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Engineering Specification Electrical

MESP 040800-01

TECHNICAL SPECIFICATION FOR AN UNINTERRUPTABLE POWER SUPPLY FOR THE ESSENTIAL SERVICES POWER DISTRIBUTION

NETWORK

Version: 3

Issued: 14 October 2016

Owner: Chief Engineer

Approved By:

Andrew Russack

Head of Engineering - Electrical

TECHNICAL SPECIFICATION FOR AN UNINTERRUPTABLE POWER SUPPLY FOR THE

ESSENTIAL SERVICES POWER DISTRIBUTION NETWORK

MESP 040800-01 Version: 3 Effective from: 14th October 2016

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Approving Manager: Head of Engineering - Electrical Approval Date: 14/10/2016 Next Review Date: 14/10/2019 PRINTOUT MAY NOT BE UP-TO-DATE; REFER TO METRO INTRANET FOR THE LATEST VERSION of 17

Approval

Amendment Record

Approval Date Version Description

23/06/2015 1 Initial Issue.

27/06/2016 2

Updated to remove references to specific locations, change input voltage, generalise output configurations. Requirements for modular buildings to house UPS removed. Requirements for output transformer moved to MESP 040100-02. Technical data schedule added. Technical document number added.

14/10/2016 3 System diagram updated, synchronisation requirements and standard capacities revised




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Table of Contents 1 Purpose ........................................................................................................................... 4

2 Scope ............................................................................................................................... 4

3 Acronyms and Abbreviations ........................................................................................ 4

4 Definitions ....................................................................................................................... 4

5 Reference Documents .................................................................................................... 5

5.1 Standards .......................................................................................................................... 5 5.2 Other Documents .............................................................................................................. 7

6 Overview .......................................................................................................................... 8

7 Load Characteristics ...................................................................................................... 9

8 Network Harmonics ...................................................................................................... 10

9 Requirements ................................................................................................................ 10

9.1 UPS ................................................................................................................................. 10 9.2 Synchronisation .............................................................................................................. 10 9.3 Batteries .......................................................................................................................... 11 9.4 Manual Bypass Switch .................................................................................................... 11 9.5 Control & Indicating Panel .............................................................................................. 11 9.6 Service Ports ................................................................................................................... 13 9.7 Software for Microprocessor Based Functionality .......................................................... 13 9.8 Spare Parts ..................................................................................................................... 13

10 Ratings .......................................................................................................................... 13

11 Electrical Protection ..................................................................................................... 14

12 UPS Reliability .............................................................................................................. 15

13 Testing ........................................................................................................................... 15

14 Appendices ................................................................................................................... 15

Appendix A – Information to be Supplied by Tenderers ................................................................... 16 List of Tables Table 1: SCADA Requirements ..................................................................................................... 12

Table 2: UPS System Characteristics ........................................................................................... 13




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1 Purpose This document is the technical specification for the Uninterruptable Power Supplies (UPS for power conditioning and maintenance of supply to the Essential Services (Signals) Power Distribution Network

2 Scope This functional specification describes the requirements for a UPS to be supplied for power conditioning and maintenance of power to the MTM Essential Services Power Distribution Network.

This functional specification is not exhaustive. The Supplier is required to ensure that all necessary functionality is provided in the UPS and its related systems such that the UPS may be safely operated and maintained to meet the requirements of this specification.

The Supplier is required to ensure and demonstrate that all tasks required for the operation and maintenance of the UPS can be conducted safely, in accordance with Victorian legislation and best OH&S practice.

Any requirements in addition to those contained within this document will be specified at the time of purchase.

Applicable Standards are listed in this specification. Compliance with the standards or an approved alternative standard is mandatory.

3 Acronyms and Abbreviations AC Alternating Current

ACCB Alternating Current Circuit Breaker

AS Australian Standard

CB Circuit Breaker

DC Direct Current

EN European Standards

HV High Voltage

MTM Metro Trains Melbourne Pty. Ltd.

