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SAMPLE
GENERATOR
SET
SPECIFICATION
THE FOLLOWING SPECIFICATIONS COVER REQUIREMENTS FOR DIESEL GENERATOR
SETS WITH OPTIONAL ATTACHMENTS, IT IS APPLICABLE FOR GENERATOR SETS
RATED FROM 230-250kW. NOTE SOME FEATURES ARE DESCRIBED IN THE TEXT OF
THIS DOCUMENT IN RED. THE DESIGNER MUST SELECT THESE FEATURES BASED ON
THE DESIGN CRITERIA.
Issued: July 30, 2003
Expires: January 30, 2004*
*
Due to expected future product changes, please consult with your local
dealer for sample product bid spec updates.
Division 16- Electrical
Emergency/Standby power Systems: 200-250 kW
Diesel Generator Set
1 GENERAL SPECIFICATIONS ............................................................................................................. 4
1.1 REFERENCES........................................................................................................................................ 4
1.1.1 Reference Standards ................................................................................................................... 4
1.2 RELATED SECTIONS ............................................................................................................................. 4
1.2.1 Division 3 - Concrete .................................................................................................................. 4
1.2.2 Division 15 - Mechanical............................................................................................................ 4
1.3 WORK INCLUDED ................................................................................................................................ 4
1.3.1 Installation .................................................................................................................................. 4
1.3.2 Fuel System ................................................................................................................................. 4
1.3.3 System Test.................................................................................................................................. 4
1.4 SUBSTITUTION ..................................................................................................................................... 4
1.4.1 Substitution Time Requirement .................................................................................................... 4
1.4.2 Substitution Responsibility .......................................................................................................... 5
1.5 SUBMITTALS ........................................................................................................................................ 5
1.6 FACTORY TESTING .............................................................................................................................. 5
1.7 SYSTEM RESPONSIBILITY .................................................................................................................... 5
1.7.1 Generator Set Manufacturer ....................................................................................................... 5
1.7.2 Requirements, Codes and Regulations........................................................................................ 5
1.7.3 Authorized Distributor ................................................................................................................ 6
1.7.4 Automatic Transfer Switch.......................................................................................................... 6
1.8 WARRANTY ......................................................................................................................................... 6
1.8.1 Two Year Warranty..................................................................................................................... 6
1.8.2 Warranty Administration .......................................................................................................... 6
1.9 PARTS AND SERVICE QUALIFICATIONS ................................................................................................ 6
1.9.1 Service Facility ........................................................................................................................... 6
1.9.2 Service Personnel........................................................................................................................ 6
2 PRODUCT REQUIREMENTS............................................................................................................... 6
2.1 GENERAL REQUIREMENTS ................................................................................................................... 6
2.1.1 Genset Requirements................................................................................................................... 6
2.1.2 Material and Parts ...................................................................................................................... 6
2.2 DIESEL ENGINE.................................................................................................................................... 7
2.2.1 Engine Requirements .................................................................................................................. 7
2.2.2 Governor..................................................................................................................................... 7
2.2.3 Block Design ............................................................................................................................... 7
2.2.4 Lubrication System...................................................................................................................... 7
2.2.5 Fuel System ................................................................................................................................. 7
2.3 GENERATOR ........................................................................................................................................ 7
2.3.1 Generator Specifications............................................................................................................. 7
2.3.2 Insulation .................................................................................................................................... 7
2.3.3 Exciter......................................................................................................................................... 7
2.3.4. Automatic Voltage Regulator..................................................................................................... 8
2.3.5 Space Heater............................................................................................................................... 8
2.3.6 Motor Starting............................................................................................................................. 8
2.4 CIRCUIT BREAKER ............................................................................................................................... 8
2.4.1 Circuit Breaker Specifications .................................................................................................... 8
2.5 CONTROL PANEL ................................................................................................................................. 8
2.5.1 Generator Mounted Control Panel ............................................................................................. 8
2.5.2 Digital Readouts ......................................................................................................................... 8
