Section_16370_variable_frequency_drives.pdf

VARIABLE FREQUENCY DRIVES

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SECTION 16370

PART 1 - GENERAL

1.01 SCOPE OF WORK

A. Furnish all labor, materials, equipment and incidentals required and install variable frequency drives as shown on the Drawings and as specified herein.

B. These specifications are intended to give a general description of what is required, but do not cover all details which will vary in accordance with the requirements of the equipment furnished. They are, however, intended to cover the furnishing, the shop testing, the delivery and complete installation and field testing, of all materials, equipment and appurtenances for the variable frequency drives herein specified.

1.02 DESCRIPTION OF SYSTEM

A. The variable frequency drives shall be furnished by the Contractor. The Contractor is responsible for complete system operation and necessary coordination.

B. The drives furnished herein under shall be totally compatible and adequately sized with the new Pumps and Motors.

C. VFDs shall be sized as shown on the electrical drawings.

D. VFDs shall be provided with Reduced Voltage Solid State (RVSS) bypass starters.

1.03 QUALIFICATIONS

A. Variable speed drives shall be of sufficient size for the duty to be performed and shall not exceed their full-rated capacity when the driven equipment is operating as specified. To assure unity of responsibility, all equipment specified in this Section of the specifications shall be furnished and coordinated by the pumping system supplier.

B. The drives covered by these Specifications are intended to be equipment of proven ability as manufactured by reputable manufacturers having long experience in the production of identical units. The equipment furnished shall be designed, constructed and installed in accordance with the best practice and methods, and shall operate satisfactorily when installed.

C. The variable frequency control shall operate satisfactorily when connected to a bus supplying other solid state power conversion equipment which may be causing up to

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10% total harmonic voltage distortion and commutation notches up to 36,500 volt microseconds, or when other variable frequency drives are operated from the same bus.

D. Operation of all pump VFDs shall not add more than 3% total harmonic voltage distortion or 10% total current distortion to the normal bus (calculated at the load side of the utility transformer). Calculations shall be as described by IEEE-519 1992 edition. The load side of the utility transformer is the point of common coupling.

Transformer short circuit capability shall be 30,000 amps symmetrical. Non linear peak loading of the transformer shall be assumed to be 400 amps. The Contractor shall provide the necessary filtering components as required to meet these criteria.

The Contractor shall submit a harmonic analysis detailing compliance with the VFD shop drawing submittal.

E. The variable frequency drive manufacturer shall maintain and staff engineering service and repair shops through the United States, including the State of Florida, trained to do start up service, emergency service calls, repair work, service contracts and training of customer personnel.

F. Approved Manufacturers:

1. Square D by Schneider Electric ATV 660 with passive harmonic filters.

2. Eaton PowerXL DG1

3. Yaskawa GA Configured

4. The VFD manufacturer shall state in writing that the new VFD will fit in the existing electrical room as shown on the drawings and will meet the requirements of the VFD elementary diagrams.

1.04 SUBMITTALS

A. Copies of all materials required to establish compliance with the specifications shall be submitted. Submittals shall include at least the following:

1. Certified shop and erection drawings showing all important details of construction, dimensions and anchor bolt locations.

2. Descriptive literature, bulletins and/or catalogs of the equipment.

3. Data on the characteristics and performance of the variable frequency drives.

Data shall include certification that the variable frequency drives are warranted for use with the existing motors.

4. Complete drawings shall be furnished for approval before proceeding with manufacture and shall consists of master wiring diagrams, elementary or control schematics including coordination with other electrical control devices operating in conjunction with the variable frequency drive, and suitable outline drawings with sufficient details for locating conduit stub-ups and field wiring. Generic schematics not specific to this project shall not be acceptable.

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5. A list of the manufacturer's recommended spare parts with the manufacturer's current price for each item. Include gaskets, packing, etc. on the list. List bearings by the bearing manufacturer's numbers only.

1.05 OPERATING INSTRUCTIONS

A. Three copies of the operating and maintenance manuals shall be furnished. The manuals shall be prepared specifically for this installation and shall include all required cuts, drawings, equipment lists, descriptions, etc. that are required to instruct operating and maintenance personnel unfamiliar with such equipment.

B. A factory representative who has complete knowledge of proper operation and maintenance shall be provided for one (1) day after completion of all training to instruct representatives of the Owner on proper operation and maintenance.

1.06 PRODUCT HANDLING

A. All parts shall be properly protected so that no damage or deterioration will occur during a prolonged delay from the time of shipment until installation is completed and the units and equipment are ready for operation.