RTU Remote Terminal Unit of the SCADA system

SCADA Supervisory Control And Data Acquisition

VRIOGS Victorian Rail Industry Operators Group Standard

4 Definitions Bypass The automatic or manual bypass of a UPS such that the load is not

protected by the operation of the UPS

Essential Services

Refers to services, apparatus and systems described in L1-CHE-SPE-154. Also refers to the power distribution system supplying these services.




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Islanded The operation of a UPS independently and not interconnected with or synchronised with the 2.2kV network

Shall Is used as the descriptive word to express a requirement that is mandatory to achieve conformance.

Should Is used as the descriptive word to express a requirement that is recommended in order to achieve compliance. ‘Should’ can also be used if a requirement is a design goal but not a mandatory requirement.

5 Reference Documents

5.1 Standards The UPS system shall comply with all relevant Standards, including:

AS 1042 - 1973 Direct-acting indicating electrical measuring instruments and their accessories

AS 1318 - 1985 Use of colour for the marking of physical hazards and the identification of certain equipment in industry

AS 1319 - 1994 Safety signs for the occupational environment

AS 1470- 1986 Health and safety at work, Principles and practices

AS 1775- 1984 Low voltage switchgear and control gear

AS 60529 Degrees of protection provided by enclosures for electrical equipment (IP Code)

AS 2067 - 2008 Substations and high voltage installations exceeding 1 kV a.c.

AS 2374.1.2 - 2003 Power transformers - Minimum Energy Performance Standard (MEPS) requirements for distribution transformers

AS 2676.2 - 1992 Guide to the installation, maintenance, testing and replacement of secondary batteries in buildings - Sealed cells

AS 4070 - 1992 Recommended practices for protection of low voltage electrical installations and equipment in MEN systems from transient overvoltages

AS 4072.1 - 2005 Components for protection of openings in fire-resistant separating elements

AS 60146.1.1 -2002 Semiconductor converters

AS 62040.1.1 - 2006 Uninterruptible Power Systems (UPS) – Part 1-1: General and safety requirements for UPS used in operator access areas

AS 62040.1.2 - 2003 Uninterruptible power systems (UPS) – Part 1-2: General and safety requirements for UPS used in restricted access locations




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AS 62040.2 - 2008 Uninterruptible power systems (UPS) – Part 2: Electromagnetic compatibility (EMC) requirements

AS 62040.3 - 2012 Uninterruptible power systems (UPS) – Part 3: Method of specifying the performance and test requirements

AS 62271 - 2012 High Voltage Switchgear and Control gear

AS/NZS 1768- 2007 Lightning protection

AS/NZS 2053 - 2001 Conduits and fittings for electrical installations

AS/NZS 3000 - 2007 Electrical installations (Wiring Rules)

AS/NZS 3013 - 2005 Electrical installations

AS/NZS 3084 - 2007 Telecommunications installations

AS/NZS 3108- 1994 Approval and test specification

AS/NZS 3439 - 2009 Low voltage control switchgear and control gear

AS/NZS 3835.2-2006 Earth potential rise

AS/NZS 3947.3 - 2001 Low voltage control switchgear and control gear

AS/NZS 3947.5.1 - 2000 Low voltage control switchgear and control gear

AS/NZS 4801 - 2001 Occupational health and safety management systems

AS/NZS 5000.1 - 2005 Electrical cables - polymeric insulated voltages up to and including 0.6/1 (1.2 kV)

AS/NZS 60137 - 2008 Insulated bushings for alternating voltages above 1000 V

AS/NZS 60479.1-2010 Effects of current on human beings and livestock

AS/NZS ISO 14001 - 2004 Environmental management systems

AS/NZS ISO 9001 - 2008 Quality management systems

EN 50121-1 Railway Applications - Electromagnetic Compatibility - Part 1: General

EN 50121-2 Railway Applications - Electromagnetic Compatibility - Part 2: Emission of the Whole Railway System to the Outside World

EN 50121-5 Railway Applications - Electromagnetic Compatibility - Part 5: Emission and Immunity of Fixed Power Supply Installations and Apparatus

All materials and components shall comply with the relevant Australian Standard or, where these do not exist, with the relevant IEC or EN Standard.

Reference to all standards shall be read as a reference to the latest edition of that standard and amendments available at the time of tendering.




