Post on 29-Mar-2020
THE ISRAEL ELECTRIC CORPORATION LTD. Engineering Projects & Business Development SPEC: STR-1416 Engineering Division Substation Planning Sector
STR-1416
GENERAL SPECIFICATION FOR BATTERY CHARGERS
ANNEXURE “B”
February 2017
THE ISRAEL ELECTRIC CORPORATION LTD. Engineering Projects & Business Development SPEC: STR-1416 Engineering Division Substation Planning Sector
2017/SPECS/STR-1416 B - 2
STR-1416
GENERAL SPECIFICATION FOR BATTERY CHARGERS
ANNEXURE “B”
DRAFT FINAL DRAFT CONTRACT
Name Date Sig Name Date Sig Name Date Sig
Prepared S. Bar Oz 02/16 Prepared S. Bar Oz 02/17 Prepared
Checked Z. NIR 02/16 Checked Z. NIR 02/17 Checked
Approved Z. NIR 02/16 Approved Z. NIR 02/17 Approved
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TABLE OF CONTENTS
ANNEXURE “B” 1. Purchaser……………………………………………………………………. B – 6 2. Scope of Work………………………………………………………………. B – 6 3. Delivery, Shipment, Storage………………………………………………. B – 8 4. Standards and Specifications……………………………………………… B – 10 5. Tender Documents…………………………………………………………. B – 12 6. General Approval of Technical Documentation…………………………. B – 13 7. Quality Assurance and Quality Control…………………………………… B – 16 8. Tests…………………………………………………………………………. B – 18 9. Name Plates………………………………………………………………… B – 22 10. Spare and Renewal Parts…………………………………………………. B – 22 11. Detailed Specification………………………………………………………. B – 27 11.1 Service ....................................................................................... B – 27 11.2 AC System Data ........................................................................ B – 27 11.3 Charger Ratings ........................................................................ B – 27 11.4 Environmental Conditions ..........................................................
11.5 EMC Compatibility Requirements………………………………… B – 27 B – 28
11.6 Operating Characteristics .......................................................... B – 30 11.6.1 Normal Service ............................................................ B – 30 11.6.2 Equalizing Charge ....................................................... B – 32 11.6.3 Boost Charge……………………………………………... B – 33 11.6.4 Transient Behavior of the Charger ...............................
11.6.5 Start-Up Behavior ........................................................ B – 34 B – 34
11.7 Mechanical Design Requirements ............................................ B – 35 11.8 Electrical Design Requirements ................................................ B – 38 11.9 Charger Components ............................................................... B – 40 11.9.1 Insulating Transformers and Reactor .......................... B – 40 11.9.2 Rectifier Bridge ........................................................... B – 40 11.9.3 Capacitors for Filter .................................................... B – 40 11.9.4 M.C.B.’s and C.B.'s ..................................................... B – 41 11.9.5 Control Circuits ........................................................... B – 42 11.9.6 Measuring Instruments ............................................... B – 42 11.9.7 Control ........................................................................ B – 43
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TABLE OF CONTENTS cont.
11.9.8 Communication……………………………………………. B – 44 11.9.9 Programmable Controller………………………………… B – 45 11.10 Alarms .................................................................................... B – 46 11.11 Labeling .................................................................................... B – 47 ANNEXURE "C" 1. For Summary of Prices of Battery Chargers 220VDC, 30A. See
Annexure "C; in Specification,STR-1416
2. For Summary of Prices of Battery Chargers 220VDC, 100A
see Annexure "C" in Specification STR-1416
APPENDIXES Appendix 1 - Painting requirements:
1A - specification No. 1400: Specification for Electrostatic Painting of aluminum plates.
1B - Specification No. 1500: Specification for Electrostatic Painting of electrical cabinets or other equipment constructed from mild steel.
Appendix 2 - Electrical Standard Specification Control Cubicles Wiring Requirements – IEC NO. EPD-A.03
Dated 09/2004. Appendix 3 - General Specification for Testing Industrial Rectifiers IEC No. S-83/04/1.80 Dated 02/2004 . Appendix 4 - Procurement Quality Requirements Q-APP-02 Rev. 4
Dated 03/2011.
Appendix 5 - Reliability, Maintainability and Safety Requirements for Battery Chargers 220V,30A and 220V 100A.
Appendix 6 - Nameplates Specification Dated 08/2015
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TABLE OF CONTENTS cont. DRAWINGS Charger characteristic IU according to DIN 41773 – EVK-6375. Principle diagram of a double DC system in a switching station – EVK-7212. Principle diagram of a single DC system in a substation – EVK-6374
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SPECIFICATION FOR
BATTERY CHARGERS
1. PURCHASER:
The Israel Electric Corporation Limited.
2. SCOPE OF WORK:
This Specification deals with technical requirements for two types of battery
chargers with nominal currents: 30 A and 100 A, intended for use in substation
auxiliary DC system with nominal voltage 250 V and main 3 phase AC
nominal voltage 230/400V.
2.1 GENERAL REQUIREMENTS
Design, develop, manufacture, test, preserve, pack and furnish
with adequate packing to Purchaser Battery Chargers with all
accessories as per this Specification detailed hereunder
including a communication adaptor (SNMP – Simple Network
Management Protocol) as specified in Clause No. 11.9.8. and a
Programmable Controller as specified in Clause No. 11.9.9.
Each Battery Charger shall be supplied complete with all the
appurtenances and accessories as specified herein to form a
complete unit which will achieve and assure safe and reliable
operation of the system with the best overall performance. All
components supplied shall be of proven design.
2.2 Contractor's Firm Price will include all required components,
parts, accessories and instructions as they are necessary to
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achieve high reliability and good performance, in accordance
with the requirements of present specification and as they will be
delivered to the Purchaser. All the service prices, spare and
renewal parts price, as manufacturer's option prices, shall be
included in " Annexure C ".
IEC shall have the right to change the quantities of the items in
the second stage of the tender.
2.3 CONTRACTOR SERVICES
Contractor shall furnish, if requested by the Purchaser the
following services at the per diem rates per day as stated in the
proposal. The field personnel provided by the Contractor shall
be capable, qualified and able to perform the duties required to
the satisfaction of the Purchaser and shall be vested with
authority to make decisions binding on the Contractor.
