Civil Engineering Studies Trnsporttion Engineering Series No. 127 Trffi Opertions Lb Series No. 7 UILU-ENG-2003-2007 ISSN-0917-9191 Evlution of UPS for Intersetion Trffi Signls with LEDs: Findings for Myers PB-1250PC UPS By Mdhv V. Chitturi Rhim F. Benekohl A study onduted by Trffi Opertions Lbortory Deprtment of Civil nd Environmentl Engineering University of Illinois t Urbn-Chmpign Prepred for Illinois Deprtment of Trnsporttion Deember 2003
Tehnil Report Doumenttion Pge 1. Report No, FHWA-IL/UI-TOL-7 2. Government Aession No. 3. Reipient's Ctlog No 4. Title nd Subtitle Evlution of UPS for Intersetion Trffi Signls with LED: Findings for Myers PB-1250PC UPS 5. Report Dte Deember 15, 2003 6. Performing Orgniztion Code 7. Author(s) Mdhv V. Chitturi nd Rhim F. Benekohl 8. Performing Orgniztion Report No. UILU-ENG-2003-2007 9. Performing Orgniztion Nme nd Address 10. Work Unit (TRAIS) Deprtment of Civil nd Environmentl Engineering University of Illinois t Urbn-Chmpign 205 N. Mthews Ave. Urbn, Illinois 61801 11. Contrt or Grnt No. 13. Type of Report nd Period Covered Projet Report 2002-2003 12. Sponsoring Ageny Nme nd Address The Illinois Deprtment of Trnsporttion 14. Sponsoring Ageny Code 15. Supplementry 16. Abstrt Uninterruptible Power Supply (UPS) systems re used to power the intersetion trffi signls tht hve Light Emitting Diode (LED) signl modules, in se of power filure. The objetive of this study ws to test the PB-1250PC UPS mnuftured by Myers Power Produts nd verify if it meets the Illinois DOT s speifition for UPS. Multiple tests with full lod (pproximtely 700 W) nd prtil lods (flshing reds with bout 350W) were onduted t room temperture to determine hrge nd dishrge times. The time to fully hrge the btteries ws on verge 14hrs 17min. The UPS powered full lod for 2hrs 15mins. When powering full lod, the UPS took 1hr 8min to reh 40% bttery level. After rehing the 40% level, the UPS powered the flshing reds for 1hr 46min. Myers PB-1250PC UPS meets the mjority of the IDOT Speifition requirements. It hs three mjor nd some minor shortomings tht n be orreted to stisfy ll IDOT Speifition requirements. The mjor shortomings of this model re: the model does not hve NO nd NC ontt losure for inditing inverter/hrger filure: the mnufturer gives 48 hr burn-in period to eh unit insted of 100 hrs required by IDOT speifition, the fn in the bttery binet runs on 48VDC insted of AC power. 17. Key Words 18. Distribution Sttement Uninterruptible Power Supply for Intersetions, UPS, Intersetion Trffi Signls, LED Signl Modules, Bttery Bk up System for Trffi Lights, BBS. 19. Seurity Clssif. (of this report) Unlssified 20. Seurity Clssif. (of this pge) Unlssified 21. No. of Pges 17 22. Prie `Form DOT F 1700.7 (8-72) Reprodution of ompleted pge uthorized ii
Aknowledgment nd Dislimer This study ws onduted by the Trffi Opertions Lbortory (TOL) t the University of Illinois t Urbn-Chmpign. The Illinois Deprtment of Trnsporttion sponsored the study. The ontents of this report reflet the views of the uthors who re responsible for the fts nd ury of the dt presented herein. The ontents do not reflet the offiil views or poliies of the Illinois Deprtment of Trnsporttion. This report does not onstitute stndrd, speifition, or regultion. iii
TABLE OF CONTENTS OBJECTIVE... 1 METHODOLOGY... 1 COMPANY LITERATURE... 1 QUESTIONS FROM MANUFACTURERS... 1 VISUAL INSPECTION... 2 LABORATORY EXPERIMENT... 2 NO nd NC Rely Contt Closures... 2 Swithing from AC to UPS nd bk:... 2 Dishrge nd Rehrge Times... 3 TEST RESULTS... 5 SUMMARY OF FINDINGS... 10 APPENDIX A... 11 iv
OBJECTIVE Myers Power Produts prospetive supplier of UPS for Illinois Deprtment of Trnsporttion (IDOT) provided one PB-1250PC UPS system for evlution. The objetive of this study is to test the UPS model provided by the mnufturers nd see whether it meets the Speifition for UPS developed by IDOT. The evlution ws onduted t the Trffi Opertions Lb t the University of Illinois. This report disusses the methodology for testing nd the interim results of the evlution of the PB-1250PC unit. The mnufturer hs lso provided unit of PB2000ITS, whih is being evluted urrently. The results of tht evlution will be dded to the report. METHODOLOGY IDOT hs developed n interim UPS Speifition tht is modeled fter the ClTrns Speifition. Bsed on the disussions