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USACE / NAVFAC / AFCESA / NASA UFGS-26 32 33.00 20 (April 2006)
------------------------------
Preparing Activity:
NAVFAC Replacing without change
UFGS-16262N (February 2004)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated 1 April 2006
Latest change indicated by CHG tags.
Section Table of Contents
SECTION 26 32 33.00 20
INSTALLATION OF UNINTERRUPTIBLE POWER SUPPLY (UPS) SYSTEM
04/06
PART 1 GENERAL
1.1 REFERENCES
1.2 DEFINITIONS
1.2.1 Uninterruptible Power Supply (UPS)
1.2.2 Battery System
1.2.3 Electrolyte
1.3 SUBMITTALS
1.4 DELIVERY, STORAGE, AND HANDLING
1.4.1 Government-Furnished Equipment (GFE)
1.4.2 Pick-Up
1.4.3 Delivery
PART 2 PRODUCTS
2.1 CONTRACTOR FURNISHED MATERIAL AND EQUIPMENT
2.2 GOVERNMENT-FURNISHED MATERIAL
PART 3 EXECUTION
3.1 INSTALLATION
3.1.1 Control Cable
3.1.2 Grounding Conductor
3.1.3 UPS Output Conductors
3.1.4 DC Power Conductors
3.1.5 Emergency Control Contacts
3.1.6 Cable Lugs
3.1.7 Seismic Protection
3.1.8 Conduit Entries
3.1.9 Battery Rack Assembly
3.1.10 Battery Cabinet
3.1.11 Battery Installation
3.1.11.1 Positioning Cells
3.1.11.2 Connecting Cells
3.1.11.3 Inter-Rack and Inter-Tier Cables
3.1.12 UPS Spare Parts and Manuals
3.2 UPS TECHNICAL REPRESENTATIVE
3.2.1 Contractor Duties
3.2.2 Installation Inspection
3.3 BATTERY FILLING AND CHARGING
3.3.1 General Instructions for Lead Calcium Alloy Battery
3.3.1.1 Hydrogen Gas Safety Instructions
3.3.1.2 Sulfuric Acid Safety Instruction
3.3.1.3 Battery Filling Instruction
3.3.2 General Instructions for Sealed Type, Valve Regulated Battery
3.3.3 Electrical Safety Instructions
3.3.4 Battery Charging Instructions
3.3.5 Battery Refreshing Charge Instructions
3.3.6 Float Charge
3.4 FIELD QUALITY CONTROL
3.4.1 UPS Unit Performance Test
3.4.1.1 Emergency Generator Operation
3.4.2 Battery Performance Test (Constant KW)
3.5 FINAL ADJUSTMENTS
3.6 DISPOSAL
SECTION 26 32 33.00 20
INSTALLATION OF UNINTERRUPTIBLE POWER SUPPLY (UPS) SYSTEM
NOTE: This guide specification covers the requirements for
Installation of
Government-furnished\Contractor installed Uninterruptible Power Supply (UPS)
System.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of
technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a
Criteria Change Request
(CCR).
Use of electronic communication is encouraged.
Brackets are used in the text to indicate designer choices or locations where
text must be supplied by the designer.
NOTE: This guide specification will be used in the preparation of project documents
for installation of Government-furnished UPS systems. (Navy-type UPS).
NOTE: This section contains Appendix A, "UPS Manufacturer's Installation Drawings"
and Appendix B, "Battery Manufacturer's Rack Assembly and Battery Installation
Instructions."
Appendices must be obtained from NFESC ECDET, Code 65, BLDG 218, 901 M Street
SE, Washington Navy Yard, Washington, DC 20374-5063, Telephone: (202) 433-2515,
DSN 288-2515, Fax (202) 433-6379.
All plans/specifications having uninterruptible power supply systems, which
were procured as Government-furnished/Contractor installed equipment, must be
reviewed and concurred by NFESC ECDET, Code 65.
PART 1 GENERAL
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
| NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) |
| |
| NFPA 70 | | (2005) National Electrical Code |
1.2 DEFINITIONS
1.2.1 Uninterruptible Power Supply (UPS)
The uninterruptible power supply system described herein shall denote a solid state power system which will provide
continuous regulated single phase or three phase AC power at its output terminals, while operating from either
an AC power source or from a battery system.
