253-_263543_-_400_HZ_Solid_State_Frequency_Converter.pdf

NEW HAMPSHIRE AIR NATIONAL GUARD HEADQUARTERS 157TH REFUELING WING

PEASE AIR NATIONAL GUARD BASE, NEW HAMPSHIRE

KC-46A ADAL FUEL CELL, BUILDING 253 TYPE B3 SUBMISSION PROJECT NO. SZCQ139901

400 HZ SOLID STATE FREQUENCY CONVERTER 263543 - 1

SECTION 263543 – 400 HZ SOLID STATE FREQUENCY CONVERTER

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Specification describes the requirements for a Solid State Frequency Converter (SSFC) designed to be capable of powering commercial and military aircraft type loads with a power quality of MIL- STD-704E at 400 Hertz, 115/200 volts AC, 3-Phase, 4 Wire from a utility power supply. This unit shall have a 12 Pulse front end.

1.3 GENERAL

A. Applicable Publications - The publications listed below form a part of this specification to the extent referenced herein. The publications are referred to in the text by the basic designation only.

1. Military Standards.

MIL-STD-704E (1991) Aircraft Electrical Power Characteristics.

MIL-STD-461B (1980) Electromagnetic Interference Characteristics Requirements for Equipment.

MIL-STD-16878D General Specifications for Insulated Electrical Wire.

MIL-W-586-IB Wire, Electrical, Polyvinyl Chloride Insulated, Copper or Alloy Copper.

MIL-I-8500 Interchangeability and Replaceability of Component Parts for Aircraft and Missiles.

2. Other Publications

NFPA 70 National Electrical Code (NEC).

Institute of Electrical and Electronic Engineers (IEEE).

ICS 6-78 (NEMA) Enclosures for Industrial Control Devices and Systems.

ASTM A123.

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ST 20 (NEMA) Dry Type Transformers for General Applications.

ICS-1 General Standards for Industrial control Systems.

C84.1-1977 (ANSI) Voltage Ratings for Electrical Power Systems and Equipment.

38-1975 IEC Standard Voltages (AM I-1977)

ATA-101 Rev. 4 Ground Equipment Data

B. Requirements – Provide a SSFC with accessories, auxiliary equipment, and associated Work as specified. The SSFC shall be a standard product of the manufacturer and shall be the manufacturer’s latest design that complies with the Specification requirements.

1. Materials -Shall be new, unused and suitable for the purpose intended.

2. Basic Assembly Design - The SSFC shall be designed as a modular assembly containing a solid state, 400 Hertz frequency converter and accessories needed to form an operating power supply.

3. Provisions shall be made for lifting and moving the unit by means of a forklift.

4. Environmental Conditions - The SSFC shall be capable of withstanding or operating satisfactorily when exposed to the following conditions:

a. Ambient temperatures ranging from -40°C to 52°C when operating.

b. Relative humidity of 10% to 100%.

c. Altitude - Operation at altitudes up to 6,600 feet (2,000 meters), above sea level without derating.

d. Wind - Up to 80 Mph (175 KM/HR) steady; with gusts to 125 Mph (200 KM/HR).

5. Life Expectancy - The SSFC shall have minimum life expectancy of 20-30 years and a mean time between failures of 24,000 hours, while operating within the Specifications herein at loads to, and including rated load. The unit shall be capable of operating within Specifications after storage up to seven years when properly preserved, packaged and protected.

6. Audible Noise Level - The SSFC noise level shall not exceed 65 dBA at a distance of 4.5 feet (1.5M) height and 3 feet (1M) from the unit.

7. The SSFC shall meet radiated and conductor limits of Radio Suppression Specification MIL-

STD-461.