B. All equipment and spare parts must be properly protected against any damage during a prolonged period at the site.

C. Factory assembled parts and components shall not be dismantled for shipment unless permission is received in writing from the Engineer.

D. Each box or package shall be properly marked to show its net weight in addition to its contents.

1.07 WARRANTY

A. All equipment supplied under this Section shall be warranted by the CONTRACTOR and the equipment manufacturers for a period of five (5) years, parts and labor from date of substantial completion.

B. The equipment shall be warranted to be free from defects in workmanship, design and materials. If any part of the equipment should fail during the warranty period, it shall be replaced in the machine(s) and the unit(s) restored to service at no additional cost to the Owner.

C. The manufacturer's warranty period shall run concurrently with the

CONTRACTOR's warranty period. No exception to this provision shall be allowed.

PART 2 - PRODUCTS

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2.01 GENERAL

A. The CONTRACTOR shall furnish and install complete variable frequency drives as described in this specification and as detailed on the applicable Drawings.

B. The CONTRACTOR shall be responsible for the erection, installation, and start up off the equipment covered by this specification.

C. The variable frequency drive shall be furnished by an approved manufacturer, a vendor who has actively been manufacturing variable frequency drives for a period of at least five (5) years.

D. The variable frequency drive shall comply with the latest applicable standards of

ANSI, NEMA, IEEE, and the National Electrical Code.

E. Variable frequency drive shall operate as specified on standby generators or normal power sources.

F. The variable frequency drive shall have the ability to communicate via Profinet® to the controlling PLC. The Profinet® communication shall be native to the VFD and shall not use any gateway or protocol conversion hardware or software.

G. Reduced Voltage Solid State Bypass Starter:

1. Reduced voltage starter shall be combination solid state motor controller with circuit breaker.

2. Starters shall be provided with isolation and full voltage bypass contactors with overloads. Selector switch shall be on WPCP inner door. AIC rating shall be 25,000 amps.

3. Motor starter shall have a 120-volt operating coil, overload relay in each phase and control power transformer.

4. Motor starter shall have 1-N.O. and 1-N.C. auxiliary contacts. Additional auxiliary contacts shall be furnished where shown on the Drawings or as required by the control scheme.

5. Overload relays shall be adjustable and manually reset by push button in compartment door. Replaceable individual overload relay heaters of the proper size shall be installed in each phase.

6. Control power transformer shall be sized for additional load where required. Transformer secondaries shall be equipped with time-delay

16370 - 5 of 12 fuses.

7. Motor circuit protector shall be molded case with adjustable magnetic trip only. They shall be specifically designed for use with solid state reduced voltage starters. Motor circuit protectors shall have auxiliary disconnect contacts when used with starters having external control circuits.

8. The following options shall be required:

a. Soft Start

b. Soft Stop

c. Protective module – line side of each starter

9. The RVSS shall have the ability to send data via Profinet to the controlling

PLC. The Profinet communication shall be native to the RVSS, where no gateway or protocol conversion is needed. In the case a native Profinet solution is not available, a Siemens Simocode Pro-V PN and a properly sized Simocode CT/VT shall be provided. Mode, running status and fault signals shall be wired to the on-board I/O on the Simocode base unit. A

Siemens Simocode Ground Fault module shall be provided as well.

H. Operational Description

1. The description which follows generally describes the intended operation of the VFD/SSS combination as given in the elementary diagrams in the

Contract Drawings.

2. The selection of whether the VFD or the SSS is driving the pump is determined by the BYPASS mode. Normally, the VFD controls the pump; however, when in Bypass (indicated and set by relay “BYP”) all control is transferred to the SSS.

3. While in VFD control, the pump is started and stopped by the position of the H/O/A switch as follows:

a. When in HAND, the pump will run using the speed signal from the

VFD control panel.

b. When in OFF, the pump will not run.

c. While in AUTO, the pump starts and stops based on the PLC control output while the VFD is forced by digital input to use the speed signal from the PLC.

4. Bypass mode is entered in one of the following ways:

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a. Setting the switch on the VFD/SSS to BYPASS.

b. Failure of the VFD while in automatic mode set by the H/O/A.

c. Override by the Backup Control Panel.

5. In Bypass, the pump is started and stopped by the position of the H/O/A switch as follows:

a. When in HAND, the pump will run.

b. When in OFF, the pump will not run.

c. While in AUTO, the pump starts and stops based on the PLC control output except when overridden by the Backup Control

Panel, at which point the start/stop control from that panel is used instead.

2.02 CONSTRUCTION

A. Each variable frequency drive shall consist of a 460V, 3 phase rectifier, DC link and variable frequency inverter with features, functions and options as specified. The inverter shall be voltage source design using pulse width modulation (PWM) techniques. VFD design shall be “quiet type” utilizing IGBT transistors in the inverter section.