2.5.3 Alarm NFPA 110......................................................................................................................... 9
2.5.4 Remote Annunciator NFPA 110.................................................................................................. 9
2.5.5 Programmable Control Panel..................................................................................................... 9
2.6 COOLING SYSTEM................................................................................................................................ 9
2.6.1 Radiator ...................................................................................................................................... 9
2.7 FUEL SYSTEM .................................................................................................................................... 10
2.7.1 Fuel Filter ................................................................................................................................. 10
2.7.2 Fuel Piping................................................................................................................................ 10
2.7.3 Fuel Line Rating ....................................................................................................................... 10
2.7.4 Fuel Tank .................................................................................................................................. 10
2.8 EXHAUST SYSTEM ............................................................................................................................. 10
2.8.1 Silencer ..................................................................................................................................... 10
2.8.2 Exhaust System.......................................................................................................................... 10
2.9 STARTING SYSTEM ............................................................................................................................ 11
2.9.1 Starting Motor........................................................................................................................... 11
2.9.2 Jacket Water Heater.................................................................................................................. 11
2.9.3 Batteries .................................................................................................................................... 11
2.9.4 Battery Trays............................................................................................................................. 11
2.9.5 Battery Charger ........................................................................................................................ 11
2.10 STANDARD ENCLOSURE – UL2200 LISTED .................................................................................... 11
2.11
AUTOMATIC TRANSFER SWITCH ................................................................................................ 12
3 EXECUTION.......................................................................................................................................... 15
3.1 INSTALLATION ................................................................................................................................... 15
3.2 START-UP AND TESTING ................................................................................................................... 15
3.3 OPERATION AND MAINTENANCE MANUALS ...................................................................................... 15
3.3.1 Manuals Provided ..................................................................................................................... 15
3.4 TRAINING .......................................................................................................................................... 16
3.4.1 On-Site Training ....................................................................................................................... 16
3.5 SCHEDULED OIL SAMPLING ............................................................................................................... 16
1 General Specifications
1.1 References
1.1.1 Reference Standards
The generator covered by these specifications shall be designed, tested, rated,
assembled and installed in strict accordance with all applicable standards of ANSI, NEC, ISO,
U.L., IEEE and NEMA.
1. NFPA 70 – National Electrical Code. Equipment shall be suitable for use in systems in
compliance to Article 700, 701, and 702.
2. NFPA 99 – Essential Electrical Systems for Health Care Facilities
3. NFPA 110 – Emergency and Standby Power Systems. The generator set shall meet all
requirements for Level 1 systems. Level 1prototype tests required by this standard shall
have been performed on a complete and functional unit, component level type tests will
not substitute for this requirement.
4. UL 508A. The entire control system of the generator set shall be UL508 Listed and
labeled.
5. CSA 282, 1989 Emergency Electrical Power Supply for Buildings (Canada only)
6. UL2200. The package genset shall be UL2200 Listed.
1.2 Related Sections
1.2.1 Division 3 - Concrete
1.2.2 Division 15 - Mechanical
1.3 Work Included
1.3.1 Installation
The work includes supplying and installing a complete integrated emergency generator
system to provide an alternate source of power to the plant emergency load in the event of a
utility outage. The system consists of a diesel generator set with related component
accessories and automatic transfer switches.
1.3.2 Fuel System
Coordination with Division 15 is required to provide a complete fuel system. The
CONTRACTOR shall provide a full tank of diesel fuel at the completion of all testing.
1.3.3 System Test
A complete system resistive load bank test at unity power factor is required after all
equipment is installed.
1.4 Substitution
Proposed deviations from the specifications shall be treated as follows:
1.4.1 Substitution Time Requirement
Requests for substitutions shall be made a minimum of ten (10) days prior to bid date.
Manufacturers catalog data shall accompany each request and authorized acceptance shall
be addenda only.
Issued: July 30, 2003
Page 4 of 16
Expires: January 30, 2004
1.4.2 Substitution Responsibility
The emergency power system has been designed to the specified manufacturer's
electrical and physical characteristics. The equipment sizing, spacing, amounts, electrical
wiring, ventilation equipment, fuel and exhaust components have all been sized and designed
around CATERPILLAR equipment. Should any substitutions be made, the CONTRACTOR
shall bear responsibility for the installation, coordination and operation of the system as well
as any engineering and redesign costs, which may result from such substitutions.
1.5 Submittals
Engine-generator submittals shall include the following information
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Factory published specification sheet indicating standard and optional accessories,
ratings, etc.
Manufacturer's catalog cut sheets of all auxiliary components such as isolators,
battery charger, silencer, exhaust flex, main circuit breaker, etc.
Dimensional elevation and layout drawings of the generator set, enclosure and
transfer switchgear and related accessories.
Engine mechanical data at varying loads up to full load, including heat rejection,
exhaust gas flows, combustion air and ventilation air flows, noise data, fuel
consumption, etc.