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5.2 Other Documents L0-SQE-PRO-031 Enterprise Risk Management Procedure

L1-AMS-MAN-005 RAMS Manual

L1-AMS-PRO-003 RAMS Procedure

L2-ELN-REP-002 RAMS Requirements – MTM Substation Standardization

MEST 000002-01 Traction Substations and Tie Stations Standard

PTV Infrastructure Drafting Standard

IPG OR-01 Electrical Safety Rules

Victorian Traction Industry Electrical Safety Rules 2014 (HV Rules)

VSIR 2014 - Victorian Service and Installation Rules




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6 Overview 6.1 The UPS forms part of the Essential Services Power Supply system, as shown in Figure 1.

22kV/400VDyn1

Step Up Transformer

Substation L&P 400V

Board

Essential Services / Signal Switchgear

Synchronisation Signal

Synchronisation Logic

Battery Bank

Static Switch

400V 3 phase UPS

22kV Bus

400V Bus

Synchronisation Signal

Battery Isolator

Manual Bypass Switch

Substation Earth

Figure 1: UPS System Interconnections




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6.2 The UPS shall be a double conversion (online) type supplied at 400V three phase and delivering a conditioned power supply output for signalling and other essential services.

6.3 The UPS shall be capable of supplying consistently unbalanced outputs.

6.4 The UPS shall be designed for a minimum service life of 25 years. The batteries of the UPS shall have a service life of not less than 10 years.

6.5 The Supplier shall liaise with MTM’s nominated designer at no additional cost.

7 Load Characteristics 7.1 The UPS is to supply equipment supporting the operation of the Melbourne metropolitan

railway. The system consists of an AC ring main network supplied from the railway traction substations and other locations and distributing power to signalling apparatus at signal relay rooms and track side locations as well as other essential services such as lifts, CCTV and ticketing systems, known as the Essential Services Power Distribution Network.

7.2 The capacity of the supply is based on the load to be fed from the location. Typically, the required capacity varies between 25kVA and 50kVA.

7.3 The Essential Services Power Distribution Network is of various types taking in the legacy signal power distribution systems, including:

• 2.2kV single phase, 50 Hz, two wire unearthed, in phase with 22kV white-blue phase

• 2.2kV single phase, 25 Hz, two wire unearthed

• 1kV three phase, 50 Hz, earthed, leading 22kV system by 30 degrees

• 650V single phase, 50 Hz, two wire unearthed, in phase with 22kV white-blue phase

• 3.3kV three phase, 50Hz, in phase with 22kV system.

7.4 In order to provide power to the systems outlined in clause 7.3, at some locations, only the blue and white phases of the UPS will be loaded at any time.

7.5 The loads are supplied via an open ring feed arrangement. For maintenance and continuity of supply purposes, the Essential Services supplies from adjacent substations or supply points are paralleled during switching. Paralleling of supplies is limited to the minimum possible time to affect the load transfer consistent with control through the SCADA system.

7.6 Where the Essential Services Power Distribution Network is an unearthed system designed to permit one phase of the supply to be earthed through fault without interruption of supply, the system is fitted with transformers and devices that provide line alive and line earth indications at various locations. The indications are relayed by SCADA to Electrol.

7.7 The Essential Services supply is transformed to 110 volts for the signalling and communications systems. Transformers of various ratings between 3kVA and 40kVA supply the 110 volt equipment at multiple locations. The 110 volt equipment comprises computers controlling train movements, communications routers, electromechanical relays, electronic relays and electric motors.

7.8 The signalling and communications equipment is not tolerant of supply transients and disruptions. The UPS shall condition power and maintain supply during short time supply outages and during switching.

7.9 The Essential Services supply is also transformed to 400V for supply of essential loads at stations and other locations, as described in MEST 000002-06 - Electrical Networks Principles and Performance.




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8 Network Harmonics 8.1 The UPS is to be supplied from either MTM 22kV distribution system or power company

distribution feeders via 22kV/400V transformers. The 22kV system also provides the power for the 1500V DC train traction supply through transformers and rectifiers. The rectification process produces harmonics that may interfere with other devices.