2.3.1 Training – ITEM 3
Upon Purchaser's request, a Contractor's personnel shall assist
Purchaser's personnel, by conducting a thorough training,
including but not necessarily limited to correct start-up, safe
operation, safe shut-down and maintenance for all equipment
provided under this Specification. Contractor shall verify that the
operators are completely familiar with all phases of such
procedures and are capable of successfully operating the
equipment.
The training course shall be carried out over a period of five (5)
days for fifteen (15) persons from the Purchasers personnel. The
course shall take place in the Israel Electric company's training
school.
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In the first section of two day period, with the syllabus:
- General review of the battery charger.
- Start-up, safe operation, safe shut-down.
- Maintenance.
In the second section of three days period, with the syllabus:
- Internal setting, aiming and repairing.
- Software
- Calibration
- Maintenance of electronic boards level including practice.
3. DELIVERY, SHIPMENT, STORAGE
3.1 Contractor shall furnish the equipment free of expense, or charge, to the
Purchaser’s store of sites.
3.2 Contractor shall supply, free of charge, all packing material and transport
facilities to ensure safe transfers and storage.
3.3 The equipment package for shipment shall be so designed and carried out as
to prevent any damage to equipment during shipment and during prolonged
storage under the following climatic and environmental conditions:
3.3.1 Altitude not exceeding 1000m.
3.3.2 Ambient temperatures -5C to + 55C.
3.3.3 Severe atmospheric and industrial air pollution.
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3.3.4 Salt spray and/or sand dust.
3.3.5 Long dry periods.
3.3.6 Long periods of high humidity and rain.
3.4 Contractor shall state his own requirements for the storage of equipment for a
prolonged period under the climatic and environmental conditions described
under Clause 3.3.
3.5 Each shipping container shall have a packing list and in addition shall be
marked with the following information:
3.5.1 Descriptive name(s) of equipment or supplies contained.
3.5.2 Quantity packed in container.
3.5.3 Serial number.
3.5.4 Contract number.
3.5.5 Contractor’s name and address (city, state and country).
3.5.6 Gross weight of container.
3.5.7 Cubic volume of container.
3.5.8 Complete destination marking.
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4. STANDARDS AND SPECIFICATIONS
4.1 This specification is a general frame specification. The chargers shall comply
with an additional specification (“Charger Specification”) containing all the
required ratings and performances data.
4.2 The charger and charger components shall be manufactured and tested
according to the following standards (the latest edition):
- IEC-60146-1-1.
- IEC-61204, IEC-61000-3, IEC-60076-2, IEC-60981.
- EN-60529, EN-50272, EN-60898.
- DIN 41772, 41773, 41774.
- NEMA PE5.
- Standards Institution of Israel (SII) 165/1175
In any case of contradiction the requirements of this specification and charger
specification shall be binding.
4.3 The following standards/prescriptions of Israel Electric Co. are an integral part
of this specification:
- Painting requirements:
Specification No. 1400: Specification for electrostatic
painting of aluminum plates.
Specification No. 1500: Specification for electrostatic
painting of electrical cabinets or other equipment
constructed from mild steel.
- Control Cubicles Wiring Standard Specification: IEC NO. EPD-A.03
DATED 09/2004.
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- Quality system requirements for suppliers – ISO-9001:2008.
- General Specification for Industrial Rectifiers – IEC No. S-83/04/1.80
Dated 02.2004.
- Procurement Quality Requirements Q-APP-02 Rev. 4.
- Reliability, Maintainability and Safety Requirements.
- Name Plate Specification
4.4 In case the Contractor cannot meet one or more requirements of the above-
mentioned standards, he shall specify this in the tender.
4.5 Evaluation of Contractor's Technical Proposal
4.5.1 Contractor's offered data and parameters as well as definite answers or
comments will be evaluated from a technical point of view using an expert
computer program for decision making. The decision making process consists
of identifying all relevant criteria and attaching to each criterion an appropriate
weight for technical evaluation. All proposals (alternatives) made by different
contactors will be evaluated taking into account the same relevant criteria. The
computer program uses a pair wise comparison technique based on statistical
analysis to evaluate criteria importance and to rank alternatives (proposals).
4.5.2 The main criteria used for the technical evaluation are according to the main
paragraphs in this Specification as follows:
Electrical Data, Design and Construction, Tests Requirements, Maintenance
Requirements, Operating Experience (in the world and in Israel), Technical
support from Contractor. All sub clauses for which different contractors offer
different technical data will form the sub-criteria of the relevant main criteria.
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4.5.3 All sub clauses in this Specification indicated by the symbol © are compulsory
requirements. In case Contractor's proposal will not comply with one of the
compulsory requirements his offer will be disqualified.
5. TENDER DOCUMENTS
The Contractor shall present to the tender all the documents and
data required in Annexure “B” of Charger Specification, in four
(4) copies.
The Purchaser reserves for himself the right to reject an
incomplete quotation.
The following quality related documentations shall be submitted:
- A full description of Contractor's Quality Assurance Program.
- Certification of Approval of the Quality Assurance System
according to the ISO 9001:2008 Standard given by Israel
Standardization Institute or International Standards Institute.
- Design control Procedures.
- Qualification of Subcontractor's Procedure.
- List of qualified suppliers of the most important part and
Components.
- A general front view of the proposed Battery Charger.
- Prospects, leaflets, catalogues.
- All data of reliability (R.A.M)
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- A basic electrical diagram for the Battery Charger.
- Calculation of the life cycle (20 years) of the proposed capacitors, including
catalogs and graphs.
6. GENERAL APPROVAL OF TECHNICAL DOCUMENTATION
6.1 After notification of award, Contractor shall submit to the Purchaser for
approval, within 60 days of the date of award, four (4) sets of prints covering
the following information:
6.1.1 Mechanical drawings of the charger comprising outlines, front view of charger
with instruments location, front (and rear if necessary) view of charger with
open doors (covers) showing the component location, terminals and cable
entrances.
