26 29 23.pdf

UFGS

SECTION 26 29 23 Page 1

SECTION 26 29 23

VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS

04/06

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.

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

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

Circuits

IEEE C62.41.2 (2002) IEEE Recommended Practice on

Characterization of Surges in Low-Voltage

(1000 V and Less) AC Power Circuits

IEEE Std 519 (1992; Errata 2004) Recommended Practices and

Requirements for Harmonic Control in

Electrical Power Systems

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2003) Enclosures for Electrical Equipment

(1000 Volts Maximum)

NEMA ICS 1 (2000; R 2005) Standard for Industrial

Control and Systems General Requirements

NEMA ICS 3.1 (1997; R 2003) Industrial Control and

Systems: Handling, Storage and Installation

Guide for AC General-Purpose Medium Voltage

Contactors and Class E Controllers, 50 and 60

Hertz

NEMA ICS 6 (1993; R 2006) Standard for Industrial

Controls and Systems Enclosures

NEMA ICS 7 (2006) Industrial Control and Systems:

Adjustable-Speed Drives

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2007) National Electrical Code - 2008

Edition

U.S. DEPARTMENT OF DEFENSE (DOD)

SECTION 26 29 23 Page 2

MIL-STD-461 (Rev F) Requirements for the Control of

Electromagnetic Interference Characteristics of Subsystems and Equipment

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

47 CFR 15 Radio Frequency Devices

UNDERWRITERS LABORATORIES (UL)

UL 489 (2002; Rev thru Jun 2006) Standard for

Molded-Case Circuit Breakers, Molded-Case

Switches and Circuit-Breaker Enclosures

UL 508C (2002; Rev thru Feb 2008) Power Conversion

Equipment

1.2 RELATED REQUIREMENTS

Section 26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS, and Section

26 20 00 DISTRIBUTION WIRING SYSTEM apply 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, MIL-STD-461 rules and regulations, shall be certified to comply with the requirements for class A computing devices and labeled as set forth in part 15.

1.3.1.2 Electromechanical and Electrical Components

Electrical and electromechanical components of the Variable Frequency Drive

(VFD) shall 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 Std 519 Control panel shall have surge protection, included within the panel to protect the unit from damaging transient voltage surges. Surge arrestor shall be mounted near the incoming power source and properly wired to all three phases and ground. Fuses shall not be used for surge protection.

1.3.2.2 Sensor and Control Wiring Surge Protection

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

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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. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Schematic diagrams

Interconnecting diagrams

Installation drawings

Submit drawings for government approval prior to equipment construction or integration. Modifications to original drawings made during installation shall be immediately recorded for inclusion into the as-built drawings.

SD-03 Product Data

Variable frequency drives

Wires and cables

Equipment schedule

Include data indicating compatibility with motors being driven.

SD-06 Test Reports

VFD Test

Performance Verification Tests

Endurance Test

SD-08 Manufacturer's Instructions

Installation instructions

SD-09 Manufacturer's Field Reports

VFD Factory Test Plan

Factory test results

SD-10 Operation and Maintenance Data

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Variable frequency drives, Data Package 4

Submit in accordance with Section 01 78 23 OPERATION AND

MAITNENANCE DATA. Provide service and maintenance information including preventive maintenance, assembly, and disassembly procedures. Include electrical drawings from electrical general sections. Submit 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.

1.5 QUALITY ASSURANCE

1.5.1 Schematic Diagrams

Show 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 V.F.D.'s and motors indicated. Indicate ventilation requirements, adequate clearances, and cable routes.

1.5.4 Equipment Schedule

Provide schedule of equipment supplied. Schedule shall provide a cross reference between manufacturer data and identifiers indicated in shop drawings. Schedule shall include the total quantity of each item of equipment supplied. For complete assemblies, such as VFD'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 Factory Test Results

Document test results and submit to government within 7 working days after completion of test.

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1.6 DELIVERY AND STORAGE

Equipment delivered and placed in storage shall be stored with protection from the weather, humidity and temperature variations, dirt and dust, or other contaminants.

1.7 WARRANTY

The complete system shall be warranted by the manufacturer for a period of one year, or the contracted period of any extended warrantee agreed upon by the contractor and the Government, after successful completion of the acceptance test. Any component failing to perform its function as specified and documented shall be repaired or replaced by the contractor at no additional cost to the Government. Items repaired or replaced shall be warranted for an additional period of at least one year from the date that it becomes functional again, as specified in the FAR CLAUSE 52.246-21.

1.8 MAINTENANCE

1.8.1 Spare Parts

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

1.8.2 Maintenance Support

During the warranty period, the Contractor shall provide on-site, on-call maintenance services by Contractor's personnel on the following basis: The service shall be on a per-call basis with 36 hour response. Contractor shall support the maintenance of all hardware and software of the system.

Various personnel of different expertise shall be sent on-site depending on the nature of the maintenance service required. Costs shall 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, shall be borne by the Contractor.

PART 2 PRODUCTS

2.1 VARIABLE FREQUENCY DRIVES (VFD)

Provide frequency drive to control the speed of induction motor(s). The VFD shall 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 shall change fixed voltage, fixed frequency, ac line power to a fixed dc voltage. The converter shall utilize a full wave bridge design incorporating diode rectifiers.