with IDOT representtives, the vrious requirements of (luses) the UPS Speifition were lssified into four tegories: Informtion tht is in ompny literture Questions sked from mnufturers/suppliers Visul inspetion of the unit Lbortory experiment Appendix A shows the tegory in whih eh of the luses ws pled. Compny Literture The mnufturer s literture ws reviewed to see to wht degree the literture lims tht the requirements of the Speifition re met. In generl the luses whih ould not be esily verified in the Trffi Opertions Lbortory were lssified under this tegory. For exmple, Operting temperture for both the inverter/power trnsfer rely nd mnul bypss swith shll be -37 C to +74 C (1.4 in IDOT Speifition). For ll the luses grouped under this tegory it ws deided tht literture provided by the ompny would be used for verifition. The literture provided by the ompnies ws studied. Questions from Mnufturers The mnufturers were ontted nd requested to provide dditionl informtion, if it ws not ler from the literture whether their models stisfied ertin luses. Also they were sked to provide ertifitions for the lims mde in their literture, if vilble. The luses in setion 5 of the Speifition del with the Qulity Assurne progrm, design qulifition testing nd Prodution qulity ontrol testing employed by the 1
mnufturers. For exmple, QA proess nd test results doumenttion shll be kept on file for minimum period of seven yers (5.2 in IDOT Speifition). Sine this informtion is not publi knowledge, it ws deided tht pproprite questions be sent to the mnufturers to sertin if they stisfied these luses. Questions were sent to the mnufturers nd their responses hve been inorported in the report. Visul Inspetion For heking if the UPS met ertin luses of the speifition, visul inspetion ws suffiient. For exmple, the temperture sensor shll be externl to the inverter/hrger unit. The temperture sensor shll ome with 2 meters (6 6 ) of wire (1.6.1 in IDOT Speifition). Visul Chek ws performed on the models nd the results were inorported. Lbortory Experiment Certin luses of the speifition ould be verified by running simple experiments, with redily vilble equipment, t the Trffi Opertions Lb. For exmple, when the utility line power hs been restored t bove 105 VAC +/- 2 VAC for more thn 30 seonds, the UPS shll dropout of bttery bkup mode nd return to utility line mode (1.11 in IDOT Speifition). The experiments performed were essentilly of three kinds: rely ontt losures, swithing from AC to UPS nd bk, nd dishrge nd rehrge times of the btteries. NO nd NC Rely Contt Closures The luses under this group re relted to the four NO nd NC rely ontt losures tht need to be provided nd when they would be energized. They re luses 1.3.1 through 1.3.4. For verifying these luses the events tht would result in energizing the losures were reted nd it ws verified, if indeed the losures were energized. For exmple, for verifying 1.3.1, while monitoring the rely, AC power ws shut down nd it ws heked if the On Btt losure ws energized. Similr experiments were performed to verify the rest of the luses while monitoring the relys. Swithing from AC to UPS nd bk: The luses under this group speify under wht onditions the UPS should bypss/return to the utility power. Cluses 1.8, 1.11 nd 1.12 ome under this tegory. A vrible trnsformer ws used for reting the neessry modifitions to the AC voltge nd it ws verified if the UPS performed s it is supposed to. 2
Dishrge nd Rehrge Times The luses under this tegory pertin to the durtion the btteries n power the lod nd the durtion of hrging required for the btteries. They re 1.1.1 nd 1.15. Dishrge Times: Aording to the speifition UPS STANDARD is required to power minimum lod of 700 W for minimum of two hours. Using the LED signl modules nd the intersetion pnel vilble t the Trffi Opertions Lb, lod of round 700 wtts ws set up. The dishrge times of the btteries obviously depend on the kind of the lod tht is being powered i.e., solid inditions ll through or solid inditions followed by flshing red inditions. Speifilly, it is being onsidered tht the intersetion should go to flsh opertion fter the btteries reh 40% level. Therefore prospetive user would be interested in the durtions under these two kinds of opertion. For mesuring the durtion of Solid opertion ll through, AC power ws shut down nd