8. Wiring - Control panel wiring shall be extra flexible, standard-type conforming to MIL-W- 16878D, MIL-W-5086 or equivalent. Wiring shall have ample service loops and formed into neat appearance and laced tightly. Each wire shall be identified using bold faced, stamped cable with numbers in accordance with the wiring diagram of the unit. Cable markers other than those specified shall be approved by the Contracting Officer. Wiring bundles shall be adequately supported and installed in the control cabinet in a neat workmanlike manner. All wiring shall be point to point meaning that every wire starts at one place and ends at another place without any tapping off of that wire to a different destination.

9. Terminals - Wiring terminals shall be selected to result in a permanent, secure bond between the wire and terminal. Circuits which continue to field-wired components shall terminate at suitably identified, easily accessible, terminal boards.

10. ELECTRICAL CHARACTERISTICS

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Input:

a. Nominal voltage - 460 volts nominal (408 to 528).(-15% +10%)

b. Phase - three

c. Frequency - 60 Hertz, ±10%

d. Full load current - 200 Amps, maximum

e. At full load the input current harmonics shall not exceed 10%.

Output:

a. Power rating - 180 KVA

b. Output voltage - 115/200 volts RMS

c. Phase – three

d. Frequency - 400 Hertz, ±0.1 Hertz

e. Power factor - .8 lagging at full load

f. Full load current - 520 Amps, maximum

g. This machine may have a single or dual output contactors ganged together controlled by a single ON pushbutton to close the output contactor(s).

h. Individual Phase Steady-State Voltage – 104.0 – 122 Volts rms

i. 3-Phase Steady State Voltage – 105.5 – 120.5 Volts rms

j. Phase Displacement - 120±1.5°

k. Voltage Modulation, Max. – 3.25 Peak Volts, Peak to Valley

l. Harmonic Content – 5% Max

m. Crest Factor - 1.41±0.1

n. Steady State Frequency - 400±5 Hz

o. Frequency Modulation - ± 2 Hz, Max

p. Load Switching Transient Voltage – 80-134 Volts

q. Voltage Spike - ±600 Volts, Max

r. Transient Frequency – 382.5-417.5 Hz

1.4 SUBMITTALS

A. Submit manufacturer's data on SSFC and components. Include manufacturer's product warranty for replacement of materials and equipment used in SSFC.

B. Operation, Installation, and Maintenance Manuals: Submit operation, installation and maintenance manuals including recommended routine service and maintenance check-list and record form. Submit a proposed shop testing and field testing plan for Contracting Officer's approval with the submittals at least sixty (60) days prior to testing. The plan shall include methods and provisions for validating the

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functionality of complete system, special control sequences and routines and the proper operation for sensors, operators and control panels.

C. Shop Drawings: Submit dimensioned Drawings of SSFC and accessories including, but not limited to output contactors, circuit boards, and their spatial relationship to associated equipment, and connections to remote equipment. Submit schematic and wiring diagrams, material list, foundation requirements, anchor bolt locations, loading and control panel layout Drawings.

D. Certified Test Reports: Submit certified test reports of inspection, tests showing that the equipment meets power, voltage, frequency and specified rating requirements.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Hobart – 180 KVA Hobart ADV

B. Or Approved equal

2.2 MAJOR COMPONENT LIST

A. Input Power Converter

B. Output Power Inverter

C. Controls and Monitors

D. Housing and Ventilating

E. Aircraft Power Cable Assembly

2.3 CHARACTERISTICS

A. The SSFC shall operate and provide electrical power in accordance with the requirements specified herein when supplied with adequate and suitable power as specified herein.

B. Input Voltage and Frequency:

1. The SSFC shall function properly when supplied from an AC source delivered by foreign or domestic utility company at -15% and +10% of nominal voltage rating.

2. On starting the SSFC, the input starting inrush shall not exceed 100% of that input current required when unit is operating at rated load output.

3. With the SSFC supplying loads from 10% to rated load, the input line current shall be balanced to the extent that the current in the line shall not differ by more than 5% from the arithmetic average current in the three input lines. This shall apply when the input voltage unbalance is not greater than 3%.

