GENERAC ELECTRIC POWER SYSTEM SPECIFICATION FOR MODULAR POWER SYSTEM (MPS) TYPICAL NATURAL GAS SYSTEMS 350

1000 kW TOTAL OUTPUT w/SYSTEM CONTROLLER NOTE: Paragraphs 2.1.1, 2.2.1, and 3.2.1 require editing. The author should select or add ratings to meet the specific application. Delete this and any other unneeded text. 1. GENERAL 1.1. DESCRIPTION OF SYSTEM 1.1.1.Provide an integrated standby modular power system (MPS) to supply electrical power in event of failure of normal supply, consisting of liquid cooled engines, AC alternators and system controls with all necessary accessories for a complete operating system, including but not limited to the items as specified hereinafter. 1.1.2.The MPS shall be expandable up to five (5) generator sets in a 150kW and 200 kW per generator set configuration. 1.1.3.Provide an automatic transfer switch described elsewhere in this specification so that the system comes on-line automatically in the event of a utility failure, and on restoration of utility power automatically re-transfers load to normal power, shuts down the generator system and returns to readiness for another operating cycle. 1.2. REQUIREMENTS OF REGULATORY AGENCIES 1.2.1.An electric generating system, consisting of prime movers, generators, governors, coupling and all controls, must have been tested, as a complete unit, on a representative engineering prototype model of the equipment to be sold. 1.2.2.The transfer switch must be UL listed for use in emergency systems. 1.2.3.The generator set must conform to applicable National Electrical Code and applicable inspection authorities. 1.2.4.The generator set must carry the Underwriters Laboratories listing as a stationary engine generator assembly 1.3. MANUFACTURER QUALIFICATIONS 1.3.1.This system shall be supplied by GENERAC or an approved equal who has been regularly engaged in the production of engine-alternator sets, automatic transfer switches, and associated controls for a minimum of fifteen years, thereby identifying one source of supply and responsibility. 1.3.2.To be classified as a manufacturer, the builder of the generator set must manufacture, at minimum, engines or alternators. 1.3.3.The manufacturer shall have printed literature and brochures describing the standard series specified, not a one of a kind fabrication. 2. ENGINE-GENERATOR SET 2.1. Engine 2.1.1.Each of the (2) (3) (4) (5) prime movers shall be a liquid cooled, natural gas fueled, turbo charged, after cooled engine of 4-cycle design. It will have a 6 cylinder block with minimum displacements of 13.3L (811 cu. in.), with a minimum standby rating of 168 psi (BMEP). Each unit requires a minimum rated output of 200 kW at an operating speed of 1800 RPM for a total system rating of (400) (600) (800) (1000) kW.

2.1.2.Each engine is to be cooled with a unit mounted radiator, fan, water pump, and closed coolant recovery system providing visual diagnostic means to determine if the system is operating with a normal engine coolant level. The radiator shall be designed for operation with 140 degrees Fahrenheit, 60 degrees Celsius air on radiator. 2.1.3.The intake air filter with replaceable element must be mounted on each unit. A positive displacement lube oil pump shall supply full pressure lubrication. Each engine shall have a replaceable oil filter with internal bypass and replaceable elements. Engine coolant and oil drain extensions, equipped with pipe plugs, must be provided for drainage outside of the mounting base for cleaner and more convenient engine servicing. A fan guard must be installed for personnel safety. 2.1.4.Each engine shall have a battery charging DC alternator with a transistorized voltage regulator capable of maintaining battery charge and supplying parasitic DC loads. Remote 2-wire starting shall be by a solenoid shift, electric starter. 2.1.5.Engine speed shall be governed by a digital electronic governor to maintain alternator frequency within .5% from no load to rated alternator output. Steady state regulation is to be 0.25%. 2.1.6.The engines fuel system shall be designed for operation on natural gas having a BTU content of 875 BTU per cubic foot delivered to the unit in a vapor state. A carburetor, secondary regulator, fuel lock-off solenoid and all piping must be installed at the point of manufacturing, terminating at a single pipe opening external to the mounting base. 2.1.7.Sensing elements to be located on each engine for low oil pressure shutdown, w/pre-alarm; high coolant temperature shutdown, w/pre-alarm; low coolant level shutdown, overspeed shutdown and overcrank shutdown. These sensors are to be connected to control panel using a wiring harness with the following features: wire number labeling on each end of the wire run for easy identification, a molded rubber boot to cover the electrical connection on each sensor to prevent corrosion and all wiring to be run in flexible conduit for protection from the environment and any moving objects. 2.1.8.Provide the following items installed at the factory: 2.1.8.1.The manufacturer shall supply its recommended stainless steel, flexible connector to couple each engine exhaust manifold to the exhaust system. 