8.2 The UPS shall be designed and constructed to be immune to harmonics in the alternating current system supplying the UPS. The Supplier shall demonstrate that the operation and output of the UPS is not affected by harmonics or transients on the incoming 400V supply.

9 Requirements

9.1 UPS 9.1.1 The UPS shall be a double conversion (online) type with a bypass device as defined

in AS/IEC 62040.3 – 2012.

9.1.2 The UPS shall be provided with all necessary devices for the safe and reliable operation and maintenance of the UPS in accordance with AS 62040.1.1 – 2003.

9.1.3 The UPS shall be sufficiently rated such that the required output power of the UPS system is achieved, taking into consideration the characteristics of the output transformer.

9.1.4 The minimum rated output power shall be 60kVA for three phase, or 40kVA for single phase two wire distribution systems.

9.1.5 The UPS shall be capable of supplying the rated load for a minimum of 10 minutes with the battery condition at 80 percent of capacity.

9.1.6 The UPS shall be provided with automatic switching to maintain supply in the event of UPS failure.

9.1.7 The inverter stage of the UPS shall be capable of supplying highly unbalanced loads.

9.2 Synchronisation 9.2.1 The phase of the UPS output shall be synchronised with the input voltage when this

is present.

9.2.2 Where no input voltage is available, the UPS output shall be able to be synchronised with an additional reference voltage signal.

9.2.3 The reference voltage will be provided at 230V from a voltage transducer provided by others.

9.2.4 The reference voltage shall be able to be provided either as a three phase or single phase signal in phase with the UPS output. If a single phase signal is provided, it shall be 30° out of phase with respect to the white-blue connection. A selectable or fixed phase shift may be provided.

9.2.5 When neither the input voltage nor reference voltage is available, the UPS shall synchronise with its internal clock at the last detected frequency.




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9.3 Batteries 9.3.1 Batteries shall be hermetically sealed, maintenance free stationary batteries and

shall be housed in a separate cabinet.

9.3.2 Adequate provision shall be made for protection against any contact for voltages above 50V DC as directed in EN 60950.

9.3.3 Charging of the batteries shall be temperature compensated.

9.4 Manual Bypass Switch 9.4.1 A manual bypass switch shall be provided for maintenance purposes.

9.4.2 The manual bypass switch shall enable isolation of the UPS, by switching the UPS output to an alternative 400V supply. The manual bypass switch shall be of a make before break type. Operation of the switch shall be indicated to the SCADA. The operation of the switch shall not affect the functionality of the UPS in any way.

9.4.3 When the manual bypass switch is operated and the UPS input supply isolated, all serviceable components of the UPS shall be accessible without exposure to live terminals or components.

9.5 Control & Indicating Panel 9.5.1 The UPS shall be fitted with a local control and indicating panel which shall be

capable of showing the operating status, fault alarms and other parameters.

9.5.2 The measurement parameters shall include but not be limited to:

i. input and output voltage and current;

ii. battery voltage;

iii. last battery maintenance;

iv. battery backup time and capacity;

v. charging current;

vi. internal temperature of all modules;

vii. number of bypass interventions;

viii. number of thermal protection interventions;

ix. number of battery commutations; and

x. the number of total battery discharges.

9.5.3 The alarms shall include:

i. normal operation;

ii. input and output frequency not synchronised;

iii. battery mode operation;

iv. automatic or manual bypass mode;

v. faulty power module;

vi. overload;




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vii. generic fault (be activated by any number of internal faults requiring further attention); and

viii. runtime reserve and end of run time.

9.5.4 The control functions shall include:

i. manual bypass switch

ii. UPS on load / on bypass

iii. emergency stop

9.5.5 An emergency stop mushroom button shall be provided. The emergency stop mushroom shall be located so as to prevent inadvertent operation but allow easy access. Operation of the emergency stop shall place the UPS into stand-by mode automatically.

9.5.6 Each of the measurements and alarms listed in clauses 9.5.2 and 9.5.3 shall be communicated to the RTU using the Modbus or DNP3 protocol, then via the SCADA system to the MTM Electrical Systems Control Centre (Electrol).