Silicon Controlled Rectifiers (SCR) is not acceptable. The converter shall be insensitive to three phase rotation of the ac

SECTION 26 29 23 Page 6 line and shall not cause displacement power factor of less than .95 lagging under any speed and load condition.

c. An inverter stage shall change fixed dc voltage to variable frequency, variable voltage, and ac for application to a standard

NEMA design B squirrel cage motor. The inverter shall be switched in a manner to produce a sine coded pulse width modulated (PWM) output waveform.

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

e. The VFD shall be designed to operate from a 480 volt, + or - 10 percent, three phase, 60 Hz supply, and control motors with a corresponding voltage rating.

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

g. Adjustable full-time current limiting shall limit the current to a preset value which shall not exceed 120 percent of the controller rated current. The current limiting action shall maintain the V/Hz ratio constant so that variable torque can be maintained. Short time starting override shall allow starting current to reach 175 percent of controller rated current to maximum starting torque.

h. The controllers shall 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 shall be included such that a failure in the controller electronic circuitry shall not cause frequency to exceed 110 percent of the maximum controller output frequency selected.

i. Minimum and maximum output frequency shall 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 shall not be less than 96 percent.

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

l. Protection of power semiconductor components shall be accomplished without the use of fast acting semiconductor output fuses. Subjecting the controllers to any of the following conditions shall 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

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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 shall be included such that current exceeding an adjustable threshold shall activate a 60 second timing circuit. Should current remain above the threshold continuously for the timing period, the controller will automatically shut down.

n. A slip compensation circuit shall be included which will sense changing motor load conditions and adjust output frequency to provide speed regulation of NEMA B motors to within + / - 0.5 percent of maximum speed without the necessity of a tachometer generator.

o. The VFD shall be factory set for manual restart after the first protective circuit trip for malfunction (over-current, under-voltage, over-voltage or over-temperature) or an interruption of power. The VFD shall 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.

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

q. Provide critical speed lockout circuitry to prevent operating at frequencies with critical harmonics that cause resonant vibrations.

The VFD shall have a minimum of three user selectable bandwidths.

r. Provide the following operator control and monitoring devices mounted on the front panel of the VFD:

1. Manual speed potentiometer.

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

3. Power on light.

4. Drive run power light.

5. Local display.

s. Provide properly sized NEMA rated by-pass and isolation contactors to enable operation of motor in the event of VFD

SECTION 26 29 23 Page 8 failure. Mechanical and electrical interlocks shall be installed between the by-pass and isolation contactors. Provide a selector switch and transfer delay timer.

2.2 ENCLOSURES

Provide equipment enclosures conforming to NEMA 250, NEMA ICS 7, and NEMA

ICS 6.

2.3 WIRES AND CABLES

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

2.4 NAMEPLATES

Nameplates external to NEMA enclosures shall conform to the requirements of

Section 26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS. Nameplates internal to enclosures shall be manufacturer's standard, with the exception that they must be permanent.

2.5 SOURCE QUALITY CONTROL

2.5.1 VFD Factory Test Plan

To ensure quality, each VFD shall be subject to a series of in-plant quality control inspections before approval for shipment from the manufacturer's facilities. Provide test plans and 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 shall supervise the installation of all equipment, and wiring.

3.2 FIELD QUALITY CONTROL

Specified products shall be tested as a system for conformance to specification requirements prior to scheduling the acceptance tests.

Contractor shall conduct performance verification tests in the presence of

Government representative, observing and documenting complete compliance of the system to the specifications. Contractor shall submit a signed copy of the test results, certifying proper system operation before scheduling tests.

3.2.1 VFD Test

A proposed test plan shall be submitted to the contracting officer at least

28 calendar days prior to propose testing for approval. The tests shall conform to NEMA ICS 1, NEMA ICS 7, and all manufacturers’ safety regulations. The Government reserves the right to witness all tests and review any documentation. The contractor shall inform the Government at least 14 working days prior to the dates of testing. Contractor shall provide video tapes, if available, of all training provided to the

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Government for subsequent use in training new personnel. 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.

3.2.2 Performance Verification Tests

"Performance Verification Test" plan shall provide the step by step procedure required to establish formal verification of the performance of the VFD. Compliance with the specification requirements shall 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.

The contractor shall inform the Government 14 calendar days prior to the date the test is to be conducted.

3.2.3 Endurance Test

Immediately upon completion of the performance verification test, the endurance test shall commence. The system shall be operated at varying rates for not less than 192 consecutive hours, at an average effectiveness level of .9998, to demonstrate proper functioning of the complete PCS.

Continue the test on a day-to-day basis until performance standard is met.

During the endurance test, the contractor shall not be allowed in the building. The system shall respond as designed.

3.3 DEMONSTRATION

3.3.1 Training

Coordinate training requirements with the Contracting Officer.

3.3.1.1 Instructions to Government Personnel

Provide the services of competent instructors 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 shall be thoroughly familiar with the subject matter they are to teach. The

Government personnel designated to attend the training will have a high school education or equivalent. The number of training days of instruction furnished shall 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 shall be turned over to the Government at the end of last training session.

3.3.1.2 Operating Personnel Training Program

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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

3.3.1.3 Engineering/Maintenance Personnel Training

Accomplish the training program as specified. Training shall be conducted on site at a location designated by the Government. Provide a one day training session to train 4 engineering personnel in the functional operations of the system. This training shall 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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