Appendix E - VFD Specification.docx

SECTION 26 29 23

ADJUSTABLE SPEED DRIVE (ASD) SYSTEMS UNDER 600 VOLTS

02/20

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

EUROPEAN COMMITTEE FOR STANDARDIZATION (CEN/CENELEC)

EN 61800-3 (2017) Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 519 (2014) Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

IEEE C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000 V and Less) AC Power Circuits

IEEE C62.41.2 (2002) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2018) Enclosures for Electrical Equipment (1000 Volts Maximum)

NEMA ICS 1 (2000; R 2015) Standard for Industrial Control and Systems: General Requirements

NEMA ICS 3.1 (2019) Guide for the Application, Handling, Storage, Installation and Maintenance of Medium-Voltage AC Contactors, Controllers and Control Centers

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NEMA ICS 7 (2014) Adjustable-Speed Drives

NEMA ICS 7.2 (2015) Application Guide for AC Adjustable Speed Drive Systems

NEMA MG 1 (2018) Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2020; ERTA 20-1 2020; ERTA 20-2 2020; TIA 20-1; TIA 20-2; TIA 20-3; TIA 20-4) National Electrical Code

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

47 CFR 15 Radio Frequency Devices

UNDERWRITERS LABORATORIES (UL)

UL 489 (2016) UL Standard for Safety Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures

UL 508C (2002; Reprint Nov 2010) Power Conversion Equipment

1.2 RELATED REQUIREMENTS

Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM applies to this section with additions and modifications specified herein.

1.3 SYSTEM DESCRIPTION

1.3.1 Performance Requirements

1.3.1.1 Electromagnetic Interference Suppression

Computing devices, as defined by 47 CFR 15 and EN 61800-3 rules and regulations, must be certified to comply with the requirements for class A computing devices and labeled.

1.3.1.2 Electromechanical and Electrical Components

Ensure electrical and electromechanical components of the Adjustable Speed Drive (ASD) do not cause electromagnetic interference to adjacent electrical or electromechanical equipment while in operation.

1.3.2 Electrical Requirements

1.3.2.1 Power Line Surge Protection

IEEE C62.41.1 and IEEE C62.41.2, IEEE 519 Control panel must have surge protection, included within the panel to protect the unit from damaging transient voltage surges. Surge protective device must be mounted near the incoming power source and properly wired to all three phases and ground.

Fuses must not be used for surge protection.

1.3.2.2 Sensor and Control Wiring Surge Protection

I/O functions as specified must be protected against surges induced on control and sensor wiring installed outdoors and as shown. Test the inputs and outputs in both normal mode and common mode using the following two waveforms:

a. A 10 microsecond by 1000 microsecond waveform with a peak voltage of 1500 volts and a peak current of 60 amperes.

b. An 8 microsecond by 20 microsecond waveform with a peak voltage of 1000 volts and a peak current of 500 amperes.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings Schematic Diagrams; G Interconnecting Diagrams; G Installation Drawings; G As-Built Drawings; G

SD-03 Product Data Adjustable Speed Drives; G Wires and Cables Equipment Schedule

SD-06 Test Reports ASD Test Performance Verification Tests Endurance Test

SD-08 Manufacturer's Instructions Installation instructions

SD-09 Manufacturer's Field Reports ASD Test Plan; G Standard Products

SD-10 Operation and Maintenance Data Adjustable Speed Drives, Data Package 4

1.5 QUALITY ASSURANCE

1.5.1 Schematic Diagrams

Submit diagrams showing circuits and device elements for each replaceable module. Schematic diagrams of printed circuit boards are permitted to group functional assemblies as devices, provided that sufficient information is provided for government maintenance personnel to verify proper operation of the functional assemblies.

1.5.2 Interconnecting Diagrams

Show interconnections between equipment assemblies, and external interfaces, including power and signal conductors. Include for enclosures and external devices.

1.5.3 Installation Drawings

Show floor plan of each site, with ASD's and motors indicated. Indicate ventilation requirements, adequate clearances, and cable routes. Submit drawings for government approval prior to equipment construction or integration. Immediately record modifications to original drawings made during installation for inclusion into the as-built drawings.

