232923 sf - variable frequency motor controllers.pdf

USDA / ARS

Repair Bldg 1 HVAC System Akron, CO

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SECTION 232923 – VARIABLE FREQUENCY MOTOR CONTROLLERS

PART 1 - GENERAL

1.1 SUMMARY

A. This Section includes solid-state, PWM, VFCs for speed control of three-phase, squirrel-cage induction motors.

1.2 DEFINITIONS

A. BMS: Building management system.

B. IGBT: Integrated gate bipolar transistor.

C. LAN: Local area network.

D. PID: Control action, proportional plus integral plus derivative.

E. PWM: Pulse-width modulated.

F. VFC: Variable frequency controller.

1.3 SUBMITTALS

A. Product Data: For each type of VFC. Include dimensions, mounting arrangements, location for conduit entries, shipping and operating weights, and manufacturer's technical data on features, performance, electrical ratings, characteristics, and finishes.

B. Shop Drawings: For each VFC.

1. Include dimensioned plans, elevations, sections, and details, including required clearances and service space around equipment. Show tabulations of installed devices, equipment features, and ratings. Include the following:

a. Each installed unit's type and details.

b. Nameplate legends.

c. Short-circuit current rating of integrated unit.

d. Listed and labeled for series rating of overcurrent protective devices in combination controllers by an NRTL acceptable to authorities having jurisdiction.

e. Features, characteristics, ratings, and factory settings of each motor-control center unit.

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2. Wiring Diagrams: Power, signal, and control wiring for VFCs. Provide schematic wiring diagram for each type of VFC.

C. Coordination Drawings: Floor plans, drawn to scale, showing dimensioned layout, required working clearances, and required area above and around VFCs where pipe and ducts are prohibited. Show VFC layout and relationships between electrical components and adjacent structural and mechanical elements. Show support locations, type of support, and weight on each support. Indicate field measurements.

D. Manufacturer Seismic Qualification Certification: Submit certification that VFCs, accessories, and components will withstand seismic forces defined in Division 26 Section "Vibration and Seismic Controls for Electrical Systems." Include the following:

1. Basis for Certification: Indicate whether withstand certification is based on actual test of assembled components or on calculation.

a. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified."

b. The term "withstand" means "the unit will remain in place without separation of any parts from the device when subjected to the seismic forces specified and the unit will be fully operational after the seismic event."

2. Dimensioned Outline Drawings of Equipment Unit: Identify center of gravity and locate and describe mounting and anchorage provisions.

3. Detailed description of equipment anchorage devices on which the certification is based and their installation requirements.

E. Field quality-control test reports.

F. Operation and Maintenance Data: For VFCs, all installed devices, and components to include in emergency, operation, and maintenance manuals.

1. Routine maintenance requirements for VFCs and all installed components.

2. Manufacturer's written instructions for testing and adjusting overcurrent protective devices.

G. Load-Current and Overload-Relay Heater List: Compile after motors have been installed and arrange to demonstrate that selection of heaters suits actual motor nameplate full-load currents.

H. Load-Current and List of Settings of Adjustable Overload Relays: Compile after motors have been installed and arrange to demonstrate that dip switch settings for motor running overload protection suit actual motor to be protected.

1.4 QUALITY ASSURANCE

A. Manufacturer Qualifications: A qualified manufacturer. Maintain, within 100 miles of Project site, a service center capable of providing training, parts, and emergency maintenance and repairs.

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B. Testing Agency Qualifications: An independent agency, with the experience and capability to conduct the testing indicated, that is a member company of the InterNational Electrical Testing Association or is a nationally recognized testing laboratory (NRTL) as defined by OSHA in 29 CFR 1910.7, and that is acceptable to authorities having jurisdiction.

1. Testing Agency's Field Supervisor: Person currently certified by the InterNational Electrical Testing Association or the National Institute for Certification in Engineering Technologies to supervise on-site testing specified in Part 3.

C. Source Limitations: Obtain VFCs of a single type through one source from a single manufacturer.

D. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

E. Comply with NFPA 70.

F. Product Selection for Restricted Space: Drawings indicate maximum dimensions for VFCs, minimum clearances between VFCs, and adjacent surfaces and other items. Comply with indicated maximum dimensions and clearances.