Generator electrical data including temperature and insulation data, cooling
requirements, excitation ratings, voltage regulation, voltage regulator, efficiencies,
waveform distortion and telephone influence factor.
Generator resistances, reactances and time constants.
Generator current decrement curve.
Generator motor starting capability.
Jacket water heater connection diagram.
Control panel schematics.
Automatic load transfer switch (es).
Oil sampling analysis, laboratory location, and information.
Manufacturer's and dealer's written warranty.
Emissions data
1.6 Factory Testing
The system manufacturer must certify that engine; generator, controls, and switchgear
have been tested as complete system of representative engineering models (not on
equipment sold). The manufacturer shall supply equipment that is a current factory production
model.
The Generator Set shall be tested in accordance with the power, voltage, and frequency
shown on the generator set information plate.
1.7 System Responsibility
1.7.1 Generator Set Manufacturer
To qualify as a MANUFACTURER, the engine must be the principal item manufactured
and the completed engine generator set shall be supplied by that, MANUFACTURER's
authorized distributor only.
1.7.2 Requirements, Codes and Regulations
The equipment supplied and installed shall meet the requirements of the current Edition
of the NEC and all applicable local codes and regulations. All equipment shall be of new and
Issued: July 30, 2003
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Expires: January 30, 2004
current production by a MANUFACTURER who has 60 years of experience building this type
of equipment.
1.7.3 Authorized Distributor
The equipment supplier shall be the local authorized distributor for the product supplied.
1.7.4 Automatic Transfer Switch
The automatic transfer switch (es) specified shall be supplied by the engine-generator
manufacturer in order to establish and maintain a single source of system responsibility and
coordination.
1.8 Warranty
1.8.1 Two Year Warranty
The manufacturer's standard warranty shall in no event be for a period of less than two
(2) years from date of initial start-up of the system and shall include repair parts, labor,
reasonable travel expense necessary for repairs at the job site, and expendables (lubricating
oil, filters, antifreeze, and other service items made unusable by the defect) used during the
course of repair. Running hours shall not be a limiting factor for the system warranty by either
the manufacturer or servicing distributor. Submittals received without written warranties as
specified will be rejected in their entirety.
1.8.2 Warranty Administration
The manufacturer's authorized dealer shall be capable of administering the manufacturer
and dealer's warranty for all components supplied by the selling dealer.
1.9 Parts and Service Qualifications
1.9.1 Service Facility
The engine-generator supplier shall have service facilities within __ miles of the project
site and maintain 24-hour parts and service capability. The distributor shall stock parts as
needed to support the generator set package for this specific project.
1.9.2 Service Personnel
The dealer shall maintain qualified; factory trained service personnel that can respond to
an emergency call within __ hours of notification.
2 Product Requirements
2.1 General Requirements
2.1.1 Genset Requirements
The generator set shall be Standby rated at ___ ekW, ___kVA, 1800 RPM,_.__ power
factor, 480 VAC, 3 phase, _ _ wire, 60 hertz, including radiator fan and all parasitic loads.
2.1.2 Material and Parts
All materials and parts comprising the unit shall be new and unused.
Issued: July 30, 2003
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Expires: January 30, 2004
2.2 Diesel Engine
2.2.1 Engine Requirements
The engine shall be as manufactured by Caterpillar or approved equal. The engine shall
be water-cooled inline, four-cycle compression ignition diesel. It shall meet specifications
when operating on number 2 diesel fuel. Two cycle engines will not be considered. The
engine shall be equipped with fuel, lube oil, and intake air filters, lube oil cooler, fuel transfer
pump, fuel priming pump, service meter, gear-driven water pump.
2.2.2 Governor
2.2.2.1 Governor -- Hydra-Mechanical
The governor shall be mechanical with hydraulic assist as required. It shall maintain 3%
or less speed droop from no load full rated load. Steady state speed regulation shall be +/0.33%. The governor shall be equipped with a vernier control and positive locking to allow
manual speed adjustment.
2.2.3 Block Design
The complete engine block shall be machined from one casting. Designs incorporating
multiple blocks bolted together are not acceptable.
2.2.4 Lubrication System
The engine shall utilize a gear-type, positive displacement, full pressure lubricating oil
pump and water-cooled lube oil cooler. Pistons shall be spray-cooled. Provide oil filters, oil
pressure gauge, dipstick and oil drain.
2.2.5 Fuel System
Fuel filter and serviceable fuel system components shall be located to prevent fuel from
spilling onto generator set batteries.