1.5.4 Equipment Schedule

Provide schedule of equipment supplied. Schedule must provide a cross reference between manufacturer data and identifiers indicated in shop drawings. Schedule must include the total quantity of each item of equipment supplied and data indicating compatibility with motors being driven. For complete assemblies, such as ASD's, provide the serial numbers of each assembly, and a sub-schedule of components within the assembly. Provide recommended spare parts listing for each assembly or component.

1.5.5 Installation Instructions

Provide installation instructions issued by the manufacturer of the equipment, including notes and recommendations, prior to shipment to the site. Provide operation instructions prior to acceptance testing.

1.5.6 Standard Products

Provide materials and equipment that are products of manufacturers regularly engaged in the production of such products which are of equal material, design and workmanship and:

a. Have been in satisfactory commercial or industrial use for 2 years prior to bid opening including applications of equipment and materials under similar circumstances and of similar size.

b. Have been on sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the 2-year period.

c. Where two or more items of the same class of equipment are required, provide products of a single manufacturer; however, the component parts of the item need not be the products of the same manufacturer unless stated in this section.

1.6 DELIVERY AND STORAGE

Store delivered equipment to protect from the weather, humidity and temperature variations, dirt and dust, or other contaminants.

1.7 WARRANTY

The complete system must be warranted by the manufacturer for a period of one year. Repair or replace any component failing to perform its function as specified and documented at no additional cost to the Government. Items repaired or replaced must be warranted for an additional period of at least one year from the date that it becomes functional again, as specified in FAR 52.246-21 Warranty of Construction.

1.8 MAINTENANCE

1.8.1 Spare Parts

Manufacturers provide spare parts in accordance with recommended spare parts list.

1.8.2 Operation and Maintenance Data

Provide in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA. Provide service and maintenance information including preventive maintenance, assembly, and disassembly procedures. Include electrical drawings from electrical general sections. Provide additional information necessary to provide complete operation, repair, and maintenance information, detailed to the smallest replaceable unit. Include copies of as-built submittals. Provide routine preventative maintenance instructions, and equipment required. Provide instructions on how to modify program settings, and modify the control program. Provide instructions on drive adjustment, trouble-shooting, and configuration. Provide instructions on process tuning and system calibration.

1.8.3 Maintenance Support

During the warranty period, provide on-site, on-call maintenance services by drive manufacturer's personnel on the following basis: The service must be on a per-call basis with 36 hour response. Contractor is responsible for the maintenance of all hardware and software of the system during the warranty period. Various personnel of different expertise must be sent on-site depending on the nature of the maintenance service required. Costs must include travel, local transportation, living expenses, and labor rates of the service personnel while responding to the service request. The provisions of this Section are not in lieu of, nor relieve the Contractor of, warranty responsibilities covered in this specification. Should the result of the service request be the uncovering of a system defect covered under the warranty provisions, all costs for the call, including the labor necessary to identify the defect, must be borne by the Contractor.

1.8.4 Technical Support

Provide the ASDs with manufacturer's technical telephone support in English, readily available during normal working hours.

PART 2 PRODUCTS

2.1 ADJUSTABLE SPEED DRIVES (ASD)

Provide adjustable speed drive to control the speed of induction motor(s). The ASD must include the following minimum functions, features and ratings.

a. Input circuit breaker per UL 489 with a minimum of 10,000 amps symmetrical interrupting capacity and door interlocked external operator.

b. A converter stage per UL 508C must change fixed voltage, fixed frequency, ac line power to a fixed dc voltage. The converter must utilize a full wave bridge design incorporating diode rectifiers. Silicon Controlled Rectifiers (SCR) are not acceptable. The converter must be insensitive to three phase rotation of the ac line and must not cause displacement power factor of less than .95 lagging under any speed and load condition.

c. An inverter stage must change fixed dc voltage to variable frequency, variable ac voltage for application to a standard NEMA MG 1 Part 30 motor designed for use with adjustable frequency power supplies. Switch the inverter to produce a sine coded pulse width modulated (PWM) output waveform.

d. The ASD shall be capable of supplying 120 percent of rated full load current for one minute at maximum ambient temperature.