1.2.2 Battery System
NOTE: Sealed battery or valve regulated is more commonly known as maintenance
free battery. The term maintenance free is a misnomer, since all battery systems
require maintenance. The term "maintenance free" signify that no water may
be added to the cell.
The battery is an electrochemical device that stores energy at one time for use at another. The energy is stored
in chemical form and converted to electrical form during discharge, in the event of AC power failure. Battery
system may be lead calcium alloy type, water must be added in the cells, or sealed type, (valve regulated), water
cannot be added in the cells.
1.2.3 Electrolyte
The acid solution surrounding the plates of a battery cell, usually consisting of 1.250 specific gravity sulfuric
acid.
1.3 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are [for Contractor Quality Control approval.][for information only. When used, a designation following the
"G" designation identifies the office that will review the submittal for the Government.] The following shall
be submitted in accordance with Section
01 33 00
01 33 00
01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
NOTE: Typical installation and module arrangement shall be based in accordance
with manufacturer's installation drawings. Installation drawings may be obtained
from NFESC ECDet, Code 65.
Overall dimensions, front view, and sectional view; G
Typical installation and module arrangement; G
Ventilation and exhaust system; G
Submit drawings for [UPS] and [battery] installation.
SD-03 Product Data
Inter-rack and inter-tier cables; G
Control cable; G
Cable lugs; G
1.4 DELIVERY, STORAGE, AND HANDLING
1.4.1 Government-Furnished Equipment (GFE)
The Government will furnish various components and equipment listed in article entitled "GOVERNMENT-FURNISHED
MATERIAL" for installation by the Contractor.
[1.4.2 Pick-Up
The GFE will be available on [_____]. Contractor shall pickup, transport form [_____], unload, unpack and install
all GFE. The Contractor shall notify Contracting Officer [_____] calendar days in advance of the date the GFE
is required for installation. The GFE shall be unpacked by Contractor in the presence of Contracting Officer
to determine damage or missing parts. Contractor shall be responsible for damages sustained by the materials
and equipment after this inspection. UPS equipment is heavy and easily damaged. Do not bump or bounce equipment
at any time. When lifting, do not tip beyond 0.087 radians 5 degrees.
][1.4.3 Delivery
Activity will receive, store and deliver the GFE to jobsite. Contractor shall unload, unpack, and install GFE.
Notify Contracting Officer [_____] calendar days prior to when delivery on the site is required. GFE shall be
unpacked in the presence of Contracting Officer to determine damage or missing parts. Contractor shall be responsible
for damage sustained by the materials and equipment after this inspection. UPS equipment is heavy and easily
damaged. Do not bump or bounce equipment at any time. When lifting, do not tip beyond 0.087 radians 5 degrees
.
]PART 2 PRODUCTS
2.1 CONTRACTOR FURNISHED MATERIAL AND EQUIPMENT
Materials, equipment, and devices not specifically indicated or specified to be Government Furnished-Contractor
Installed, shall be Contractor Furnished-Contractor Installed (CFCI). Such equipment required to provide the
completely operable UPS installation includes, but is not necessarily limited to, conduit, conduit fittings,
insulated conductors, compression lugs, cable trays, supports, fasteners, and other such items.
2.2 GOVERNMENT-FURNISHED MATERIAL
The Government will furnish the following components of the UPS system:
NOTE: This information may be obtained from NFESC ECDet, Code 65.
a. [_____][One]-[_____] KVA - [_____] (Volts) UPS Systems. Type: [Non-Redundant] [Parallel
Redundant].
b. [_____][One]-[Maintenance Bypass Cabinets] [System Control Cabinet(s)]
c. [_____][One]-Remote Monitor Panels
d. [_____][One]-3 Pole Motor Operated Battery Circuit Breakers
e. [_____][One] Battery system(s) each consisting of [182] [192] [210] [240] [_____] cells,
inter-cell connecting hardware, terminal connectors, connector bolt package, solderless lugs,
cell identification decals, and miscellaneous hardware. This does not include tier-to-tier
or rack-to-rack cables specified in paragraph entitled "Inter-Rack and Inter-Tier Cables."