the time the lod ws powered before the btteries were shutdown by the UPS to void deep dishrge ws obtined. It ws neessry to visully observe the UPS to obtin the time t whih the btteries rehed 40% level. A ontinuity tester ws onneted between the ommon nd normlly open ends of the seond rely ontt losure. When the btteries reh 40% level, this rely would be energized nd the ontinuity tester would glow inditing tht btteries hve rehed 40% level. To obtin this time, morder ws used to reord the UPS front pnel during the test. The morder ws run in intervl reording mode using n intervl of one minute nd reording durtion of 2 seonds. Therefore the time ould hve n error of one minute t the worst. The blok digrm of the experimentl setup is shown in Figure 1. Voltmeter Bttery Cbinet Computer UPS nd PTS Intersetion pnel, LED modules Controller Cbinet AC Power Cmer Figure 1. Blok digrm of the experimentl setup. 3
One the btteries rehed the 40 % level, the intersetion ws put on flsh nd the time the flshing lod ws powered before the btteries were shutdown by the UPS ws obtined. Under flshing onditions the lod ws pproximtely hlf of the full lod. Therefore it would be expeted tht the btteries would power the flshing lod for pproximtely twie the time they would hve powered the full lod. Using this onept, from this dt the durtion the btteries would hve powered full lod n be estimted. If the time to reh 40% bttery level is lled t 1 nd flshing durtion fter rehing 40% bttery level is lled t 2, the durtion the btteries would hve powered full lod (ll it t f ) n be estimted using the following reltionship. t f = t 1 + t 2 /2 The verge of these estimted vlues is ompred with the verge durtion the btteries powered the full lod. If these two numbers re lose, tht would further inrese the onfidene in the results of these tests. Rehrge times: After every dishrge experiment, the btteries were put to hrge. While the btteries were being hrged their voltge ws monitored using voltmeter tht ould log in the voltge redings into omputer. One the btteries re fully hrged, the voltge of the btteries would stbilize. Using the voltge dt logged in to the omputer by the voltmeter, the time for fully rehrging the btteries ws obtined. It is expeted tht there would be some vribility in the dishrge nd rehrge times of the btteries. Therefore multiple tests re required to sertin if the systems meet the speifitions. Severl tests were performed for obtining the dishrge nd rehrge times of the btteries t room temperture. Bsed on 90 % onfidene level, smple size nd the vrine in the test results the error in the estimte ws obtined. It ws found tht in ll the ses the error ws signifintly less thn the tolerble error. Therefore further testing ws not onduted. The results of these tests re disussed in the Test Results setion of the report. To ompre the men vlues returned by the tests to the speifition requirements, t- tests were performed. The test ssoites onfidene level with whih one n onlude tht the men vlue is greter or lesser thn the speifition requirement. The findings of the evlution re presented in Appendix A. For eh luse of the speifition, Does it meet the spe olumn indites if the UPS stisfies the requirements of the speifition. In the ourse of the evlution it ws found tht there were severl instnes when the nswer to the question Does it meet the speifition? is not strightforwrd or No. For this reson, bsed on our disussions with IDOT representtives, the responses in this olumn ould be, No, * nd No*. nd No lerly indite tht the system stisfies or does not stisfy the speifition respetively. * nd No* indite tht the system stisfies or does not stisfy with 4
some reservtion. Plese red the Comments olumn for explntion of the speifi nswer. TEST RESULTS In this setion the results of the hrge nd dishrge tests (t room temperture) re disussed. First the results for dishrging the btteries t full lod (700W) ll through nd rehrging the btteries re presented. Following this the results for operting in flsh ondition fter rehing 40% bttery level re presented. The UPS model supplied by the mnufturer ws PB-1250PC nd btteries were Chirmn btteries (model AGM-12100T). The results of the dishrge tests performed t full lod for Myers UPS re shown in Tble 1 nd Figure 2. Test Number Dte Durtion full lod ws powered (hh:mm) Beginning