The distances required from the surrounding objects (equipment, walls) shall
be specified on the above-mentioned drawings in order to assure the correct
operation and maintenance of the charger.
6.1.2 Full set of detailed circuit diagrams, comprising all the charger internal circuits
(including printed circuit boards – PCB) and location of typical test points
6.1.3 A complete list of materials/items comprising all the electronic components,
transformers, chokes, capacitors, switches, instruments, terminals wiring, etc.
The list shall specify the type of the components, manufacturer and catalogue
number or drawings. Wiring insulation and canal shall be halogen free.
6.1.4 A general block diagram of the charger showing the main circuits and the
topical interconnection between the different parts.
6.1.5 Nameplates with all required data.
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All items shall be identified by the same notations used in both the electrical
diagrams and mechanical drawings.
6.1.6 Test report certification according to Appendix 3:
"I.E.C. Specification S-83/04/1.80"
6.2 The above-mentioned documents will be modified, if necessary, according to
Purchaser’s requirements. After the final approval, the Contractor shall submit
a C.D. (compact disk) of the approved drawings and documents.
6.3 One month before delivery of the first Battery Charger or disks, the Contractor
shall submit for Purchaser’s approval three (3) Instruction Manuals comprising
all the information as may be required for erecting, commissioning, operating,
testing and maintaining the charger.
Periodic test instructions shall indicate the measuring points and the
permissible range of the measured values.
The contractor will submit complete adjustment instruction.
The instruction manuals shall comprise all the approved drawings, as well as
the relevant catalogue leaflets (prospects) of the components recommended
spare parts list. After approval eight (8) instruction manuals shall be
submitted.
Each Battery Charger will be supplied with his own Instruction Manual and
Drawings during delivery.
6.4 Quality Assurance documentation
Quality Assurance manual (4 copies) including a full description of
Contractor's Quality Assurance program:
THE ISRAEL ELECTRIC CORPORATION LTD. Engineering Projects & Business Development SPEC: STR-1416 Engineering Division Substation Planning Sector
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- Certification of Approval of the Quality Assurance System according to
the ISO 9001:2008 Standard given by Israel Standardization Institute or
International Standards Institute.
- Design control Procedures.
- Qualification of Subcontractor's Procedure.
- List of qualified suppliers of the most important part and Components
6.5 Quality Control Documentation
6.5.1 Inspection and Tests plan according to Appendix 4 Procurement Quality
Requirement Q-APP-02 REV.4.
6.5.2 Quality Control Procedures.
6.5.3 The following documentation:
- Electrical Testing Procedures as per applicable Standards.
- Non Conformance's and Deviation Control Procedures.
- Certificates of Electrical Tests, according to this Specification.
- Inspection and Test Report.
6.6 The Purchaser reserves himself the right to reject equipment not
manufactured according to approved drawings.
6.7 All data and descriptive material in the above drawings and instructions books
shall be in English. All dimensions shall be shown in international system of
units (S.I.).
6.8 Contractor shall complete engineering details immediately after award of
Contract, regardless of delivery date.
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6.9 The serial number of the equipment shall be clearly labeled on all items. In
addition, the packaging shall contain the serial numbers of all included
equipment in said package. The shipping documents shall contain the serial
numbers of all equipment in said shipment.
7. QUALITY ASSURANCE AND QUALITY CONTROL
7.1. The Contractor's quality Assurance Program shall meet the requirements
described in ISO Standard 9001:2008
7.2. The Purchaser shall have the right to audit and comment on Contractor's
Quality Assurance System regardless of whether it was previously audited by
a certifying agency or any other body.
7.3. The Contractor shall be responsible for assuring that his subcontractor's
Quality Assurance/Quality Control Programs, including their organizations,
procedures, personnel qualification etc., are approved and are consistent with
the specific requirements imposed by the Purchaser in the Specification.
7.4. The Contractor shall submit with his proposal a preliminary Inspection and
Test Plan (I & T Plan).
7.5. A mutually agreed inspection point plan, including witness and points, shall be
agreed between the purchaser and the Contractor. Any subsequent
alternation to this program shall require the Purchaser's agreement, prior to
start of any work affected by these alterations.
7.6. Test and Inspection certificates as required in the Specification and the
applicable Standards, shall be submitted immediately following their
generation. The certificates shall be original, signed by the Contractor, and
contain actual measured values.
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The generation of certificates, including those generated by Subcontractors
and sub-suppliers, shall bear no extra cost to Purchaser.
7.7. Any equipment non-conformance to drawings, specifications or other
purchase order requirements which are considered by the Contractor as
"acceptable as is" or for "repair", shall be submitted to the Purchaser for
approval, with their recommended dispositions. All such non-conformances
shall be approved by the Purchaser, shall be documented, and a copy of the
approval shall accompany each shipment.
7.8. All materials used in the manufacture of the equipment shall conform to the
Specification, approved drawings and accepted Standards.
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8. TESTS
8.1 The Purchaser will have the right to demand acceptance tests at the
manufacturer's facility with a representative of the Purchaser being present.
The acceptance test results will be considered an integral part of the
equipment delivery.
8.2 Prior to the Contract signature, Contractor shall propose a meaningful set of
Factory Acceptance Tests as Field Acceptance Tests. The Purchaser and the
Contractor shall agree upon these sets of tests, which after the contract
signature, will become part of the contract requirements. These tests shall be
done for two first Battery Chargers. Any changes, after the Contract
signature shall be by written agreement only.
8.3 The stages for the test shall be as follows:
- The Contractor shall submit documents such as process procedures and
test procedures to the Purchaser for review, comment and approval.
- The Contractor shall perform the test after receiving from the Purchaser all
the comments and approval to the documents.
- The Contractor shall submit the test results to the Purchaser that the
Charger complies with the Specification requirements.
- The Purchaser shall check the charger in Contractor's site.
8.4 The test shall be performed as close as possible to real service
conditions.
The test shall be performed according (but not limited) to relevant Clauses of
IEC 60146-1-1, Section 7: Test for valves device assemblies and convertor
equipment and to Purchaser’s requirements mentioned in Clause: 4.3 and
according to I.E.C. Specification No. S-83/04/1.80
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The temperature and stability test will be performed for 24 hours.