C. Output Voltage and Frequency:

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1. The output voltage of the SSFC shall be 115/200V at 400 Hertz.

2. With SSFC operating at a constant load, a change in ambient temperature up to 52°C in an eight hour period or as the SSFC stabilizes from cold condition at the load shall not cause the voltage to change by more than 1% of its rated values.

3. With SSFC operating at a constant load, a change in ambient temperature up to 52°C in an eight hour period, or as the SSFC stabilizes from cold condition at the load shall not cause the frequency to change by more than 0.05% of its rated frequency.

4. The frequency shall be 400 Hertz ±0.1 Hertz at every load condition.

5. There shall be no evident discontinuities, spikes or notches in the waveform when viewed on a high frequency oscilloscope having DC-15M Hertz bandwidth and a 25 nanosecond rest time.

A discontinuity is defined as step in the waveform that exhibits a rise time of less than one-fourth the width of the succeeding step in the output waveform. A spike or notch is defined as an over-shoot or under-shoot observed during a step change that falls outside the bank defined by the final amplitudes of the previous succeeding step. This requirement is based on using linear (nonsaturating) reactors to obtain the lagging power factor load component.

6. Load conditions from no load to and including rated load, the total harmonic distortion of the output voltage waveform shall not exceed 3% when measured line-to-line and line-to-neutral.

Single harmonic shall not exceed 2.0 percent of the fundamental at steady state voltage and not otherwise exceed the distortion spectrum limits of Figure 3 of MIL-STD-704.

7. The DC voltage component as measured at the output terminals shall not exceed 100 millivolts from no load to and including rated load.

8. When reviewed on an oscilloscope, the output voltage envelope of line-to-line or line-to-neutral voltages for loads to and including rated load on the SSFC shall not show a difference in voltage amplitude for adjacent peaks of more than 0.25% of rated voltage (rms). This applies to both the upper and lower halves of the envelope.

9. Frequency modulation shall not exceed 0.001% under load conditions.

10. For 3 phase voltage connection, the displacement angle between adjacent output phases shall be 120±1.5 degrees under operating conditions.

11. The overall efficiency shall be not less than 91% at loads and power factors above 50% of rated.

"No load" losses shall not exceed 2% of unit rating.

12. When the SSFC is initially operating at rated input frequency and rated voltage, and following sudden change in load of up to 100% of rated load, the transient output voltage shall not deviate beyond the limits of Figure 5 of MIL-STD-704. Output voltage shall recover and stay within the regulation band within 50 milliseconds.

13. The SSFC output voltage shall be capable of being adjusted over a minimum range of plus or minus 15 percent from rated voltage.

14. With a 15% unbalanced load the maximum output voltage deviation of any of the three output phases will not exceed 3% from the average of the three phase voltages or in accordance with the limits of Figure 1 of MIL-STD-704, whichever is greater.

15. Under balanced load conditions up to and including 100% load, the maximum output voltage deviation of any of the three output phases will not exceed 1% from the average of the three output phase voltages.

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16. The voltage regulation from no load to rated load and from rated load to no load shall not be more than 1.0 percent of rated voltage. This regulation shall be maintained with input line voltage variations of plus or minus 10 percent.

17. The crest factor shall be 1.414, ± 0.07.

18. The SSFC shall have an adjustable line drop compensation feature. It shall be adjustable to 8 % boost.

19. The SSFC shall have a 28 VDC interlock circuit operating from the E & F pins in the aircraft connector. There shall be a manual toggle switch to defeat this circuit. This shall be used for testing only.

20. A circuit shall be included in the frequency converter to allow for operation during the transfer of power from aircraft to external power and vice versa for aircraft that have this No Break Power Feature (NBPT) feature.

21. The unit shall be equipped with a protective package that contains an over and under voltage circuit that will be set to comply with the requirements of MIL-STD-704E. When either of the relays operates it opens an output contactor which removes output power to the load.