2.1.8.2.Each engine shall have a unit mounted, thermostatically controlled water jacket heater to aid in quick starting. It will be of adequate wattage as recommended by the engine manufacturer. The contractor shall provide proper branch circuit from normal utility power source. 2.1.9.The following equipment is to be provided by the engine-generator set manufacturer and shipped loose with each unit: 2.1.9.1.The manufacturer will supply its recommended flexible fuel line to connect each engine to the external fuel source. On stationary applications the fuel line shall match the fuel fitting on the unit base rail and have braided stainless steel covering with brass fittings. 2.2. ALTERNATOR 2.2.1.Each alternator shall be a 4-pole revolving field type, wired for (120/208) (277/480) (600) VAC, three phase, 60 Hz rated at 200 kW, with a PMG driven brushless exciter. Photosensitive components will not be permitted in each rotating exciter. The stator shall be direct connected to the engine to insure permanent alignment. The generator shall meet temperature rise standards for Class "H" insulation while operating within Class "F" standards for extended life. All leads must be extended into an AC connection panel. The alternator shall be protected by internal thermal overload protection and an automatic reset field circuit breaker. 2.2.2.One step load acceptance shall be 100% of engine-generator set nameplate .

2.2.3.A solid state, digital voltage regulator must be used to maintain the system voltage within +/0.25%. It will have digital communications with the system controller to allow and maintain parallel operation. 2.2.4.The regulator will have programmable over and under voltage and frequency alarms and shutdowns. The voltage regulator must contain a limiting circuit to prevent output voltage surges in excess of 125% of rated voltage during generator set operation. The waveform harmonic distortion shall not exceed 5% total RMS measured line to line at full rated load. The TIF factor shall not exceed 50. 2.2.5.A NEMA 1 panel that is an integral part of each generator set must be provided to allow the installer a convenient location in which to make electrical output connections. A fully rated isolated neutral bar must be included by the generator set manufacturer to insure proper sizing. 2.2.6.Each electric plant shall be mounted with vibration isolators on a welded steel base that shall permit suitable mounting to any level surface. 2.2.7.A thermal magnetic UL listed main line circuit breaker rated per UL2200 must be mounted in each AC connection panel. The line side connections are to be made at the factory with compression lugs for load connections. A system utilizing a manual reset field circuit breaker and current transformers is unacceptable. 2.2.8.The unit mounted main line circuit breaker shall have an internal set of form "C" contacts that change state whenever the breaker is opened or closed to give proper control operation. 2.2.9.A paralleling contactor manufactured by Generac or approved equal shall be integrated into each NEMA 1 panel to allow for automatic electrical closure onto a dead bus or in parallel with other generators once required conditions are satisfied. The contactor shall be an electrically operated (line power closed, DC power trip) mechanically held device with main contacts composed of silver alloy to resist welding and minimize voltage dip on closure. 2.2.10.Each contactor shall be capable of 65,000 amp maximum RMS symmetrical fault current. 2.2.11.It shall have mechanical lugs for connecting cable (250 MCM to 350 MCM) installed. 2.3. CONTROLS 2.3.1.All engine alternator controls and instrumentation shall be designed, built, wired, tested and shock mounted in NEMA 1 enclosures on each engine-generator set by the manufacturer. It shall be based on a 32-bit industrial microprocessor digital control platform. It shall have, as a minimum, 45 input, 30 output connections to monitor and control all required functions. It shall have an on-board plc to allow programming of other customer requirements. 2.3.2.Each engine-generator set control panel shall contain a complete automatic engine start-stop control where a digital signal from the remote system controller initiates the start and stop functions of each engine. A programmable cyclic cranking limiter shall be provided to open the starting circuit after the selected number of starting cycles, latching a shutdown fault if exceeded. 2.3.3.Each unit shall contain the paralleling and protection functions to allow each unit to assume a dead generator system bus or parallel to it. Included will be the governor control, voltage regulator, auto-synchronizer, load sharing, sync check, reverse power and an independent over-speed sensor. 2-way digital communications with a system controller will direct these functions to assure autosynchronization, and proportional load sharing between gensets. It will feature complete factory-programmed default functions adjustable to customer requirements: 2.3.4.Each unit shall include; an emergency stop switch, battery charger fuse, a key operated manual, off, auto switch, audible alarm, common alarm LED, Not in Auto LED and a programmable unit control and monitoring touch screen module.

