Bridge_Crane_No.1_and_No.2_VFD_Specifications.pdf

DIVISION 26 – ELECTRICAL SECTION 26 29 23

BONNEVILLE BRIDGE CRANE #1 AND #2 - VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS

PART 1 GENERAL

1.1 Provide a total of fourteen fully programmed and tested 480VAC Variable Frequency Drives

(VFD) with dynamic braking units and/or braking resistors for two bridge cranes at Bonneville Project Powerhouse I. The VFD for the CMAA class A Bridge Cranes #1 and #2 are assigned as follows:

- Two bridge travel VFD each driving four 25HP motors.

- Four trolley travel VFD each driving one 20HP motor.

- Eight hoist VFD each driving a 60HP motor.

- VFD parameterization and monitoring software. Provide two sets of the manufacturer’s latest software to be licensed to the government.

The VFD shall meet IEEE 519 specifications and shall be the same manufacture and of a type regularly supplied for cranes in the last five years. Drive controllers for the four main hoists and four aux hoists shall be variable-frequency AC with closed-loop flux vector control with feedback from a motor-shaft-mounted encoder. Drives for bridge travel and trolley travel shall be variable-frequency AC with open- or closed-loop vector control.

1.2 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 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; C 2012) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

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

NEMA ICS 2 (2000; R 2005) Industrial Control and System Controllers, Contactors, and Overload Relays Rated 600 Volts

NEMA ICS 8 (2000: R 2005) Industrial Control and Systems Crane and Hoist

Controllers

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014; AMD 1 2013; Errata 1 2013; AMD 2 2013; Errata 2 2013; AMD 3 2014; Errata 3-4 2014; AMD 4-6 2014) National Electrical Code

UNDERWRITERS LABORATORIES (UL)

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

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-STD-461 (2007; 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 (2014) Radio Frequency Devices

1.3 SYSTEM DESCRIPTION

1.3.1 General Performance Requirements

Electromagnetic Interference Suppression

Certify computing devices, as defined by 47 CFR 15, MIL-STD-461 rules and regulations, comply with the requirements for class A computing devices and labeled as set forth in part 15.

1.3.2 Electromechanical and Electrical Components

Ensure electrical and electromechanical components of the Variable Frequency Drives do not cause electromagnetic interference to adjacent electrical or electromechanical equipment while in operation.

1.3.3 Electrical Requirements

Sensor and Control Wiring Surge Protection Ensure I/O functions as specified are protected against surges induced on control and sensor wiring installed indoors. Protect the inputs and outputs in both normal mode and common mode using the following two waveforms:

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

(2) 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.

SD-02 Shop Drawings

Schematic Diagrams; G Interconnecting Diagrams; G Installation Instructions; G

Submit drawings for Government approval prior to equipment construction or integration.

Record modifications to original drawings made during construction immediately for inclusion into the as-built drawings.

SD-03 Product Data

Variable Frequency Drives; G Dynamic braking units; G Braking resistors; G Motor Compatibility Information and VFD programing; G

SD-08 Manufacturer's Instructions

Installation Instructions; G Transition Guide; G

SD-10 Operation and Maintenance Data

Variable Frequency Drives; G

Provide service and maintenance information including preventive maintenance, assembly, and disassembly procedures. Submit additional information necessary to provide complete operation, repair, and maintenance information, detailed to the smallest replaceable unit.

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.

1.4 QUALITY ASSURANCE

1.4.1 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.

1.4.2 Interconnecting Diagrams

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

1.4.3 Equipment Schedule

Provide a schedule of equipment to be supplied. Provide a cross reference in the schedule between manufacturer data and identifiers indicated in shop drawings. Include the total quantity of each item of equipment supplied in the schedule. For complete assemblies, such as VFD, 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.

1.4.4 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 delivery.

1.4.5 Transition Guide

Prior to shipment to the site, provide product transition guide from CIMR-G5U drives to the type of provided drive. The transition guide shall include connection diagrams and all applicable CIMR-G5U drive parameters relationship to the new drive parameters.

