ASCO 4000 Series Power Control System Low Voltage - Emerson ...

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ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

1


Publication 3135
R
4

SUGGESTED SPECIFICATION

For ASCO 4000 Series Power Control System

Low Voltage (600V) Digital Generator Paralleling Control Switchgear


Division 16


Electrical

Standby Power Generator Systems



PART 1 GENERAL

1.1

SCOPE OF WORK

-

provide a complete digital po
wer control and distribution system to automatically start
and parallel ____ (2
-

8) engine generator sets, rated _______ kW ____ Vac, at 0.8 PF for three phase,
_____ (3 or 4) wire, _______ (50 or 60) Hz.

The switchgear lineup shall be free
-
standing an
d shall be based on a modular design principle. The lineup
shall contain the necessary number of standard control modules and standard distribution modules
(sections), including optional accessories. All modules and optional accessories shall be selectab
le
through a catalog ordering matrix which will allow for integrated selection of items into a complete paralleling
switchgear lineup.

1.2

REFERENCE STANDARDS

-

The Engine
-
Generator Control Switchgear and all related components shall be
designed, manufactured
and tested in accordance with the latest edition of the following applicable
standards:

A.

American National Standards Institute, Inc. (ANSI)

C37.20.1

Metal
-
Enclosed Low
-
Voltage Power Circuit Breaker Switchgear

C37.51


Testing of Metal
-
Enclosed Low
-
Voltage
Power Circuit Breaker
Switchgear Assemblies

B.

National Fire Protection Association (NFPA)

NFPA
-

70

National Electrical Code

NFPA
-

99

Essential Electrical Systems for Health Care Facilities

NFPA
-

110

Standard for Emergency and Standby Power Systems

C.

Under
writers Laboratories, Inc. (UL)

UL 1558

Switchgear Assemblies

D.

National Electrical Manufacturers Association (NEMA)

NEMA SG
-
5

Power Switchgear Assemblies

E.

International Standards Organization (ISO)

ISO 9001:2000

1.3

MANUFACTURER’S QUALIFICATIONS

-

Equipment man
ufacturer who has produced this type of
equipment for a period of at least 25 years and is certified under ISO
9001:2000.

1.4

SUBMITTALS



UPON RECEIPT OF PURC
HASE ORDER, MANUFACT
URER SHALL PROVIDE S
ix (6)
submittals for approval within twenty (20) working da
ys after receipt of an order which shall include the
following:

A.

Sequence of Operation

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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Publication 3135
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B.

Bill of Material

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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C.

Mechanical Drawings:

1.

Dimensional plans and elevations, with front view, side views and other pertinent elevation
views.

2.

Conduit entrance locations and d
imensions within all assemblies for both bottom and top
entrance.

3.

Door details.

4.

Circuit breaker ratings.

5.

Weight of equipment.

6.

Assembly ratings including:

a.

Short circuit rating

b.

Voltage

c.

Continuous current


7.

Cable terminal sizes.

8.

Base plan showing dimensions o
f base with anchoring provisions.

D.

Electrical Drawings:

1.

Typical AC Three
-
Line Schematic diagrams with all components cross referenced.

2.

Typical DC Schematic diagrams with all components cross referenced.

3.

Typical equipment interconnect drawings showing termin
al points and external device
function.

E.

Major component product data sheets.


PART 2 PRODUCTS

2.1

GENERAL REQUIREMENTS

A.

The equipment described is a SYNCHROPOWER
®

ASCO 4000 Series Power Control
System as manufactured by ASCO Power Technologies and is the basis
for the
design of this system. Any alternates to this bid shall only be considered if a
complete written description of the proposed system along with any variances from the

specification, are received ten (10) days prior to bid due date. Any variances n
ot
specifically enumerated prior to bidding shall be considered non
-
responsive. Costs
incurred to modify the building and/or interfacing equipment which are affected as a
result of an alternate, shall be the responsibility of the contractor.

B.

Systems that
use paralleling controls that are mounted on the engine generator are
not acceptable.

2.2

CONSTRUCTION

A.

The enclosures shall be, freestanding, floor supported, with front and rear access.
Removable lifting eyes shall be supplied for lifting purposes. Adequate n
umber of
anchor bolt
-
holes spaced to place the base in direct contact with the concrete pad
when bolted. All doors shall be pan type and be provided with sufficient hinges to
support the door and components for minimum deflection and wobbling when opening

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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or closing. Front doors shall be supplied with a lockable handle. All door locks shall
be keyed alike to operate from a single key, with one key supplied for each lock. All
panel covers are secured with captive screws as necessary.

B.

The complete assembly
shall be degreased, and thoroughly cleaned through a three
stage aqueous process. The finish shall be ANSI
-
61, light gray, electrostatically
charged polyester powder paint process, minimum 1.5 mils in density. Finish shall be
suitable for indoor and outdo
or environments.

2.3

BUS

A.

Bus shall be silver plated copper and shall have a maximum current density of 1000
amperes per square inch.

B.

Bus shall have a minimum bracing level not less than 100,000 amperes.

C.

A full capacity neutral bus shall be provided when it i
s indicated on the drawings (3
Phase, 4 Wire Systems).

D.

A copper ground bus shall be provided.

2.4

WIRING/TERMINATIONS

A.