voltge (V) Cutoff voltge (V) 1 4/12/2003 2:13 13.917 11.701 2 4/15/2003 2:09 13.567 11.701 3 4/16/2003 2:17 13.505 11.685 4 4/17/2003 2:23 13.526 11.664 5 4/18/2003 2:23 13.583 11.665 6 4/19/2003 2:23 13.548 11.661 7 4/20/2003 2:22 13.565 11.667 8 4/21/2003 2:14 13.589 11.702 9 4/22/2003 2:15 13.607 11.682 Tble 1. Results of dishrge tests performed t full lod for Myers UPS To void deep dishrge of the btteries, the UPS monitors the bttery voltge nd disonnets the btteries from the UPS when the bttery voltge rehes ertin speified voltge. Therefore run time of the btteries is diretly relted to the speified utoff voltge. In generl, the deeper the dishrge btteries go through, the lesser the number of yles of hrge nd dishrge the btteries n endure. During the testing the bttery voltge ws monitored nd the dt ws logged into omputer. Tble 1 shows the dy of test, the run time nd the voltge of one of the btteries t the beginning of the test nd when the btteries were disonneted by the UPS. The men voltge t the beginning of the test ws 13.6 VDC nd the men voltge 5
t the shutdown point ws 11.68VDC. The voltge t shutdown vried from 11.661 to 11.702 VDC. The estimte of the error from the true men, bsed on these observtions is 5.8 minutes whih is 4.9% of 2 hours (speifition requirement). Therefore more tests were not performed From Figure 2, we n see tht the durtion onsistently exeeds the speifition requirement of powering full lod for 2 hours. Bsed on the results, the verge durtion the btteries powered the full lod ws 2:15 nd the minimum nd the mximum vlues re 2:09 nd 2:23. Bsed on these observtions, from the results of t-test, it n be onluded tht the estimted men of 2:15 is greter thn 2:00 with onfidene level greter thn 99.9%. Therefore it n be onluded tht this system meets the speifition requirement for powering full lod. Figure 1. Durtion of bttery power (hh:mm) t full lod for Myers UPS 2:31 2:23 2:23 2:23 2:22 Durtion (hh:mm) 2:13 2:09 2:17 2:14 2:15 2:00 1 1 2 3 4 5 6 7 8 Test # The results for fully hrging the btteries for Myers UPS re shown in Tble 2. The estimte of the error from the true men, bsed on these observtions is 40.3 minutes whih is 3.4% of 20 hours (speifition requirement). Therefore more tests were not performed. From Figure 3 we n see tht the time to fully hrge the btteries is onsistently nd signifintly less thn the speifition requirement of 20 hours. The verge time to hrge the btteries fully ws 14:17 nd the minimum nd mximum vlues re 12:17 nd 15:22. The speifition requires tht the rehrge time for the bttery, from protetive low-utoff to 80% or more of full bttery hrge pity, shll not exeed twenty (20) hours. Bsed on these observtions, from the results of t-test, it n be 6
onluded tht the estimted men of 14:17 is less thn 20:00 with onfidene level greter thn 99.9%. Therefore this system meets the speifition requirement for hrging the btteries. Test Number Dte Chrging Time (hh:mm) 1 4/11/2003 12:40 2 4/12/2003 13:20 3 4/16/2003 14:06 4 4/17/2003 15:07 5 4/18/2003 15:22 6 4/19/2003 15:23 7 4/20/2003 15:20 8 4/21/2003 14:51 9 4/22/2003 14:25 10 7/17/2003 12:17 Tble 2. Results for fully hrging the btteries for Myers UPS. Figure 3. Time to fully hrge the btteries (hh:mm) for Myers UPS 17:33 Time to fully hrge (hh:mm) 15:02 12:32 10:01 7:31 5:00 12:40 13:20 14:06 15:07 15:22 15:23 15:20 14:51 14:25 12:17 2:30 0:00 1 2 3 4 5 6 7 8 9 10 Test # 7
The time tken by the btteries to reh 40% level under full lod nd the time the btteries powered the flshing lod from tht point for Myers UPS re shown in Tble 3 nd Figure 4. Test Number Time to reh 40% Bttery Level (hh:mm) Flshing durtion (hh:mm) fter rehing 40 % bttery level Durtion Btteries were hrged (hrs) before the test 1 1:12 1:48 44 2 1:11 1:43 20 3 1:05 1:48 24 4 1:03 1:53 20 5 1:09 1:40 21 Tble 3. Durtions for flshing opertion fter rehing 40% bttery level for Myers UPS The estimte of the error from the true men for time to reh 40% bttery level is 2.61 minutes nd for flshing durtion fter rehing 40 % bttery level is 3.39. These vlues orrespond to 3.84 nd 3.89 % of their mens. Therefore further testing ws not performed. The verge time to reh 40% bttery level is 1:08 nd verge flshing durtion fter rehing 40 % bttery level is 1:46. 8
