The capacitors shall be Heavy Duty Type, industrial grad at the temperature of

105 C at least and designed to operating life of 20 years at the temperature

of 40 C.


2017/SPECS/STR-1416 B - 41

ESR (Equivalent Series Resistance) of output filtering electrolytic capacitor

must be not more than 45 mOhm at 100 Hz and 20 C, maximal working

temperature 105 C. These capacitors must be suitable for use with high

ripple current and manufactured by world known manufacturers, such as

EPCOS, Vishay, KEMET, Nippon Chemi-Con, BHC Aerovox, Hitachi AIC.

A catalog shall be added to each kind of capacitor.

The Bidder shall include the calculations for capacitors to be chosen.

The calculations shall be also for life time at work without battery.

DC Filter

The filter capacitors (electrolytic capacitors) shall have not less than 400VDC

rated voltage.

AC Filter

The AC filter capacitors (non-electrolytic) shall have not less than 630VAC

rated voltage.

11.9.4 Main Circuit Breaker and Molded Circuit Breaker

The charger shall be equipped with at least the following M.C.B.’s and

according to IEC 60898.

- AC input M.C.B., at least 10KA, ultimate switching capacity with N.C.

auxiliary contact for alarm.

- DC output C.B., 15KA switching capacity with N.C. auxiliary contact for

alarm.


2017/SPECS/STR-1416 B - 42

- C.B. of suitable characteristic (Z characteristic) for main diodes (thyristor)

overload protection and for bridge protection.

- The main AC input and DC output C.B.’s shall be operated from inside the

cubicle.

- The bidder shall include a tripping characteristic curve of each type of C.B.

11.9.5 Control Circuits

Electronic control circuits and assemblies must be suit to requirements of

standards IPC-A-610, IPC-A-620 and IPC-TM-650.

Boards will be protected by transparent perspects.

11.9.6 Measuring Instruments

The measuring instruments should not be part of the controller or the Display

Panel.

11.9.6.1 Output DC Digital Voltmeter

a. Size: 96 x 48mm (at least).

b. Accuracy: 1% accuracy from reading value.

The resolution need to be accurate to one

digit after the decimal point.

c. Operating temperature: -5 C to 40 C

d. Digits: Four and half (4.5) digits measuring for 220V DC.

11.9.6.2 Output DC Digital Ammeters

a. Size: 96 x 48mm (at least).


2017/SPECS/STR-1416 B - 43

b. Accuracy: 1% accuracy from reading value. The resolution need to be

accurate to one digit after the decimal point.

c. Operating temperature: -5 C to 40 C.

d. Digits: Four (4) digits measuring 100A and three (3) digits measuring for

30A.

11.9.7 Control

The charger shall be provided with the following controls:

- A three position selector switch for float operation or equalizing charge

operation or boost charge operation (internally mounted), or three push

buttons for operating mode of operation.

The charger shall have potential free contacts, for charging mode

indication (one contact for each mode).

The Charger shall have one potential free contact, closed in boost charge

position, for customer’s use.

- Voltage regulating knob locked type or push buttons for floating charge

operation (internally mounted).

- Voltage regulating knob locked type or push buttons for boost charge

operation (internally mounted).

In case of use of push buttons the manufacturer will supply two pushbuttons

for each operation to insure double action for operation.

- A 220VAC, 16A socket including an earth leakage relay shall be installed

in the cubicle for auxiliary uses.


2017/SPECS/STR-1416 B - 44

11.9.8 COMMUNICATION

11.9.8.1 All the Battery Charger shall be provided with a communication adaptor

(SNMP-Simple Network Management Protocol) to transfer all needed data

such as System Parameters, history of events, identification and diagnostic, to

the dispatch center or client by using TCP/IP communication protocol with

MIB's standard. The SNMP adaptor is connected to Ethernet networks using

standard communications cables. There will be no possibility of shut-down or

change of parameters from remote station.

11.9.8.1.1 SNMP Module

Using the SNMP module, the Battery Charger is seen as a network device in

the WAN or LAN applications, and with this way it can be monitored more than

once. Battery Charger will be connected to the network through site

monitoring program which will allow monitoring of 40 systems Battery Charger

or more from one PC. It will not be possible to shutdown change parameters

of the servers or users with Client mate Software that communicates with

SNMP module. SNMP software installation is described as follows:

11.9.8.1.2 SNMP Software

Battery Charger will be equipped with SNMP agent. The SNMP Agent should

be configured properly and Battery Charger Management software should be

installed in the monitoring computer. The SNMP Agent will be supplied with

software CD which contains the following programs and tools:

a. SNMP Agent Operating manual in PDDF format.

b. Configuration utility for SNMP Agent IP address and firmware

upgrade.


2017/SPECS/STR-1416 B - 45

c. SNMP monitoring soft ward – Battery Charger management

software for multi-system Agent environment in Windows operating

systems.

d. Battery Charger MIB – MIB Management Information Base

definition file for SNMP management console.

e. Time Server – Time calibration program for SNMP Agent.

11.9.9 Programmable Controller

The Programmable Controller will be of known manufacturer and type.

Function of the programmable controller:

11.9.9.1 Operation, supervision and indication in accordance with the functions of the

charger.

11.9.9.2 Control all operations of the battery charger.

11.9.9.3 Able to be connected to a portable personal computer and supplied with PC

based GUI (Graphic User Interface) Windows supported.

11.9.9.4 Able to be controlled from a remote control center by using TCP/IP and

communication line with a friendly protocol.

11.9.9.5 Able to transmit to the control center the read parameters, trouble, alarms.

11.9.9.6 The programmable controller operation modes shall be:

11.9.9.6.1 - Float charge

- Equalizing charge

- Boost charge


2017/SPECS/STR-1416 B - 46

11.9.9.6.2 In case of programmable controller failure, the control functions will be held by

internal controller PCB without charger interruption.

11.9.9.6.3 If, prior to programmable controller failure, charger was in equalizing/boost

mode, it will be switched to the float mode.

11.9.9.7 Technical characteristics of the Programmable Controller.

11.9.9.7.1 The programmable controller shall be connected to the charger and shall have

a memory at least for 500 events.

11.9.9.7.2 The programmable controller shall be supplied with at least with 20 inputs and

20 outputs in accordance with the requirements of the battery charger.

11.10 Alarms

The charger shall be provided with the following alarms:

11.10.1 Open of each circuit breaker.

11.10.2 Boost charge.

11.10.3 Float charge.

11.10.4 Equalize charge.

11.10.5 Low output voltage.

11.10.6 Over temperature (95ºC on the tyrstor heat sink).

11.10.7 Over and under input AC voltage and phase failure.

11.10.8 High output voltage.


2017/SPECS/STR-1416 B - 47

11.10.9 Current limit.

11.10.10 P.C. failure.

11.11 Labeling

All the charger components, cables/wires and their connections shall be

clearly labeled for easy identification.

The front mounted components shall be labeled with sandwich type labels,

5mm high black letters of white background.

The labels shall be in Hebrew or English. Internally mounted components and

wiring shall also be labeled. The labeling technique is according to

manufacturer’s decision, but shall get Purchaser’s approval.

Date post:	29-Mar-2020
Category:	Documents
Upload:	others
View:	1 times
Download:	0 times