e. The ASD must be designed to operate from a 480 volt, ±10 percent, three phase, 60 Hz supply, and control motors with a corresponding voltage rating.

f. Acceleration and deceleration time must be independently adjustable from one second to 60 seconds.

g. Adjustable full-time current limiting must limit the current to a preset value which must not exceed 110 percent of the controller rated current. The current limiting action must maintain the V/Hz ratio constant so that variable torque can be maintained. Short time starting override must allow starting current to reach 175 percent of controller rated current to maximum starting torque.

h. The controllers must be capable of producing an output frequency over the range of 3 Hz to 60 Hz (20 to one speed range), without low speed cogging. Over frequency protection must be included such that a failure in the controller electronic circuitry must not cause frequency to exceed 110 percent of the maximum controller output frequency selected.

i. Minimum and maximum output frequency must be adjustable over the following ranges: 1) Minimum frequency 3 Hz to 50 percent of maximum selected frequency; 2) Maximum frequency 40 Hz to 60 Hz.

j. The controller efficiency at any speed must not be less than 96 percent.

k. The controllers must be capable of being restarted into a motor coasting in the forward direction without tripping.

l. Protection of power semiconductor components must be accomplished without the use of fast acting semiconductor output fuses. Subjecting the controllers to any of the following conditions must not result in component failure or the need for fuse replacement:

(1) Short circuit at controller output

(2) Ground fault at controller output

(3) Open circuit at controller output

(4) Input undervoltage

(5) Input overvoltage

(6) Loss of input phase

(7) AC line switching transients

(8) Instantaneous overload

(9) Sustained overload exceeding 115 percent of controller rated current

(10) Over temperature

(11) Phase reversal

m. Solid state motor overload protection must be included such that current exceeding an adjustable threshold must activate a 60 second timing circuit. Should current remain above the threshold continuously for the timing period, the controller will automatically shut down.

n. Include slip compensation circuit that will sense changing motor load conditions and adjust output frequency to provide speed regulation of NEMA MG 1 Part 30 designed for use with adjustable frequency power supplies motors to within plus or minus 0.5 percent of maximum speed without the necessity of a tachometer generator.

o. The ASD must be factory set for manual restart after the first protective circuit trip for malfunction (overcurrent, undervoltage, overvoltage or overtemperature) or an interruption of power. The ASD must be capable of being set for automatic restart after a selected time delay. If the drive faults again within a specified time period (adjustable 0-60 seconds), a manual restart will be required. Provide Bidirectional Autospeed Search capable of starting the ASD into rotating loads spinning in either direction and returning motor to set speed in proper direction, without causing damage to drive, motor, or load.

p. The ASD must include external fault reset capability. All the necessary logic to accept an external fault reset contact must be included.

q. Provide critical speed lockout circuitry to prevent operating at frequencies with critical harmonics that cause resonant vibrations. The ASD must have a minimum of three user selectable bandwidths.

r. Provide properly sized NEMA rated by-pass and isolation contactors to enable operation of motor in the event of ASD failure. Install mechanical and electrical interlocks between the by-pass and isolation contactors. Provide a selector switch and transfer delay timer. Motor overload and short circuit protective features must remain in use during the bypass mode.

s. Each individual ASD must meet the following Total Harmonic Distortion (THD) requirements at the input terminals to the factory assembly of the ASD or at the load disconnecting means serving the ASD and filter assembly. These measurements should be taken with the drive set at 90 percent frequency (rpms) and the motor under a minimum of 50 percent demand.

(1) The Voltage THD should not exceed 2.0 percent THD.

(2) The Current THD should not exceed 15.0 percent THD.

(3) If the standard factory ASD does not meet or exceed these requirements the factory must install appropriate equipment (Harmonic Traps, Filters, different Drive technology, etc.) to mitigate the distortion to assure performance of the VFD is within the limits.

(4) These tests should be performed at the Manufacturers Laboratory facilities and submitted as part of the Product Data Submittals, in order to prevent the necessity of adding mitigation equipment in the field. If the requirements listed above are met, IEEE 519 will also be met.

t. Minimum Operating Conditions. Designed and constructed ASD's to operate within the following service conditions:

(1) Ambient Temperature Rating: 0 to 120 degrees F.

