MHCEA
40th Annual Minnesota Health Care Engineers Seminar
Jackpot Junction
September 17, 2015
WELCOME MHCEA
Ziegler Power Systems
Loren Bahls: Senior Sales Engineer
Kyle From:
Customer Support Representative (CSR)
TOPICS
• Automatic Transfer Switch (ATS) Features and Operation
•
ATS Settings


Transfer timers, delay
Transfer settings, pick up, drop out
•
10 Second Starting
•
ATS Options
•
Testing to Meet Codes and Accreditation
•
Ratings of Generators – Achieving 30% load
•
Questions & Answers
ATS - Seven Major Functions
•
Carry Current Continuously
•
Detect Power Failures
•
Initiate Alternate Source Generator Set
•
Transfer Load
•
Sense Restoration of Normal
•
Re-Transfer Load to Normal
•
Withstand and Close On
Fault Currents
Standard “Factory Set” ATS Timing

Loss of Normal Source: 1 second delay (adjustable)
 Verifies that Utility power is out and/or unstable
 Brownout, Single Phase, Blackout
 Closes contact to start generator set(s)

Transfer to Emergency: 0 time delay (0 – 60 min. adjust.)
 Generator reaches 90% voltage (adjustable 85 – 100%)
 Generator reaches 95% frequency (adjustable 90-100%)
 Can be delayed in some schemes – lower priority ATS’s
 Can be inhibited in some schemes – prevent overload

Retransfer to Normal: 30 minutes (adjustable 0-60 min.)
 Assures that Utility is stable. Timer resets if Utility falters.

Cooldown: 5 minutes (adjustable 0-60 minutes)
 Allows generator to cool down and stabilize. Opens start contact.
ATS Evolution
Time
(sec)
Power Fails
EVENT
Generator Start Signal
10 Second Start and Transfer
1
Engine Cranks
via DC Starter
Motor(s)
2
Commit to transfer
3
4
Engine Builds Oil Pressure
– Governor Accelerates to ATS Transfers
1800 RPM
Load
60 HZ
5
6
7
8
9
10
Automatic Transfer Switches (ATS)
• Open Transition
• Closed Transition
• Closed Transition with
Soft loading
• Bypass Isolation

Open or Closed Transition
ATS - Open Transition
• Standard Automatic Transfer Switch
• Most Common for Standby & Emergency System
• Break Before Make Transfer
• Transfer Time: 1/6th of a second during testing and re-transfer
Automatic Transfer Operations(Open Transition)
UTILITY OUTAGE TRANSFER
OR
PEAK SHAVING TRANSFER
RETRANSFER TO UTILITY
Interconnection for Closed Transition Transfer
Bypass / Isolation ATS
• Two ATS’s Bussed in Parallel
Bypass ATS
Fixed Type
• One switch is drawout and used for
regular operation as a normal ATS.
• The other switch is fixed and used
Standard ATS
Drawout Type
only as the Bypass Manual Transfer
Switch when the regular ATS is
removed for maintenance.
• The twin ATS’s are mechanically and
electrically interlocked to prevent
accidental closure of both sources.
Closed Transition ATS
• Special Automatic Transfer Switch
• Make Before Break Transfer

Seamless Transfer - Only on Hot to Hot Transfers
• On power failure, operates open transition
• During monthly testing, delay in actual transfer time is likely to be more
than 10 seconds
• Overlap Time 100 Milliseconds

Generator is “Block Loaded”
• Utility Requirements for Intertie Approval (typical)



Visible Disconnect
Parallel Timer (62PL)
Lockout Relay (86LO)
Closed Transition Transfer Operation
PEAK SHAVING TRANSFER
UTILITY OUTAGE TRANSFER
RETRANSFER TO UTILITY
Closed Transition Transfer Operation
PEAK SHAVING TRANSFER
UTILITY OUTAGE TRANSFER
RETRANSFER TO UTILITY
Closed Transition Softloading
• Make Before Break Transfer with Soft loading Controls
• Active synchronizing, phase angle, voltage
and frequency match
• No power interruptions
• No Deviation in Voltage or Frequency
• Parallel with Utility – No-Break Curtailment

Load is ramped from source to source
• 10 - 30 second load/unload is typical
• Transfer is invisible to the facility
New Installations - Certifications
• Generators are built to all standards applicable

UL, NEMA, IEEE, NFPA, NEC, ISO 8528, IEC
• Factory Testing, for Healthcare, at 0.8 PF

Published Test Reports
• Alternator Testing
• Field Testing per NFPA 99/110 load bank test

Published Test Reports
• Training of Owner’s personnel

Names of Trainers and Attendees recorded
• Establish logs for monthly testing
Calculating Loads
• 3 Phase Power
• Per regulatory agencies, U.S. Generators are rated and nameplated at
0.8 Power Factor (P.F.)

