15056 Add 2.doc

Interior Renovations at U.S. Courthouse

GSA Number: GS-03P-98-CDC-0019

Pittsburgh, Pennsylvania

SECTION 15056

VARIABLE FREQUENCY CONTROLLERS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

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

B. Related Sections include the following: Refer to specification 15910 Commissioning for additional requirements.

1.3 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.

1.4 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.

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. Qualification Data: For manufacturer and testing agency.

E. Operation and Maintenance Data: For VFCs, all installed devices, and components to include in emergency, operation, and maintenance manuals. In addition to items specified in Division 1 Section "Operation and Maintenance Data," include the following:

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

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

1.5 QUALITY ASSURANCE

A. Manufacturer Qualifications: A qualified manufacturer. Maintain, within 100 miles (160 km) of Project site, a service center capable of providing training, parts, and emergency maintenance and repairs.

B. Manufacturer Qualifications: Engage a firm experienced in manufacturing variable frequency drive systems similar to those indicated for this Project and that have a record of successful in-service performance. It is required that the drive manufacturer have an existing sales representative exclusively for HVAC products, with expertise in HVAC systems and controls and must have an independent service organization within a 50 mile radius of the project site. The drive and all necessary controls, as herein specified, shall be supplied by the drive manufacturer. The manufacturer shall have been engaged in the production of VFDs for a minimum of ten (10) years.

C. Startup Personnel Qualifications: Engage specially trained personnel in direct employ of manufacturer of variable frequency drives.

D. Testing: The VFD and options shall be tested to ANSI/UL Standard 508. The complete VFD, including all specified options, shall be assembled by the manufacturer, which shall be UL‑508 certified for the building and assembly of option panels. Local representative panel shop assembly for option panels is not acceptable. The appropriate UL stickers shall be applied to both the drive and option panel, including Bypass section, in the case where these are not contained in one panel.

1. All printed circuit boards shall be completely tested and burned-ion before being assembled into the completed VFD. The VFD shall then be subjected to a computerized systems test (cold), burn-in, and computerized system test (hot). The burn-in shall be at 104 deg. F. (40 deg. C), at full rated load.

2. All testing and manufacturing procedures shall be ISO 9001 certified.

E. Failure Analysis:

1. VFD manufacturer shall have an analysis laboratory to evaluate the failure to any component. The failure analysis lab shall allow the manufacturer to perform complete electrical testing, x-ray of components, and decap or delaminate of components and analyze failures within the component.

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

G. 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.

H. Comply with NFPA 70.

I. Comply with UL 508C.

J. Comply with NFPA 90A.

K. Comply with IEEE Standard 519-1992, Guide for Harmonic Content and Control.

L. Comply with NEMA ICS 7.0 AC Adjustable Speed Drives.

M. Comply with IEC 16800 Parts 1 and 2.

1.6 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.

1.7 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: 14 to 104°F.

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

3. Altitude: Not exceeding 3300 feet (1005 m).

4. 0 to 95% relative humidity, non-condensing.

1.8 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 size and location of concrete bases. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements are specified in Division 3 Section "Cast-in-Place Concrete.”

1.9 WARRANTY

A. Warranty shall be 24 months from the date of certified start-up. The warranty shall include all parts, labor, travel time and expenses.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work are limited to the following:

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

2. Eaton Corporation; Cutler-Hammer Products.

3. Rockwell Automation; Allen-Bradley Co.; Industrial Control Group.

4. Siemens Energy and Automation; Industrial Products Division.

5. Toshiba International Corporation.

2.2 VARIABLE FREQUENCY CONTROLLERS

A. Description: NEMA ICS 2, IGBT, PWM, VFC; 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. 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.

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

D. 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.

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.

E. 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.

F. 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.

G. 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.

H. 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.

I. 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.

J. 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.

K. Input Line Conditioning: The VFC shall have a DC link reactor to minimize power line harmonics. VFCs without a DC link reactor shall provide a 3% impedance line reactor.

L. 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.

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

N. 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).

O. 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. 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.

e. RS485.

f. Keypad display for local hand operation.

3. 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).

4. 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.

5. Communications: Communications: Factory-installed hardware and software to enable LON interface with building management system. LON controller shall be LonMark® version 3.3 certified. Coordinate communication interface with control contractor prior to submitting shop drawings.

6. Serial communication capability shall include, but not be limited to, run-stop control; speed set adjustment, proportional/integral/derivative PID control (Set Point) adjustments, current limit, andf accel/decel time adjustments. The drive shall have the capability of allowing the DDC to monitor feedback such as process variable feedback, output speed/frequency, current (in amps), % torque, power (kW), kilowatt hours (resettable), operating hours (resettable), relay outputs, digital inputs and diagnostic warning and fault information. Additionally, remote (LAN) VFC fault reset shall be possible. A minimum of 15 field parameters shall be capable of being monitored.

7. The VFC shall allow the DDC to control the drive's digital and analog outputs via the serial interface. The serial communications interface shall allow for DO (relay) control and AO (analog) control without being tied to a VFC function. In addition, all drive digital and analog inputs shall be capable of being monitored by the DDC system.

P. Integral Disconnecting Means: NEMA KS 1, nonfusible switch with lockable handle.

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

2.3 ENCLOSURES

A. NEMA 250, Type 1 enclosure.

2.4 ACCESSORIES

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

B. Microprocessor based Bypass Controller - Automatic transfer to line power via contactors. A keypad to control the bypass controller is to be mounted on the enclosure door. The bypass keypad shall include a one line diagram and status LEDs to indicate the mode of operation, drive and bypass status and ready & enable conditions. When in the "Normal" mode, the bypass contactor is open and the drive output contactor is closed. In the "Test" position, the drive output contactor is open, in the "Bypass" position, the drive output contactor is open, and the bypass contactor is closed via Start/stop command. Start/stop via customer supplied maintained contact shall be 24V or 115V compatible and shall function in both the "Normal" and "Bypass" mode. The voltage tolerance of the bypass power supply shall be +30/-35% to eliminate the problem of contactor coil burnout. The design shall include single-phase protection in both the VFC and bypass modes.

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

D. 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.

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

F. 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).

G. 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.

2.5 FACTORY FINISHES

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

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. 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.

B. Controller Fuses: Install fuses in each fusible switch. Comply with requirements in Division 16 Section "Fuses."

3.4 IDENTIFICATION

A. Identify VFCs, components, and control wiring according to Division 16 Section "Electrical Identification."

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.

3.5 CONTROL WIRING INSTALLATION

A. Install wiring between VFCs and remote devices according to Division 16 Section "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 16 Sections. Drawings indicate general arrangement of conduit, fittings, and specialties.

B. Ground equipment according to Division 16 "Grounding and Bonding."

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 including pretesting and adjusting of solid-state controllers.

3. Report results in writing.

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

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

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

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. Refer to Division 1 Section "Demonstration and Training."

END OF SECTION 15056

October 26, 2010

Addendum 2 15056 - 2 Variable Frequency Controllers