The load test will be performed with the required rated voltage and the current.
The load will be of a resistance type.
The test will be performed continuously for a period of at least 24 hours.
The load test shall check the relevant points of the normal service and boost
charge operating characteristics (EVK-6375) including the short circuit
condition. The test shall be performed by Contractor and test certificate shall
be submitted for Purchaser approval.
The charger functions shall be tested with batteries 220V, 150AH for
220V/30A charger, with batteries 220V, 500AH for 220V/100A charger.
The Contractor shall prove that he has all the necessary equipment to perform
the test.
Only after the test is approved by Purchaser (this includes drawing approval,
quality control approval and test approval), Contractor may proceed to
manufacture the rest of the ordered chargers. The required test of the first unit
is not necessary if Contractor can submit a test certificate for a similar unit.
The tested unit shall have the same rated voltage and the same rated current
of the proposed charger.
All the components of the tested unit (rectifier bridge, main transformer,
capacitors, automatic control) shall be of the same type and same
manufacturer as for the proposed charger.
The Purchaser reserves the right to verify the compliance of the delivered
items with this specification. Delivery which will not pass acceptance test will
be rejected.
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8.5 The purpose of the above tests is two fold:
a. To demonstrate that the delivered equipment answers to the requirements
of the Specification.
b. To expose any design or manufacturing flaws.
At the factory, two complete Battery Chargers, shall be assembled and tested.
The first set of Battery Chargers tests is for steady-state performance; it shall
be conducted for variation of load, Line Voltage, D.C. voltage, power factor,
frequency and temperature.
The second set of tests is for dynamic performance, such as for tripping the
D.C. input power line, short circuiting the output terminals and fuse clearing.
Output voltage deviation will not be more than 3.6% of rated value even for
fast dynamic changes of the load in full range.
The final set of tests shall represent the reliability by operating the Battery
Charger without failure for a time and loading schedule to support the MTBF
predictions and the Gamma-Percentage Operating Time to Failure indicator.
At the site, the system shall be re-tested to check damage or failure due to
packing and/or shipping and for operation with the actual switchgear as
follows:
1. The factory steady-state performance test shall be repeated, using the two
AC power suppliers.
2. Part of the factory dynamic tests shall be repeated to check the switching
operation of the system.
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3. The system shall be run with a dummy load for an extended period (3
hours) as a final Acceptance Test.
8.6 Routine test:
Contractor shall perform and submit routine test reports for Battery Charger
specifying the relevant Standards, Norms, Recommendations, etc. to prove
that Battery Charger have the capability to meet all the ratings as specified,
after receiving from the Purchaser all the comments and approval to the
documents.
Routine tests shall be performed according to relevant clauses of I.E.C. 60146
PT1-1 section 7.1.3 table 13 "Routine tests" and Purchaser’s requirements
mentioned in Clause 4.3
The routine test shall be performed at Contractor's laboratory in presence of
the Purchaser's staff.
8.7 Contractor shall submit a list of all tests to be performed on site, after
mounting of the Battery Charger to the approval of the Purchaser.
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9. NAME PLATES & MARKING
All the equipment items are to be provided with name plates. The name plates
content and installation mode should be according to Appendix No. 6.
In addition Each internal modules of the charger will be marked with a serial
number.
10. SPARE AND RENEWAL PARTS
10.1 The Contractor shall include in its technical proposal a catalogue
containing all relevant potential Spare Parts for the proposed
Equipment as well as propose a detailed list of Spare Spares
recommended for:
10.2 The catalogue and the lists shall include:
- Description and designation for blocks and printed cards.
- Name of supplier and manufacturer.
- Necessary catalogue data for separate order.
- Optimal stocking level of PC boards.
- If the supply is from stock or by manufacturing after order.
- Lead time before supply (including transport time to Israel).
See columns below.
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PROVISION OF THE CATALOGUE AND THE LISTS, AS
WELL AS ANY AMENDMENTS THERETO AS MAY BE
REQUIRED BY PURCHASER, IS A CONDITION TO THE
EVALUATION OF THE TECHNICAL PROPOSAL. FAILURE
TO PROVIDE SAME SHALL ENTITLE PURCHASER, AT
ITS SOLE DISCRETION, TO DISQUALIFY THE
PARTICIPANTS.
10.3 The Contractor shall identify the materials and items which have
critical effects on the System’s reliability and items that required
special maintenance treatments.
10.4 Purchaser shall review the catalogue and the lists of
recommended Spare Parts during the technical clarifications.
10.5 Upon Purchaser’s demand, each participant shall be required to
provide to Purchaser amended lists and catalogue, as part of its
final technical offer.
10.6 After Contract execution and during the drawing approval
process, the Contractor shall provide Purchaser with the
following details regarding each item in the catalogue:
a. Identity of manufacturer (if not previously known);
b. Supplier’s part number;
c. Manufacturer’s part number;
d. Name of recommended alternate supplier and part number;
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e. Detailed description of each item as required for ordering (if not previously
provided);
f. Whether the part is repairable or not;
g. Storage instructions for spare parts.
h. MTBF - meantime between failure.
i. Gamma-Percentage Operating Time to Failure.
j. MTTR - meantime to repair.
The above information shall be transmitted to Purchaser as a
computer data base allowing for easy searches.
10.7 All Spare Parts shall be new and unused in all cases.
10.8 The Purchaser reserves the right to purchase said parts directly
from the manufacturer or from another sub-supplier.
10.9 The Contractor warrants that spare and renewal parts shall be
available for at least twenty (20) years for the equipment
supplied under this Contract.
10.10 The Contractor guarantees that all the Spare Parts features will
be according to its catalogue and that the catalogue is
periodically updated to stay current.
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10.11 SPARE PARTS
Bidder shall give here, a list of recommended spare parts according to clause
10 for one Battery Charger with price quotation.
The part number and technical description shall be specified for each quoted
item.
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Name of Bidder_______________
Table No. 1: Spare Part List until end of warranty.
Spare Part
Name & No.