2.4 OVERLOAD AND SHORT CIRCUIT

A. The SSFC shall be capable of supplying overloads of up to 125% of rated load for 10 minutes, 150% of rated load for 30 seconds, and 200% of rated load for 10 seconds.

B. The SSFC shall be self-protecting for overcurrents up to and including 90% of component thermal capacities.

C. The SSFC shall be capable of withstanding without damage, a bolted line-to-ground fault, a bolted line-to-line fault, or a bolted phase-to-phase fault cleared by internal solid state circuitry.

D. The SSFC shall be designed to be self-protecting through solid state technology.

2.5 AC INPUT PROTECTION DEVICES

A. A circuit shall detect the loss of a phase and prevent unit from starting.

B. Control circuit transformers with a fused primary shall be provided for operation of control and indicating devices.

C. Fuses shall be suitably marked as to circuit designation.

D. The SSFC shall have an internally mounted circuit breaker connected to the input power lines to allow the input power to be removed in the case of a fault or for maintenance.

2.6 OPTIONAL FEATURES

A. Lights: There shall be a minimum of three (3) lights mounted on the front of the unit.

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1. One Red light: indicate the presence of a fault

2. Green light: indicate unit is functioning and power is available

3. Amber light: indicate output contactor on.

B. Each module shall have an alphanumeric display or RS-232 output with the ability to be read on a PC to be used in gathering data from the unit or trouble shooting. The RS-232 output or alphanumeric displays shall provide the following information as a minimum:

1. Internal and External parameters

a. Input voltage (three phases, A-B, B-C, C-A)

b. DC Buss Voltage

c. Output Voltage (L-N, three phases)

d. Output Current

e. Output Power (KW)

f. Power Factor

g. Output Frequency

h. Run Time

2. GPU Settings

3. GPU Memory Data

4. Setup Values

C. Metering: A digital panel meter shall be provided on the front of the unit to indicate output voltage and output current. The following information shall be available on the front panel:

1. Phase "A" Output Voltage

2. Phase "B" Output Voltage

3. Phase "C" Output Voltage

4. Average Output Voltage

5. Phase "A" Output Current

6. Phase "B" Output Current

7. Phase "C" Output Current

8. Average Output Current

D. Other means of monitoring and troubleshooting will be acceptable if, after submittal review, they are deemed to identify, at a minimum, the points shown in 2.6, A through C.

2.7 DIAGNOSTICS

A. The unit shall perform a self-diagnostic test each time the unit is started.

B. These memory records must be capable of being down loaded via a RS232 connection.

2.8 PHYSICAL CHARACTERISTICS

A. The weight of the SSFC shall not exceed 2173 pounds.

B. The maximum dimensions shall be 23.2" wide x 51" deep x 78" high exclusive of accessories.

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C. The enclosure shall be aluminum rated as NEMA-3R.

D. Where practical, screws, pins and bolts shall be furnished with standard AN or MS locking devices.

E. Major components and subassemblies shall be marked or labeled with an identification number or letter code, or both, on or near the device. The code shall be readily visible when examining the

SSFC.

F. Breather and drain assemblies, to maintain interior pressure and release condensation in NEMA 250, Type 4X enclosures installed outdoors or in unconditioned interior spaces subject to humidity and temperature swings.

G. Space heaters, with NC auxiliary contacts, to mitigate condensation in NEMA 250, Type 4X enclosures installed outdoors or in unconditioned interior spaces subject to humidity and temperature swings.

H. Cooling Fan and Exhaust System: For NEMA 250, Type 1; UL 508 component recognized: Supply fan, with stainless-steel intake and exhaust grills and filters; 120-V ac; obtained from integral CPT.

I. Sun shields installed on fronts, sides, and tops of enclosures installed outdoors and subject to direct and extended sun exposure.

J. Spare control-wiring terminal blocks; wired.

2.9 MEMORY STORAGE

A. The unit shall be capable of recording the last 200 power deliveries to an aircraft and retain the memory for a least 10 years during the absence of external power.