2.3 Generator
2.3.1 Generator Specifications
The synchronous three phase generator shall be a single bearing, self-ventilated, dripproof design in accordance with NEMA MG 1 and directly connected to the engine flywheel
housing with a nose pilot .
2.3.2 Insulation
The insulation material shall meet NEMA standards for Class H insulation and be vacuum
impregnated with epoxy varnish to be fungus resistant. Temperature rise of the rotor and
stator shall not exceed NEMA class F (130 ºC rise by resistance over 40 C ambient). The
excitation system shall be of brushless construction. The generator insulation system shall be
UL 1446 Recognized.
2.3.3 Exciter
2.3.3.1 Self-Excited
The self-excited, brushless exciter shall consist of a three-phase armature and a threephase full wave bridge rectifier mounted on the rotor shaft. Surge suppressors shall be
included to protect the diodes from voltage spikes.
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Expires: January 30, 2004
2.3.4. Automatic Voltage Regulator
The automatic voltage regulator (AVR) shall maintain generator output voltage within +/- 0.5%
for any constant load between no load and full load. The regulator shall be a totally solid state
design, which includes electronic voltage buildup, volts per Hertz regulation, three phase sensing,
over-excitation protection, loss of sensing protection, temperature compensation, shall limit voltage
overshoot on startup, and shall be environmentally sealed. The voltage regulator shall be UL 508
Listed.
2.3.5 Space Heater
Provide a generator mounted space heater, 120/240 VAC, and 1 phase.
2.3.6 Motor Starting
Provide motor starting capability of __.___ kVA SKVA at > 40% instantaneous voltage
dip as defined per NEMA MG 1. Sustained voltage performance data is not acceptable.
2.4 Circuit Breaker
2.4.1 Circuit Breaker Specifications
Provide a generator mounted circuit breaker, molded case or insulated case construction,
_ _ _ amp trip, 3 pole, NEMA 1P22. Breaker shall be Merlin Gerin or equal and utilize a
thermal magnetic trip unit and 24 VDC shunt trip. The breaker shall be UL Listed with shunt
trip device connected to engine/generator safety shutdowns. Breaker shall be housed in an
extension terminal box mounted on the side of the generator. Mechanical type lugs, sized for
the circuit breaker feeders shown on drawing, shall be supplied on the load side of breaker.
2.5 Control Panel
2.5.1 Generator Mounted Control Panel
Provide a generator mounted control panel for complete control and monitoring of the
engine and generator set functions. Panel shall include automatic start/stop operation;
adjustable cycle cranking, digital AC metering (0.5% true RMS accuracy) with phase selector
switch, digital engine monitoring, shutdown sensors and alarms with horn and reset,
adjustable cooldown timer and emergency stop push-button. Panel shall incorporate selfdiagnostics capabilities and fault logging. Critical components shall be environmentally sealed
to protect against failure from moisture and dirt. Components shall be housed in a NEMA
1/IP22 enclosure with hinged lid. Control panel shall be UL 508A Listed.
2.5.2 Digital Readouts
Provide the following digital readouts:
1. Engine oil pressure
2. Coolant temperature
3. Engine RPM
4. System DC Volts
5. Engine running hours
6. Generator AC volts
7. Generator AC amps
8. Generator frequency
9. KW meter
10. Percentage of rated Power
11. KVA meter
12. KVAr meter
13. Power Factor meter
14. KWHR meter
Issued: July 30, 2003
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Expires: January 30, 2004
2.5.3 Alarm NFPA 110
Provide the following indications for protection and diagnostics according to NFPA 110
level 1:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Low oil pressure
High water temperature
Low coolant level
Overspeed
Overcrank
Emergency stop depressed
Approaching high coolant temperature
Approaching low oil pressure
Low coolant temperature
Low voltage in battery
Control switch not in auto. position
Low fuel main tank
Battery charger ac failure
High battery voltage
EPS supplying load
Spare
2.5.4 Remote Annunciator NFPA 110
Provide a remote annunciator to meet the requirements of NFPA 110, Level 1. The
annunciator shall provide remote annunciation of all points stated above and shall incorporate
ring-back capability so that after silencing the initial alarm, any subsequent alarms will sound
the horn.