Producer’s
Name
Spare Part
Purpose
Probability
of Failure
Technical
Data
Is it in
stock (Y/N)
Supply time
after ordering
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11. DETAILED SPECIFICATION
11.1 Service
The charger will be connected to the D.C. system of an unattended substation
or switching station, and operate continuously (24 hours per day) according to
diagram EVK-6374 & EVK-7212. During the service the charger shall meet
the operating requirements mentioned in clause 11.6 of this specification.
11.2 AC System Data
The charger will be supplied from the main AC distribution of the substation.
The supply voltages are either:
3 x 400V 10% (three phase)
Total Harmonic Distortion (THD) in main voltage up to 5 %.
Frequency may vary between 48.5 – 50.5 Hz. The AC short circuit current at
chargers supply terminals is 10KA.
11.3 Charger Ratings
Charger main ratings and the AC system data will be mentioned in charger
nameplate.
11.4 Environmental Conditions
The charger will be installed in ventilated rooms of a switching station or
substation.
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Ambient temperature range: -5 to +40C. The average relative humidity is
equal to or less than 75% and for 30 days the relative humidity can reach
95%. Altitude not exceeding 1000m above sea level.
11.5 EMC Compatibility Requirements
11.5.1 Insulation Resistance
>100 MOhm at 500 V, during 5 sec minimum:
- between all terminals (except earth terminal) connected together and the
case (earth terminal).
- between terminals of independent circuits including contact circuits.
- across the open contacts of the all circuit breakers and output (signaling)
relays.
11.5.2 Dielectric withstand
According to IEC 60664-1:
- 2kV r.m.s., 50 Hz, 1 minute between all input and output terminals (except
earth terminal) connected together and the case (earth terminal).
- 2kV r.m.s., 50 Hz, 1 minute between all input and output terminals of
independent circuits.
- 1kV r.m.s., 50 Hz, 1 minute across the open contacts of the circuit breakers
and signaling relays.
11.5.3 High voltage impulse
According to IEC 61439-1 and IEC 61180-1, III overvoltage category
Three positive and three negative impulses at interval of 5 sec: 4.8 kV peak,
1.2/50µs, 0.5J .
- between all input and output terminals of independent circuits (except output
relay contacts).
- between all input and output terminals of independent circuits and case (earth
terminal).
11.5.4 Overvoltage
According to IEC 60664-1 basic and supplementary insulation in charger shall
withstand:
- short-term (during 5 sec) temporary overvoltage of UN + 1200V . - long-term (longer than 5 sec) temporary overvoltage of UN + 250V .
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11.5.5 Power supply (dips) interruption
According to IEC 61000-4-11, class 3, criteria acceptance B
The charger must withstand interruption (U= 0% UN) and dips (U= 40% UN ; U=
70% UN) in the auxiliary supply, under normal operating conditions, without
change of operating state, de-energizing and losses of data during the test, but
degradation of performance is allowed:
U= 0% UN – during 20 ms;
U= 40% UN – during 200 ms;
U= 70% UN – during 500 ms.
11.5.6 High frequency burst disturbance
According to IEC 61000-4-12, level 3, criteria acceptance A:
- 2.5kV (peak), 1 MHz for common-mode test between independent circuits and case (earth). - 1.25 kV (peak), 1 MHz for differential (transverse) test across terminals of the same circuit (except metallic contacts and communication port). - 1.25 kV (peak), 1 MHz for common mode for communication port.
Test duration 2 s, 6-10 bursts per period of power supply frequency.
11.5.7 Fast transient/burst immunity
According to IEC 61000-4-4, level 4, criteria acceptance A
Common-mode test between each independent circuits and case (earth):
- 4 kV (peak) for input/output circuits and internal auxiliary power supply. - 2 kV (peak) for communication ports.
Repetition rate during burst 5 kHz; Burst period 300 ms, Burst duration 15 ms.
Test duration 1 min, each polarity.
11.5.8 Surge immunity test
According to IEC 61000-4-5, level 4, criteria acceptance A
- 4 kV (peak) for common-mode test between each independent circuits and case (except communication port). - 2 kV (peak) for differential (transverse) test across terminals of the same circuit (except communication port).
The test wave shape: 1.2/50 µs voltage pulse.
11.5.9 Immunity to radiated electromagnetic energy
According to IEC 61000-4-3, level 3, criteria acceptance A:
The frequency range is swept from 80 MHz to 800 MHZ with the signal 80%
amplitude-modulated with 1 kHz sine wave, field strength 20V/m
Spot frequencies: 80, 160, 450 and 800 MHz
11.5.10 Immunity to conducted radio frequency interferences
According to IEC 61000-4-6, level 3, criteria acceptance A:
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- 10 V (r.m.s) for frequency 150 kHz to 80 MHz with amplitude modulated by frequency 1 kHz at 80% sine wave. 11.5.11 Power frequency magnetic field immunity
According to IEC 61000-4-8, level 5, criteria acceptance A
- 100 A/m applied continuously.
- 1000 A/m applied during 3 s.
11.5.12 Pulse magnetic field immunity
According to IEC 61000-4-9, Class V, criteria acceptance A
1000A/m, waveform 8/20 µs, 5 positive and 5 negative pulses every 10 s.
11.5.13 Damped oscillatory magnetic field immunity
According to IEC61000-4-10, Class V, criteria acceptance A
100A/m for frequency 100kHz and 1MHz with a burst duration of 2 s, applied in
all planes.
11.5.14 Radiated immunity from digital communications
According to IEC 61000-4-3, level 4, criteria acceptance A
Test field strength 30 V/m at frequency band 800 to 960 MHz and 1.4 to 2.0
GHz with the 80% amplitude-modulated signal, 1 kHz.
11.5.15 Electrostatic discharge test (ESD)
According to IEC 61000-4-2, Class 4, criteria acceptance A:
- 8 kV – contact discharge
- 15 kV discharge in air to user interface, display and exposed metalwork
Class 3, criteria acceptance A :
- 6 kV discharge in air to all communication ports;
11.6 Operating Characteristics
The operating characteristics of the charger shall be IU-type according to
standard DIN 41773.