2.3.5.Each module will display all pertinent unit parameters including: Generator Status Current unit status in real time Instrumentation Real time readouts of the engine and alternator analog values Oil pressure and temperature Coolant temperature and level Fuel level (where applicable) Engine speed DC battery voltage Run time hours Generator voltages, amps, frequency Power, power factor Generator Commands Current engine start/stop status Alarm Status Current alarm(s) condition High or low AC voltage High or low battery voltage High or low frequency Low or pre-low oil pressure High and pre-high oil temperature Low water level and temperature High and pre-high engine temperature High, low and critical low fuel levels (where applicable) Overcrank Over and under speed Unit not in "Automatic Mode" Alarm Log Memory of last twenty alarm events Operating parameters Secure access to and manipulation of the operating parameters and alarm limits Software Information Version information and module display test function 2.3.7.Each module must be accessible by PC based software via either standard RS232, RS485 or modem. The software must display operating stats and conditions, be updated in real time and allow for complete access to all module functions. Communication output and its software must be fully compatible and allow for incorporation into an existing control program. 3. SYSTEM CONTROLLER 3.1. GENERAL 3.1.1.All intersystem communications and load management functions shall be controlled by a 32-bit industrial microprocessor based, programmable system control module contained in a surface mount NEMA 1 cabinet. This will allow for ease of service access, but prevent access by unauthorized personnel. 3.1.2.On sensing an engine start contact closure in any attached automatic transfer switch, a digital signal shall be sent to all units via the RS485 communications line requesting engine start. 3.1.3.On receiving communications from the first genset that has successfully closed to the generator bus, the control module will close the first of three prioritized, permissive relay contacts allowing the attached, priority one, transfer switch(s) to resume the load transfer operation. 3.1.4.As additional gensets synchronize and parallel to the generator bus, the system controller will

accumulate the available kW and will close the second and third permissive relays respectively if needed, as their programmed kw requirements are met, allowing the full connected load to be systematically applied to the generator bus. 3.1.5.The manager shall allow for load shed capability via programmed outputs based on the number of generators in the system. Load shed contacts will be invoked, in a priority sequence, if any of the generators fail to start, synchronize or shut down due to alarm fault during operation, so that the critical portion of the load can be maintained. A minimum of three load-shed outputs (dry contacts) shall be provided. 3.1.6.The system controller will follow the load profile and performance of the individual generators, communicating any required changes to the genset control panels. 4. AUTOMATIC TRANSFER SWITCH 4.1. GENERAL 4.1.1.The automatic transfer switch shall be furnished by the manufacturer of the engine-generator set so as to maintain system compatibility and local service responsibility for the complete emergency power system. It shall be listed by Underwriter's Laboratory, Standard 1008 with circuit breaker protection. Representative production samples of the transfer switch supplied shall have demonstrated through tests the ability to withstand at least 10,000 mechanical operation cycles. One operation cycle is the electrically operated transfer from normal to emergency and back to normal. Wiring must comply with NEC table 373-6(b). The manufacturer shall furnish schematic and wiring diagrams for the particular automatic transfer switch and a typical wiring diagram for each entire system. 4.2. RATINGS and PERFORMANCE 4.2.1.The automatic transfer switch shall be a (3) (4) pole design rated for (insert amp rating) amperes continuous operation in ambient temperatures of -20 Degrees Fahrenheit (-30 Degrees Celsius) to +140 Degrees Fahrenheit (+60 Degrees Celsius). Main power switch contacts shall be rated for 600 Volt AC minimum. The transfer switch supplied shall have a minimum withstand and closing rating when fuse protected of 200,000 amperes. Where the line side overcurrent protection is provided by circuit breakers, the short circuit withstand and closing ratings shall be (insert rating) amperes RMS minimum. These RMS symmetrical fault current ratings shall be the rating listed in the UL listing or component recognition procedures for the transfer switch. All withstand tests shall be performed with the overcurrent protective devices located external to the transfer switch. 