Figure 4. Myers UPS: Flsh fter rehing 40 % bttery level 2:09 1:55 1:40 1:48 1:43 1:48 1:53 1:40 Time (hh:mm) 1:26 1:12 0:57 1:12 1:11 1:05 1:03 1:09 0:43 0:28 0:14 0:00 1 2 3 4 5 Test # Time to reh 40% Bttery Level (hh:mm) Flshing durtion (hh:mm) fter rehing 40 % bttery level Bsed on this dt the durtion the btteries would hve powered full lod ws estimted nd the results re shown in Tble 4. The verge of these estimtes is 2:01 whih is very lose to 2:15, the verge durtion the btteries powered full lod. The disrepny ould be beuse the lod under flshing onditions ws pproximtely hlf of the lod under full lod onditions. Test Number Time to reh 40% Bttery Level (hh:mm) Flshing durtion (hh:mm) fter rehing 40 % bttery level Estimted durtion for full lod (hh:mm) 1 1:12 1:48 2:06 2 1:11 1:43 2:02 3 1:05 1:48 1:59 4 1:03 1:53 1:59 5 1:09 1:40 1:59 Tble 4. Estimted durtion for full lod for Myers UPS 9
SUMMARY OF FINDINGS The verge run time with full lod (pproximtely 700 W) t room temperture for Myers PB-1250PC ws 2 hrs 15 min nd the minimum nd mximum vlues were 2 hrs 9 min nd 2 hrs 23 min respetively. The men voltge of bttery t the shutdown point ws 11.68VDC. On the verge the time to hrge the btteries fully t room temperture ws 14 hrs 17 min nd the hrging times rnged from 12 hrs 17 min to 15 hrs 22 min. Sttistil tests onluded tht for run time t full lod nd rehrge time the Myers PB- 1250PC UPS meets the speifition requirements. Also it ws observed tht the UPS took 1 hr 8 min on the verge to reh 40% bttery level (when operting on full lod) nd powered flshing reds for 1 hr 46 min more on the verge. Detils on how Myers PB-1250PC meets eh speifi requirement of the IDOT Speifition is given in Appendix A. The mjor shortomings of this model re: this model does not hve NO nd NC ontt losure for inditing inverter/hrger filure. The speifition requires tht eh UPS be given minimum 100 hr burn-in period to th ny premture filures. However the mnufturer gives 48 hr burn-in period to eh unit. Also the fn in the bttery binet runs on 48VDC s opposed to the speifition requirement of running on AC power. This model hs some minor shortomings suh s not providing suffiiently long bles, bord-level shemti nd wiring digrms et. Myers hs provided new model (PB 2000 ITS) for evlution tht hs progrmmble ontt losures. The mnufturer lims tht PB 2000 ITS n be progrmmed to indite inverter/hrger filure. This would be verified in the lb. In summry, Myers PB-1250PC UPS meets the mjority of the IDOT Speifition requirements. It hs three mjor nd some minor shortomings tht n be orreted to stisfy ll IDOT Speifition requirements. 10
Appendix A Findings for Myers PB-1250PC UPS The tble below shows the lssifition of the different luses of the Speifition into ) Compny Literture b) Question for Mnufturer ) Visul Inspetion d) Lbortory Experiment Note: For rows whih ontin "*" or "No*" in "Does it meet the spe" olumn, plese red the "Comments" olumn Cluse # Cluse Method Comments Does it meet the spe? 1 1 The UPS shll be line intertive nd provide voltge regultion nd power onditioning when utilizing utility power. Mnufturer's response: "The UPS provides voltge regultion nd power onditioning vi buk nd boost. The UPS is Line Intertive" 1 1 1 The UPS shll provide minimum two (2) hours or minimum six (6) hours of full run-time opertion for n LED-only intersetion (minimum 700W/1000VA tive output pity, with 80% minimum inverter effiieny). The two UPS, differing in the minimum durtion of full run-time opertion, shll be designted s UPS STANDARD nd UPS EXTENDED respetively. d Rn ten yles of dishrge nd rehrge t room temperture. for UPS STANDARD 1 2 The mximum trnsfer time from loss of utility power to swithover to bttery bked inverter power shll be 65 milliseonds. Brohure sys trnsfer time is 60 milliseonds. Meets ClTrns Spe 1 3 The UPS shll provide the user with 4-sets of normlly open (NO) nd normlly losed (NC) single-pole double-throw (SPDT) rely ontt losures, vilble on pnel-mounted terminl blok, rted t minimum 120V/1A, nd lbeled so s to identify eh ontt (Mnul Bypss Swith nd Rely Contts Stndrd). Only three NO/NC ontt losures re provided. Newer model provides six progrmmble relys. No* 1 3 1 The first set of NO nd NC ontt losures shll be energized whenever the unit swithes to bttery power. Contt shll be lbeled or mrked On Btt. d Experimented 11