The battery cells are as follows:
Cell type: [_____]
Cell dimensions: [_____]
Cell weight (dry): [_____]
Electrolyte per cell: [_____]
f. [_____](Each)-[_____] foot battery rack(s) [standard], [shock protected], [seismic] type,
each weighing [_____] kg [_____] lbs.
g. [_____](Each) battery cabinets each weighing [_____] kg [_____] lbs.
h. [_____](Each) 56.83 liters 15 gallon DOT 37P-2U poly-lined steel drums of electrolyte.
Each drum of electrolyte weighs approximately 77 kg 170 pounds.
PART 3 EXECUTION
3.1 INSTALLATION
NOTE: Manufacturer's installation drawing, wiring diagrams, battery, racks
and cabinets' information shall be obtained from NFESC ECDet, Code 65. Appropriate
information and data will form an integral part of these specifications.
Conform to the requirements for electrical equipment installations specified in Section
26 20 00
26 20 00
26 20 00 INTERIOR DISTRIBUTION
SYSTEM, to the requirements specified herein, and in strict accordance with
NFPA 70, and manufacturer's installation
drawings and wiring diagrams to include
overall dimensions, front view, and sectional view,
typical installation
and module arrangement, and
ventilation and exhaust system. During and after installation, until the system
is accepted by the Contracting Officer, Contractor shall protect UPS equipment, including batteries, from moisture,
dust, and contamination. Upon completion of the UPS system installation, Contracting Officer and UPS manufacturer's
technical representative will inspect the installation for contract compliance. Contractor shall correct installation
deficiencies as directed.
3.1.1 Control Cable
NOTE: UPS sizes 200 KVA and above are shipped in sections. Control wiring
between module sections will be connected by the UPS manufacturer's technical
representative.
UPS control wiring shall be stranded type and must be installed in individual separate rigid steel conduits.
Tag control wires with numeric identification tags corresponding to the terminal strip location to where the
wires are connected. In addition to manufacturer's requirements, provide four additional spare conductors between
UPS module and remote alarm panel in same conduit. When routing control cables inside UPS module, maintain a
minimum 155 mm 6 inches separation from power cables.
3.1.2 Grounding Conductor
Provide an insulated equipment grounding conductor in feeder and branch circuits. Conductor shall be separate
from the electrical system neutral conductor. Ground battery racks and battery breaker cabinets with a separate
equipment grounding conductor to the UPS cabinet.
3.1.3 UPS Output Conductors
Isolate the UPS output conductors from the UPS cabinet to the critical load panels and from other conductors
by installing in separate conduit. Isolation shall prevent inductive coupling from other conductors.
3.1.4 DC Power Conductors
When installed in conduits, place DC power conductors from the UPS cabinet to the battery circuit breaker such
that each conduit contains an equal number of positive and negative conductors, for example, two positive and
two negative conductors in each conduit.
3.1.5 Emergency Control Contacts
Provide normally open contacts for each UPS system to signal when power is supplied to the UPS from emergency
engine generators. Installation shall conform to manufacturer's installation drawings.
3.1.6 Cable Lugs
Provide appropriate compression type lugs on all AC and DC power connections to the UPS system and battery as
required. Aluminum or bare copper cable lugs are not suitable.
3.1.7 Seismic Protection
NOTE: If zone is not considered to be seismic, text below shall be deleted.
If seismic zone, applicable local regulations shall be referenced.
For UPS installations within Seismic zones [1] [2] [3] [4], provide equipment anchor to protect against seismic
shock in accordance with applicable local regulations.
3.1.8 Conduit Entries
Provide conduits using the available conduit areas shown on manufacturer's installation drawings. Conduit entries
shall not be made through the front, side or rear panels of the UPS or [Maintenance Bypass Cabinets] [System
Control Cabinet].
[3.1.9 Battery Rack Assembly
NOTE: Choose this paragraph or the one below entitled "Battery Cabinet".
Battery racks are shipped dismantled in separate rail, frame, and brace packages. Ensure that necessary assembly
hardware is included in the frame packages. Installation of battery racks shall conform to the manufacturer's
instructions provided as Attachment B to this section.