B. The variable frequency drives shall be rated for the HP, full load current and rpm of the motor. The variable frequency drives shall be designed to provide continuous speed adjustment of three-phase motors. The variable frequency output voltage shall provide constant volts-per-Hertz excitation to the motor terminals up to 60 Hertz.

C. Inverters shall be capable of converting incoming three phase, 460V (+10 to -10%) and 60 Hertz (+/-2) Hertz power to DC bus levels. The DC voltage shall be inverted to an variable frequency output.

D. Controllers shall be rated for an ambient temperature of 0 degrees C to 40 degrees C, an altitude of up to 3,300 feet above sea level and humidity of 0 to 95% non-condensing.

E. Controller enclosures shall be NEMA Type 1. The inverters shall have complete front accessibility with easily removable assemblies. All air openings shall be filtered. All VFD components shall be front facing, no side mounted equipment, components, etc. will be permitted. VFD enclosure shall provide dedicated 15% free space within the enclosure for future use.

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F. The following standard basic control features shall be provided on the inverter:

1. Start, Stop, "Power On" indicating light and speed control potentiometer.

Terminations for remote mounted operator control devices shall be furnished.

Cooling fans shall be controlled as follows: VFD start up and operation, fans shall run continuously; on VFD shutdown, fans shall operate for a period of time necessary to remove the excess heating within the VFD. A field adjustable timing relay shall be provided and set per VFD manufacturer recommendations.

2. Unidirectional operation, coast to rest upon stop.

3. Variable linear independent timed acceleration.

4. Variable torque performance from 4 to 60 Hertz.

5. All variable frequency drives shall be furnished with AC power line reactors or integral DC link reactor.

6. Frequency stability of ½% for 24 hours with voltage regulation of +2% of maximum rated output voltage.

7. LED status indication for Power On, Run, Inverter Enable, Overcurrent, Overvoltage, Overtemperature, Low Supply, and Phase Loss.

8. 115V AC control power for operator devices.

9. Phase insensitive to input power.

10. Automatic restart upon return of power following a utility outage. Drive shall require manual reset after three (3) attempts in a 60 second period.

G. The following protective features shall be provided on the drive:

1. Input AC circuit breaker with an interlocked, pad lockable handle mechanism and AC input line current limiting fuses for fault current protection of AC to DC converter section and circuit breaker. Minimum short circuit rating 42,000 AIC.

2. Electronic overcurrent trip for instantaneous overload protection.

3. Undervoltage and phase loss protection of output.

4. Over-frequency protection.

5. Over-temperature protection.

6. In addition to Surge protection in the AC drive, additional surge suppression from input AC line transients located external from the drive, shall be provided.

7. Electrical isolation between the power and logic circuits, as well as between the

115V AC control power and the static digital sequencing.

8. Drive to be capable of withstanding output terminal line short or open circuits without component failure.

9. Output dv/dt protection filter to minimize dv/dt to acceptable levels at motor terminals.

10. Common mode filter shall be provided in the drive on VFD output (2 minimum per drive) to reduce bearing current and Radio Frequency Interference (RFI).

11. VFD Display:

a. VFD shall provide an alphanumeric backlit display keypad (LCP) which may be remotely mounted using a standard 9-pin cable. VFD may be operated

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b. VFD Keypad shall feature an INFO key that, when pressed, shall display the contents of the programming manual for the parameter that is currently viewed on the display. The description shall explain the feature and how the settings can be made by the operator.

c. VFD shall display all faults in plain text; VFD’s which can display only fault codes are not acceptable.

d. The keypad shall feature a 6-line graphical display and be capable of digitally displaying up to five separate operational parameters or status values simultaneously (including process values with the appropriate engineering unit) in addition to Hand/Off/Auto, Local/Remote, and operating status.

e. Keypad shall provide an integral H-O-A (Hand-Off-Auto) and Local-Remote selection capability, and manual control of speed locally without the need for adding selector switches, potentiometers, or other devices.

f. All VFD’s shall be of the same series, and shall utilize a common control card and LCP (keypad/display unit) throughout the rating range. The control cards and keypads shall be interchangeable through the entire range of drives used on the project.

g. VFD keypad shall be capable of storing drive parameter values in non-volatile RAM uploaded to it from the VFD, and shall be capable of downloading stored values to the VFD to facilitate programming of multiple drives in similar applications, or as a means of backing up the programmed parameters.