1 3 2 The seond set of NO nd NC ontt losures shll be energized whenever the bttery pprohes pproximtely 40% of remining useful pity. Contt shll be lbeled or mrked Low Btt. d Experimented 1 3 3 The third set of NO nd NC ontt losures shll be energized two hours fter the unit swithes to bttery power. Contt shll be lbeled or mrked Timer. d Experimented 1 3 4 The fourth set of NO nd NC ontt losures shll be energized in the event of inverter/ hrger filure. Contt shll be lbeled or mrked UPS Fil. d Fourth set of NO/NC ontt losures not provided in present model. Newer model provides six progrmmble relys. No* 1 4 Operting temperture for both the inverter/power trnsfer rely nd mnul bypss swith shll be -37 C to +74 C (-35 F to 165 F). Brohure indites the operting rnge for the unit s 37 C to +74 C. Meets ClTrns Spe 1 5 Both the Power Trnsfer Rely nd Mnul Bypss Swith shll be rted t 240VAC/30 mps, minimum. Verified with the mnufturer 1 6 The UPS shll use temperture-ompensted bttery hrging system. The hrging system shll ompenste over rnge of 2.5 4.0 mv/ C or (1.4 2.2 mv/ F) per ell. Stted on pg. 61of the Mnul. Meets ClTrns Spe 1 6 1 The temperture sensor shll be externl to the inverter/hrger unit. The temperture sensor shll ome with 2 meters (6.5 ft) of wire. Sensor is externl. Wire is 2 inh shorter * 1 7 Btteries shll not be rehrged when bttery temperture exeeds 50 C ± 3 C (122oF + 5oF). Stted on pg. 61of the Mnul tht btteries will not be hrged when bttery temperture exeeds 50 C +/- 3 C. Meets ClTrns Spe 1 8 UPS shll bypss the utility line power whenever the utility line voltge is outside of the following voltge rnge: 100VAC to 130VAC (± 2VAC). d Used vrible trnsformer to modify line power 1 9 When utilizing bttery power, the UPS output voltge shll be between 110 VAC nd 125 VAC, pure sine wve output, 3% THD, 60Hz ±3Hz. d Voltge between 110 nd 125 V, Frequeny 60+/- 3 Hz 1 10 UPS shll be omptible with Illinois DOT s trffi ontroller ssemblies utilizing NEMA TS 1 or NEMA TS 2 ontrollers nd binet omponents for full time opertion. d Tested UPS in TS2 Type 1 Cbinet 1 11 When the utility line power hs been restored t bove 105 VAC ±2 VAC for more thn 30 seonds, the UPS shll dropout of bttery bkup mode nd return to utility line mode. d Used vrible trnsformer to modify line power 12
1 12 When the utility line power hs been restored t below 125VAC ±2 VAC for more thn 30 seonds, the UPS shll dropout of bttery bkup mode nd return to utility line mode. d Used vrible trnsformer to modify line power 1 13 UPS shll be equipped to prevent mlfuntion feedbk to the binet or from feeding bk to the utility servie. Verified with the mnufturer 1 14 In the event of inverter/hrger filure, the power trnsfer rely shll revert to the NC stte, where utility line power is reonneted to the binet. d Experimented 1 15 Rehrge time for the bttery, from protetive low-utoff to 80% or more of full bttery hrge pity, shll not exeed twenty (20) hours. d Rn ten yles of dishrge nd rehrge t room temperture. 2 1 1 Inverter/Chrger Unit shll be rk or shelf-mounted. 2 1 2 (Reserved) 2 1 3 All interonnet wiring provided between Power Trnsfer Rely, Bypss Swith nd Cbinet Terminl Servie Blok shll be no less thn 2 meters (6.5 ft) of #10 AWG wire. Wire is #14 AWG nd 3 inh shorter * 2 1 4 Rely ontt wiring provided for eh set of NO/NC rely ontt losure terminls shll be 2 meters (6 6 ) of #18 AWG wire. Wire is #10 AWG * 2 1 5 To ensure interhngebility between ll UPS mnufturers, UPS Power Trnsfer Rely nd Mnul Bypss Swith shll be interonneted with Type IV or Type V NEMA binets ording to the Deprtment stndrds. 2 1 6 (Reserved) 2 2 * ( Reserved) - 2 3 1 Inverter/Chrger, Power Trnsfer Rely nd mnully operted Bypss Swith shll fit inside typil fully equipped Type IV or Type V NEMA Cbinet tht houses one NEMA TS 1 or NEMA TS 2 ontroller. d Inverter: PTS: Probbly no No* 2 3 2 Btteries shll be housed in NEMA Stndrd TS 2 rted binet, self supported nd mounted on the onrete foundtion ording to the Deprtment stndrds. This externl bttery binet shll onform to the IDOT Stndrd Speifitions for the onstrution nd finish of the binet. Did not test for the onformne of the binet to IDOT Speifition * 2 3 3 Btteries shll be mounted on individul shelves for the binet housing four (4) btteries nd two (2) btteries per shelf for the binet housing eight (8) btteries. Cbinet provided n ommodte only four btteries 2 3 4 Four shelves shll be provided. Eh shelf shll support lod of 30 kg (66 lb) minimum for single bttery or 60 kg (132 lb) minimum for dul btteries. 2 3 5 (Reserved) 2 3 6 Cbinets housing four (4) btteries shll hve nominl outside dimensions of width 356 mm (14 in.) depth 229 mm (9 in.) nd height within 1143 mm to 1397 mm (45 in. to 55 in.). Cbinets housing eight (8) btteries shll hve nominl outside dimensions of width 711 mm (28 in.) depth 229 mm (9 in.), nd height within 1143 mm to 1397 mm (45 in. to 55 in.). Clerne between shelves shll be minimum of 254 mm (10 in.). 13