1.4.6 Motor Compatibility Information and VFD programing

Prior to shipment to the site, for each VFD provide specific crane application data showing VFD compatibility with the corresponding motor listed below and a complete list of each VFD parameters settings required for the VFD to meet all the requirements listed in Part 2.

Name plate info Bridge Motors Trolley Motors Hoist Motors Manufacturer Marathon Electric Blue Max Marathon Electric Model 6N 286THTP8042AA L 6N 256THTPA8036AA L 6N 364THDS7042AN W

HP 25 20 60

Base Frequency Hz 60 60 60 Nominal RPM 1775 1750 1780 Max RPM 3600 4200 2700 Phases/Voltage/Amps 3/460/32.5 3/460/26 3/460/72 Duty/Service factor CONT/1.0 60 min/1.0 CONT/1.15 Speed Reducer N1/N2 1800/52.67 1800/7.30 1750/39.6*

*Additional hoists speed reduction is provided in the drums gear box.

1.5 DELIVERY AND STORAGE

Store equipment delivered and placed in storage with protection from the weather, humidity and temperature variations, dirt and dust, or other contaminants.

1.6 WARRANTY

Warranty the variable speed drives furnished under this contract against defects in materials and workmanship for a minimum period of one year from the date of acceptance of the drives by the Bonneville Project. Provide delivery of parts and/or service to the Government with 24 hours of notice by the Government to the Contractor as part of the warranty.

1.8 MAINTENANCE SUPPORT

During the warranty period, Provide on-site, on-call maintenance services by Contractor's personnel on a per-call basis with 36-hour response. Provide support for the maintenance of all hardware and software of the system supplied. Send various personnel of different expertise on-site depending on the nature of the maintenance service required. Include costs for 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 General

The new VFD and brake units shall fit in the existing enclosures without relocating any other existing components, use existing power supply and interface with the existing sensors and 120VAC controls.

2.1.1 The existing bridge VFD configuration and dimensions in inches are as follows:

a. 145kVA 460/460V Delta/Wye isolation transformer

b. VFD name plate IDM CIMR-G5U4075 output 0-460V 0-400Hz 165A

c. CDBR-4220 brake unit

d. Interface board P/N 101830

e. Single brake system

f. Existing enclosure dimensions 60H x 60W x 18D

g. Existing drive dimensions 18.11W x 32.25H x 13.78D

h. Existing main hoist brake unit dimensions 9.875W x 13H x 8D

i. Existing braking resistor dimensions 24W x 18H x 30.25D

j. Controls inputs: Fwd. 1st speed, Rev. 1st speed, 2nd speed, 3rd speed, 4th speed, 5th speed, and normal/slow speed

k. Rated travel speed 95 feet per minute

2.1.2 The existing trolley VFD configuration and dimensions in inches are as follows:

a. 27kVA 460/460V Delta/Wye isolation transformer

b. VFD name plate IDM CIMR-G5U4011 output 0-460V 0-400Hz 28.6A

c. Resistor only brake system

d. Interface board P/N 101830

e. Single brake system

f. Existing enclosure dimensions 60H x24W x 18D

g. Existing drive dimensions 9.84W x 14.96H x 8.86D

h. Existing braking resistor dimensions 10W x 10H x 28.125D

i. Controls inputs: Fwd. 1st speed, Rev. 1st speed, 2nd speed, 3rd speed, 4th speed, 5th speed, and normal/slow speed

k. Rated travel speed 50 feet per minute

2.1.3 The existing main hoists VFD configuration and dimensions in inches are as follows:

a. 75kVA 460/460V Delta/Wye isolation transformer

b. VFD name plate IDM CIMR-G5U4037 output 0-460V 0-400Hz 80A

c. CDBR-4220 brake unit for Main Hoists

d. DBC-4060 9.6 Ohms 43,466W resistor for Main Hoist

e. PG-X2 encoder interface card with Slim Tach SL56 Encoder 5-15 VDC 1025 PPR

f. 120/240 VAC interface board P/N 101810

g. Interface board P/N 101830

h. Redundant brake system

j. Existing enclosure dimensions 60.06H x 48.06W x 18.06D

k. Existing drive dimensions 12.99W x 30.91H x 11.22D

l. Existing main hoist brake unit dimensions 9.875W x 13.25H x 8D

m. Existing braking resistor dimensions 23W x 24H x 30D

n. Controls inputs: Hoist 1st speed, Lower 1st speed, 2nd speed, 3rd speed, 4th speed, 5th speed, and normal/slow speed