(2) Non-condensing relative humidity rating: less than 95 percent.

(3) Ambient rating: Not exceed 3,300 feet.

2.1.1 ASD for Industrial Application

Provide the following operator control and monitoring devices mounted on the front panel of the ASD:

a. Manual speed potentiometer.

b. Hand-Off-Auto (HOA) switch.

c. Power on light.

d. Drive run power light.

e. Local display capable of including ASD status, frequency, motor RPM, phase current, fault diagnostic in descriptive text, and all programmed parameters.

ASDs must have the following features:

a. A local operator control providing the following functions:

(1) Remote/Local operator selection with password access.

(2) Run/Stop and manual speed commands.

(3) All programming functions.

(4) Scrolling through all display functions.

b. A local operator control panel with the following data displayed:

(1) ASD status.

(2) Frequency.

(3) Motor RPM.

(4) Phase current.

(5) Scrolling through all display functions.

(6) Fault diagnostics in descriptive text.

(7) All programmed parameters.

c. Standard PI loop controller with input terminal for controlled variable and parameter settings.

d. User interface terminals for remote control of ASD speed, speed feedback, and an isolated form C SPDT relay, which energizes on a drive fault condition.

e. An isolated form C SPDT auxiliary relay which energizes on a run command.

f. An adjustable carrier frequency with 16 KHz minimum upper limit.

g. A built-in or external line reactor with 3 percent minimum impedance to protect the DC bus capacitors and rectifier section diodes, reduce power line transient voltage, line notching, DC bus over-voltage tripping and improve the inverter over-current and over-voltage conditions.

h. Historical logging information and displays:

i. ASDs must include the following operator programmable parameters:

(1) Upper and lower limit frequency.

(2) Acceleration and deceleration rate.

(3) Variable torque volts per Hertz curve.

(4) Starting voltage level.

(5) Starting frequency level.

(6) Display speed scaling.

(7) Enable/disable soft stall feature.

(8) Motor overload level.

(9) Motor stall level.

(10) Jump frequency and hysteresis band.

(11) PWM carrier frequency.

j. ASD must have the following protective features:

(1) An electronic adjustable inverse time current limit with consideration for additional heating of the motor at frequencies below 45Hz, for the protection of the motor.

(2) An electronic adjustable soft stall feature, allowing the ASD to lower the frequency to a point where the motor will not exceed the full-load amperage when an overload ASD will automatically return to the requested frequency when load conditions permit.

(3) A separate electronic stall at 110 percent ASD rated current, and a separate hardware trip at 190 percent current.

(4) The ability to shut down if inadvertently started into a rotating load without damaging the ASD or the motor.

(5) The ability to keep a log of a minimum of four previous fault conditions, indicating the fault type and time of occurrence in descriptive text.

(6) The ability to sustain 110 percent rated current for 60 seconds.

(7) The ability to shutdown safely or protect against and record the following fault conditions:

(a) Over current (and an indication if the over current was during acceleration, deceleration, or running).

(b) Over current internal to the drive.

(c) Motor overload at start-up.

(d) Over voltage from utility power.

(e) Motor running overload.

(f) Over voltage during deceleration.

(g) ASD over heat.

(h) Load and ground fault.

(h) Abnormal parameters or data in ASD EEPROM.

2.2 ENCLOSURES

Provide equipment enclosures conforming to NEMA 250, NEMA ICS 7, and NEMA ICS 6, with a heater if located outdoors.

2.3 WIRES AND CABLES

All wires and cables must conform to NEMA 250, NEMA ICS 7, NFPA 70.

2.4 NAMEPLATES

Nameplates external to NEMA enclosures must conform with the requirements of Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Provide manufacturer's standard, permanent nameplates for internal areas of enclosures.

2.5 SOURCE QUALITY CONTROL

2.5.1 ASD Test Plan

To ensure quality, each ASD must be subject to a series of in-plant quality control inspections before approval for shipment from the manufacturer's facilities. Provide test plans.