KW =
1.73 x volts x amperes x P.F.
1000

Amperes =

See conversion formulas at MHCEA.org
KW x 1000
1.73 x volts x P.F.
Generator Rating Documentation
KW
Amperes
Controller Evolution
Electro-Mechanical
1970
1975
1980
1985
1990
1995
2000
First digital
• Early units only displayed volts, amps and frequency
• Newer units have direct KW and P.F. on digital display
2005
2010
Power, Exhaust Temperature
Measured at engine outlet
POWER
OUTPUT, KW
PERCENT
HORSEPOWE
R
EXHAUST
TEMP
FUEL RATE
600
100
900
994
42.7
540
90
808
957
39.1
480
80
718
930
35.9
420
70
629
902
32.4
360
60
541
870
28.5
300
50
454
833
24.2
240
40
370
779
19.5
180
30
286
712
14.6
120
20
201
635
10.2
60
10
114
543
6.7
EC.02.05.07, EPs 4-6
• EP 4 Twelve times a year, at intervals of not less than 20 days and not more than 40
days, the organization tests each emergency generator for at least 30 continuous
minutes. The completion dates of the tests are documented.
• EP 5 The emergency generator tests are conducted with a dynamic load that is at least
30% of the nameplate rating of the generator or meets the manufacturer’s recommended
prime movers’ exhaust gas temperature. If the organization does not meet either the 30%
of nameplate rating or the recommended exhaust gas temperature during any test in
EC.02.05.07, EP 4 then it must test each emergency generator once every 12 months
using supplemental (dynamic or static) loads of 25% of nameplate rating for 30 minutes,
followed by 50% of nameplate rating for 30 minutes, followed by 75% of nameplate rating
for 60 minutes, for a total of 2 continuous hours.
• EP 6 Twelve times a year, at intervals of not less than 20 days and not more than 40
days, the organization tests all automatic transfer switches. The completion date of the
tests is documented.
Joint Commission - Generator Set Testing
• Monthly Test





Minimum 30 minute continuous run time
Minimum 30% load
--- OR --Must run at minimum required exhaust temperature per manufacturer
Required to run 12 times per year
Intervals to be from 20-40 days
• 25/50/75 Annual Test



Run at 25% load for 30 minutes, followed by;
Run at 50% load for 30 minutes, followed by;
Run at 75% load for 60 minutes, for 2 hour continuous test
• Three Year Test



Minimum of 4 continuous hours
Minimum 30% load
--- OR --Must run at minimum required exhaust temperature per manufacturer
The Joint Commission - Reporting Features
• Individual screens and reports for each generator set in
the system
• Date and time stamps





Test initiated
Test completed
Generator mechanical and electrical set points
ATS parameters
BAS Interface
• Generator Output values recorded





Voltage (phase to phase)
Current (phase)
Frequency
Output, real KW, % of full load
Exhaust temperature
The Joint Commission - Test Report Screen
Generator & Electrical Equipment
Maintenance
Kyle From
Customer Support Representative (CSR)
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Inspections
Daily

Walk around inspection
Weekly

Perform weekly inspection
Monthly

Perform monthly inspection
& test run
Semi-Annual

Fluid analysis
Inspections
Annual





Inspection
Oil change w/ new oil & fuel filters
Load bank test (2-hours)
Megohmeter test
Fuel analysis
Triennial




Annual maintenance
Adjust intake/exhaust valve lash
Cooling system service
Replace batteries
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Starting System
Components
•
•
•
Battery charger
Starter
Batteries
Starting System
Typical Battery Installation: (Unsafe)
•
•
•
No acid containment
No terminal protection against shorts
Batteries need cleaning & charge rate checked
Starting System
Fiberglass Battery Enclosures: (Safe)
• Protects posts
• Contains spills
• Come in multiple sizes
Starting System
Battery Preventative Maintenance
• Recommended every 36 months
• Complete check of electrical system

Charger, cables & connections
• Check engine starter & amperage under normal operating conditions
• Remove & dispose of old lead acid batteries (per EPA standard)
• Install new batteries
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Cooling System
Components
•
•
•
•
Coolant system drain valve
Water Pump
Flex Connector
Low Coolant Sensor