2 3 7 The bttery binet shll be ventilted through the use of louvered vents, filter, nd one thermosttilly ontrolled fn s per NEMA TS 2 speifitions. Vent, Fn nd Filter re there. Vendor lims tht fn meets NEMA TS2 Speifition 2 3 8 The bttery binet fn shll be AC operted from the sme line output of the Mnul Bypss Swith tht supplies power to the Type IV or Type V Cbinet. Fn runs on 48VDC, 1A No 2 3 9 The bttery binet shll hve door opening to the entire binet. The door shll be tthed to the binet through the use of ontinuous stinless steel or luminum pino hinge. The binet shll be provided with min door lok whih shll operte with trffi industry onventionl No. 2 key. Provisions for pdloking the door shll be provided. Visully inspeted 2 3 10 3 1 The UPS with bttery binet shll ome with ll bolts, onduits nd bushings, gskets, shelves, nd hrdwre needed for mounting. The UPS shll inlude disply nd /or meter to indite urrent bttery hrge sttus nd onditions. Visully inspeted. LEDs indite urrent bttery hrge sttus nd onditions. 3 2 The UPS shll hve lightning surge protetion omplint with IEEE/ANSI C.62.41. Seeking ertifition from mnufturer * 3 3 The UPS shll be equipped with n integrl system to prevent bttery from destrutive dishrge nd overhrge. Verified with the mnufturer 3 4 The UPS nd btteries shll be esily repled with ll needed hrdwre nd shll not require ny speil tools for instlltion. 3 5 The UPS shll inlude resetble front-pnel event ounter disply to indite the number of times the UPS ws tivted nd front-pnel hour meter to disply the totl number of hours the unit hs operted on bttery power., they re resetble 3 6 Mnufturer shll inlude two (2) sets of equipment lists, opertion nd mintenne mnuls, nd bord-level shemti nd wiring digrms of the UPS, nd the bttery dt sheets. Only O & M mnuls re there. Others re not there No* 4 1 Individul btteries shll be 12V type, 65 mp-hour minimum pity t 20 hours, nd shll be esily repled nd ommerilly vilble off the shelf. Btteries re 12 V 100 mp-hour 4 2 Btteries used for UPS shll onsist of 4 to 8 btteries with umultive minimum rted pity of 240 mp-hours. Provided 4 btteries eh 100 Amp-hr 4 3 Btteries shll be deep yle, ompletely seled, prismti ledlium bsed AGM/VRLA (Absorbed Glss Mt/ Vlve Regulted Led Aid) requiring no mintenne. 4 4 Btteries shll be ertified by the mnufturer to operte over temperture rnge of 25 C to +71 C (-13oF to 160oF). Brohure indites the sme rnge for bttery opertion. Verified with the mnufturer 14
4 5 The btteries shll be provided with pproprite interonnet wiring nd orrosion-resistnt mounting trys nd/or brkets pproprite for the binet into whih they will be instlled. Provided 4 6 Btteries shll indite mximum rehrge dt nd rehrging yles. Btteries do not indite mximum rehrging yles. No* 4 7 Bttery interonnet wiring shll be vi modulr hrness. Btteries shll be shipped with positive nd negtive terminls pre-wired with red nd blk bling tht termintes into typil power-pole style onnetor. Hrness shll be equipped with mting power-pole style onnetors for btteries nd single, insulted plug-in style onnetion to inverter/hrger unit. Hrness shll llow btteries to be quikly nd esily onneted in ny order nd shll be keyed nd wired to ensure proper polrity nd iruit onfigurtion. 4 8 Bttery terminls shll be overed nd insulted so s to prevent identl shorting. 