9.5.7 Hard wired connections to the RTU shall be provided in the form of voltage free contacts or interposing relays. The RTU provides 1 second pulses at the control voltage of the substation which may be 48V, 110V or 125V DC for control purposes. The consumption of interposing relay coils shall be 1-2W.

9.5.8 The SCADA connections shall be provided on a single, appropriately located, labelled terminal strip and shall be suitable for connection to cabling in accordance with MESP 081000-01 Technical Specification for SCADA Cabling in Substations.

9.5.9 The control and indication points described in Table 1 are required to be provided as hard wired connections.

Table 1: SCADA Requirements

Function Device/area Requirement

UPS Normal / Static Bypass UPS Trip => Static Bypass, Close => Normal mode, Indicate (changeover)

UPS Fail (General Alarm) UPS Indicate only (changeover)

Other UPS alarms UPS Indicate only (changeover)

UPS remote shutdown UPS Trip only

Manual Bypass Manual switch Indicate only (changeover)

Battery alarm Battery Monitoring system

Indicate only (changeover)

9.5.10 The Supplier shall provide an I/O schedule and detailed information relating to the software interface along with its package of drawings to MTM.




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9.6 Service Ports 9.6.1 A service port shall be provided on the UPS in a readily accessible position. The

service port shall allow maintenance, service and software updates to the UPS functionality.

9.7 Software for Microprocessor Based Functionality 9.7.1 The UPS shall be supplied with software to enable maintenance, service and

software updates for the microprocessor based functionality.

9.8 Spare Parts 9.8.1 The UPS shall utilise components which are likely to have replacement availability

for a minimum period of 30 years from the date of order.

10 Ratings 10.1 The UPS System shall have the following characteristics, as shown in Table 2:

Table 2: UPS System Characteristics

Nominal voltage of UPS 400V

Input voltage for normal operation 400V ± 15 percent

UPS Output voltage 400V 3Ø

Frequency 50Hz ± 1 percent

Standard values of full time load rating of output

60kVA / 120kVA / 180kVA (specified at the time of purchase)

Stored energy time at full rated load

10 minutes

Restored energy time 6 hours

Environmental range As described in AS 2067, except that the maximum ambient temperature shall be 50°C

Communication circuits As required to interface MTM SCADA system

Network earthing Earthed input. Earthing of output to be specified at time of purchase

Output total harmonic distortion The UPS output that shall limit ripple voltage to less than 2% RMS. The inverter shall limit total harmonic distortion (THDV) of output voltage to less than 3% for linear loads and less than 5% for non-linear loads through methods of filtering and neutralisation

Load power factor 0.6 and variable




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Minimum efficiency at rated load and power factor

90 per cent1

Bypass capability (static switch) Full current rated (including fault current and rated time) and operating time </= 6 milliseconds

Electromagnetic Compatibility and Immunity

The UPS system shall meet minimum emission and immunity requirements for UPS Category C3 as per the designation and requirements of AS62040.2. The UPS system shall operate as intended and not adversely affect nearby equipment within the electrified rail environment. EN 50121 may be used as a guide for compliance.

Output Performance Each UPS system shall meet the output performance classification VFI-SS-222 defined in AS62040.3 Annex D10 as a minimum Steady state voltage regulation shall be ±3% of nominal for all steady state linear and non-linear loads with 0 and 100% of UPS rating and with power factor in the range 0.6 lagging to unity. The above mentioned performance shall be maintained both whilst the UPS is supplied from an AC source which is within the specified range and when the UPS is operating from batteries which are charged within the design range.

Harmonic Tolerance The UPS system shall not be adversely affected by significant 11th, 13th, 23rd and 25th harmonics of 50Hz which may be present on the UPS input mains supply. These harmonics are produced by 12-pulse uncontrolled rectifiers.

Notes: 1 - Table to be provided by the Supplier compiling predicted efficiency versus output power and current.

10.2 The Supplier shall declare the full characteristics of the UPS by completion and submission to MTM Table D1 – UPS technical data – Manufacturer’s declaration as detailed in AS IEC 62040.3 – 2012.