Signals Temp to ECM
Sounds alarm below 70 Deg.
• High water temperature sender

Signals coolant temperature to gauge
Cooling System
Components
• Coolant ball valve shut off
• Watlow Block Heater
Cooling System
Components
• Kim Hotstart Heater - Thermostatically controlled
Cooling System
Signs of Trouble
• Rust/scale deposits and thermostat failure
• Can be prevented by servicing cooling system every 36 months
• Fumes or debris clog radiator fins reducing cooling capacity
Cooling System
Crankcase Ventilation Filtration System
• Filters fumes
• Protects



Radiator fins
Air cleaner pleats
Environment
• Replaceable Filter

Change every 250 hours
Cooling System
Cooling System Preventative Maintenance
• Recommended every 36 months
• Drain and flush the cooling system and refill with high-grade antifreeze
• Replace coolant hoses. including engine block heater hoses
• Replace engine thermostats and test for proper operation
• Test run engine generator
• Dispose of all parts and fluids per EPA standards
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Fuel System
Components

Priming pump

Fuel pressure gauge

Canister spin on fuel
filters

Fuel system shut-off
valves

Fuel lines

Transfer pumps

Governor (linkage)
Fuel System
Inspection

Base / day tank

Transfer pumps

Priming pump

Drain water seperator

Fuel lines

Governor (linkage)

Filters
Fuel System
Testing Options
Basic Fuel Test
Comprehensive Fuel Test

Water

API gravity

Stability

Distillation

Cetane index

Flash point

Color

Stability

Pour point

Water

Microbial
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Lubrication System
Preventative Maintenance

Change oil

Annually / 250 hours

Replace oil filters

Oil sample



Wear/condensation
Coolant/fuel
Debris
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Air System
Components

Intake



Air cleaners
Piping
Exhaust




Exhaust flex, piping
Silencers
Manifold
Turbo(s)
Preventative Maintenance

Inspect piping for cracks or leaks

Inspect air filters for dirt and/or debris

Inspect air restriction indicator
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Generator System
Components

Generator barrel

Electrical connections

Voltage regulator

Control panel
Inspection / Testing

Megohmeter



Winding Resistance
Perform annually
Visually inspect generator components and bearing(s)
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Load Bank Testing
Recommended Annually


Exercise the cooling system
Reseat engine piston rings in the cylinders and liners



Reduces blow-by and oil consumption
Burn off carbon deposits in combustion chamber, injector nozzles,
piston rings, turbocharger and exhaust system
Dissipate any condensation on generator copper windings
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Electrical Equipment - Transfer Switch
Monthly

Test transfer switch with generator
Annually

Visual inspection




Dust, dirt & moisture accumulation
Look for arcing or hot spots
Clean by vacuuming, dry cloth, or soft brush
Testing/Inspection




Voltage drop across main contacts
Voltage drop across emergency contacts*
Loose contacts (wires, terminals & relays)*
Operation of timers, remote start contacts and phase monitor*
* Testing requires load transfer
Electrical Equipment - Transfer Switch
Annually Continued…

Infrared inspection for evidence of hot spots (thermal imaging)

Check with your insurance company to see if annual thermal imaging will
reduce your premium
Electrical Equipment - Switchgear
Annually



Clean and inspect
Lubricate all moving parts
Inspect insulators






Physical damage
Contaminated surfaces
Exercise active components
Perform ground-resistance tests
Determine accuracy of meters and calibrate
Verify correct function of control transfer relays located in the switchgear
Electrical Equipment - Circuit Breaker
Annually

Operation & alignment

Lubricate moving parts

Inspect

Arc chutes & contacts

Primary & secondary injection testing

Verify the trip results are set to manufacturers recommended trip intervals

Long-time, short-time, instantaneous & ground fault
Electrical Equipment - Relays
Annually

Inspect





Bearings & pivots
Tightness of mounting hardware
Disc, contact & spring clearances
Spiral spring convolutions
Test & Record


Insulation-resistance test
Pickup, dropout & time delays
Generator & Electrical Equipment Maintenance
•
Inspections
•
Air Systems
•
Starting System
•
Generator Systems
•
Cooling System
•
Load Bank Testing
•
Fuel System
•
Electrical Equipment
•
Lubrication System
•
Power System Safety
Power Systems Safety
NFPA 70E – Personal Safety
Power Systems Safety
Lockout / Tagout Boxes

OSHA approved

Easy to use

Protects employees
Thank You
Questions?
References
Web sites
•
Ziegler Power Systems site:
 www.zieglercat.com/power
 Links to CAT, spec sheets, white papers etc.

www.CAT.com

www.activepower.com
Ziegler Power Systems

8050 State Highway 101
Shakopee, MN 55379
952.445.4292