4.3. CONSTRUCTION 4.3.1.The transfer switch shall be double throw construction, positively electrically and mechanically interlocked to prevent simultaneous closing and mechanically held in both normal and emergency positions. Independent break before make action shall be used to positively prevent dangerous source to source connections. The switch construction shall allow for a maintained tripped to neutral function. When switching the neutral, this action prevents the objectionable ground currents and nuisance ground fault tripping that can result from overlapping designs. The transfer switch shall be approved for manual operation. The electrical operating means shall be by electric solenoid. Every portion of the contactor is to be positively mechanically connected. No clutch or friction drive mechanism is allowed, and parts are to be kept to a minimum. This transfer switch shall not contain integral overcurrent devices in the main power circuit, including molded case circuit breakers or fuses. 4.3.2.The transfer switch electrical actuator shall have an independent disconnect means to disable the electrical operation during manual switching. Maximum electrical transfer time in either direction shall be 160 milliseconds, exclusive of time delays. Main switch contacts shall be high-pressure silver alloy contacts with arc chutes to resist burning and pitting for long life operation. Switches rated at 600 amps or larger shall also have arcing contacts.

4.3.2.1.There shall be a SPDT (form C), 10 ampere, 250 volt auxiliary contact on both normal and emergency sides, operated by the switch mechanism for monitoring switch position. Full rated neutral bar (or contacts on switched neutral applications) with lugs for normal, emergency and load conductors shall be provided inside the cabinet. 4.4. CONTROLS 4.4.1.All control equipment for the switch shall be mounted on the inside of the cabinet door in a metal lockable enclosure with transparent safety shield to protect all solid state circuit boards. This will allow for ease of service access when main cabinet lockable door is open, but to prevent access by unauthorized personnel. Control boards shall have installed cover plates to avoid shock hazard while making control adjustments. The solid state voltage sensors and time delay modules shall be plug-in circuit boards with silver or gold contacts for ease of service. 4.4.2.A solid state undervoltage sensor shall monitor all phases of the normal source and provide adjustable ranges for field adjustments for specific application needs. Pick-up and drop-out settings shall be adjustable from a minimum of 70% to a maximum of 95% of nominal voltage. A utility sensing interface shall be used, stepping down system voltage to 24VAC, helping to protect the printed circuit board from voltage spikes and increasing personnel safety when troubleshooting. 4.4.3.In the event of a power interruption, an engine start relay shall close to signal the engine-generator system to start and open for an engine shutdown signal. A solid state time delay start, adjustable, . 1 to 10 seconds, shall delay this signal to avoid nuisance start-ups on momentary voltage dips or power outages. 4.4.4.The transfer function shall be inhibited by the system controller until sufficient electrical power is available. Then the transfer switch logic will monitor the emergency system voltage and frequency. When the voltage (adjustable from 70% - 90%% and frequence (adjustable from 80% 90%) are stable, the transfer function will be initiated. A solid state time delay, adjustable from 5 seconds to 3 minutes, shall delay the transfer to allow the engine-generators to warm-up before application of load. There shall be a switch to bypass this warm-up timer when immediate transfer is required. 4.4.5.Retransfer the load to the line after normal power restoration. A return to utility timer, adjustable from 1-30 minutes, shall delay this transfer to avoid short term normal power restoration. 4.4.6.The operating power for transfer and retransfer shall be obtained from the source to which the load is being transferred. Controls shall provide an automatic retransfer of the load from emergency to normal if the emergency source fails with the normal source available. 4.4.7.Signal the engine-generator system to stop after the load retransfers to normal. A solid state engine cooldown timer, adjustable from 1-30 minutes, shall permit the engine to run unloaded to cooldown before shutdown. Should the utility power fail during this time, the switch will immediately transfer back to the generator. 4.4.8.Provide an engine minimum run timer, adjustable from 5-30 minutes, to ensure an adequate engine run period. 4.4.9.The transfer switch shall have a time delay neutral feature to provide a programmable time delay during the transfer in either direction, during which time the load is isolated from both power sources. This allows residual voltage components of motors or other inductive loads (such as transformers) to decay before completing the switching cycle. A switch will be provided to bypass all transition features when immediate transfer is required. 4.4.10.The transfer switch shall have an inphase monitor, which allows the switch to transfer between live sources if their voltage waveforms become synchronous within 20 electrical degrees within 10 seconds of transfer initiation signal. A switch must be provided to bypass this feature if not required.