5 1 Eh UPS shll be mnuftured in ordne with mnufturer qulity ssurne (QA) progrm. The QA progrm shll inlude two types of qulity ssurne: (1) Design qulity ssurne nd (2) Prodution qulity ssurne. The prodution qulity ssurne shll inlude sttistilly ontrolled routine tests to ensure minimum performne levels of UPS units built to meet this speifition nd doumented proess of how problems re to be resolved. b Mnufturer Response: Adheres to ISO 9001 nd 900. Meets ClTrns Spe * 5 2 QA proess nd test results doumenttion shll be kept on file for minimum period of seven yers. b Mnufturer Response: Adheres to ISO 9001 nd 900. Meets ClTrns Spe * 5 3 Bttery Bkup System designs not stisfying design qulifition testing nd the prodution qulity ssurne testing performne requirements desribed below shll not be lbeled, dvertised, or sold s onforming to this speifition. Conlusion of the test Conlusion of this test 5 4 1 The mnufturer, or n independent testing lb hired by the mnufturer, shll perform design Qulifition Testing on new UPS designs, nd when mjor design hnge hs been implemented on n existing design. A mjor design hnge is defined s design hnge (eletril or physil) whih hnges ny of the performne hrteristis of the system, or results in different iruit onfigurtion. b Mnufturer Response: s stndrd prtie 5 4 2 A single unit for eh design shll be submitted for Design Qulifition Testing. Vendor furnished 5 4 2 1 Test units shll be submitted to the Trffi Opertions Lb, 1605 Titn Drive, Rntoul, IL 61866, fter the mnufturer s testing is omplete. Vendor furnished 5 4 2 2 Mnufturer s testing dt shll be submitted with test units for IDOT s verifition of Design Qulifition Testing dt. Vendor furnished No 15
5 4 3 The smple systems shll be energized for minimum of 5 hours, with full lod of 700 wtts, t tempertures of +74 C nd -37 C (+165oF nd 35oF), exluding btteries, before performing ny design qulifition testing. b Mnufturer Response: s stndrd prtie 5 4 4 Any filure of the UPS, whih renders the unit non-omplint with the speifition fter burn-in, shll be use for rejetion. b Mnufturer Response: s stndrd prtie 5 4 5 For Design Qulifition Testing, ll speifitions will be mesured inluding, but not limited to: b 5 4 5 1 Run time while in bttery bkup mode, t full lod. 5 4 5 2 5 4 5 3 5 4 5 4 5 4 5 5 Proper opertion of ll rely ontt losures ( On-Btt, Low- Btt, Timer nd UPS-Fil ). Inverter output voltge, frequeny, hrmoni distortion, nd effiieny, when in bttery bkup mode. All utility mode bttery bkup mode trnsfer voltge levels. See UPS Spe 1.8, 1.11 nd 1.12. Power trnsfer time from loss of utility power to swithover to bttery bked inverter power. 5 4 5 6 Bkfeed voltge to utility when in bttery bkup mode. Seeking ertifition from mnufturer * 5 4 5 7 IEEE/ANSI C.62.41 ompline. Seeking ertifition from mnufturer * 5 4 5 8 Bttery hrging time. Verified t room temperture only. 5 4 5 9 Event ounter nd runtime meter ury. 5 5 1 Prodution Qulity Control tests shll onsist of ll of the bove listed tests nd shll be performed on eh new system prior to shipment. Filure to meet requirements of ny of these tests shll be use for rejetion. The mnufturer shll retin test results for seven yers. b On eh unit, tests orresponding to 5.4.5.3, 5.4.5.5 nd 5.4.5.6 re performed. One out of bth of 300 units is piked nd tests orresponding to 5.4.5.4 nd 5.4.5.7 re performed. No* 5 5 2 Eh UPS shll be given minimum 100-hour burn-in period to th ny premture filures. b Compny response: 48 hours No* 5 5 3 Eh system shll be visully inspeted for ny exterior physil dmge or ssembly nomlies. Any defets shll be use for rejetion. b Mnufturer Response: s stndrd prtie 5 6 1 5 6 2 The IDOT will perform rndom smple testing on ll shipments, onsistent with ANSI/ASQC Z1.4-1993 Smpling Proedures nd Tbles for Inspetion by Attributes. Smple testing will normlly be ompleted within 90 dys fter delivery to the Trffi Opertions Lbortory, brring defiienies in the shipment, whih would reset the lok. Under onsidertion Under onsidertion 16
5 6 3 All prmeters of the speifition my be tested on the shipment smple. 5 6 4 The number of units tested (smple size) shll be determined by the quntity in the shipment. The smple size nd eptne or rejetion of the shipment shll onform to ANSI/ASQC Z1.4. Under onsidertion 6 0 Mnufturers shll provide two (2) yer ftory-repir wrrnty for prts nd lbor on the UPS from dte of eptne by the Stte. Btteries shll be wrrnted for full replement for two (2) yers from dte of purhse. The wrrnty shll be inluded in the totl bid prie of the UPS. Wrrnty on pg. 65 of Mnul sttes tht the wrrnty is vlid for 24 months from the dte of Mnufture, NOT dte of eptne by the stte. Also for btteries the wrrnty is provided by the originl mnufturer nd NOT Myers. * 17