][3.1.10 Battery Cabinet
Battery cabinets are factory assembled and are suitable for 25, 50 and 100 KVA UPS systems.
]3.1.11 Battery Installation
Installation of battery shall conform to the manufacturer's instructions provided in Attachment B.
NOTE: Appendix B provides information on the type of battery used in the UPS
application. This information will include battery and racks data, mounting
information, charging instruction, etc. It is the Contractors responsibility
to familiarize himself with this information prior to the start of work.
3.1.11.1 Positioning Cells
Use lifting belt and spreader when lifting the cells with mechanical equipment such as a crane or hoist. Install
cells on racks in accordance with manufacturer's instructions. Ensure each hydrometer tube is located on aisle
side of each cell.
3.1.11.2 Connecting Cells
Cleaning contact surfaces, application of no-oxide grease, and connection of cells shall be in accordance with
the manufacturer's instructions. No-oxide grease is applied only on connection surfaces.
3.1.11.3 Inter-Rack and Inter-Tier Cables
Provide flexible, welding type cable for all inter-rack and inter-tier connections. Number and size shall be
as indicated. Battery cables shall have a long bending radius to avoid excessive stress at the point of termination.
3.1.12 UPS Spare Parts and Manuals
NOTE: Three (3) volumes of UPS maintenance manuals are provided as part of
the UPS package. These manuals are not commercially available and contain proprietary
information. Additional manuals must be procured by NFESC ECDet, Code 65.
Three volumes of the UPS maintenance manuals and one package of spare parts are shipped with the UPS equipment.
Perform inventory and store these items until notified by the Contracting Officer.
3.2 UPS TECHNICAL REPRESENTATIVE
NOTE: The UPS manufacturer's technical representative will inspect the completed
UPS and battery installation as part of the UPS procurement package, and at
no additional cost to the activity. The representative's visit to the site
must be scheduled by NFESC ECDet, Code 65. If the station or Contractor requests
UPS technical representative's services without notifying Code 65, they may
incur additional expenses.
Contractor shall notify Contracting Officer in writing at least 45 calendar days prior to completion of the UPS
system installation. At this time the Contracting Officer, via NFESC ECDet, Code 65, will schedule the UPS manufacturer's
technical representative to inspect the completed installation. The UPS technical representative will provide
15 days of service including five days of instruction for activity personnel. The following items shall be completely
installed by the Contractor and be operational prior to the arrival of the UPS representative for inspection,
unit start-up and testing:
a. Ventilation equipment in the UPS and battery rooms.
b. Battery [racks][cabinets] and cells. Cells shall not be filled with electrolyte until directed
by the Contracting Officer. This is not applicable for maintenance free battery.
c. Battery connections including cell-to-cell, tier-to-tier, and rack-to-rack connections,
with correct polarity;
d. DC power and control connections between UPS and battery circuit breaker, with correct polarity;
e. DC power connection between battery circuit breaker and battery, with correct polarity;
f. Clockwise phase rotation of AC power connections;
g. AC power to rectifier input bus;
h. AC power to UPS bypass input bus;
i. AC power to UPS maintenance bypass circuit breaker;
j. AC power from UPS output to UPS maintenance bypass output circuit breaker;
k. Remote monitors and control wiring;
l. UPS system and battery system properly grounded;
m. Emergency shower and eye wash;
n. Control connections between UPS and emergency engine generator signal contacts;
o. Control connections between UPS modules and [UPS maintenance bypass cabinet][system control
cabinet]; and
p. Clean and vacuum UPS and battery room floors, battery cells, and UPS equipment, both inside
and outside.
3.2.1 Contractor Duties
Prior to the arrival of the UPS technical representative, Contractor shall furnish the following for testing:
a. Load bank with temporary jumper cables, unless provided as CFCI equipment in the contract,
and
b. Calibrated digital voltmeter with 0.01 volt resolution.
3.2.2 Installation Inspection
The UPS technical representative and the Contracting Officer, in the presence of the Contractor, will inspect
the completed installation. The Contractor shall correct construction or installation deficiencies as directed.