4.4.11.If the inphase monitor will not allow such a transfer, the control must default to time delay neutral operation. Switches with inphase monitors, which do not default to time delay neutral operation, are not acceptable. 4.4.12.The transfer switch shall allow a maintained neutral function. Circuitry in the switch will accept a load shed signal from the system controller and drive the contactor to its neutral position. 4.4.13.Provide bright lamps to indicate the transfer switch position in either UTILITY (white) or EMERGENCY (red). A third lamp is needed to indicate STANDBY OPERATING (amber). These lights must be energized from utility or the engine-generator set. Front mounted controls shall include a selector switch to provide for a NORMAL TEST mode with full use of time delays, FAST TEST mode which bypasses all time delays to allow for testing the entire system, or AUTOMATIC mode to set the system for normal operation. 4.4.14.Provide manual operating handle to allow for manual transfer. This handle must be mounted inside the lockable enclosure so accessible only by authorized personnel. 4.4.15.Provide a safety disconnect switch to prevent load transfer and automatic engine start while performing maintenance. This switch will also be used for manual transfer switch operation. 4.4.16.Provide LED status lights to give a visual readout of the operating sequence. This shall include utility on, engine warm-up, standby ready, transfer to standby, inphase monitor, time delay neutral, return to utility, engine cooldown and engine minimum run. A "signal before transfer" lamp shall be supplied to operate from optional circuitry. 4.5. MISCELLANEOUS TRANSFER SWITCH EQUIPMENT 4.5.1.The transfer switch mechanism and controls are to be mounted in a NEMA 12, lockable enclosure. 4.5.2.For thee (3) or more gensets in a MPS, a connection cabinet with a bus rating of 4500 amps minimum shall be available to facilitate landing of multiple generator power cables. In turn, the number of power supply cables from the emergency MPS to the ATS can be reduced by utilizing larger cabling (500 to 750 MCM). The connection cabinet shall be NEMA 3R construction. 5. ADDITIONAL UNIT REQUIREMENTS 5.1. UNIT ACCESSORIES 5.1.1.The following equipment is to be installed in each engine-generator set at the manufacturers facility: 5.1.1.1.Provide an automatic dual rate battery charger manufactured by the engine-generator set supplier. The automatic equalizer system shall monitor and limit the charge current to 10 amps. The output voltage is to be determined by the charge current rate. The charger must have a maximum open circuit voltage of 35 volts and be protected against a reverse polarity connection. The battery charger is to be factory installed on the generator set. Due to line voltage drop concerns, a battery charger mounted in the transfer switch will be unacceptable 5.1.1.2.A heavy duty, lead acid battery set shall be provided by the generator set manufacturer of adequate voltage and amperage capacity to start and operate the engine. Provide all intercell and connecting battery cables as required. 5.1.1.3.The unit will provide means for attaching a flexible coupling between the engine radiator and the building cooling air discharge duct. 5.1.1.4.Weather protective enclosure: Each engine-generator set shall be factory enclosed in a heavy gauge steel enclosure constructed with 12 gauge corner posts, uprights and headers. The roof shall aid in the runoff of water and include a drip edge. The enclosure shall be

coated with electrostatically applied power paint, baked and finished to manufacturer's specifications. The enclosure is to have large, hinged doors to allow access to the engine, alternator and control panel. The doors must lift off without the use of tools. The door will have lockable hardware with identical keys. Padlocks do not meet this specification. 5.1.1.5.The exhaust silencer(s) shall be provided of the size as recommended by the manufacturer and shall be of critical grade. The silencer(s) shall be mounted within the weather protective enclosure for reduced exhaust noise and provide a clean, smooth exterior design. It shall be connected to the engine with a flexible, seamless, stainless steel exhaust connection. A rain cap will terminate the exhaust pipe. All components must be properly sized to assure operation without excessive backpressure when installed. 