B. These memory records must be capable of being down loaded via a RS232 connection.

2.10 FINISHES

A. Case components shall be painted and suitable protected from oxidation and corrosion.

B. External surfaces shall be painted to customer specified color, upon request.

2.11 MAINTAINABILITY

A. The Mean-time-to-repair for the SSFC shall be no greater than 30 minutes at the module level.

B. Replaceable module accessibility shall be consistent with mean-time-to-repair.

C. No preventative maintenance shall be required.

D, The SSFC shall incorporate built-in-test equipment capable of permitting detection of no less than 98% of the faults. No less than 100% of faults shall be detected by augmenting built-in-test-equipment with the use of off line checkout routines.

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2.12 FAULT ISOLATION

A. The SSFC shall be designed such that an operator can report a single occurring fault.

B. The SSFC shall be designed such that a technician shall be capable of isolating 98% of single occurring faults.

C. No less than 100% of faults shall be detected and localized by augmenting diagnostic routines with the use of portable type test equipment.

2.13 REPAIR

A. The SSFC design shall be such that no less than 99% of faults are correctable at the user level using recommended spare parts.

B. The SSFC design shall be such that no less than 100% of faults are correctable using avionic support resources.

2.14 ENVIRONMENTAL CONDITIONS

A. The SSFC shall be capable of being operated from -40°C to 52°C, when operating.

B. The SSFC shall be capable of operating during and after illumination by air electromagnetic radiation.

C. The SSFC shall be transportable by air, rail, road, ship and helicopter to the point of installation and use.

D. A suitable mounting support shall be provided for attaching to the underside of the PLB cab.

E. The unpackaged SSFC shall withstand, without damage, and remain operable, the rail impact as specified in MIL-STD-705, Method 740-56.

2.15 CONSTRUCTION

A. The converter and inverter sections of the SSFC shall be grouped for easy inspection or replacement.

Each individual module shall be arranged for removal without disassembly of the SSFC.

2.16 COOLING

A. The phase modules shall be cooled by a long life (10 years), fan and the air flow shall be separated from the internal electronic components to provide a separate physically sealed, environmentally clean electronic subsection.

2.17 MATERIALS AND PROCESSES

A. Materials and processes required shall be readily commercially available.

B. Flammable and fungus nutrient materials shall not be used.

2.18 TEST POINTS

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A. Test points shall be built into the equipment to permit rapid isolation of defective assemblies, modules, price parts and facilitate alignment, calibration and test.

2.19 CABINET

A. The cabinet enclosure shall be designed to be suitable for the intended environmental conditions. The components and sub-assemblies shall be mounted in an enclosure suitable for the intended environmental conditions.

B. Access doors and cover shall be provided for easy access to component parts.

C. The control panel shall be mounted within the enclosure with provisions included for attaching remote controls.

2.20 FACTORY TESTS

A. The Manufacturer shall test every SSFC to assure compliance with the Specifications. Certification test sheets shall be sent to the Contracting Officer at the time of shipment of the unit. The Contracting Officer shall be notified fourteen (14) days prior to the date of such tests. The Contracting Officer reserves the right to witness tests and request additional tests that show compliance with the Specifications. Tests shall include, but not be limited to, the following:

1. Operational Checkout:

a. SSFC shall undergo a high potential test of 2500Vdc for 1 minutes on the input of the unit to detect wiring errors. Additional checks shall include over temperature alarm, under voltage alarm, hour meter, and fans.

2. No Load Losses:

a. Operate at no load and nominal input voltage. Measure and record input voltage, output voltage, and output frequency.

3. Load Test:

a. Operate SSFC at 0%, 50%, and 100% loads. Measure and record output voltage, THD,and DC bus voltage.

4. Burn-In:

a. Before delivery, operate each SSFC for a minimum of 16 hours.