11.6.1 Normal Service – (Floating charge)
The charger is connected in a floating (trickle) charge mode. It supplies the
load current and charges the battery simultaneously with the maintenance
charging current, thus maintaining its full capacity available. The voltage is
maintained constant ( 1%).
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The current limitation must be 30A and 100A respectively.
On AC supply failure, the battery takes over the supply of the load without
break. On restoration of the AC supply, the charger takes over the load and
charges the battery with the difference between charger rated current and
load current. The current supplied by the charger to the load and battery shall
be limited to the rated current of the charger ( 2%), regardless of the
discharging degree of the battery.
The transients occurring upon the AC supply restoration (inrush currents,
current spikes etc.) shall by no means affect the charger operation, even in
the case of an extremely short supply interruption.
When the charger reaches the preset floating voltage, it starts to operate with
the constant voltage characteristics. The current will decrease until the full
capacity of the battery is restored.
The required operating characteristic appears in drawing EVK-6375.
Means of inrush current limitation will be provided.
The charger shall be stable at any point of the operating characteristic.
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11.6.2 Equalizing Charge
An internally mounted manual selector switch shall permit change over to the
equalizing charge mode of operation.
The operating characteristic of the equalizing charge will be IU characteristic,
as in float mode but with different voltage.
The Contractor is to take this into effect and supply the necessary control
circuit and connection terminals.
In case of AC failure the charger shall return to float charge mode.
In case of load changes all M.C.B. and C.B. will not be affected by the
transformer inrush current.
All the operating characteristic shall be according to DIN 41773.
The required equalizing charge characteristic, as well as its parameters will be
mentioned in charger specification and the list of compulsory requirements.
Equalizing charge (2.4V per cell) intended to bring all the cells to equally
charged condition. Equalizing charge requires low current limit value (5-7 A
per every 100 Ah of a battery).
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11.6.3 Boost Charge
An internally mounted manual selector switch shall permit change over to the
boost charge mode of operation.
1. The operating characteristic of the boost charge will be
IU characteristic, as in normal service, but with different parameters.
2. A boost charge mode operation requires the operation of the exhaust fans
in the battery room.
When the exhaust fans power supply circuit will interrupt, the charger will pass
automatically to the floating charge mode with the last adjusted values.
Change-over will be initiated by the boost charge blocking relay connected in
the exhaust fan circuit. Return to boost mode may only be carried normally by
an operator.
The Contractor is to take this into effect and supply the necessary control
circuit and connection terminals.
In case of AC failure the charger shall return to float charge mode.
In case of load changes all M.C.B. and C.B. will not be affected by the
transformer inrush current.
All the operating characteristic shall be accordin/g to DIN 41773.
The required boost charge characteristic, as well as its parameters will be
mentioned in charger specification and the list of compulsory requirements.
The charger will include a timer that can be set ahead to switch from boost
charge to float charge.
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Current limitation in a BOOST mode will be half of float mode value.
11.6.4 Transient Behavior of the Charger
The speed at which the charger reacts to sudden load changes is very
important to the correct behavior of the charger in the DC system. After a
sudden load change including short circuits, the current and voltage shall
return to the values of the operating characteristics within 200ms, and within
the range of 94% to 106% of voltage setting.
11.6.5 Start-up behavior
In all working modes the output voltage shall not exceed 106%.
Start-up amplitude of AC current shall not exceed the value of 2 x In nominal
current.
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11.7 Mechanical Design Requirements
11.7.1 General
11.7.1.1 The charger shall be designed as a steel cubicle, mounted over cable
channels, 30 to 40cm wide, or on floating floors. Similar cubicles may
be mounted on both sides.
11.7.1.2 All the ventilation openings shall be front located. The cable will enter
the charger from below through cable glands. The quantity and cross
sectional area of cables will be mentioned in charger specification. The
cubicle shall be provided with profile to attach the ingoing and outgoing
cables.
11.7.1.3 The Battery Chargers, delivered under this Contract shall consist of free
standing, floor mounted Cabinet, made of welded steel frame work,
steel frontal doors and panels, heavy duty industrial constructed. Doors and
panels shall be of at least 2 mm steel; frame work shall be of at least 3 mm,
steel. Plates smaller than 600 x 600mm may be manufactured from
1.5mm steel plates.
11.7.1.4 No ventilation openings shall be located on cubicle top unless protected by an
additional cover (roof).
The ventilation of the unit will be by natural ventilation only.
11.7.1.5 Control switches shall be located on the front panel, not higher than 1800 mm
or lower than 600 mm. For measuring instruments the mounting heights shall
be between 800/1200-1800 mm.
11.7.1.6 The cubicle shall be protected against splash water, 600mm from the floor.
The cubicle shall be provided with appropriate lifting hooks for transport. The
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cubicles shall be cleaned and painted according to Purchaser’s standard No.
1400, No. 1500 as specified in Annexure 1.
11.7.1.7 The charger shall be IP23 degree of protection according to IEC60529.
11.7.1.8 The Battery Charger and control systems shall be in modular construction for
ease of maintenance and to minimize downtime. They will be reinforced in
such a manner that they will provide adequate rigidity and strength to
withstand all stresses which can occur during transportation, installation,
testing and operation, without any distortion or damage of the cabinets or
components mounted inside the cabinets.
11.7.1.9 All chargers modules shall be of the draw-out type, removable from the front
of the Battery Charger.
11.7.1.10 The Battery Charger shall permit easy access to modules and assemblies for
control and maintenance. They will permit easy checking, adjustment or
maintenance without the removal of any adjacent module or assembly.
The Battery Charger Cabinet shall have all instruments, status indicators, and
controls placed easily visible to the operator. All warning labels shall be
clearly visible when any of the cabinet doors are open.
Easy access to terminal blocks shall be provided. Separating plate between
terminals for different voltages or functions shall be provided.
11.7.1.11 Cable entrances into the Battery Charger cabinet shall be done on the bottom
side of the cabinet, through removable plate, with cable glands supplied by
the Purchaser.
Necessary framework and brackets for fixing the cables into the cabinets will
be supplied by the Manufacturer.
All the wiring and cables shall be installed in cable ducts.