h. VFD Display shall have the ability to display 5 different parameters pertaining to the VFD or the load including: current, speed, DC bus voltage, output voltage, input signal in mA, or other values from a list of 92 different user-selectable parameters.

i. VFD display shall indicate which digital inputs are active and the status of each relay.

j. It shall be possible to toggle between three status read-out screens by pressing the key. Various operating variables, even with different formatting, can be shown in each status screen.

k. VFD display shall indicate the value of any voltage or current signal, including the engineering units of measurement, connected to the analog input terminals.

l. VFD display shall indicate the value of the current at the analog output terminals, including the engineering units of measurement.

m. A red FAULT light, a yellow WARNING light and a green POWER-ON light shall be provided. These indications shall be visible both on the keypad and on the VFD when the keypad is removed.

12. Provide passive harmonic filtering to reduce harmonic distortion to required specified levels.

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H. The following standard independent adjustments shall be provided on the inverter:

1. Minimum speed (0 HZ to Max HZ).

2. Maximum speed (Min to Max HZ).

3. Acceleration time 0.1 to 600 Sec. (minimum).

4. Deceleration time 0.1 to 600 Sec. (minimum).

5. Volts per Hertz.

6. Stability adjustment, if required.

I. The following shall be furnished with each controller:

1. Built-in self diagnostics shall include an I/O map and fault messages stored.

2. Isolated process instrument speed input signal of 4-20 mA DC.

3. Isolated process instrument speed output signal 4-20 mA DC.

4. Relay output auxiliary contacts as shown on the drawings or as required herein, in Division 11 or Division 15.

5. Keypad functionality to include load ammeter, voltmeter, and speed output indicating meters.

6. Relay output auxiliary contacts as shown on the drawings.

7. Local/Off/Remote, Start/Stop and speed potentiometer selector switches.

8. Additional line filtering as required for harmonic abatement.

9. Permanent wire markers on all wiring.

J. Additional control circuitry as required in Division 13 and as shown on the electrical drawings.

PART 3 - EXECUTION

3.01 SOFTWARE AND PROGRAMMING DEVICES

A. Programming Device. The CONTRACTOR shall provide a new Siemens PG M6 to the OWNER in the OWNER’S name with all the latest projects stored on the machine. The PG shall be provided with the latest version of TIA Portal Step 7 and

WinCC Advanced. The owner shall be provided with a 1-year SUS on the PG and shall be transferred to the OWNER’S name after turnover.

B. Simocode ES. The CONTRACTOR shall provide a licensed copy of Simocode ES

V15.1 in TIA Portal in the OWNER’S name. A programming cable shall be provided to the OWNER by the CONTRACTOR.

3.02 INSTALLATION

A. Installation shall be in strict accordance with the manufacturer's instructions and recommendations in the locations shown on the Drawings. Field wiring shall be in

16370 - 10 of 12 accordance with manufacturer’s recommendations. Anchor bolts shall be stainless steel and set in accordance with the manufacturer's recommendations. VFD motor leads shall be in rigid conduit. Each VFD shall have its own rigid conduit for its motor leads. Motor leads shall not be mixed with any other wiring. See VFD manufacturer’s instruction manuals for detailed directions on installation of the

VFD’s and the installation of the motor leads.

3.03 SHOP PAINTING

A. Prior to shop painting, all surfaces shall be thoroughly cleaned, dry, and free from all mill/scale, rust, grease, dirt, and other foreign matter.

B. Drives shall be shop painted.

3.04 TESTING

A. Tests and Check

1. The drive manufacturer shall test the drive controller with a motor load prior to shipment. The motor shall have equal or greater full load current than the specified motor.

2. A certified copy of all tests and checks performed in the field, complete with meter readings and recordings, where applicable, shall be submitted to the

Owner.

B. After the drives have been completely installed, and working under the direction of the Manufacturer, conduct in the presence of the Owner, such tests as necessary to indicate that operation conforms to the Specifications.

3.05 TRAINING

A. The cost of training programs to be conducted with Owner's personnel shall be included in the Contract price. The training and instruction, insofar as practicable, shall be directly related to the System being supplied. The Supplier shall provide factory training for two (2) county personnel. Classes to be selected by the Owner.

B. On-site Training: Additional on-site (field) training shall be conducted at the Owner's

Plant Site and shall provide detailed hands-on instruction to Owner's personnel covering: system debugging, program modification, trouble-shooting, maintenance procedures, calibration procedures, and system operation. On site training for general plant staff shall be conducted over a period of one day.

3.06 START UP SERVICES

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A. The supplier shall provide start up services for the VFDs to the Contractor. A minimum of two days and two trips shall be provided.

END OF SECTION

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