2.5.2 ASD Test Report

To ensure quality, each ASD must be subject to a series of in-plant quality control inspections before approval for shipment from the manufacturer's facilities. Provide test reports.

PART 3 EXECUTION

3.1 INSTALLATION

Per NEMA ICS 3.1, install equipment in accordance with the approved manufacturer's printed installation drawings, instructions, wiring diagrams, and as indicated on project drawings and the approved shop drawings. A field representative of the drive manufacturer must supervise the installation of all equipment, and wiring.

3.2 GROUNDING

Per NEMA ICS 7.2, ASD must be solidly grounded to the main distribution.

3.3 FIELD QUALITY CONTROL

Specified products must be tested as a system for conformance to specification requirements prior to scheduling the acceptance tests. Conduct performance verification tests in the presence of Government representative, observing and documenting complete compliance of the system to the specifications. Submit a signed copy of the test results, certifying proper system operation before scheduling tests.

3.3.1 ASD Test

A proposed test plan must be submitted to the contracting officer at least 28 calendar days prior to the proposed testing for approval. The tests must conform to NEMA ICS 1, NEMA ICS 7, and all manufacturer's safety regulations. The Government reserves the right to witness all tests and review any documentation. Inform the Government at least 14 working days prior to the dates of testing. Perform the ASD test with the assistance of a factory-authorized service representative.

3.3.2 Performance Verification Tests

"Performance Verification Test" plan must provide the step by step procedure required to establish formal verification of the performance of the ASD. Compliance with the specification requirements must be verified by inspections, review of critical data, demonstrations, and tests. The Government reserves the right to witness all tests, review data, and request other such additional inspections and repeat tests as necessary to ensure that the system and provided services conform to the stated requirements. Inform the Government 14 calendar days prior to the date the test is to be conducted.

3.3.3 Endurance Test

Immediately upon completion of the performance verification test, the endurance test must commence. The system must be operated at varying rates for not less than 192 consecutive hours, at an average effectiveness level of 0.9998, to demonstrate proper functioning of the complete PCS. Continue the test on a day-to-day basis until performance standard is met. The contractor is not allowed in the building during the endurance test. The system must respond as designed.

3.4 DEMONSTRATION

3.4.1 Training

Coordinate training requirements with the Contracting Officer. Provide video tapes, if available, of all training provided to the Government for subsequent use in training new personnel. Provide all training aids, texts, and expendable support material for a self-sufficient presentation shall be provided, the amount of which to be determined by the contracting officer.

3.4.1.1 Instructions to Government Personnel

Provide the services of competent instructors with minimum two-year field experience with the operation and maintenance of similar ASDs who will give full instruction to designated personnel in operation, maintenance, calibration, configuration, and programming of the complete control system. Orient the training specifically to the system installed. Instructors must be thoroughly familiar with the subject matter they are to teach. The number of training days of instruction furnished must be as specified. A training day is defined as eight hours of instruction, including two 15-minute breaks and excluding lunch time; Monday through Friday. Provide a training manual for each student at each training phase which describes in detail the material included in each training program. Provide one additional copy for archiving. Provide equipment and materials required for classroom training. Provide a list of additional related courses, and offers, noting any courses recommended. List each training course individually by name, including duration, approximate cost per person, and location of course. Unused copies of training manuals must be turned over to the Government at the end of last training session.

3.4.1.2 Operating Personnel Training Program

Provide one 2-hour training session at the site at a time and place mutually agreeable between the Contractor and the Government. Provide session to train 4 operation personnel in the functional operations of the system and the procedures that personnel will follow in system operation. This training shall include:

a. System overview

b. General theory of operation

c. System operation

d. Alarm formats

e. Failure recovery procedures

f. Troubleshooting

3.4.1.3 Engineering/Maintenance Personnel Training

Accomplish the training program as specified. Training must be conducted on site at a location designated by the Government. Provide a one-day training session to train four engineering personnel in the functional operations of the system. This training must include:

a. System overview

b. General theory of operation

c. System operation

d. System configuration

e. Alarm formats

f. Failure recovery procedures

g. Troubleshooting and repair

h. Maintenance and calibration

i. System programming and configuration

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