11.7.1.12 Copper ground bus, of at least 50mm² shall be installed in each power line
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bounded or bolted to the structure. All metallic parts of electrical components,
normally not under voltage, but which can assign voltage as result of a trouble
should be grounded to this ground bus. The ground bus shall have two bolts
for Purchaser's ground cables' connections, each at least 50mm².
11.7.1.13 Access to the electrical equipment mounted in the cabinets shall be made, on
front side, through 3 points latched doors, made with stainless steel hinges,
easily removable from their mounting places, lockable with two sets of keys.
Purchaser prefers cabinets which need only front access, with the conditions
that the Battery Charger unit overall dimensions will be indicated by
Purchaser during approval of the drawings.
11.7.1.14 All screws and mounting devices used for fastening equipment and
nameplates, inside/outside the cabinets shall be of rustproof type.
Screws shall not penetrate outside faces of the cabinet/s.
11.7.1.15 Indicators LEDs denoting abnormal conditions shall be readily observable by
operator without removing panels or opening cabinet/s doors. Power circuit
breakers shall be actuated preferable from front side without opening
cabinet's doors.
11.7.1.16 All status, alarm and instrumentation displays shall be arranged on a single or
more frontal panels, easily visible and accessible to a person standing on the
floor. All factory adjustments or non-operator controls should be located
behind the lockable cabinet/s doors. All alarms and signals shall be remotely
indicated by Potential Free contacts of output relays.
11.7.1.17 The Battery Charger shall have a modular construction, permitting easy and
fast maintenance. Replacement of the faulty module will be possible only
operating connectors and screws, without use of soldering. The
replacement shall be done only through the frontal door/s of the cabinet.
11.7.1.18 Painting of the furnished equipment shall be done in accordance with the
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Purchaser's Standard attached to this specification (appendix No. 1).
11.7.1.19 The enclosure of the Battery Charger shall be grounded.
11.7.1.20 In general internal wiring shall be performed in accordance with enclosed
EPD-A.03-Standard (see Appendix No. 2).
11.7.2 Mechanical Requirements to Internal Control and Protection Circuits and
Modules of Charger:
11.7.2.1 Vibration
IEC 60255-21-1, class 2
- Vibration response (energized): sinusoidal; frequency 60 to 150 Hz;
acceleration 1g; sweep rate 1 octave/min; 1 cycle in 3 orthogonal directions.
- Vibration withstand (de-energized): sinusoidal; frequency 60 to 150 Hz;
constant acceleration 2g; 40 cycle in 3 orthogonal directions.
- Vibration during transportation: 2 g in each of three mutually perpendicular
axes swept over range of 10 to 500 Hz for a total of six sweeps, 15 min each
sweep, without structural damage or degradation of performance.
11.7.2.2 Seismic
IEC 60255-21-3, level 2, criteria acceptance A
- X- and Y-axes: 3g, 11 mm, 1 – 50 Hz
- Z-axis: 2g, 7.5 mm, 1 - 50 Hz
11.8 Electrical Design Requirements
11.8.1 The charger will be based on a full wave, thyristor controlled rectifier,
connected through an isolating transformer, to the AC supply.
A solid state control system shall provide the rectifier with the required
characteristic. The rectifier shall be protected by automatic circuit breaker with
appropriate characteristics.
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11.8.2 A filtering and smoothing system shall assure that the ripple of the output
voltage measure at the output terminals will be:
a. 0.2% of the output r.m.s voltage with battery connected.
b. 1% of the output r.m.s voltage without battery connected.
11.8.3 Appropriate filtering or other means shall prevent voltage disturbances being
fed by the charger to the AC system.
11.8.4 Interference suppression devices and filters shall be provided in order to limit
the electromagnetic interference voltage levels from charger to power system
and from power system to charger.
11.8.5 Acoustical Requirements:
The maximum noise level at 1m distance shall be no more than 55dBA.
The noise test will be performed with the rated voltage and current, at full load.
11.8.6 The charger shall be natural air-cooled. The temperature rise of any
component shall be a maximum of 55 C above ambient temperature,
according to Clause 11.4 (-5 to +40 C).
Exceptions will not be permitted even if the components have an insulation
class which permits higher temperatures.
If the heat dissipater of the thyristor controlled rectifier bridge reaches the
temperature of 95ºC, the Battery Charger's main switch shall be tripped and
an alarm shall be provided by a N.O. dry contact in addition to indicator lamp
(led) in the front panel.
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11.9 Charger Components
The charger shall include (but not be limited to) the following components:
11.9.1 Insulating Transformers and Reactors
The transformer shall comply with the requirements of IEC 60146 PT 1-3. The
transformer core shall be of low losses steel sheets.
The transformer winding must be made with Class "F" wiring insulation (at
least, or better).
The Insulating Transformer's external maximum temperature T=85ºC. The
measuring can also be done with Infrared Thermometer.
The electronic parts maximum temperature T=70 ºC.
11.9.2 Rectifier Bridge
Max. voltage of SCR must be not less than 1200 Volt.
Rectifier Bridge must be equipped with overvoltage protected elements.
The rectifier bridge shall be of full wave type, thyristor controlled, for three
phase supply. The heat sink of the bridge shall be of the cast or rolled
aluminum type, as originally supplied with the bridge. Maximum allowable
temperature of the heat sink is 85ºC.
Heat sink must be protected from over temperature by thermo switch
connected to control circuit.
11.9.3 Electrolytic capacitors for DC filters
The capacitors shall be Heavy Duty Type, industrial grad at the temperature of
105 C at least and designed to operating life of 20 years at the temperature
of 40 C.
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ESR (Equivalent Series Resistance) of output filtering electrolytic capacitor
must be not more than 45 mOhm at 100 Hz and 20 C, maximal working
temperature 105 C. These capacitors must be suitable for use with high
ripple current and manufactured by world known manufacturers, such as
EPCOS, Vishay, KEMET, Nippon Chemi-Con, BHC Aerovox, Hitachi AIC.
A catalog shall be added to each kind of capacitor.
The Bidder shall include the calculations for capacitors to be chosen.
The calculations shall be also for life time at work without battery.