5.2. APPLIED STANDARDS 5.2.1.Each unit shall be UL2200, or Canadian Standards Association certified as required. 5.3. FACTORY TESTING 5.3.1.Before shipment of the equipment, the engine-generator set shall be tested under rated load for performance and proper functioning of control and interfacing circuits. Tests shall include: 5.3.1.1.Verifying all safety shutdowns are functioning properly. 5.3.1.2.Demonstrate full automatic operation of the system to verify the its integrity. 5.3.1.3.Transient and voltage dip responses and steady state voltage and speed (frequency) checks. 5.4. OWNER'S MANUALS 5.4.1.Three (3) sets of owners manuals specific to the product supplied must accompany delivery of the equipment. General operating instruction, preventive maintenance, wiring diagrams, schematics and parts exploded views specific to this model must be included. 5.5. INSTALLATION 5.5.1.Contractor shall install the complete electrical generating system including all fuel connections in accordance with the manufacturers recommendations as reviewed by the Engineer. 5.6. SERVICE 5.6.1.Supplier of the electric plant and associated items shall have permanent service facilities in this trade area. These facilities shall comprise a permanent force of factory trained service personnel on 24 hour call, experienced in servicing this type of equipment, providing warranty and routine maintenance service to afford the owner maximum protection. Delegation of this service responsibility for any of the equipment listed herein will not be considered fulfillment of these specifications. Service contracts shall also be available. 5.7. WARRANTY 5.7.1.The standby electric generating system components, complete engine-generator and instrumentation panel shall be warranted by the manufacturer against defective materials and factory workmanship for a period of 24 months. Such defective parts shall be repaired or replaced at the manufacturers option, free of charge for travel and labor. The warranty period shall commence when the standby power system is first placed into service. Multiple warranties for individual components (engine, alternator, controls, etc.) will not be acceptable. Satisfactory warranty documents must be provided. Also, in the judgment of the specifying authority, the manufacturer supplying the warranty for the complete system must have the necessary financial

strength and technical expertise with all components supplied to provide adequate warranty support. 5.8. STARTUP AND CHECKOUT 5.8.1.The supplier of the electric generating plant and associated items covered herein shall provide factory trained technicians to checkout the completed installation and to perform an initial startup inspection to include: 5.8.1.1.Ensuring each engine starts (both hot and cold) within the specified time. 5.8.1.2.Verification of engine parameters within specification. 5.8.1.3.Set no load frequency and voltage. 5.8.1.4.Test all automatic shutdowns of the engine-generator. 5.8.1.5.Perform a load test of the electric plant, ensuring full load frequency and voltage are within specification by using building load. 5.9. SUBMITTALS 5.9.1.Provide three sets of Engineering Submittal for approval, prior to production release, showing all components, in addition to the engine and generator. Submittals shall include compliance with these specifications. 5.10. SUBSTITUTIONS

5.10.1.The emergency power system has been designed to the specified manufacturers electrical and physical characteristics. The equipment sizing, spacing, amounts, electrical wiring, ventilation equipment, fuel and exhaust components have all been sized and designed around GENERAC equipment. Should any substitutions be made, the contractor shall bear responsibility for the installation, coordination and operation of the system as well as any engineering and redesign costs, which may result from such substitutions. Alternate equipment suppliers shall furnish equipment submittals 14 days prior to bid date for approval to bid. As part of the submittals, the substitute manufacturer shall supply as a minimum engine, alternator and control panel wiring diagrams and schematics. A separate list of all printed circuit boards with part numbers and current pricing must also be included.