11 Electrical Protection 11.1 The Supplier shall provide protection to the entire electrical installation associated with the

UPS.

11.2 MTM shall provide protection to the incoming 400V supply based on the protection requirements necessary for the UPS as provided by the Supplier.

11.3 The Supplier shall provide protection to the outgoing UPS supply as required. The Supplier shall note that a significant cable length may be required from the output terminals of the UPS to the connection point to the Essential Services Power Distribution Network. The protection of the output of the UPS shall not rely on the protection provided by Essential Services Power Distribution Network circuit breakers.




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11.4 The Supplier shall liaise with MTM to ensure that the electrical protection of the UPS and the Essential Services Power Distribution Network follows best practice and is graded to minimise the loss of supply to the Essential Services Power Distribution Network under fault condition.

12 UPS Reliability 12.1 The UPS will be designed for a reliability of better than 10 years MTBF. The availability of

the UPS must be better than 99.9%.

13 Testing 13.1 A draft Inspection and Test Plan (ITP) and associated Inspection and Test Checklist (ITC)

shall be submitted with tenders for assessment. The ITP must nominate hold points for witness tests and inspections by MTM

13.2 Type test certificates in accordance with AS62040.3 shall be provided to MTM.

13.3 Factory acceptance testing will be undertaken and the results recorded and will be made available for inspection by MTM at least four (4) weeks prior to the commissioning of the UPS. The factory acceptance testing shall include all the routine tests listed in Table 3 of AS 62040.3

13.4 MTM reserves the right to witness all or none of the factory acceptance testing to be undertaken by the Supplier.

14 Appendices Appendix A – Information to be Supplied by Tenderers




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Appendix A – Information to be Supplied by Tenderers The Tenderer shall supply the following information and guaranteed performance thereof.

General Manufacturer Name ……………………

Country of Manufacture ……………………

Model catalogue reference ……………………

Does the system fully comply with this specification? Yes No

Is a Type Test Certificate attached? Yes No

Is a general arrangement sketch attached? Yes No

Rated Output Power Total for system (kVA) ……………………

Per phase (kVA) ……………………

Rated Voltage Nominal Input / Output Voltage (V AC) ……………………

Input voltage tolerance (V AC) ……………………

Output voltage variation (V AC) ……………………

Battery voltage (V DC) ……………………

Input Input frequency range (Hz) ……………………

Input power factor ……………………

Inrush current (%) ……………………

Nominal input current (A) ……………………

Maximum input current (A) ……………………

UPS Output Nominal output frequency (Hz) ……………………

Output frequency range (Hz) ……………………

Short circuit capability ……………………

Overload capability ……………………

Maximum rate of change of output frequency (Hz/s) ……………………

Range of permitted load power factor ……………………

Efficiency (output/input) (%) ……………………

Bypass Circuit Automatic Bypass Switch Type Mech. Static

Automatic Bypass - No break transfer? Yes No

Maximum continuous current of bypass circuit (A) ……………………




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Battery Manufacturer ……………………

Country of Manufacture ……………………

Model ……………………

Battery Type ……………………

Number of Cells ……………………

Nominal Capacity @ C10 (Ah) ……………………

Nominal battery voltage (V) ……………………

Type of intercell connection ……………………

Maximum voltage drop across intercell connections (V) ……………………

Operating Ambient Temperature Range (°C) ……………………

Short Circuit Current (A) ……………………

Design life (years) ……………………

Construction

Overall Length (mm) ……………………

Overall Width (mm) ……………………

Overall Depth (mm) ……………………

Enclosure material ……………………

Degree of protection (refer AS60529) IP…………………

Enclosure finish / colour ……………………

Mass of system excluding batteries (kg) ……………………

Mass of batteries (kg) ……………………

Environmental Ambient storage temperature range (°C) ……………………

Ambient service temperature range (°C) ……………………

Acoustic noise at 1m – normal mode (dBA) ……………………

Acoustic noise at 1m – stored energy mode (dBA) ……………………

Reliability Mean Time Between Failures (years) ……………………

Mean Time To Repair (hours) ……………………

Availability ……………………

Failure Modes: