262923 variable frequency controllers.pdf

F5W61608 USPFO Warehouse Ohio Army National Guard Rev. 0 Defense Supply Center Columbus, Ohio

30 January 2009

Bid Final

VARIABLE FREQUENCY CONTROLLERS 262923 - 1

SECTION 262923 - VARIABLE FREQUENCY CONTROLLERS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

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

B. Requirements of the following Division 26 Sections apply to this Section:

1. "Basic Electrical Requirements."

1.2 SUMMARY

A. This Section includes ac motor Variable Frequency Drives rated 600 V and below.

1.3 SUBMITTALS

A. General: Submit the following in accordance with Conditions of Contract and Division1 Specification Sections.

B. Submit the following to the Engineer before ordering equipment:

1. Product data for products specified in this Section. Include dimensions, ratings, and data on features and components, including certified harmonic values to show compliance with limits indicated in this specification section.

2. Efficiency of the overall Variable Frequency Drive system from input to the output terminals, taking all ancillary devices such as filters, reactors, and cooling fans into account.

3. Guaranteed input current harmonic spectrum, based upon the parameters in this specification.

C. Submit the following to the Owner before final project closeout:

D. Maintenance data for products for inclusion in Operating and Maintenance Manual specified in Division 1 and in Division 26 Section "Basic Electrical Requirements”.

E. Load Current and Overload Relay Heater List: Compiled by Contractor after motors have been installed.

Defense Supply Center Columbus, Ohio

30 January 2009

Bid Final

VARIABLE FREQUENCY CONTROLLERS 262923 - 2

1.4 QUALITY ASSURANCE

A. Manufacturer Qualifications: Provide Variable Frequency Drives from manufacturers regularly engaged in the manufacture of equipment of the types and capacities indicated, with such products in satisfactory use in similar service for not less than 5 years.

Manufacturer must also maintain, within 100 miles of the project site, a service center capable of providing training, parts, and emergency maintenance and repairs.

B. Single-Source Responsibility: Obtain Variable Frequency Drives from a single manufacturer.

1.5 EXTRA MATERIALS

A. Circuit Boards: Provide 20 percent, but no less than one set of complete control sub-assemblies for the VFDs, such that spare control sub-assemblies are supplied for all of the VFDs.

B. Spare Fuses: Ten percent, but not fewer than six of each type and rating of fuse used.

Include spares for power fuses, potential transformer fuses, control power fuses, and fusible devices for fused circuit breakers.

C. Spare Indicating Lamps:

1. LED type: Five percent, but not fewer than two of each type installed.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Subject to compliance with requirements, provide products by the following:

1. Robicon

2. Toshiba

3. Allen-Bradley

4. Rockwell- Reliance

2.2 VARIABLE FREQUENCY DRIVES, GENERAL

Defense Supply Center Columbus, Ohio

30 January 2009

Bid Final

VARIABLE FREQUENCY CONTROLLERS 262923 - 3

A. VFDs shall be suitable for connection to a three phase, three wire plus ground system, supplied from either a delta or wye source. No neutral conductor shall be used to supply the VFD.

B. Coordinate the features of each drive with the ratings and characteristics of the supply circuit, the motor, the required control sequence, the duty cycle of the motor, drive, and load, and the pilot device, and control circuit affecting drive functions. Provide drives that are horsepower rated to suit the motor controlled.

C. Air-gap mechanical contacts shall open each ungrounded connection to the motor.

D. Overload Relays: Ambient-compensated type with inverse-time- current characteristic.

Provide with heaters or sensors in each phase matched to nameplate full-load current of the specific motor to which connected with appropriate adjustment for duty cycle.

E. Enclosures: Provide metal enclosures suitable for the environmental conditions at the controller location. Provide NEMA Type 1 enclosures except as otherwise indicated.

2.3 VARIABLE FREQUENCY DRIVES

A. General: Provide VFDs listed and labeled as a complete unit and arranged to provide variable speed of a standard NEMA Design B, 3-phase, inverter duty induction motor by adjusting output voltage and frequency of the VFD. VFD shall be designed and rated by the manufacturer for the type of load (e.g., fans, blowers, and pumps) with which used.

All VFD control circuitry shall be digital. Pulse Width Modulation design (PWM) inverters shall operate at 8 kHz or higher for inverters rated up to 100 horsepower and at 5 kHz or higher for inverters rated larger than 100 horsepower.

B. Input Voltage Tolerance: The VFD shall have a voltage tolerance of +/- 10% and a frequency tolerance of +/- 2 Hz.

C. Control Power: The VFD shall not require external control power.

D. AC to DC converter (rectifier). Only full-wave AC to DC converters shall be used. No converters which require a power system neutral connection shall be used. The harmonic current fed back into the AC supply system shall not exceed the following values based upon Table 10.3 IEEE Standard 519-1992 - Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems. Note that some values in the following tables might be more stringent then the above standard. The point of common coupling (PCC) shall be considered as the connection to the source bus for the VFD, and no further than fifteen feet away.

E. Pulse number: Use minimum 18-pulse AC to DC converters for variable frequency drives larger than 300 horsepower and minimum 12-pulse AC to DC converters for variable frequency drives between 100 and 300 horsepower. Minimum 6-pulse AC to DC

Defense Supply Center Columbus, Ohio

30 January 2009

Bid Final

VARIABLE FREQUENCY CONTROLLERS 262923 - 4

converters may be used for variable frequency drives of less than 100 horsepower.

F. Ratings: As follows:

VFDs with 18-pulse AC to DC converters:

The PCC shall be considered to have the following impedance: ISC/IL <20.

Odd Order Harmonic→

<11 11#h<17 17#h<23 23#h<35 35#h TDD

Percent Harmonic Current→

4.0 2.0 1.5 0.6 0.3 < 5

Even ordered harmonics are not to exceed 25 percent of the odd order harmonic within the same range.

VFDs with 12-pulse AC to DC converters:

The PCC shall be considered to have the following impedance: ISC/IL > 1000.

Odd Order Harmonic→

<11 11#h<17 17#h<23 23#h<35 35#h TDD

Percent Harmonic Current→

4.0 7.0 6.0 2.5 1.4 < 20

Even ordered harmonics are not to exceed 25 percent of the odd order harmonic within the same range.

VFDs with 6-pulse AC to DC converters:

The PCC shall be considered to have the following impedance: ISC/IL > 1000.

Odd Order Harmonic→

<11 11#h<17 17#h<23 23#h<35 35#h TDD

Percent Harmonic Current→

40 7.0 6.0 2.5 1.4 < 20

Even ordered harmonics are not to exceed 25 percent of the odd order harmonic within the same range.

Defense Supply Center Columbus, Ohio

30 January 2009

Bid Final

VARIABLE FREQUENCY CONTROLLERS 262923 - 5

G. DC to AC Converters (Inverters): Inverters shall be rated for continuous duty, using the motor full load currents listed in NEC Table 430-150, over the full range of possible carrier frequencies. Each inverter power electronics component (e.g. IGBT) shall have a minimum DC breakdown rating of at least 150 percent of the DC bus voltage.

H. Ratings: As follows:

1. Output Rating: 3-phase, 480 volts. Output frequency shall vary over the range of at least 6 Hz to 90 Hz. Voltage shall be proportional to frequency up to 60 Hz; voltage shall not exceed 110 percent of rated 60 Hz output voltage at frequencies above 60 Hz. Frequency accuracy shall be within 0.1 Hz over the entire operating range of the VFD. The frequency at maximum voltage shall be adjustable from 25 Hz to 90 Hz. Voltage boost during motor starting shall be adjustable from 0% to 30% with starting frequency adjustable over the range of 1 Hz to 10 Hz or wider.

2. Output Overcurrent Rating: 110% of nameplate rating continuously and 120% for one minute with automatic stall prevention and voltage boost to prevent nuisance tripping during load or line side transient condition.

I. Line Terminators: Provide a line impedance matching terminator at the motor where motor lead length would otherwise cause voltage reflection and consequent higher voltage impulses.

J. Torque: Variable torque.

K. Speed Regulation: Plus or minus 1 percent.

L. Ambient Temperature: -10 to + 115 degrees Fahrenheit

M. Efficiency: 95 percent minimum through full operating range.

N. Isolated control interfaces to allow the VFD to follow all of the following electrical signals over full speed range:

1. 4 to 20 milli-amperes DC, floating connection.

2. 0-10 volts DC

3. 0-5 volts DC

O. Internal Adjustments: Provide the following internal adjustment capabilities:

1. Speed: 0 to 100 percent of maximum RPM.

2. Acceleration: 0.1 to 60 seconds with choice of S or C curves.

3. Deceleration: 0.1 to 60 seconds with choice of S or C curves.

4. Current Limit: 50 to 110 percent of maximum rating continuous.

5. Standard Dynamic Electric Braking: 0 to 5 seconds.

6. Electronic Overload Protection: 10% to 100%.

7. Self-protection and reliability features shall include:

Defense Supply Center Columbus, Ohio

30 January 2009

Bid Final

VARIABLE FREQUENCY CONTROLLERS 262923 - 6

a. Input transient protection: Protection for a Category B, medium exposure environment, as defined by ANSI C62.41 - 1991 - IEEE Recommended Practice on Surge Voltages in Low-Voltage AC power Circuits.

b. Snubber networks to protect against malfunction due to system voltage transients.

c. Motor Overload Relay: Adjustable and capable of NEMA Class 10 performance.

d. Critical Speed Bypass: Provide a minimum of 3 adjustable, field selectable, critical frequency bypass settings with individual bandwidth to prevent operation of the VFD-motor-load combination at a natural frequency of the combination. Upper and lower frequency limits shall be capable of being varied.

e. Instantaneous Overcurrent Trip.

f. Over-temperature trip.

g. Under voltage and over voltage trips.

8. Loss of Phase Protection.

9. Reverse Phase Protection or ability to properly operate with both ABC and CBA

Phase Rotation on Input Power.

10. EEPROM Fault Protection.

11. Ground Fault Protection.

12. Short Circuit Protection.

13. Lockout: Provide input to lockout VFD upon receipt of momentary external contact opening. Open circuit voltage to be less than 25-volts nominal. Lockout must not automatically reset; it shall be re-settable only by manual means at the VFD.

14. Remote Fault Trip Terminal: Provide terminal to shut down VFD upon receipt of momentary external contact closure.

P. Remote Reset Terminal: Provide terminal to reset VFD upon receipt of momentary external contact closure.

1. Automatic Reset and Restart: Attempt 5 restarts after VFD fault or on return of power to the system following an interruption and before shutting down for manual reset or fault correction. Provide for restarting during deceleration without damage to the VFD, motor, or load. The VFD shall restart into a rotating motor by sensing the coasting motor speed and matching that frequency.

Q. Operation and maintenance features shall include:

1. Status: Door-mounted alpha-numeric display to indicate power on, run, overvoltage, line fault, overcurrent, and external fault.

2. Panel-Mounted Operator Station: Provide switch to select either local or remote speed control of VFD. Provide separate Hand-Off-Auto selector switch for the control circuit which shall provide for external contact control of start-stop of the VFD when in the auto position, forced start of the VFD when in the hand position

Defense Supply Center Columbus, Ohio

30 January 2009

Bid Final

VARIABLE FREQUENCY CONTROLLERS 262923 - 7

and stopping of the VFD when in the off position. Off position shall the air-gap open mechanical output contacts, in addition to turning off power semiconductors.

3. Current-Voltage-Frequency-Motor RPM Indicating Devices: Mount digital readout device and selector switch flush in VFD door and connect to indicate VFD output.

4. Integral Main Disconnect: Air-gap mechanical contacts for disconnection of all power to the VFD. Interlock main disconnect with VFD cabinet door so that the main disconnect must be opened before the VFD cabinet door can be opened.

5. Bypass Switch: Provide bypass switch that will allow the motor to be driven at full voltage while the VFD is shut down for service. The bypass and disconnect switches shall make it possible to completely de-energize the VFD and its electronics, while operating the motor at full voltage.

2.4 AUXILIARY CONTROL DEVICES

A. General: Factory installed in VFD enclosure except as otherwise indicated. Provide NEMA 1 enclosure where separately mounted, except as otherwise indicated.

B. Pushbutton Stations, Pilot Lights, and Selector Switches: Heavy-duty type.

C. Control Power Supply: Provide 24 VDC control power supply, isolated from the VFD's input power by a transformer. Both primary leads and all ungrounded secondary output leads of the power supply are to be fused. Secondary leads are allowed to be floating or one secondary lead may be grounded. Inherent current limiting circuitry which will limit the DC short circuit current to 5 amperes is acceptable in lieu of fusing of the ungrounded conductors of the DC control power supply output circuit. All fuses shall be current limiting rejection type mounted in a rejection type fuse holder that will only accept current limiting fuses.

D. Provide the following signals and contacts at a customer accessible and marked barrier type terminal strip.

1. 4 to 20 milli-amperes DC, floating connection, which is proportional to the motor speed.

2. Contacts which indicate if the VFD is in normal or bypass mode.

3. External start-stop for both 2-wire and 3-wire control.

4. Interface Card: Provide interface card compatible with the Owner’s control system.

PART 3 - EXECUTION

3.1 INSTALLATION

Defense Supply Center Columbus, Ohio

30 January 2009

Bid Final

VARIABLE FREQUENCY CONTROLLERS 262923 - 8

A. General: Install independently mounted Variable Frequency Drive in accordance with manufacturer's written instructions.

B. Manufacturer's Field Services: Arrange and pay for the services of a factory-authorized service representative to inspect the field assembly and connection of components, and supervise the pretesting and adjustment of Variable Frequency Drives.