Control wiring 600 volt, UL 1015 or SIS. Use solderless compression screw type
connectors for terminating all wires. Current transformer circu
it terminations shall be
ring tongue compression type. Other circuits shall be ring tongue compression type
where feasible, otherwise they shall be spade type applied with the proper tooling.

B.

Control wires shall be numbered every six (6) inches and visibl
e next to the terminals.
Low level signal circuits shall be provided with shielded wire to minimize
electromagnetic interference. Shielded wire grounded at one point.

C.

Current transformer circuits are connected through shorting terminal blocks.

2.5

POWER CIRC
UIT BREAKERS

A.

The generator and distribution circuit breakers shall be draw
-
out low voltage power
circuit breakers with interrupting current ratings no less than 100KAIC and will be UL
1066 rated. The draw
-
out feature shall provide for connected, test and
disconnected
positions. In the connected position the main line and load terminals and all auxiliary
control contacts and circuitry shall be connected and the breaker shall be fully
operable. In the test position, the breaker auxiliary control contacts a
nd circuitry only
shall be connected to permit automatic operation of the complete control system
without actually connecting the generator to the main bus. In the disconnect position,
main and auxiliary control contacts and circuitry shall be completely d
isconnected.
The breaker draw
-
out mechanism shall be mechanically interlocked with the breaker
to permit draw
-
out operation only when the breaker main contacts are open.

B.

The generator circuit breakers shall be furnished with electronic trip units, with
Ad
justable Long Delay, Short Delay and Instantaneous over current trips and Ground
Fault
Alarm
.

C.

The distribution circuit breakers shall be furnished with electronic trip units and rated
as described on the drawings.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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PART 3


DIGITAL PARALLELING
CONTROL SY
STEM (DPCS)

3.1

ENGINE GENERATOR CONTROL


The controls are the ASCO 4000 Series Digital Paralleling Controls and
will be equipped with the following functions:

A.

Each engine generator control shall have its own dedicated processor and controls
performing functio
ns such as start/stop, synchronizing, load sharing, VAR/PF sharing,
without depending upon master controller, or any other generator controllers.

B.

Generator processor redundancy will be standard. In the event of a processor ever
going down, a backup process
or shall immediately take over and control the operation
of the engine generator controller I/O.

C.

Door Mounted Control station with the following controls for each Engine Generator:

1.

Five Position Engine Control Selector Switch

a.

Lockout/Reset

-

In this positi
on, the engine shall not be capable of starting and/or
running. If the engine was shutdown due to the operation of a protective device, the
shutdown malfunction shall be reset when the switch is moved to this position. If
the engine is running when the swi
tch is moved to this position, it shall
immediately shutdown.


b.

Off/Cool
-
down

-

In this position, the engine shall shutdown after a cool
-
down period.


c.

Automatic

-

In this position, the engine control shall be in readiness for fully
automatic operation upon
receipt of a start signal.


d.

Test Off
-
Line

-

When placed in this position, the engine shall start and run as if a
start signal were received except it shall not be connected to the bus unless a start

signal is received. When returned to the Automatic posi
tion, the engine shall
shutdown.


e.

Test On
-
Line

-

When placed in this position, the engine shall start, run and connect
to the bus as if a start signal were received. When returned to the Automatic
position the circuit breaker shall open and the engine sh
all run for its cool
-
down
period before shutting down.


2.

Generator Running Green Lamp (On for Running, Flashing for Cool
-
down).

3.

Controls Not In Auto Red Lamp (Flashing).

3.2

MASTER CONTROL
-

shall have a color touch screen operator interface which allows the ope
rator to view
status and to allow the operator to adjust system variables.
The Master Control and Monitoring Panel

shall be an integrated controller and shall combine the touch screen interface, networking and I/O into a
single compact unit utilizing sing
le programming software for graphics and logic.


A.

The
Master Control and Monitoring Panel

shall provide the following features and
characteristics:

1.

The color touch screen display shall have at a minimum a resolution of 800 x 600, TFT,
supporting 32768 diff
erent colors. System shall be a true controller with its own operating
system, and the reliability of an industrial Programmable Logic Controller. Windows PC
based systems are Not Acceptable. The Control logic shall be ladder. The faceplate shall
be ma
de of Lexan
®

and shall be resistant to most corrosive substances found in industrial
environments.

Lexan is a registered trademark of General Electric Company.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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Publication 3135
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2.

The Master Control and Monitoring Panel shall have Portable memory in the form of a
Compact FLA
SH slot to accommodate flash memory which is readily available in most
electronic stores. The Master Control and Monitoring Panel shall have the capability of
reading, and updating the program from the Compact Flash Card. The Master Control and
Monitorin
g Panel shall have the capability of storing and capturing any of the displayed
screens onto Compact Flash, in the form of .jpg or .bmp files. The Master Control and
Monitoring Panel shall also have the capability of reading any of these screen captures
d
irectly from the compact flash card.

3.

The Master Control and Monitoring Panel shall be powered with a 24 Vdc control voltage
using engine batteries. Necessary equipment shall be installed to prevent “brownout”
situations during the engine crank cycle. Ope
rating temperatures shall range from 32 to
122 degree F, with humidity 5 to 95% Non
-
condensing. The Unit shall be UL labeled and
CE approved, including any ancillary AC power monitoring devices.

B.

The

Master Control and Monitoring Panel

shall have the follo
wing
screens
:

1.