DC Filter
The filter capacitors (electrolytic capacitors) shall have not less than 400VDC
rated voltage.
AC Filter
The AC filter capacitors (non-electrolytic) shall have not less than 630VAC
rated voltage.
11.9.4 Main Circuit Breaker and Molded Circuit Breaker
The charger shall be equipped with at least the following M.C.B.’s and
according to IEC 60898.
- AC input M.C.B., at least 10KA, ultimate switching capacity with N.C.
auxiliary contact for alarm.
- DC output C.B., 15KA switching capacity with N.C. auxiliary contact for
alarm.
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- C.B. of suitable characteristic (Z characteristic) for main diodes (thyristor)
overload protection and for bridge protection.
- The main AC input and DC output C.B.’s shall be operated from inside the
cubicle.
- The bidder shall include a tripping characteristic curve of each type of C.B.
11.9.5 Control Circuits
Electronic control circuits and assemblies must be suit to requirements of
standards IPC-A-610, IPC-A-620 and IPC-TM-650.
Boards will be protected by transparent perspects.
11.9.6 Measuring Instruments
The measuring instruments should not be part of the controller or the Display
Panel.
11.9.6.1 Output DC Digital Voltmeter
a. Size: 96 x 48mm (at least).
b. Accuracy: 1% accuracy from reading value.
The resolution need to be accurate to one
digit after the decimal point.
c. Operating temperature: -5 C to 40 C
d. Digits: Four and half (4.5) digits measuring for 220V DC.
11.9.6.2 Output DC Digital Ammeters
a. Size: 96 x 48mm (at least).
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b. Accuracy: 1% accuracy from reading value. The resolution need to be
accurate to one digit after the decimal point.
c. Operating temperature: -5 C to 40 C.
d. Digits: Four (4) digits measuring 100A and three (3) digits measuring for
30A.
11.9.7 Control
The charger shall be provided with the following controls:
- A three position selector switch for float operation or equalizing charge
operation or boost charge operation (internally mounted), or three push
buttons for operating mode of operation.
The charger shall have potential free contacts, for charging mode
indication (one contact for each mode).
The Charger shall have one potential free contact, closed in boost charge
position, for customer’s use.
- Voltage regulating knob locked type or push buttons for floating charge
operation (internally mounted).
- Voltage regulating knob locked type or push buttons for boost charge
operation (internally mounted).
In case of use of push buttons the manufacturer will supply two pushbuttons
for each operation to insure double action for operation.
- A 220VAC, 16A socket including an earth leakage relay shall be installed
in the cubicle for auxiliary uses.
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11.9.8 COMMUNICATION
11.9.8.1 All the Battery Charger shall be provided with a communication adaptor
(SNMP-Simple Network Management Protocol) to transfer all needed data
such as System Parameters, history of events, identification and diagnostic, to
the dispatch center or client by using TCP/IP communication protocol with
MIB's standard. The SNMP adaptor is connected to Ethernet networks using
standard communications cables. There will be no possibility of shut-down or
change of parameters from remote station.
11.9.8.1.1 SNMP Module
Using the SNMP module, the Battery Charger is seen as a network device in
the WAN or LAN applications, and with this way it can be monitored more than
once. Battery Charger will be connected to the network through site
monitoring program which will allow monitoring of 40 systems Battery Charger
or more from one PC. It will not be possible to shutdown change parameters
of the servers or users with Client mate Software that communicates with
SNMP module. SNMP software installation is described as follows:
11.9.8.1.2 SNMP Software
Battery Charger will be equipped with SNMP agent. The SNMP Agent should
be configured properly and Battery Charger Management software should be
installed in the monitoring computer. The SNMP Agent will be supplied with
software CD which contains the following programs and tools:
a. SNMP Agent Operating manual in PDDF format.
b. Configuration utility for SNMP Agent IP address and firmware
upgrade.
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c. SNMP monitoring soft ward – Battery Charger management
software for multi-system Agent environment in Windows operating
systems.
d. Battery Charger MIB – MIB Management Information Base
definition file for SNMP management console.
e. Time Server – Time calibration program for SNMP Agent.
11.9.9 Programmable Controller
The Programmable Controller will be of known manufacturer and type.
Function of the programmable controller:
11.9.9.1 Operation, supervision and indication in accordance with the functions of the
charger.
11.9.9.2 Control all operations of the battery charger.
11.9.9.3 Able to be connected to a portable personal computer and supplied with PC
based GUI (Graphic User Interface) Windows supported.
11.9.9.4 Able to be controlled from a remote control center by using TCP/IP and
communication line with a friendly protocol.
11.9.9.5 Able to transmit to the control center the read parameters, trouble, alarms.
11.9.9.6 The programmable controller operation modes shall be:
11.9.9.6.1 - Float charge
- Equalizing charge
- Boost charge
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11.9.9.6.2 In case of programmable controller failure, the control functions will be held by
internal controller PCB without charger interruption.
11.9.9.6.3 If, prior to programmable controller failure, charger was in equalizing/boost
mode, it will be switched to the float mode.
11.9.9.7 Technical characteristics of the Programmable Controller.
11.9.9.7.1 The programmable controller shall be connected to the charger and shall have
a memory at least for 500 events.
11.9.9.7.2 The programmable controller shall be supplied with at least with 20 inputs and
20 outputs in accordance with the requirements of the battery charger.
11.10 Alarms
The charger shall be provided with the following alarms:
11.10.1 Open of each circuit breaker.
11.10.2 Boost charge.
11.10.3 Float charge.
11.10.4 Equalize charge.
11.10.5 Low output voltage.
11.10.6 Over temperature (95ºC on the tyrstor heat sink).
11.10.7 Over and under input AC voltage and phase failure.
11.10.8 High output voltage.
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11.10.9 Current limit.
11.10.10 P.C. failure.
11.11 Labeling
All the charger components, cables/wires and their connections shall be
clearly labeled for easy identification.
The front mounted components shall be labeled with sandwich type labels,
5mm high black letters of white background.
The labels shall be in Hebrew or English. Internally mounted components and
wiring shall also be labeled. The labeling technique is according to
manufacturer’s decision, but shall get Purchaser’s approval.