2.5.5 Programmable Control Panel
Provide programmable protective relay functions inside the control panel to include the
following:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Undervoltage
Overvoltage
Overfrequency
Underfrequency
Reverse power
Overcurrent (phase and total)
KW level (overload)
Three spare LED's
Four spare inputs
2.6 Cooling System
2.6.1 Radiator
The generator set shall be equipped with a rail-mounted, engine-driven radiator with
blower fan and all accessories. The cooling system shall be sized to operate at full load
conditions and 85 F ambient air entering the room or enclosure (If an enclosure is specified)
without derating the unit and 50/50 anti-freeze mixture. The radiator shall be filled with an
extended life coolant with a minimum estimated life of 6000 hours or 6 years. The coolant
formula shall contain no phosphates or silicates, and it shall be recyclable. The generator set
supplier is responsible for providing a properly sized cooling system based on the enclosure
static pressure restriction.
Issued: July 30, 2003
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Expires: January 30, 2004
2.7 Fuel System
2.7.1 Fuel Filter
Filter/Separator - In addition to the standard fuel filters provided by the engine
manufacturer, there shall also be installed a primary fuel filter/water separator in the fuel inlet
line to the engine.
2.7.2 Fuel Piping
All fuel piping shall be black iron or flexible fuel hose rated for this service. No galvanized
piping will be permitted.
2.7.3 Fuel Line Rating
Flexible fuel lines rated 300 degrees F and 100 PSI.
2.7.4 Fuel Tank
2.7.4.1 Fuel Day Tank
A UL 142 Listed, painted steel day tank with _________ U.S. gallons capacity, to supply
fuel to the engine for a minimum of 2 hours operation at 100% of rated load, shall be
furnished. A bronze gear pump which exceeds the maximum flow of fuel drawn by the
engine-mounted fuel supply pump, including fuel returned from the engine, shall be mounted
on the tank and powered by a 120 VAC single phase motor. The pump shall be controlled by
low/high level switches mounted inside the tank.
Supply piping connections for fuel suction/return lines to fuel storage tank, fuel
supply/return lines to engine, and emergency vent. Include local fuel fill, tank drain
connection, removable inspection plate with gasket, 'press to test" switch, and fuel level
gauge. The following accessories shall be provided: steel rupture basin to contain 150%
capacity, fuel in rupture basin switch, high/low fuel level switches for remote annunciator, UL
508 Listed Control module, fuel strainer.
2.8 Exhaust System
2.8.1 Silencer
A critical type silencer, companion flanges, and flexible stainless steel exhaust fitting
properly sized shall be furnished and installed according to the manufacturer's
recommendation. Mounting shall be provided by the contractor as shown on the drawings.
The silencer shall be mounted so that its weight is not supported by the engine nor will
exhaust system growth due to thermal expansion be imposed on the engine. Exhaust pipe
size shall be sufficient to ensure that exhaust backpressure does not exceed the maximum
limitations specified by the engine manufacturer.
2.8.2 Exhaust System
The muffler and all indoor exhaust piping shall be "lagged" by the contractor to maintain a
surface temperature not to exceed 150F. The insulation shall be installed so that it does not
interfere with the functioning of the flexible exhaust fitting.
Issued: July 30, 2003
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Expires: January 30, 2004
2.9 Starting System
2.9.1 Starting Motor
A DC electric starting system with positive engagement shall be furnished. The motor
voltage shall be as recommended by the engine manufacturer.
2.9.2 Jacket Water Heater
A unit mounted thermal circulation type water heater. The heater Watt rating shall be
sized by the manufacturer to maintain jacket water temperature at 90 degrees F, and shall be
a (120/208/240/480) volt, single phase, 60 hertz.
2.9.3 Batteries
A lead-acid storage battery set of the heavy-duty diesel starting type shall be provided.
Battery voltage shall be compatible with the starting system. The battery set shall be rated no
less than 172-ampere hours. Necessary cables and clamps shall be provided.
2.9.4 Battery Trays
A battery tray shall be provided for the batteries and shall conform to NEC 480-7(b). It
shall treated to be resistant to deterioration by battery electrolyte. Further, construction shall
be such that any spillage or boil-over battery electrolyte shall be contained within the tray to
prevent a direct path to ground.
2.9.5 Battery Charger
A current limiting battery charger shall be furnished to automatically recharge batteries.
Charger shall float at 2.17 volts per cell and equalize at 2.33 volts per cell. It shall include
overload protection, silicon diode full wave rectifiers, voltage surge suppressor, DC ammeter,
DC voltmeter, and fused AC input. Ac input voltage shall be 120 volts, single phase. Charger
shall have LED annunciation for low DC volts, rectifier failure, loss of AC power, high DC volts.
Amperage output shall be no less than ten (10) amperes. Charger shall be wall-mounting type
in NEMA 1 enclosure.
2.10 Standard Enclosure – UL2200 Listed
The factory-installed engine generator set enclosure shall be performance tested as a
package with the listed and labeled engine generator set and is considered rainproof in
accordance with UL2200 performance requirements for outdoor-use units. A decal indicating the
enclosure UL2200 Listing shall be pasted on the interior edge of the left middle door.
Steel weather protective enclosure with 14-gauge sheet metal and a minimum ambient
capability of 43 C (110 F). Shall have removable, hinged doors and removable end panels to
allow easy routine maintenance. All hinges and latches shall be rust resistant and doors shall be
equipped with rubber seals. A lockable service access cover shall be provided for easy access to
the radiator fill cap. Vibration isolators between genset and base minimize engine vibration
transmitted to base, enclosure, control panel and circuit breaker, reducing noise and mechanical
stress. Directional louvers further avoid mechanical noise.
The roof shall be pitched to prevent moisture accumulation. The enclosure shall be
painted utilizing a UL Recognized paint system. Each module is fully supported by the Factory
Parts Department
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Expires: January 30, 2004
2.11 Automatic Transfer Switch
An automatic transfer switch shall be furnished as specified herein.
2.11.1 General
1.
The transfer switch shall be rated for the voltage and ampacity as shown on the plans and
shall have 600 volt insulation on all parts in accordance with NEMA standards.
2.
The current rating shall be a continuous rating when the switch is installed in an
unventilated enclosure, and shall conform to NEMA temperature rise standards. Designs which
require cabinet ventilation are unacceptable and do not meet this specification.
3.
The unit shall be rated based on all classes of loads, i.e., resistive, tungsten, ballast and
inductive loads. Switches rated 400 amperes or less shall be UL listed for 100% tungsten lamp
load.
4.
As a precondition for approval, all transfer switches complete with accessories shall be
listed by Underwriters Laboratories, under Standard UL 1008 (automatic transfer switches) and
approved for use on emergency systems.
5.
The withstand current capacity of the main contacts shall not be less than 20 times the
continuous duty rating when coordinated with any molded case circuit breaker established by
certified test data. Refer to required withstand and close ratings as detailed in this specification.
6.
Load and endurance tests to confirm the ability of the units to carry their rated currents
within the allowable temperature limits.
7.
Transfer switches shall comply with the applicable standards of UL, CSA, ANSI, NFPA,
IEEE, NEMA and IEC.
8.
The transfer switches shall be supplied with a microprocessor based control panel as
detailed further in these specifications.
2.11.2 Sequence of Operation
1.
The ATS shall incorporate adjustable three phase (or single phase as applicable) undervoltage sensing of the normal source
2.
When the voltage of any phase of the normal source is reduced to 80% of nominal
voltage, for a period of 0-10 seconds (programmable) a pilot contact shall close to initiate starting
of the engine generator.
3.
The ATS shall incorporate adjustable single phase under-voltage sensing of the emergency
source.
4.
When the emergency source has reached a voltage value within 90% of nominal voltage
and achieved frequency within 95% of the rated value, the load shall be transferred to the
emergency source after a programmable time delay.
5.
When the normal source has been restored to not less than 90% of rated voltage on all
phases, the load shall be re-transferred to the normal source after a time delay of 0 to 30 minutes
(programmable). The generator shall run unloaded for 5 minutes (programmable) and then
automatically shut down. The generator shall be ready for automatic operation upon the next
failure of the normal source.
6.
If the engine generator should fail while carrying the load, retransfer to the normal source
shall be made instantaneously upon restoration of proper voltage (90%) on the normal source.
7.
Site inspection and operational tests shall be conducted by the factory trained generator
service technician in the presence of the engineer, to indicate that the switch satisfies the
specifications.
8.
The transfer switch shall be equipped with a microprocessor based control panel. The
control panel shall perform the operational and display functions of the transfer switch. The
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Expires: January 30, 2004
display functions of the control panel shall include ATS position and source availability, sequence
indication and diagnostics.
9.
The front panel display shall include indicators for timing functions, capability to bypass the
TD on transfer or retransfer, an ATS test switch and afford on-board diagnostic capability.
10. The digital display shall be accessible without opening the enclosure door and shall be
provided with a 4 line by 20 character LCD display screen with touch pad function and display
menus. The programming functions shall be pass code protected.
11. The control panel shall be provided with menu driven display screens for transfer switch
monitoring, control and field configurable functions and settings
12. The control panel shall be opto-isolated from its inputs to reduce susceptibility to electrical
noise and provided with the following inherent control functions and capabilities:
a. Multipurpose display for continuous monitoring and control of the ATS functions and
settings. All field configurable functions shall be pass code protected and accessible through the
keypad.
b. Built-in diagnostic display that includes the capturing of historical data, such as number of
transfers and time on emergency power source, for ease of troubleshooting.
c. Capability to support external communication and network interface through an optional
RS 485 serial port.
d. Touch pad test switch to simulate a normal source failure.
e. Time delay to override momentary normal source failure prior to engine start. Field
programmable 0-10 seconds (continuously adjustable via a calibrated potentiometer factory set at
3 seconds.
f. Time delay on retransfer to normal source, continuously adjustable 0-30 minutes, factory
set at 30 minutes. If the emergency source fails during the retransfer time delay, the transfer
switch controls shall automatically bypass the time delay and immediately retransfer to the normal
position.
g. Time delay on transfer to emergency, continuously adjustable 0-15 seconds, factory set
at 1 second.
h. An in-phase monitor shall be provided. The monitor shall compare the phase angle
difference between the normal and emergency sources and be programmed to anticipate the
zero crossing point to minimize switching transients.
i. An interval-type automatic clock exerciser shall be incorporated within the
microprocessor.
j. Provide a momentary pushbutton to bypass the time delays on transfer and retransfer.
2.11.3 Construction and Performance
1.
The automatic transfer switch shall be of double throw construction operated by a reliable
electrical mechanism momentarily energized. There shall be a direct mechanical coupling to
facilitate transfer in 6 cycles or less.
2.
The normal and emergency contacts shall be mechanically interlocked such that failure of
any coil or disarrangement of any part shall not permit a neutral position.
3.
For switches installed in systems having ground fault protective devices, and/or wired so as
to be designated a separately derived system by the NEC, a 4th pole shall be provided. This
additional pole shall isolate the normal and emergency neutrals. The neutral pole shall have the
same withstand and operational ratings as the other poles and shall be arranged to break last
and make first to minimize neutral switching transients. Add-on or accessory poles that are not of
identical construction and withstand capability are not acceptable.
Issued: July 30, 2003
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Expires: January 30, 2004
4.
The contact structure shall consist of a main current carrying contact, which is a silver alloy
with a minimum of 50% silver content. The current carrying contacts shall be protected by silver
tungsten arcing contacts on all sizes above 400 Amps.
5.
The transfer switch manufacturer shall submit test data for each size switch, showing it can
withstand fault currents of the magnitude and the duration necessary to maintain the system
integrity. Minimum UL listed withstand and close into fault ratings shall be as follows:
Any Molded Case Breaker*:
Size (Amps)
(RMS Symmetrical)
Up to 200
10,000
201 - 260
35,000
261 - 400
35,000
401 - 1200
50,000
1201 - 4000
100,000
Specific Coordinated Breaker*:
Size (Amps)
(RMS Symmetrical)
Up to 150
30,000
151 - 260
42,000
261 - 400
50,000
401 - 800
65,000
801 - 1200
85,000
1201 - 4000
100,000
Current Limiting Fuse*:
Size (Amps)
(RMS Symmetrical)
Up to 4000
200,000
*All values 480 volt, RMS symmetrical, less than 20% power factor.
6.
A dielectric test at the conclusion of the withstand and closing tests shall be performed.
7.
The automatic transfer switch manufacturer shall certify sufficient arc interrupting
capabilities for 50 cycles of operation between a normal and emergency source that are 120
degrees out of phase at 480 volts, 600% of rated current at .50 power factor. This certification is
to ensure that there will be no current flow between the two isolated sources during switching.
8.
All relays shall be continuous duty industrial type with wiping contacts. Customer interface
contacts shall be rated 10 amperes minimum. Coils, relays, timers and accessories shall be
readily front accessible. The control panel and power section shall be interconnected with a
harness and keyed disconnect plugs for maintenance.
9.
Main and arcing contacts shall be visible without major disassembly to facilitate inspection
and maintenance.
10. A manual handle shall be provided for maintenance purposes with the switch de-energized.
An operator disconnect switch shall be provided to defeat automatic operation during
maintenance, inspection or manual operation.