Main Menu
: Screen to provide system status and access to One
-
Line, Manual Paralleling,
ATS Status, Individual Generator Set and Individual Generator & Bus Metering, Alarm
Status, Event Log data, System Control and C
ertified Service Tech Scree
ns.

2.

One
-
Line Diagram Screen
: Displays system paralleling configuration. Depicts system
configuration in a single line format and system status.

a.

Breaker Position of generator sets, Open/Closed.

b.

Real time power values of generator set(s) Amps, kW, PF, kVars
, Voltage, and
Frequency.


3.

Manual Paralleling Control Screen
-

Provides manual paralleling control capability over
individual generator sets.

a.

Synchroscope Graphical (real time 360
-
degree analog
movement) with digital
display.

b.

Manual Raise / Lower voltage an
d frequency.

c.

Automatic voltage and frequency set points of generator.

d.

Real time power values of generator / generator bus.

e.

Generator Breaker Position.

f.

Ability to select generator set to be paralleled.

g.

Manual closing of generator breaker.

4.

Dual Three Phase M
etering Screen
: Graphical analog (270 electrical degree) metering
representation with digital display. Ability to display metering for two generators at the
same time or one generator and the bus at the same time. Screen will display a graphical
Synchros
cope when one generator and the bus are selected. Displays the following
minimum metering data for selected generator set and generator main bus totals.

a.

True RMS three phase voltage, amps, kilowatts, kilovolt
-
amperes, kilovars, power
factor, and frequency

parameters.

b.

Engine battery voltage display.

c.

Running Time Meter.

5.

Single Three Phase Metering Screen
: Large graphical analog (270 electrical degree)
metering representation with digital display. Displays the following minimum metering data
for selected gen
erator set or selected main bus.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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Publication 3135
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a.

True RMS three phase voltage, amps, kilowatts, kilovolt
-
amperes, kilovars, power
factor, and frequency parameters.

b.

Engine battery voltage display.

6.

ATS Status Screen
: Displays status and provides control of each ATS connecte
d to
system. ATS must be equipped with proper features and accessories.

a.

ATS Connected to Normal

b.

ATS Connected to Emergency

c.

Engine Start Indication

d.

Load Shed Indication

e.

ATS Load Priority. Ability to change ATS priorities (password protected).

7.

System Se
tup Control Screen
: Displays system status, with System control.

a.

Engine priority, with Load Demand time delays (password protected).

b.

Load Demand pick
-
up and drop
-
out kW levels (password protected).

c.

Load Bus Optimization derate %, with Load Bus Optimization

time delays
(password protected).

d.

Scrolling system status: Emergency mode, Normal available, Gen(s) on
-
line,
Gen(s) failure, Gen _ available, Gen _ synchronizer active, Gen _ Var Sharing
active, Gen _ Load Sharing active.

e.

Engine Generator Alarms and Shut
downs:

Displays generator
(s)

alarms
and

shutdowns.

f.

Not in Auto (Red)

g.

Emergency Mode (Amber)

h.

Generator Circuit Breaker Ground Fault Alarm (Amber)

i.

*Pre
-
High Coolant Temperature (Amber)

j.

*Pre
-
low Oil Pressure (Amber)

k.

*Low Coo
lant Temperature (Amber)

l.

Low Battery Voltage (Amber)

m.

*Low Fuel Level Alarm (Amber)

n.

*Battery Charger Malfunction (Amber)

o.

*Engine Overcrank (Red)

p.

*Engine Overspeed (Red)

q.

*Engine Low Oil

Shutdown (Red)

r.

*Engine High Coolant Temp Shutdown (Red)

s.

*Engine Low Coolant Level Shutdown (Red)

t.

Generator Circuit Breaker Tripped (Red)

u.

Generator Reverse Power (Red)

v.

Generator Undervoltage (Red)

w.

Generator Overvoltage (Red)

x.

Generato
r Under Frequency (Red)

y.

Generator Over Frequency (Red)

z.

Generator Loss of Excitation (Red)

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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aa.

Generator Phase Reversal (Red)

bb.

Alarm reset button

cc.

Emergency Stop Button

* contact, sensor signal or serial communication must be supplied by the engine supplier.

8.

E
ngine Generator Protection and Setup Screen:

a.

Current and potential transformer ratio.

b.

Device 40Q Settings with enable feature.

c.

Device 81 O/U Settings with enable feature.

d.

Device 27/59 three phase with enable feature.

e.

Device 47 with enable feature.

f.

Device
15/25V Auto
and

manual synchronizing with voltage matchin
g settings for
both

g.

Device 32 reverse power.

9.

Bus Protection and Setup Screen:

a.

Current and potential transformer ratio.

b.

Device 81 O/U Settings with enable feature.

c.

Device 27/59 three phase with enabl
e feature.

d.

Device 47 with enable feature.

10.

Engine Generator Control and Setup Screen:
Provides gener
ator control setup and
control.

a.

Engine cool down timer setting.

b.

Cycle Crank attempts.

c.

Cranking time delay.

d.

Crank reset timer setting.

e.

Failure to synch timer
setting.

f.

Number of actual crank attempts.

g.

Actual cool down timer left.

h.

Synch Mode Switch OFF, Auto, Check, Permissive

i.

Cycle Crank logic enabled / disabled.

11.

kW Trending Screen:
kW trending of generator sets and main bus. The kW trend screen
shall have the
capability to enable or disable auto store. Auto store feature when enabled
will automatically store the trend screen onto compact

flash card every five minutes.

a.

Generator ‘X’ Trending

b.

Generator Bus Total Trending

12.

Multiple Parameter Service Trending Scree
n:
Be able to trend up to 16 different
parameters on one screen, comparing all generators/utilities, kW, kVars, voltage, current
and frequency. Trend screen shall have the capability to enable or disable auto store. Auto

store feature when enabled will a
utomatically store the trend screen onto compact flash
every five minutes. The operator shall also have the ability to manual store any screen
captures onto the compact flash card.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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13.

Event data Log Screen:

Provides viewing of events logged with time and da
te. Operator
can acknowledge and clear alarms, up to 2049 different events.

a.

Alarm History Log of the last 64 events.

b.

Alarm Summary (Active Alarms and Unacknowledged)

c.

Active Alarm Indicator

14.

Full Range of Service Screens:

Without the aid of a Laptop compute
r, a certified service
technician shall have the capability of setting up all the paralleling parameters including
proportional gains, ranges, and sensitivities of all parallel functions. The operator shall be
able to view all controlling outputs to the v
oltage regulator and speed controller, including all
power parameters of all engines on one screen.

3.3

SPECIAL FEATURES

A.

Monitoring shall be true three phase monitoring, phase to neutral on all generators.
Averaging or calculating a potential phase from the ot
her two phases is not
acceptable.

B.

Shall have Load Bus Optimization as detailed in section
3.8

Sequence of Operation
under
E
, page 11
.

3.4

COMMUNICATIONS REQUI
REMENTS

A.

The DPCS shall be interconnected to allow the control or monitoring of any unit by a
single co
nnection to a Local Area Network via Ethernet. All information including
transfer switches, engine points and parameters, and other third party devices can be
communicated with effectively.

B.

The DPCS shall have the capability of communicating directly with

different engine
generator set manufacturers.

C.

Serial RTU/Modbus
®

master/slave RS232/485.

Modbus is a registered trademark of Gould Inc.

D.

DeviceNet master/slave.

E.

CAN Network peer
-
to
-
peer protocol.

F.

Ethernet 100
-
base
-
T supporting, EGD, SRTP, Modbus/TCP slave.

3.5

SECURITY

A.

Security Code Required For Access

-

The DPCS has built
-
in security to protect
against configuration changes and alarm purges by unauthorized personnel. There are
two levels of access to the configuration menus. They are listed below. Each
success
ive level has access to all of the levels above. A four
-
digit security code is
required for access to the configuration menus.

B.

Levels Of Access:

1.

Monitor with limited control (no security code)
-

Access to all Status Screens, view Alarm /
Event Log Display
, and ability to commit (clear) an Audible Alarm, provide some limited
control.

2.

Operator /Administrator (Level one)
-

Access to system set
-
points.

3.

Technician (Level two)
-

Allows access to all set points including Engine generating
paralleling digital cali
bration

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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3.6

OPTIONAL CONTROL FEA
TURES

A.

The DPCS platform shall be fully flexible, in adding additional equipment such as
future engine generators, external third party communication devices, AND additional
I/O, with all this information easily sent to a Buildin
g Management System or owner
host computer through one connection over Ethernet.

B.

The DPCS shall have two remote diagnostic capabilities, one using industrial grade
analog modem; the other using Ethernet IP connection. Both remote methods shall
have full co
ntrol capability, with one way backing up the other. Authorized certified
technicians shall be able to connect to all DPCS(s) remotely and be able to perform
diagnostics, modify screens, change logic if necessary and down load using one
piece of software.

C.

The DPCS shall have the option to add a color
-
touch screen operator interface to each
generator control section.

D.

The DPCS shall be supplied standard with controls for 32 ATSs.

1.

Available options include controls for 64 ATSs.

E.

The DPCS shall have the option t
o add Master Controller Redundancy.

F.

The DPCS shall have the option to add
a
Master
Operator Interface Touch
Screen
with
monitoring only function
.


3.7

MISCELLANEOUS COMPON
ENTS

A.

Control Fuses

-

Control fuses shall be mounted in locations where they are readily
a
ccessible. Pullout type fuses shall be provided for all primary circuits and shall be of
the current limiting type.

B.

Electromagnetic Control Relays

-

All electromagnetic control relays shall be
suitable and adequately rated for their intended service in t
he control system. Relays
used in low
-
voltage low
-
current DC control circuits shall have gold flashed contacts to
insure positive contact make. Relays used for other than logic and dry contact
switching shall have contact ratings suitable for make and ca
rry of their duty current at
the voltage of operation. All relays for control circuit duty shall be plug
-
in type with
retaining clips and transparent plastic covers.

C.

Current Transformers

-

Current transformers are furnished with VA burden ratings
suitabl
e to supply the metering, protective devices and electronic governor without
affecting their accuracy.

D.

Potential Transformers (if required)

-

Potential transformers are provided in turns
ratio and VA burden rating to be compatible with the controls, meter
ing and the
electronic governor. Transformers shall have integrally mounted primary and secondary

fuses.

E.

Door Mounted Control station with the following system controls:

1.

Audible Alarm Horn. Located in Master.

2.

Horn Silence Push
-
button. Located in Master.

F.

DC Control Power Selector
--

Best Battery System

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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Control power for the system logic shall be derived from the engine starting batteries. The control
logic shall be powered through a suitable means which shall permit continuity of power until the last
batt
ery is no longer available. The controls shall be powered from any battery or combination of
batteries and prevent feedback to a failing battery. The transition of control logic power from any
battery combination to any other battery combination shall be
accomplished without disruption in
the power flow.

3.8

SEQUENCE OF OPERATIO
N

A.

The ASCO 4000 Series Digital Paralleling Control

System is designed to start and
parallel all engine generator sets, upon receipt of a signal from an automatic transfer
switch(es) th
at emergency power is required.

B.

Normal Mode

Whenever the individual engine generator control switches are placed in their automatic position, the

engine generator system is on standby in readiness for automatic starting and synchronization in
the event of
a power failure signal.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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C.

Emergency Mode

In the event of a power failure, all generator(s) automatically start and come up to speed. The first
generator set to achieve 90% of nominal voltage and frequency shall be connected to the bus.
Interlocks permit t
he connection of only one engine generator to the dead generator bus in the event
of simultaneous generator relay operation. Upon sensing the availability of emergency power, the
priority
-
1 load block will be allowed to transfer their loads to the emergen
cy bus, either through
direct control or through a “permissive signal” to the automatic transfer switches (if equipped). Each
synchronizer will automatically adjust the frequency of the on
-
coming generator(s) to synchronize
with the bus. When synchronism

is achieved, the on
-
coming generator is paralleled to the bus.
When the second generator’s circuit breaker is closed the priority
-
2 load block will be allowed to
transfer their loads to the emergency bus. As each generator parallels to the bus, another b
lock of
load is allowed to be added, until all generators and all loads are online.


Upon sensing that normal utility power has been restored to acceptable limits, a sequence shall
begin to transfer the load back to the utility source. The re
-
transfer shal
l be initiated after the
retransfer to utility time delay has expired (adjustable at each ATS from 0 minute to 30 minutes)
allowing an open transition transfer return to utility. After all the transfer switches have re
-
transferred their loads to the norma
l source, the generator circuit breakers are simultaneously
opened and the engine generators run for an adjustable no
-
load cool
-
down period of zero to thirty
minutes; factory set at 5
-
minutes. The controls are released and the generators are placed in
rea
diness for the next power failure.

If a generator fails while operating in the automatic mode, it is disconnected from the bus and
shutdown. Audible and visual alarms will be activated to indicate the condition. If “Load Bus
Optimization” is not activated,

the lowest priority feeder loads (as programmed by the operator via
the Touch Screen) are signaled to shed so as to leave one block of load online per generator.

A push
-
button permits override of the load
-
shed circuits for supervised operation (one for ea
ch
priority except priority 1). Loads that have been block shed can be manually re
-
added using the
priority
-
# Load Shed Bypass/Reset push
-
button located on the Master control section Touch
Screen. By pressing the
Load Shed Bypass/Reset

push
-
button, the sys
tem will transfer the
priority
-
# load block to the emergency bus. By pressing the Load Shed Bypass/Reset push
-
button
a second time, the ENTIRE priority
-
# load block will shed. Indication from the Touch Screen will
annunciate the status of each Priority lo
ad block, indicating if it is shed or manually bypassed. If the

operator inadvertently bypasses the load shed and overloads the Generator(s) resulting in a bus
under
-
frequency, all manually bypassed loads will be automatically shed along with blocks of loa
d
such that the remaining load blocks shall be one less than the number of generators remaining on
the bus. The “
Bus Underfrequency
” condition will be indicated.

If the online load exceeds 100% of rated generator capacity, loads will be stepped off in reve
rse
priority at one second intervals. The Bus Overload indication will light to indicate that the bus is
overloaded. This condition will automatically reset as the overload is corrected. Once the online
load no longer exceeds the generating capacity, st
ep shedding will cease and the system will
continue to power the remaining loads. Indicators will annunciate the status of each Priority load
block, indicating if any loads in that block are shed or if the load block is manually bypassed. If the
operator

bypasses the load shed to bring the shed loads back online, and the online load exceeds
100% of the capacity again, the system will again step loads off in reverse priority at one second
intervals. This condition will automatically reset as the overload
is corrected. This is done in an
attempt to prevent an underfrequency condition, thereby preventing the entire load block from being
shed.

Note:

Individual ATS loads shall step on the Emergency bus based on their “Step Add Time Delay
values”; these Time
Delays are adjustable by the operator via the Touch Screen and are Factory
set at zero.


ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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D.

Generator Load Demand Control

After all generators sets have been paralleled to the bus and all loads are connected, a stabilization
time delay (0
-

900 seconds) fact
ory sets at 60 seconds will be initiated while a Load Demand Mode

indication flashes. At the expiration of the time delay period, the system will operate in a load
demand mode at which time the mode indication remains illuminated. The load demand logic
c
ontrols the number of generating sets on the bus, such that the on
-
line reserve capacity of the bus
is not less than 10%, nor more than 110%, of the capacity of a single generator set.

Upon sensing that the connected load has decreased the reserve capacity

to 10% or less (field
adjustable from 1
-
29% displayed as 81
-
99% of Generator rating), a 10 second time delay is initiated
and a “Gen Start TD Active “ indication starts flashing. This time delay will be field adjustable from
0
-

300 seconds. If the reser
ve capacity stays below 10% for the duration of the 10
-
second time
delay, the controls will initiate the starting and paralleling of the next set in sequence. If, during the
time delay period, the reserve capacity decreased to 0 or less (signifying bus ov
erload), the time
delay will be bypassed and the next set in sequence will be immediately started and paralleled. At
the same time, loads shall begin to shed in reverse order every second until the online load does
not exceed 100% of rated online generator

capacity.