3.3 BATTERY FILLING AND CHARGING
NOTE: Battery system provided is either lead calcium alloy type or sealed (valve
regulated) type. Use appropriate instructions.
Inspection of the battery installation, filling, charging and testing shall be supervised by an authorized representative
of the battery manufacturer. Representative shall supervise and instruct the Contractor as to the proper installation,
charging, and testing procedures described herein for the battery system. Contractor shall be responsible for
arranging and paying costs of the battery manufacturer's representative. The following instructions shall be
read completely before commencing work on the battery:
[3.3.1 General Instructions for Lead Calcium Alloy Battery
NOTE: Delete paragraph and subparagraph if sealed (valve regulated) battery
is used.
a. Only authorized personnel who have been thoroughly familiarized with battery installation,
charging, and maintenance procedures will be permitted access to the battery room.
b. During initial activation, monitor the battery continuously for electrolyte level, specific
gravity, temperature, voltage, and current. Record measurements every hour.
c. Use only distilled water in the battery cells.
d. During the activation charging cycle it may be necessary to provide additional ventilation
to maintain a low ambient temperature in the area of the charging cells. This is to prevent
a possible heat induced boil-over of the cell's electrolyte.
e. During the activation charging cycle, Contractor shall provide a chemical agent, such as
soda ash or baking soda, capable of neutralizing electrolytic fluid, in sufficient quantity
to safely neutralize any spill or boil-over of electrolyte.
f. At all times while in the battery room, personnel shall wear the proper safety items as
deemed necessary by their task. This shall include, but not be limited to, face shield, impermeable
apron, and acid resistant boots and gloves. Contractor shall provide one extra set of safety
equipment for Contracting Officer.
[3.3.1.1 Hydrogen Gas Safety Instructions
a. During activation and operation of the battery, hydrogen gas is formed. Hydrogen gas is
extremely explosive when ignited. Contractor shall ensure sufficient ventilation is provided
to prevent the hydrogen level from exceeding a one percent concentration by volume of the space
in the battery room.
b. An essentially fully charged battery will generate a maximum of 0.00045 cubic meter 0.016
cubic feet of hydrogen (measured at 25 degrees C and 760 mm Hg absolute pressure) per hour from
each cell for each ampere of charging current. When necessary, additional ventilation may be
required during activation charging cycle.
c. Never bring burning material such as lit matches, cigarettes, lighters, or any type of spark
producing material or devices into the battery room or adjacent to any cell.
][3.3.1.2 Sulfuric Acid Safety Instruction
a. During handling of the electrolytic fluid, personnel shall wear the appropriate safety clothes,
as previously specified.
b. Exercise the utmost caution to avoid spilling electrolyte. When acid comes in contact with
the eyes or skin, immediately flush and rinse with water and consult a physician. Bicarbonate
of soda solution (one pound per gallon of water) will neutralize acid spilled on clothing or
material. Apply the solution until bubbling stops, then rinse with clear water. In the event
of acid spill or accident, notify the Contracting Officer as soon as practical.
c. Utilize only approved hydrometers and thermometers for monitoring the cells. Automotive
hydrometers are not acceptable. Contractor shall provide sufficient quantities of both instruments
so as to provide time efficient and accurate specific gravity and temperature measurements.
][3.3.1.3 Battery Filling Instruction
After the UPS technical representative has inspected the UPS and demonstrated proper operation of the UPS rectifier,
Contracting Officer will instruct Contractor to perform battery filling and charging in accordance with the following
instructions:
a. Clean each cell thoroughly with a cloth dampened in clear water and wipe dry with a clean
cloth prior to filling the cells with electrolyte.
b. Ensure battery connections are properly torqued to manufacturer's specifications. Torque
values are given in mN-m inch-lbs. Take and record, for cell-to-cell and terminal connections,
detailed micro-ohm resistance readings before placing battery in service. Remake connections
having a resistance of more than 10 percent above the average. Test equipment and procedure
must be approved by the Contracting Officer.
c. Electrolyte in the containers may have stratified. Contractor shall ensure the specific
gravity is between 1.205 and 1.220 by agitating each electrolyte container until the specific
gravity is within the required range.
d. Once a specific gravity between 1.205 and 1.220 is measured, and the UPS rectifier is fully
operational, remove the shipment vent plug from each cell and fill cells with electrolyte.