1.5 DELIVERY, STORAGE, AND HANDLING

A. Deliver VFCs in shipping splits of lengths that can be moved past obstructions in delivery path as indicated.

B. Store VFCs indoors in clean, dry space with uniform temperature to prevent condensation.

Protect VFCs from exposure to dirt, fumes, water, corrosive substances, and physical damage.

C. If stored in areas subject to weather, cover VFCs to protect them from weather, dirt, dust, corrosive substances, and physical damage. Remove loose packing and flammable materials from inside controllers; install electric heating of sufficient wattage to prevent condensation.

1.6 PROJECT CONDITIONS

A. Environmental Limitations: Rate equipment for continuous operation, capable of driving full load without derating, under the following conditions, unless otherwise indicated:

1. Ambient Temperature: 0 to 40 deg C.

2. Humidity: Less than 90 percent (noncondensing).

3. Altitude: Continuous duty at altitude of 5500 feet above sea level.

B. Product Selection for Restricted Space: Drawings indicate maximum dimensions for VFCs, including clearances between VFCs, and adjacent surfaces and other items. Comply with indicated maximum dimensions.

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1.7 COORDINATION

A. Coordinate layout and installation of VFCs with other construction including conduit, piping, equipment, and adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels.

B. Coordinate features of VFCs, installed units, and accessory devices with pilot devices and control circuits to which they connect.

C. Coordinate features, accessories, and functions of each VFC and each installed unit with ratings and characteristics of supply circuit, motor, required control sequence, and duty cycle of motor and load.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, the following:

1. ABB Power Distribution, Inc.; ABB Control, Inc. Subsidiary.

2.2 VARIABLE FREQUENCY CONTROLLERS (VFD)

A. Description: NEMA ICS 2, IGBT, PWM, VFC; U.L. or ETL listed and labeled as a complete unit and arranged to provide variable speed of an NEMA MG 1, Design B, 3-phase induction motor by adjusting output voltage and frequency.

1. Provide unit suitable for operation of premium-efficiency motor as defined by

NEMA MG 1.

B. Emissions: VFD shall meet the requirements of FCC Regulation 15 Subject J, for both conducted and radiated RFI emissions.

C. Design and Rating: Match load type such as fans, blowers, and pumps; and type of connection used between motor and load such as direct or through a power-transmission connection.

D. Output Rating: 3-phase; 6 to 60 Hz, with voltage proportional to frequency throughout voltage range.

E. Unit Operating Requirements:

1. Input ac voltage tolerance of 380 to 500 V, plus or minus 10 percent.

2. Input frequency tolerance of 50/60 Hz, plus or minus 6 percent.

3. Minimum Efficiency: 96 percent at 60 Hz, full load.

4. Minimum Displacement Primary-Side Power Factor: 96 percent.

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5. Overload Capability: 1.1 times the base load current for 60 seconds; 2.0 times the base load current for 3 seconds.

6. Starting Torque: 100 percent of rated torque or as indicated.

7. Speed Regulation: Plus or minus 1 percent.

F. Isolated control interface to allow controller to follow control signal over an 11:1 speed range.

1. Electrical Signal: 4 to 20 mA at 24 V.

2. Pneumatic Signal: 3 to 15 psig (20 to 104 kPa).

G. Internal Adjustability Capabilities:

1. Minimum Speed: 5 to 25 percent of maximum rpm.

2. Maximum Speed: 80 to 100 percent of maximum rpm.

3. Acceleration: 2 to a minimum of 22 seconds.

4. Deceleration: 2 to a minimum of 22 seconds.

5. Current Limit: 50 to a minimum of 110 percent of maximum rating.

H. Self-Protection and Reliability Features:

1. Input transient protection by means of surge suppressors.

2. Under- and overvoltage trips; inverter overtemperature, overload, and overcurrent trips.

3. Motor Overload Relay: Adjustable and capable of NEMA ICS 2, Class 10 performance.

4. Notch filter to prevent operation of the controller-motor-load combination at a natural frequency of the combination.

5. Instantaneous line-to-line and line-to-ground overcurrent trips.

6. Loss-of-phase protection.

7. Reverse-phase protection.

8. Short-circuit protection.

9. Motor overtemperature fault.

I. Multiple-Motor Capability: Controller suitable for service to multiple motors and having a separate overload relay and protection for each controlled motor. Overload relay shall shut off controller and motors served by it when overload relay is tripped.