C. Location: Locate Variable Frequency Drives as indicated.

3.2 IDENTIFICATION

A. Identify Variable Frequency Drives in accordance with Division 26 Section "Electrical Identification."

3.3 CONTROL WIRING INSTALLATION

A. Install wiring among motor control devices and control and indicating devices as specified in Division 26 Section "Wires and Cables" for hard-wired connections.

B. Install wiring in enclosures neatly bundled, trained, and supported.

3.4 CONNECTIONS

A. Tighten connectors, terminals, bus joints, and mountings. Tighten field connected connectors and terminals, including screws and bolts, in accordance with equipment manufacturer's published torque tightening values. Where manufacturer's torquing requirements are not indicated, comply with tightening torques specified in UL 486A.

3.5 CLEANING

A. Remove paint splatters and other spots, dirt, and debris. Touch up scratches and mars of finish to match original finish. Clean devices internally using methods and materials as recommended by manufacturer.

3.6 FIELD QUALITY CONTROL

A. Schedule visual and mechanical inspections and electrical tests with at least one week's advance notification.

1. Pre-testing: On completing installation of the system, perform the following preparations for tests, under the supervision of the factory–authorized service representative.

Defense Supply Center Columbus, Ohio

30 January 2009

Bid Final

VARIABLE FREQUENCY CONTROLLERS 262923 - 9

a. Clean devices using manufacturer's approved methods and materials.

b. Inspect for defects and physical damage, and nameplate compliance with current project drawings.

c. Check tightness of electrical connections of devices with calibrated torque wrench. Use manufacturer's recommended torque values.

d. Verify proper fuse types and ratings in fusible devices.

e. Make insulation resistance tests of conducting parts of motor control components; and of connecting supply, feeder, and control circuits. For devices containing solid-state components, use test equipment and methods recommended by the manufacturer.

f. Make continuity tests of circuits.

g. Exercise and perform operational tests of mechanical components and other operable devices in accordance with manufacturer's instructions.

2. Visual and mechanical inspection: Include the following inspections and related work.

a. Motor-Control Device Ratings and Settings: Verify that ratings and settings as installed are appropriate for final loads and final system arrangement and parameters as recommended by Division 23. Recommend final protective-device ratings and settings where differences are found. Use accepted revised ratings or settings to make the final system adjustments.

Prepare and submit the load current and overload relay heater list.

3. Electrical Tests: Perform the following in accordance with manufacturer's instructions:

a. Insulation resistance test of motor control devices conducting parts to the extent permitted by the manufacturer's instructions. Insulation resistance less than recommended by the manufacturer are unacceptable.

b. Make adjustments for final settings of adjustable-trip devices.

c. Test auxiliary protective features such as loss of phase, lockout, phase unbalance and undervoltage to verify operation.

d. Check for improper voltages at terminals in controllers that have external control wiring when controller disconnect is opened. Any voltage over 30 V is unacceptable.

B. Correct deficiencies and retest motor control devices. Verify by the system tests that specified requirements are met.

C. Labeling: On satisfactory completion of tests and related effort, apply a label to tested components indicating test results, date, and responsible organization and person.

3.7 DEMONSTRATION

A. Training: Arrange and pay for the services of a factory-authorized service representative

Defense Supply Center Columbus, Ohio

30 January 2009

Bid Final

VARIABLE FREQUENCY CONTROLLERS 262923 - 10

to demonstrate Variable Frequency Drives and to provide eight hours of on-site training.

3.8 SERVICE AND GUARANTEE

A. General Requirements: Provide, at no additional cost to the Owner, all services, materials and equipment necessary for the successful operation of the entire system for a period of one year after completion of successful performance test. Provide necessary material required for the work. Minimize impacts on facility operations when performing scheduled adjustments and non-scheduled work.

B. Description of Work: The adjustment and repair of the system includes all computer equipment, software updates, electronic and electrical components, equipment and all sensors and control devices. Provide the manufacturer's required adjustments and all other work necessary.

C Personnel: Provide qualified personnel to accomplish all work promptly and satisfactorily.

Owner shall be advised in writing of the name of the designated service representative, and of any changes in personnel.

D Emergency Service: Owner will initiate service calls when a Variable Frequency Drive is not functioning properly. Qualified personnel shall be available to provide service of the complete system, including external controls. Furnish owner with a telephone number where service representative can be reached at all times. Service personnel shall be at the site within 24 hours after receiving a request for service. Restore the Variable Frequency Drive system to proper operating condition within 3 days.

E Operating: Performance of scheduled adjustments and repair shall verify operation of the system as demonstrated by the initial performance test.

F. Systems Modifications: Provide all recommendations for system modification in writing to Owner. Do not make any system modifications, including operating parameters and control settings, without prior approval of Owner. All modifications made to the system shall be incorporated into the operations and maintenance manuals, and other documentation affected.

END OF SECTION 262923