o. Rated hoisting speed 4 feet per minute

p. Each main hoist is rated at 150 ton

2.1.4 The existing auxiliary hoists VFD configuration and dimensions in inches are as follows:

a. 75kVA 460/460V Delta/Wye isolation transformer

b. VFD name plate IDM CIMR-G5U4037 output 0-460V 0-400Hz 80A

c. CDBR-4045 brake unit for Aux Hoists

d. DBH-4040 12.00 17,156W resistor for Aux Hoist

e. PG-X2 encoder interface card with Slim Tach SL56 Encoder 5-15 VDC 1025 PPR

f. 120/240 VAC interface board P/N 101810

g. Interface board P/N 101830

h. Redundant brake system

j. Existing enclosure dimensions 60.06H x 48.06W x 18.06D

k. Existing drive dimensions 12.99W x 30.91H x 11.22D

l. Existing aux hoist brake unit dimensions 5.5W x 5.875H x 5.5D

m. Existing braking resistor dimensions 16W x 10H x 28.125D

n. Controls inputs: Hoist 1st speed, Lower 1st speed, 2nd speed, 3rd speed, 4th speed, 5th speed, and normal/slow speed

o. Rated hoisting speed 38.5 feet per minute

p. Each auxiliary hoist is rated at 30 ton

2.2 VARIABLE FREQUENCY DRIVES (VFD)

2.2.1 General

a. VFD shall be compatible with Allen Bradley Controllogix systems using the Ethernet/IP communications protocol, with documented capability for control and monitoring over Ethernet.

b. VFD shall be of a type regularly supplied for cranes in the last five years. Drive controllers for hoists shall be variable-frequency AC with closed-loop flux vector control with feedback from a motor-shaft-mounted encoder. Drives for travel shall be variable-frequency AC with open- or closed-loop vector control as necessary to meet accuracy requirements. V/Hz shall not be used in the VFD settings. VFD shall be mounted on control panels such that the digital keypad displays are visible without opening the panels; digital keypad displays shall be no lower than three feet and no higher than five feet from the walking surface in front of the displays.

2.2.2 VFD Operating Features

A separate VFD shall be provided for each motion. VFD for each motion shall provide true four-quadrant control and shall be the solid state, pulse width modulated (PWM) type with adequate capacity to drive motors at all specified loads and speeds. VFD shall be rated for continuous duty with an ambient temperature of 40 degrees C and at the motor current necessary to lift rated load at all speeds. VFD shall have an overload capacity rating of 150 percent rated load for 1 minute. Power factor shall be 0.95 or above from full speed to zero speed and at rated torque.

Speed regulation shall be less than 1.0 percent from no-load to full-load, over the entire frequency range. Acceleration and deceleration shall be separately adjustable from 0.1 to 20 seconds. Motor overload protection shall be included with the VFD. The control circuit shall include an adjustable-operating current-limiting circuit capable of limiting maximum current to not more than the current necessary to obtain 200 percent motor torque. VFD shall be capable of storing, as a minimum, the most recent ten fault condition codes which shall remain accessible after resetting the drive. VFD shall be provided with communication modules required for proper communication modules required for proper connection with future PLC. In addition, VFD shall: monitor load to verify that enough motor torque has built up before the holding brake is released; monitor load to verify that holding brakes are maintaining load before removing power from the motor; and continuously monitor and alarm if holding brakes slip while the crane is energized. Alarm circuits for the preceding brake monitoring functions shall initiate visible alarm at the operator's control station. Brake monitoring functions shall not be connected to the control system such as to de-activate the main-line contactor when brake fault is detected.