11. The switch shall be mounted in a NEMA 1 enclosure unless otherwise indicated on the
plans.
12. Switches composed of molded case breakers, contactors or components thereof not
specifically designed as an automatic transfer switch will not be acceptable.
Issued: July 30, 2003
Page 14 of 16
Expires: January 30, 2004
13. The automatic transfer switch shall be warranted against defects in material or workmanship
for a period of two years from the date of shipment.
14. To afford the advantage of a single source of supply to the owner, the automatic transfer
switch shall be supplied by the manufacturer of the engine generator set and covered under the
same warranty program. The ATS shall be the Caterpillar CTG Series.
.
3 Execution
3.1 Installation
Install equipment in accordance with manufacturer's recommendations, the project
drawings and specifications, and all applicable codes.
3.2 Start-Up and Testing
A. Coordinate all start-up and testing activities with the Engineer and Owner.
B. After installation is complete and normal power is available, the manufacturer's local
dealer shall perform the following:
1. Verify that the equipment is installed properly.
2. Check all auxiliary devices for proper operation, including battery charger, jacket
water heater(s), generator space heater, remote annunciator, etc.
3. Test all alarms and safety shutdown devices for proper operation and annunciation.
4. Check all fluid levels.
5. Start engine and check for exhaust, oil, fuel leaks, vibrations, etc.
6. Verify proper voltage and phase rotation at the transfer switch before connecting to
the load.
7. Connect the generator to building load and verify that the generator will start and run
all designated loads in the plant.
8. Perform a 4-hour load bank test at .80 power factor at full nameplate load using a
reactive load bank and cables supplied by the local generator dealer. Observe and
record the following data at 15-minute intervals:
A.
B.
C.
D.
E.
F.
G.
H.
I.
Service meter hours
Volts AC - All phases
Amps AC - All phases
Frequency
Power factor or Vars
Jacket water temperature
Oil Pressure
Fuel pressure
Ambient temperature
3.3 Operation and Maintenance Manuals
3.3.1 Manuals Provided
Provide four (4) sets of operation and maintenance manuals covering the generator,
switchgear, and auxiliary components. Include parts manuals, final as-built wiring
interconnect diagrams and recommended preventative maintenance schedules.
Issued: July 30, 2003
Page 15 of 16
Expires: January 30, 2004
3.4 Training
3.4.1 On-Site Training
Provide one day of on-site training to instruct the owner's personnel in the proper
operation and maintenance of the equipment. Review operation and maintenance manuals,
parts manuals, and emergency service procedures.
3.5 Scheduled Oil Sampling
In order to forecast and minimize engine failure, the supplier of the equipment must
provide an oil sampling analysis kit which operating personnel shall utilize for scheduled oil
sampling.
The laboratory to which oil samples will be sent shall be located at and be a part of the
local generator set supplier's facility, and shall be open to inspection during normal working
hours. Independent laboratories not a part of the engine supplier's facility are disallowed as to
conformance with this specification.
Scheduled oil sampling shall be of the atomic absorption spectrophotometer method as
opposed to the spectrographic analysis method and shall be accurate to within a fraction of
one part per million for the following elements:
a. Iron
b. Chromium
c. Copper
d. Aluminum
e. Silicon
f. Lead
In addition, the sample shall be tested for the presence of water, fuel dilution, and anti-freeze.
All equipment needed to take oil samples shall be provided a kit at the time of
acceptance and shall include the following:
a. Sample extraction gun (1)
b. Bottle (10)
c. Postage paid mailers (10)
d. Written instructions (1)
e. Metal storage box (1)
IMMEDIATE notification shall be provided to the owner when analysis shows any critical
reading. If readings are normal, a report showing that the equipment is operating within
established parameters shall be provided.
This scheduled oil sampling kit shall be made available, at additional cost, to the owner
beyond the mandatory starter kit specified previously and shall be optional for the owner to
continue purchasing after the starter kit has been depleted.
CATERPILLAR MAKES NO EXPRESS WARRANTIES AND DISCLAIMS ALL IMPLIED
WARRANTIES, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. CATERPILLAR SHALL HAVE NO LIABILITY IN LAW OR EQUITY, FOR
DAMAGES, CONSEQUENTIAL OR OTHERWISE, THAT ARISE FROM USE OF PROGRAM
AND RELATED MATERIAL OR ANY PART THEREOF.
Issued: July 30, 2003
Page 16 of 16
Expires: January 30, 2004