J. Automatic Reset/Restart: Attempts three restarts after controller fault or on return of power after an interruption and before shutting down for manual reset or fault correction.

Bidirectional autospeed search shall be capable of starting into rotating loads spinning in either direction and returning motor to set speed in proper direction, without damage to controller, motor, or load.

K. Power-Interruption Protection: To prevent motor from re-energizing after a power interruption until motor has stopped.

L. Torque Boost: Automatically varies starting and continuous torque to at least 1.5 times the minimum torque to ensure high-starting torque and increased torque at slow speeds.

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M. Motor Temperature Compensation at Slow Speeds: Adjustable current fall-back based on output frequency for temperature protection of self-cooled, fan-ventilated motors at slow speeds.

N. Input Line Conditioning: Line reactor with 3% impedence.

O. VFC Output Filtering:

P. Status Lights: Door-mounted LED indicators shall indicate the following conditions:

1. Power on.

2. Run.

3. Overvoltage.

4. Line fault.

5. Overcurrent.

6. External fault.

Q. Panel-Mounted Operator Station: Start-stop and auto-manual (HOA) selector switches with manual speed control potentiometer and elapsed time meter.

R. Main input disconnect shall provide a positive disconnect of all phases of the incoming AC line to both the controller and the by-pass circuitry. Disconnect shall have working capability.

S. Indicating Devices: Meters or digital readout devices and selector switch, mounted flush in controller door and connected to indicate the following controller parameters:

1. Output frequency (Hz).

2. Motor speed (rpm).

3. Motor status (running, stop, fault).

4. Motor current (amperes).

5. Motor torque (percent).

6. Fault or alarming status (code).

7. PID feedback signal (percent).

8. DC-link voltage (VDC).

9. Set-point frequency (Hz).

10. Motor output voltage (V).

T. Control Signal Interface:

1. Electric Input Signal Interface: A minimum of 2 analog inputs (0 to 10 V or 0/4-20 mA) and 6 programmable digital inputs.

2. Pneumatic Input Signal Interface: 3 to 15 psig.

3. Remote Signal Inputs: Capability to accept any of the following speed-setting input signals from the BMS or other control systems:

a. 0 to 10-V dc.

b. 0-20 or 4-20 mA.

c. Potentiometer using up/down digital inputs.

d. Fixed frequencies using digital inputs.

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e. RS485.

f. Keypad display for local hand operation.

4. Output Signal Interface:

a. A minimum of 1 analog output signal (0/4-20 mA), which can be programmed to any of the following:

1) Output frequency (Hz).

2) Output current (load).

3) DC-link voltage (VDC).

4) Motor torque (percent).

5) Motor speed (rpm).

6) Set-point frequency (Hz).

5. Remote Indication Interface: A minimum of 2 dry circuit relay outputs (120-V ac, 1 A) for remote indication of the following:

a. Motor running.

b. Set-point speed reached.

c. Fault and warning indication (overtemperature or overcurrent).

d. PID high- or low-speed limits reached.

U. Communications:

1. Provide an RS485 interface allowing VFC to be used with an external system within a multidrop LAN configuration. Interface shall allow all parameter settings of VFC to be programmed via BMS control. Provide capability for VFC to retain these settings within the nonvolatile memory.

2. Provide interface card for Johnson Controls. Coordinate requirements with Temperature Control Contractor.

V. Manual Bypass: Magnetic contactor arranged to safely transfer motor between controller output and bypass controller circuit when motor is at zero speed. Panel mounted controller-off-bypass selector switch sets mode, and indicator lights give indication of mode selected. Unit shall be capable of stable operation (starting, stopping, and running), with motor completely disconnected from controller (no load).

W. Bypass Controller: NEMA ICS 2, full-voltage, nonreversing enclosed controller with across-the-line starting capability in manual-bypass mode. Provide motor overload protection under both modes of operation with control logic that allows common start-stop capability in either mode.

X. Integral Disconnecting Means: NEMA AB 1, instantaneous-trip circuit breaker with handle, lockable in off position only.

Y. Isolating Switch: Non-load-break switch arranged to isolate VFC and permit safe troubleshooting and testing, both energized and de-energized, while motor is operating in bypass mode.

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Z. Remote Indicating Circuit Terminals: Mode selection, controller status, and controller fault.