If at any time, the online load exceeds 100% of available rated capacity, the system will remove the
last load that was added. If the online load does not decrease to less than 100% of rated capacity,
loads will be shed one at a time, every sec
ond in reverse order until the overload is corrected. The
Bus Overload indication will light indicating that the bus is overloaded and will automatically reset as

the overload is corrected.

If the online load exceeds 120% of capacity, signals will be given

to shed load such that the
connected priority blocks of load are reduced to equal the number of engine generator sets on line.
When the next set is paralleled to the bus, the shed load will be reconnected and all controls
automatically reset. If the nex
t generator set does not come online, the system will not
automatically reset. The Bus Overload indication will blink indicating that the bus was overloaded
and will stay on solid (not blinking) if the bus remains overloaded. Loads will not be added to t
he
bus while the Bus Overload indication is active (blinking or solid). Once the operator acknowledges
the Bus Overload indication by activating the Alarm Reset pushbutton, then the loads will be re
-
added as capacity allows (in Load Bus Optimization mode
).

If while operating in the load demand mode, an engine
-
generator set malfunction occurs, the
affected set will be removed from the bus. If the remaining loads online exceed 100% of the
remaining online generator capacity, the loads will step shed as des
cribed in the previous
paragraph. If the load does not exceed the online capacity, no loads will shed. Generator Load
Demand mode will momentarily reset and all generators will start.

Upon sensing that the on
-
line reserve capacity has increased to 120% or
more (field adjustable from
120
-
140 % displayed as 80
-
60% of Generator rating), a 10 second (adjustable 0
-
300 seconds) time
delay will be initiated and a “Gen Stop TD Active “ indication will start flashing. If the reserve
capacity stays above 110% for th
e duration of the time delay, the circuit breaker of the last set that
went on line will be opened. The engine will run for its cool down period, then shutdown.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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E.

Bus
Load

Optimization

Each ATS load should be programmed with a priority value load (field a
djustable, accessible via the
Touch Screen on the master door). A load’s priority value is a 3
-
digit number. The most significant
digit refers to the load’s block priority value (i.e. 201 => priority 2 load block, whereas 118 =>
priority 1 load block). The

two lower significant digits refer to the load’s sub
-
priority value, or load
step priority (i.e. 201 => priority 2 block, step 01; 118 => priority 1 block, step 18). Valid priority
values are 1


8 while valid sub
-
priority values are 1
-

99. Therefore, v
alid three digit priority values
are 101
-

899. Note: priority 1 loads (101
-

199) have insignificant sub
-
priority values since priority 1
loads are never optimized, also 3 digit priority values of 200, 300 and 400, etc. are not valid priority
numbers. How
ever, because of the dynamic nature of the adjustable load priorities, all loads, even
priority 1 needs to have sub
-
priority step values.

With the Bus Load Optimization soft switch in the "on" position (accessible via the Touch Screen)
during emergency mod
e and with loads shed (loads requiring power), after a stabilization time delay
(Bus Opt stable delay) the optimization feature is activated and a
Bus Optimize

Active

indication
illuminates. The
Bus Optimize

Active

indication flashes through the duration o
f the stabilization time
delay. At this time, the Bus Optimization loading control will determine if there is enough room to
add the next load by checking the pre
-
set Load Value (field adjustable, accessible via the Touch
Screen on the master door) assigne
d to the first sub
-
priority load (field adjustable, accessible via
the Touch Screen on the master door) within the highest priority block that is shed and compare it
to the excess generator bus capacity (also known as Headroom).

Should a Priority Block fai
l to be added to the bus while operating in the Emergency Mode, loads
could be added
manually

by the operator as described or
automatically

through "Bus
Optimization". This feature is provided to re
-
add shed loads one at a time based on predetermined
kW l
oading values up to the capacity of the on
-
line power.

If it is determined that the load can be added without overloading the bus, the load is signaled to
add. The real time kW demand is constantly measured and the next sub
-
priority load is evaluated.
Lo
ads are evaluated at a preset time interval defined via the operator interface (Bus Opt Step Time).
When the bus has been loaded to a level such that the next load would exceed 95% of bus
capacity, the
Next Load Exceeds Headroom

indication will activate a
nd load adding will pause. The
system will continuously monitor the generator demand and evaluate if the next load step can fit on
the bus. If building demand decreases and the next load can fit (for the duration of the step time
delay), the system will
add it and continue the evaluation process until as many loads as possible
are added to the bus.

If the load has already been added, there is no reason to compare it to see if it will fit; the program
will skip to the next available load.

If the load is no
t calling for an engine start, it will be skipped.

If at any time, the online load exceeds 100% of available rated capacity, the system will remove the
last load that was added. If the online load does not decrease to less than 100% of rated capacity,
load
s will be shed one at a time, every second in reverse order until the overload is corrected. The
Bus Overload indication will light indicating that the bus is overloaded and will automatically reset as

the overload is corrected. In this event, the system

will begin a 300 second stabilization delay time
(fixed) before evaluating another load to be added to the bus.