Use the screw-in plastic shut-off nozzles provided with the electrolyte containers. Contractor
shall provide all hoses necessary for filling the cells. Equipment used for filling the cells
shall be free of any metal to prevent electrolyte contamination.
e. The filling height of the electrolyte shall not be higher than 6 mm 1/4 inch below the bottom
of the low level line.
f. Install a flame-arrestor vent in each cell immediately after filling the cell. Lock in
place with a one-quarter turn in a clockwise direction. Then install a dust cover cap on the
top of each flame arrestor. CAUTION: Do not remove the flame arrestor vents after initial
filling.
g. Allow the battery to stand open circuit a minimum of four hours after filling the last cell.
Add acid through the funnel of the flame arrestor or the electrolyte sampling tube to again
bring the electrolyte level to 6 mm 1/4 inch below the bottom of the low level line.
h. Commence charging after the required stand period but no later than 12 hours after the filling
of the first cell.
]][3.3.2 General Instructions for Sealed Type, Valve Regulated Battery
NOTE: Delete paragraph if lead calcium alloy battery is used.
a. Only authorized personnel who have been familiarized with battery installation, charging,
and maintenance procedures will be permitted access to the battery room.
b. At all times while in the battery room, personnel shall wear the proper safety items as
deemed necessary by their task. This shall include, but not be limited to, face shield, impermeable
apron, and acid resistant boots and gloves. Contractor shall provide one spare set of safety
equipment for Contracting Officer.
c. These cells are sealed and do not present an acid danger. However if the container is damaged,
exposure to acid could occur.
d. Sealed batteries will vent potentially explosive gases, particularly in the event of a charger
malfunction. Never bring any burning material such as lit matches, cigarettes, lighters, or
any type of spark producing material or devices into the battery room or adjacent to any cell.
e. Cells connected in series have high voltages that could produce a shock hazard. Do not
ground the DC system. If a ground is placed at one end of the battery, an increased shock hazard
exists between the opposite end of the battery and ground. Also, if another ground should develop
within the system, it may create a short circuit which could start a fire.
f. Ensure that bolted battery connections are torqued to the recommended values. Loose connections
can cause excessive resistance between cells.
g. Do not lift cell by its terminal posts as this can damage the battery. Under no circumstance
attempt to remove the pressure relief valves, vents or vent covers as this will prevent proper
function of the battery.
]3.3.3 Electrical Safety Instructions
a. Cells connected in series have high voltage potentials that produce shock hazards.
b. Discharge static electricity from the body before touching cell terminal posts by first
touching a grounded surface such as the grounded battery racks.
c. Only insulated tools shall be used when working on the battery cells during and after activation
charging has begun. Never place metal tool on the top of cell.
d. Only approved digital voltmeters shall be used in monitoring the cells. Digital volt meters
shall provide a minimum of .01 volt resolution.
[3.3.4 Battery Charging Instructions
NOTE: This paragraph is applicable to the lead calcium alloy type battery.
Delete if sealed (valve regulated) battery is used.
Contracting Officer will coordinate the battery charging process with Contractor and UPS technical representative.
UPS technical representative will instruct the Contractor on adjusting the rectifier voltage as required by the
procedure. Battery charging is the Contractor's responsibility. Contractor shall provide the manpower, including
an authorized representative of the battery manufacturer, and equipment necessary to continuously monitor and
control the battery charging process.
a. The minimum charge required by each cell is [_____] Ampere-Hours.
The maximum charge current is [_____] Amps.
Therefore, the absolute minimum charging time is [_____] Continuous Hours.
Overtime will be required!
b. Provide temporary cables required for charging. This cable shall be the same size as used
for the tier-to-tier and rack-to-rack connections. Coordinate the charging configuration of
the battery with the battery manufacturer's representative and UPS technical representative.
c. Prior to the actual start of the activation charge, pilot cells shall be designated by the
Battery manufacturer's representative. Pilot cells will be designated to obtain an average
mean of the battery. A minimum of 19 cells within the battery will be designated as pilot cells.