2.3 ENCLOSURES

A. NEMA 1

2.4 ACCESSORIES

A. Devices shall be factory installed in controller enclosure, unless otherwise indicated.

B. Push-Button Stations, Pilot Lights, and Selector Switches: NEMA ICS 2, heavy-duty type.

C. Stop and Lockout Push-Button Station: Momentary-break, push-button station with a factory-applied hasp arranged so padlock can be used to lock push button in depressed position with control circuit open.

D. Control Relays: Auxiliary and adjustable time-delay relays.

E. Standard Displays:

1. Output frequency (Hz).

2. Set-point frequency (Hz).

3. Motor current (amperes).

4. DC-link voltage (VDC).

5. Motor torque (percent).

6. Motor speed (rpm).

7. Motor output voltage (V).

F. Historical Logging Information and Displays:

1. Real-time clock with current time and date.

2. Running log of total power versus time.

3. Total run time.

4. Fault log, maintaining last four faults with time and date stamp for each.

G. Current-Sensing, Phase-Failure Relays for Bypass Controller: Solid-state sensing circuit with isolated output contacts for hard-wired connection; arranged to operate on phase failure, phase reversal, current unbalance of from 30 to 40 percent, or loss of supply voltage; with adjustable response delay.

2.5 FACTORY FINISHES

A. Finish: Manufacturer's standard paint applied to factory-assembled and -tested VFCs before shipping.

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PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine areas, surfaces, and substrates to receive VFCs for compliance with requirements, installation tolerances, and other conditions affecting performance.

B. Examine roughing-in for conduit systems to verify actual locations of conduit connections before VFC installation.

C. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 APPLICATIONS

A. Select features of each VFC to coordinate with ratings and characteristics of supply circuit and motor; required control sequence; and duty cycle of motor, controller, and load.

B. Select horsepower rating of controllers to suit motor controlled.

3.3 INSTALLATION

A. Install in accordance with the manufacturer’s detailed instructions.

B. Anchor each VFC assembly to steel-channel sills arranged and sized according to manufacturer's written instructions. Attach by bolting. Level and grout sills flush with mounting surface.

C. Comply with mounting and anchoring requirements specified in Division 26 Section "Hangers and Supports for Electrical Systems."

D. Controller Fuses: Install fuses in each fusible switch. Comply with requirements in Division 26 Section "Fuses."

3.4 IDENTIFICATION

A. Identify VFCs, components, and control wiring according to Division 23 Section "Identification for HVAC Piping and Equipment."

B. Operating Instructions: Frame printed operating instructions for VFCs, including control sequences and emergency procedures. Fabricate frame of finished metal, and cover instructions with clear acrylic plastic. Mount on front of VFC units.

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3.5 CONTROL WIRING INSTALLATION

A. Install wiring between VFCs and remote devices according to Division 26 Section "Low- Voltage Electrical Power Conductors and Cables."

B. Bundle, train, and support wiring in enclosures.

C. Connect hand-off-automatic switch and other automatic-control devices where applicable.

1. Connect selector switches to bypass only manual- and automatic-control devices that have no safety functions when switch is in hand position.

2. Connect selector switches with control circuit in both hand and automatic positions for safety-type control devices such as low- and high-pressure cutouts, high-temperature cutouts, and motor overload protectors.

3.6 CONNECTIONS

A. Conduit installation requirements are specified in other Division 26 Sections. Drawings indicate general arrangement of conduit, fittings, and specialties.

B. Ground equipment according to Division 26 Section "Grounding and Bonding for Electrical Systems."

3.7 FIELD QUALITY CONTROL

A. Prepare for acceptance tests as follows:

1. Test insulation resistance for each enclosed controller element, bus, component, connecting supply, feeder, and control circuit.

2. Test continuity of each circuit.

B. Manufacturer's Field Service: Engage a factory-authorized service representative to perform the following:

1. Inspect controllers, wiring, components, connections, and equipment installation. Test and adjust controllers, components, and equipment.

2. Assist in field testing of equipment.

3. Report results in writing.

C. Perform the following field tests and inspections and prepare test reports:

1. Perform electrical study to confirm no line noise.

2. Perform each electrical test and visual and mechanical inspection, except optional tests, stated in NETA ATS. Certify compliance with test parameters.

3. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest.

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3.8 ADJUSTING

A. Set field-adjustable switches and circuit-breaker trip ranges.

3.9 DEMONSTRATION

A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain variable frequency controllers.

END OF SECTION 232923