If a generator fails, it will be removed from the bus. If the remaining loads online exceed 100% of the
remaining online generator capacity, th
e loads will step shed as described in the previous
paragraph. If the load does not exceed the online capacity, no loads will be shed. The Bus
Overload indication will activate indicating that the bus is overloaded and will automatically reset as
the over
load is corrected.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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If the connected load exceeds 120% of online capacity, all optimized loads will immediately shed in
an attempt to avoid an underfrequency event. A Bus Overload indication will activate and latch
indicating that the bus is overloaded. T
he system will NOT attempt to re
-
add loads until the Bus
Overload indication is acknowledged by pressing the Alarm Reset pushbutton.

In the event of a bus Under
-
frequency, all optimized loads will be shed as well as any additional
unsupported blocks of loa
d. Load blocks will be shed such that the remaining load blocks shall be
one less than the number of generators remaining on the bus. The
Bus Underfrequency

condition
will be indicated.

No loads can be manually added while an underfrequency indication is
active. The operator must
acknowledge the alarm by pressing the Alarm Reset push
-
button. If the Bus Opt switch remains
“on”, the stabilization timer will then re
-
initiate and the process of stepping on the loads is repeated
(after the bus underfrequency ha
s been reset).

If a load block is manually bypassed, all loads in that block will add, subject to their individual step
timers. If they were already optimized on, they will remain on. If the load block is then manually
shed, all loads in that load block wi
ll shed.

Once all loads in a priority load block have been added to the bus, the LOAD SHED indication for
the associated priority will turn off.


F.

Generator No Load Test

A system test switch is provided in the master control Touch Screen to limit access to
authorized
persons only. Operation of this switch will initiate an automatic system operation as if an ATS
Accessory 7 (engine start signal) from any of the automatic transfer switches had operated.
However, unless a normal source outage occurs during th
is mode of operation, the transfer switches

will not transfer its load to the emergency bus. To terminate this test, the system test switch is
reset to initiate a normal system shutdown sequence.

G.

Single Engine Test

Each engine can be started for test purpo
ses by placing its generator control switch to the test off
-
line position. In this mode, the generator circuit breaker will remain open. Should a normal source
outage occur during this mode of operation, the breaker will close and the remaining units wil
l be
started. Upon restoration of normal power, the system will revert to single engine test mode until
the switch is returned to the AUTOMATIC position. For on
-
line test, placing of the generator control
switch to the test on
-
line position will present
a similar operation except that the generator breaker
will close when the generator achieves nominal voltage and frequency.

H.

ATS Hand


Off


Auto (H
-
O
-
A) Controls

The system shall be capable of H
-
O
-
A control for the ATSs provided the ATSs are equipped wit
h the
load shed relay (“Acc 30B” signal). During Emergency Mode any ATS can be individually added to
the bus or shed via these controls. The operator can select the ATS to be added by placing it in the
HAND position. When placed in the HAND position, the
load shed relay (“Acc 30B” signal) at the
ATS will be energized (if not already energized via normal load control), allowing the ATS to transfer
to Emergency. If the operator inadvertently adds too much load, causing a Bus Underfrequency
condition, all HA
ND switches will be reset back to AUTO and the system will revert to Normal load
control.

When the ATS is placed back into the AUTO position, the ATS will function per normal load control.
Any switch that does not have an Acc 30B picked up by normal load
control (i.e. the switch is in
Load Shed) will be immediately transferred back to Normal.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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When an ATS first calls for an engine start, the system will immediately begin emergency mode.
Any ATS left in the HAND position will be returned to AUTO and normal l
oad control will commence.

If an ATS is placed in the OFF position, it will
NEVER transfer to emergency
. Any ATS left in the
OFF position
will not

automatically return to AUTO at the start of emergency mode. An ATS left in
the OFF position can only be tak
en out of OFF via the HOA switch. If the system is running in
emergency mode, placing an ATS in the OFF position will immediately shed it from the emergency
source.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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PART 4
-

EXECUTION

4.1

FACTORY TESTING AND
QUALITY ASSURANCE IN
SPECTION

A.

The equipment shall b
e factory tested to simulate a complete and integrated system.
The circuit breakers supplied shall be installed in their actual positions and electrically
and mechanically tested. A narrative of the system operation shall be provided and
shall be utilized

when testing the equipment. A certified factory test report shall be
furnished to verify system testing.

B.

The switchgear shall be subjected to the factory testing and quality control
inspections to insure reliable operation. These tests and inspections sh
all include,
but not necessaril
y be limited to, the following:

1.

Perform a megger test with a 1000 volt megger. The minimum acceptable megger reading
shall be 100 megohms on the switchgear, with all fuses, switches, circuit breakers, and
contactors in the o
pen position.

2.

Insulation tests of all equipment and wiring, buses, etc., in accordance with manufacturer's
standard practice.

3.

Circuit continuity and wiring.

4.

Mechanical equipment adjustment and operation of all moveable equipment and devices.

5.

Equipment arra
ngements, types, and ratings for conformance with approved drawings.

6.

Bus bar phasing and bracing.

7.

Integrity of all electrical connections.

8.

Conformity with the nameplate and circuit identification indicated on the Drawings and the
approved manufacturer's dr
awings.

9.

Demonstration of Switchgear Functions.

C.