5. Additional Tests:

a. Voltage balance (output)

b. Voltage balance (input0

c. Transient voltage dip and response at 0.8 pf (output)

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d. Frequency regulation (output)

e. Overload

f. each safety operating device

g. Line drop compensating circuit

h. Input current harmonics

2.21 CONTROLS AND SPECIAL FEATURES

A. Automatic Reset:

1. The reset function shall be accomplished by operation of the "power off" pushbutton.

B. Remote Monitoring:

1. Each SSFC shall provide a set of normally open contacts to provide ON/OFF status on the

SSFC.

2. Each SSFC shall provide a set of normally closed contacts to provide alarm status of the SSFC.

2.22 WARRANTY

A. The manufacturer shall guarantee that its products will meet all applicable specifications and other specific product and work requirements including those of performance of this agreement and will be free from defects in material and workmanship. Warranty period shall be for two (2) years from date of final acceptance by the Owner.

2.23 AIRCRAFT POWER CABLE ASSEMBLY

A. For 400 Hz wiring at 200Y/115 volts, provide 7-conductor type cable configured as 6 phase conductors (2xA, 2xB, 2xC) tightly wound around the center located neutral, twisted and jacketed in accordance with SAE AS5756/6 rated for 260 amperes minimum. Provide control cabling included within the jacket for interlock circuit and automatic line drop compensation. Terminate control wiring on accessible terminal blocks in unit. Provide cable assembly with integrally molded 400 Hertz male connector aircraft plug. Cable/connector assembly shall be suitable for severe duty. Contact terminations shall be crimped. Final cable length shall be field verified and the length shall be adequate to reach the aircraft receptacle on each type of aircraft being serviced.

PART 3 - EXECUTION

3.1 CABINET MOUNTING

A. The cabinet shall be mounted in such a manner that no damage shall occur as a result of transportation.

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3.2 ELECTROMAGNETIC COMPATIBILITY

A. Grounding:

1. AC source power shall be grounded at the source only.

2. AC output power shall be grounded to the system.

B. Bonding:

1. The chassis or enclosure shall be continuous welded for maximum shielding.

3.3 OPERATION AND MAINTENANCE MANUALS

A. Provide four (4) copies of the comprehensive Operation and Maintenance Manuals to the Contracting Officer fourteen (14) days prior to Final Acceptance date.

B. The Manuals shall fully describe each product, system, or subsystem numbered logically and separated into sections and contained in rigid plastic binders with identification inserted in clear plastic insert pockets on front and spine portions of each binder.

C. The content of the Manuals shall be limited to information and data that specifically applied to products provided and shall include routine normal and special operating instructions and sequences.

Also included shall be routine maintenance procedures and guides for troubleshooting, disassembly and reassembly instructions, and checking instructions along with a recommended spare parts list consisting of current prices and sources.

D. Wiring diagrams and schematics shall be incorporated into the manuals to clearly show features such as controls, switches, instruments and indicators by name and location.

3.4 TRAINING

A. Provide a complete training program for the Owner's operating, engineering, and maintenance personnel. Training shall include both classroom and hands-on instruction and be of sufficient duration to adequately train personnel to perform on-site routine, preventative, and remedial maintenance of the equipment, product or system.

B. The training format shall be submitted to the Contracting Officer for approval sixty (60) days prior to anticipated training date. Submittal shall include, but not be limited to, training outline and Manual, Instructor name and history of previous training for specific product, training aides and duration of program.

C. The Contracting Officer reserves the right to require the Contractor to provide, at no expense to the Owner, additional training in the event the Contracting Officer is of the opinion that the proposed training format is not satisfactory.

D. Training shall be conducted prior to final acceptance of respective equipment, products, and systems by the Contracting Officer and shall be given on the Airport property at the direction of the Contracting Officer.

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E. The Contracting Officer reserves the right to replace, at no expense to the Owner, an instructor who, in the opinion of the Contracting Officer, is not performing at a satisfactory level.

END OF SECTION