2.3 Hoist and Travel Operating Features

2.3.1 General

Five intermediate points of speed control shall be provided for both hoisting and lowering, and for each direction of travel.

a. Variable speed control from zero to 100 percent shall be provided for both hoisting and lowering. Means shall be provided to limit the maximum torque a hoist motor can develop, and the controls shall be adjusted such that hook loads greater than 200 percent rated hook load cannot be lifted. The load-speed characteristics shall be inherent in the controls at each speed setting. Speed control in the lowering direction shall be such as to permit the operator to stop the hook from any speed point, without time delay, by returning the master control switch to the "OFF" position. Positive control of the lowering movement of all hoist hooks shall be maintained under all conditions of load.

b. Controls shall be provided with adjustable compensation that allows initial electronic adjustment of the speed between hoists operating at the same selected speed and load to be within 0.1 percent of each other.

c. Variable speed control from zero to 100 percent shall be provided for each direction of travel. Travel motion controls shall provide constant speed on each respective control point for all hook loads. Circuits shall be arranged so that the operator may hold the control on any speed point. Sufficient speed droop or other acceptable means shall be provided in the travel drives to permit satisfactory operation when two drives are mechanically interlocked. Compensating circuits shall be provided so that the steady-state operating deviation and service deviation band of speed regulation shall each not exceed 1 percent of the rated speed for all hook loads.

2.3.2 Hoisting and Lowering Performances

The following hoisting and lowering performances are required, and shall be suitable for administering all loads, from no load on the hook to rated load.

a. The starting speed control setting for hoisting and lowering shall provide one-hundredth of one (0.01) percent speed regulation, 1000 to one (1000:1) control range, and position control at zero speed. The starting speed control setting shall start at the beginning of the master switch range (microswitch run command to the VFD).

b. Hoists. The highest (fastest) normal speed control setting for hoisting and lowering shall provide a hoisting speed of 100 percent rated speed at rated load.

c. Main Hoists. The highest (fastest) speed control setting for hoisting and lowering shall provide a hoisting speed of 100 percent rated speed at rated load. This setting shall be field-programmable for a range of 100 to 200 percent rated speed, operable above 100 percent rated speed only when there is light load on the hook/block and when the ultralift is selected via future ultralift selector switch. The initial setting for ultralift shall be 200 percent rated speed.

d. All intermediate speed control settings for hoisting and lowering shall operate linearly between the starting speed control setting and the highest (fastest) speed control setting.

2.3.3 Travel Performances

Bridge and trolley travel control shall provide travel speeds as follows:

a. The starting speed control setting for travel shall have a minimum operating travel speed of no more than one (1) percent of the 100 percent rated travel speed. The starting speed control setting shall start at the beginning of the master switch range (microswitch run command to the VFD).

b. The highest (fastest) speed control setting for travel shall be 100 percent rated travel speed (for normal operating speed).

c. All intermediate speed control settings for travel shall operate linearly between the starting speed control setting and the highest (fastest) speed control setting.

2.3.4 Tandem Main Hoisting and Lowering Performances

There shall be no more than one-quarter (1/4) of an inch difference per twenty (20) feet of hoisting or lowering measured in one direction, or as otherwise approved, between all hoist in tandem. All "Hoisting and Lowering Performances" shall be achieved in tandem

2.3.5 Positioning Accuracy

The control system shall be so designed that it will be possible to limit the motion of any hoist or travel motion to not more than 0.0625-inch starting from complete standstill with any load up to and including rated load. The Government will verify this during acceptance testing by monitoring drum and/or brake wheel movement in relation to block and wheel travel.

2.4 Dynamic Braking for VFD

Hoist and travel controls shall provide dynamic braking. Mechanical or electrical load brakes shall not be used. Resistors for dynamic braking circuits shall: be of the non-breakable, corrosion-resisting type; have a low temperature coefficient; have a thermal capacity of not less than Class 160 series in accordance with Part 11 of NEMA ICS 8; and be rated for continuous duty.

2.5 Source Quality Control - VFD Factory Test Plan

To ensure proper performance upon delivery, subject each VFD to 100 percent factory tests.

Provide test plans and test reports.

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Hardware installation will be performed by the government.

3.1.2 The Contractor shall work with the equipment manufacturers to make available “onsite support” services of competent installation technicians for configuration, startup, and testing.

Technicians shall have the responsibility of checking the VFD settings and making any field adjustments necessary to obtain a working system within the applicable requirements.