If, by feeling cell jars during charging, warmer cells are noted, they shall be made pilot cells
also.
d. Technical direction on the actual activation charging cycle will be provided by the UPS
and Battery manufacturer's representatives. This direction includes but is not limited to analysis
of individual and pilot cell data, adjusting the UPS rectifier output voltage and current, the
removal of electrolyte and addition of distilled water for the adjustment of the cell specific
gravity and ensuring the battery is charged to the minimum ampere hour-rating. The UPS technical
representative will also provide the Contractor with a phone number where he can be contacted
after regular working hours should there by any problems with the UPS during the charging period.
e. Immediately before starting the activation charge, measure and record the following:
(1) Voltage of each cell.
(2) Specific gravity of each cell.
(3) Temperature of each cell.
f. Measure and record the open circuit voltage of the parallel connection. Turn-on the rectifier
and adjust the voltage control to the open-circuit voltage reading. Close the battery circuit
breaker and adjust the rectifier voltage control until charging current is at maximum limit
specified herein. Continue charging at maximum rate (unless temperature limits are exceeded)
for minimum ampere-hours specified herein.
g. At the start of the activation charge the following measurements shall be taken and recorded
:
(1) Time at start of charge.
(2) Current at start of charge.
(3) Voltage at start of charge taken at the battery terminals.
h. The following measurements shall be taken and recorded on an hourly basis until the end
of charge:
(1) Battery voltage taken at the battery terminals.
(2) Charging current.
(3) Cell voltage, specific gravity and temperature of each pilot cell.
i. Do not permit cell temperatures to exceed 43 degrees C 110 degrees F. If temperature is
exceeded, interrupt the charge until the cells cool down to 38 degrees C 100 degrees F. Then
resume charging. Record times of interruptions. Ensure batteries are charged for the full number
of minimum ampere-hours required.
j. At the completion of the activation charge, as determined by the Battery manufacturers'
representative, the following measurements of ALL cells shall be taken and recorded:
(1) Cell voltage.
(2) Specific gravity.
(3) Temperature.
k. Upon completion of the activation charge, Contractor shall return the battery to its normal
operating configuration.
][3.3.5 Battery Refreshing Charge Instructions
NOTE: This paragraph is applicable to sealed (valve regulated) battery. Delete
if lead calcium alloy battery is used.
NOTE: Recommended refreshing charge values are applicable to cell temperatures
between 15 degrees to 32 degrees C 60 degrees to 90 degrees F. For cell temperatures
4 to 15 degrees C 40 degrees to 59 degrees F use twice the number of hours.
For cell temperatures 4 degrees C 39 degrees F and below, use four times the
number of hours.
Contracting Officer shall coordinate the battery refreshing charge process with Contractor and UPS technical
representative. The only acceptable method of giving a refreshing charge is constant voltage. UPS technical representative
will instruct Contractor on adjusting the rectifier voltage as required by this process. Battery refreshing charge
is Contractor's responsibility. Contractor shall provide the manpower, including an authorized representative
of the battery manufacturer, and all necessary equipment to monitor the refreshing charge process.
a. The refreshing charge shall be determined by the maximum voltage that the connected equipment
can tolerate, and of that which the charger can deliver.
Divide the voltage by the number of cells in the battery, and charge at that voltage; provided it does not exceed
2.40 volts per cell 25 degrees C 77 degrees F. After the charge current has tapered and stabilized for 24 hours,
continue the charge for the number hours as follows:
Refreshing ChargeCELL VOLTS MIN. HOURS TO CHARGE
2.22 [_____]
2.27 [_____]
2.30 [_____]
2.35 [_____]
2.40 [_____]
DO NOT EXCEED 2.40 VOLTS PER CELL 25 DEGREES C 77 DEGREES F.