All switchboard equipment shall be given complete operational tests to ascertain that
all design functions are satisfactorily performed. Testing shall include:

1.

Actuation of all alarm indication devices.

2.

All co
ntrol circuits, automatic operations and interlocks shall be tested under simulated
operating conditions.

3.

All of the above shall be tested according to design specifications for correct and positive
operations.

4.2

INSTALLATION

-

T
he installing contractor shal
l perform all receiving, unloading, storage and installation of
the equipment per all local applicable codes.

A.

User’s Manual
:

1.

One copy shall be furnished of the operation and maintenance instructions for all equipment
and devices provided under this Contrac
t for use during the installation and commissioning
into service of the emergency power system.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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Publication 3135
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B.

After installation by others, the engine
-
generator set and switchgear manufacturers
shall provide the services of competent locally based service technicians
/project
managers to instruct the Installing Contractor, and to coordinate the commissioning of
the equipment. They shall assist in placing the equipment into operation and provide
instruction, as required, to the person or persons who are delegated to op
erate the
equipment. This service shall include a minimum as follows:

1.

Pre
-
installation coordination meeting to coordinate the installation and interconnection of
the switchgear with the engine
-
generator equipment.

2.

Initial checkout of the installation of t
he equipment to allow energizing of the switchgear.

3.

Post
-
installation start
-
up and testing prior to system turnover and for the initial instruction
period for operating personnel. This shall include all service required to checkout the
emergency power sys
tem and demonstrate its complete operation, for final acceptance by
the Owner.

C.

The switchgear manufacturer shall maintain a competent factory service organization
that is available for service and on call 24 hours a day, 7 days a week.

D.

It shall be the resp
onsibility of the installing contractor to verify that the following items
have been completed and are ready to perform as specified before the arrival of the
start
-
up technician.

1.

Inspect for obvious shipping damage.

2.

The switchgear is installed, anchored
down and grounded.

3.

Shipping splits have been reinstalled with the splits bolted together, interconnect wiring
installed and bus splice plates installed.

4.

Terminate all power cables.

5.

Install customer control wiring to external equipment including engines,

batteries, ATS,
associated motor controls, etc.

6.

The engine
-
generator set is installed and ready to run. (Batteries
charged and fuel in tank,
etc.)

7.

Associated motor controls, plumbing, building utilities are complete and operational.

E.

The start
-
up technic
ian shall perform the following items:

1.

Verify contractor connections, control power availability, visually inspect any relay settings.

2.

With the engine generator supplier's technical representative controlling the engine, verify
that the switchgear and con
trol equipment are fully operational and perform per the
sequence of operation specified. Equipment or services shall be provided by the engine
generator set supplier.

3.

With the engine generator supplier's technical representative controlling the engine,
de
monstrate all functions of the control system, both automatic and manual, to the
satisfaction of the approving engineer.

4.

Provide documentation in the form of function checklists and recorded data for each section
to the approving engineer.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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Publication 3135
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5.

Provide plant
operators with instruction on the plant operating procedures and major
component operation after acceptance by the approving engineer.

ASCO Power Technologies, Florham Park, NJ 07932. 800
-
800
-
ASCO www.ascopower.com

May 30, 2008

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4.3

WARRANTY AND SERVICE

A.

Switchgear manufacturer warrants the equipment to be free from defects in material
and workmanship

for eighteen months from date of shipment.

B.

Switchgear manufacturer shall have an established network of factory owned and
operated service centers within the continental US capable of servicing the specified
equipment.

C.

The manufacturer's personnel shal
l be on call 24 hours a day, 7 days a week.
Personnel shall be factory trained and certified in the maintenance and repair of the
specified equipment.

D.

After
-
warranty service contracts shall be available to the owner by the manufacturer to
provide periodi
c maintenance and/or repair of the specified equipment.

4.4

OPERATION AND MAINTE
NANCE MATERIALS

A.

Operation Instructions and Maintenance Manuals:

1.

After completion of work and start
-
up of the equipment at the project site, deliver to the
Owner's Representative, (
3) copies of operation instructions, maintenance manuals and
drawings pre
senting full details for care and mai
nte
nance of each item of equipment
provided under this Contract.

2.

Each manual shall contain the operating and maintenance information and parts
lists for all
equipment provided under this Contract. When necessary, provide supplemental drawings
to show system operation and servicing and maintenance points. For all electrical
components, provide wiring and connection diagrams. Manuals shall inclu
de instructions
required to accomplish specified operation and functions. Data shall be neat, clean, legible
copies.

3.

Switchgear drawings and wiring diagrams shall be included and up to date at the
completion of start
-
up and system acceptance by the Owne
r. Drawings and wiring
diagrams shall include any field modifications or changes to reflect actual as installed
conditions.

4.

In general the manual shall include, but not necessarily be limited to, the following:

a.

Switchgear Elevation & One Line

b.

AC & DC Sche
matic and Physical Component Layout Drawings

c.

Remote Interface drawing

d.

Bill of Material

e.

Circuit Breaker Operation Manuals

f.

Description of Operation

g.

Recommended Spare Parts List
-

showing all consumables anticipated to be
required during routine maintenance a
nd testing.


B.

Manuals shall be in the form of three
-
ring binders and compact discs (CDs)
adequately labeled with the project name and location and the contents indexed.
Three (3) sets of manuals and three (3) sets of compact discs (CDs) shall be provided
to the Owner's Representative.