]3.3.6 Float Charge
a. The UPS technical representative will adjust UPS for float operation.
b. Allow battery to float for a minimum of 72 hours to permit cell voltages to stabilize.
c. Measure and record voltage, specific gravity and temperature of each cell.
d. Should the float voltage of any cell read below 2.08 volts DC or the specific gravity read
less than 1.190 corrected to 25 degrees C 77 degrees F, remove cell from battery and connect
the two adjacent cells with a short length of cable to maintain series connection of remaining
cells. Discharge performance test may be conducted with one or more cells missing; however,
discharge time will be reduced accordingly. NOTE: The rectifier output voltage to battery on
float shall be reduced by 2.25 volts for each cell removed from battery. Additionally, when
battery is on equalize, rectifier output voltage must be reduced by 2.33 volts for each cell
removed. UPS alarms shall be adjusted as necessary. Notify Contracting Officer immediately
if it becomes necessary to remove any cell. Defective cells should be replaced as soon as possible.
Contractor, via Contracting Officer, shall contact NFESC ECDet, Code 65 for assistance.
3.4 FIELD QUALITY CONTROL
Contractor shall be on-site during UPS system testing. Provide equipment, test instruments, power, load bank,
materials and labor required for tests. Contracting Officer will witness all tests and the tests shall be subject
to his approval. Defects resulting from improper handling or installation shall be corrected by the Contractor
and retested at no additional cost to the Government. Defects resulting from non-Contractor furnished equipment
failure shall be repaired by equipment manufacturer. Contracting Officer will make final decisions as to whether
a failure was due to improper installation or defective non-Contractor furnished equipment.
3.4.1 UPS Unit Performance Test
Upon completion of battery activation procedures and as directed by Contracting Officer, Contractor shall connect
load bank to UPS output. Load bank required shall be determined by the following:
UPS KVA RATING X 0.8 = KW of LOAD BANK
Performance test is to be run under the supervision of the UPS technical representative. UPS unit shall be operated
under full load for a minimum of one hour. Contractor shall be required to operate feeder and bypass power feeder
breakers during testing of the UPS.
[3.4.1.1 Emergency Generator Operation
NOTE: Delete this paragraph if an emergency generator is not required.
Test UPS to observe operation with emergency generator service. UPS technical representative shall verify UPS
battery current limiting feature functions properly.
]3.4.2 Battery Performance Test (Constant KW)
Furnish all labor, material and test equipment necessary to conduct performance test under the direction of UPS
technical representative. The following shall be accomplished:
a. Install a calibrated voltmeter across the battery terminals to measure voltage, and install
a calibrated voltmeter across the UPS DC shunt to read charging current. UPS technical representative
will advise connection to DC shunt.
b. Record temperature of pilot cells in battery immediately prior to start of discharge performance
test.
c. Read and record total battery voltage and battery current at start of discharge and every
minute during discharge test.
d. Record minutes and seconds when battery voltage drops below minimum discharge voltage of
291 volts DC. On initial discharge test, a battery may be expected to deliver 95 percent of
its rated capacity. This will increase to 100 percent after several complete discharge cycles
or after 12 months of float charge service.
e. Should battery fail to meet the requirements of the first discharge performance test, open
the inverted output breaker. Then put battery on equalizing charge, with rectifier adjusted
to normal equalizing voltage of [424] [_____] volts DC. Equalize for a minimum of [100] [_____]
hours. Measure and record time and battery voltage. Run a second discharge performance test.
3.5 FINAL ADJUSTMENTS
a. Remove load bank and reconnect system for normal operation.
b. Equalize battery at [424] [_____] volts for a period of [72] [_____] hours.
NOTE: Delete this test if battery is sealed (valve regulated) type.
c. Bring electrolyte level of all cells up to the bottom of the high level line by adding original
filling gravity electrolyte.
d. Resume charging battery at normal float voltage of [411] [_____] volts DC.
e. Check battery connections are properly torqued to manufacturer's specifications. Take and
record, for cell-to-cell and terminal connections, detailed micro-ohm resistance readings.
Remake connections having a resistance of more than 10 percent above the average.
f. All manufacturer's data and operation manuals, which are an integral part of, and shipped
with UPS, shall be delivered to Contracting Officer.
3.6 DISPOSAL
Upon completion of UPS installation and testing, Contractor shall remove and dispose of empty, partially full
and excess acid drums, including shipping containers, obsolete batteries, and obsolete UPS modules. Removal
shall be accomplished off-base and in conformance with local laws and regulations regarding disposal of hazardous
material.
-- End of Section --