A21_Solicitation_W91QVN18R0033_Attachment_0001_UFGS-26_35_43_(May_2011)_Change_1_-_0513.pdf

SECTION 26 35 43 Page 1

USACE / NAVFAC / AFCESA / NASA UFGS-26 35 43 (May 2011)

Change 1 - 05/13

Preparing Activity: NAVFAC Superseding UFGS-26 35 43 (April 2006)

UNIFIED FACILITIES GUIDE SPECIFICATIONS References are in agreement with UMRL dated April 2013

SECTION TABLE OF CONTENTS

DIVISION 26 - ELECTRICAL

SECTION 26 35 43

400-HERTZ (HZ) SOLID STATE FREQUENCY CONVERTER

05/11

PART 1 GENERAL

1.1 REFERENCES

1.2 GENERAL REQUIREMENTS

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Frequency Converter Drawings

1.4.2 Qualifications of Manufacturer

1.4.3 Work Plan

1.4.4 Routine Factory Test Plan

1.4.5 Special Factory Test Plan

1.4.6 Performance Test Plan

1.4.7 UL Listing

1.4.7.1 Currently Listed Products

1.4.7.2 Proposed Listed Products

1.4.8 Routine Factory Tests Report

1.4.9 Special Factory Tests Report

1.4.10 Performance Tests Report

1.5 MAINTENANCE

1.5.1 Operation and Maintenance Manuals

1.5.1.1 Additions to Operation and Maintenance Manuals

1.5.1.2 Preliminary Operation and Maintenance Manuals

1.5.1.3 Extra Material

PART 2 PRODUCTS

2.1 FREQUENCY CONVERTER

2.1.1 Electrical Characteristics

2.1.1.1 Input Voltage

2.1.1.2 Input Power Factor

2.1.1.3 Surge Protection

2.1.1.4 Inrush Current

2.1.1.5 Input Current Distortion

2.1.1.6 Output Voltage

2.1.1.7 Power Output

SECTION 26 35 43 Page 2

2.1.1.8 Load Range

2.1.1.9 Efficiency

2.1.1.10 No Load Input Losses

2.1.1.11 Overload/Overcurrent

2.1.1.12 Short Circuit

2.1.1.13 Output Voltage THD

2.1.1.14 Output Voltage Amplitude Modulation

2.1.1.15 Frequency Stability

2.1.1.16 Phase Angle Regulation

2.1.1.17 Transient Output Voltage Recovery

2.1.2 Environmental Rating

2.1.3 Monitoring and Control Panel

2.1.3.1 Controls

2.1.3.2 Indicators

2.1.3.3 Digital Instrumentation

2.1.3.4 Instrumentation

2.1.3.5 Alarm Annunciator

2.1.4 Input/Output Devices

2.1.4.1 Circuit Breaker

2.1.4.2 Input Circuit Breaker

2.1.4.3 Output Contactor

2.1.4.4 Output Circuit Breaker

2.1.5 Protective Controls

2.1.6 Electromagnetic Interference Limits

2.1.7 [DELETED]

2.1.8 [DELETED]

2.1.9 [DELETED]2.1.10 Built-In Test Equipment

2.1.11 Magnetic Devices

2.1.12 Acoustical Noise

2.1.13 Assembly Construction

2.1.14 Nameplates

2.2 POWER CABLE ASSEMBLY

2.3 [DELETED]

2.4 SOURCE QUALITY CONTROL

2.4.1 Converter Test Schedule

2.4.2 Routine Factory Tests

2.4.3 Special Factory Tests (Design Tests)

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Equipment

3.1.1.1 Floor Mounted

3.1.2 Grounding

3.1.3 Wiring and Conduit

3.1.3.1 Building Wiring

3.1.3.2 Conduit

3.1.4 Manufacturer's Representative

3.2 FIELD QUALITY CONTROL

3.2.1 Instruments

3.2.2 Performance of Acceptance Checks and Tests

3.2.3 Initial Inspection and Tests

3.2.4 Performance Tests

3.2.4.1 Preliminary Operation

3.2.4.2 Control and Protective Device Checks

3.2.4.3 Load Test

SECTION 26 35 43 Page 3

3.2.4.4 Transient Tests

3.2.4.5 Harmonic Distortion Tests

3.2.4.6 Line Drop

3.2.5 Grounding System

3.2.6 Follow-up Verification

3.3 DEMONSTRATION

3.3.1 Instructing Government Personnel

-- End of Section Table of Contents --

SECTION 26 35 43 Page 4

USACE / NAVFAC / AFCESA / NASA UFGS-26 35 43 (May 2011)

Change 1 - 05/13

Preparing Activity: NAVFAC Superseding UFGS-26 35 43 (April 2006)

UNIFIED FACILITIES GUIDE SPECIFICATIONS References are in agreement with UMRL dated April 2013

SECTION 26 35 43

400-HERTZ (HZ) SOLID STATE FREQUENCY CONVERTER

05/11

NOTE: The following information shall be shown on the project drawings:

1. Show location of all equipment including converter, and control panel.

2. Provide functional block diagram, single line diagrams, power, and control wiring interconnection diagrams, wiring diagrams, conduit entry diagrams, equipment elevations, limiting dimensions, and equipment ratings which are not covered in the specifications.

3. Design 400 Hz equipment rooms with working spaces as required by NFPA 70. Provide ventilation for equipment rooms based on 400 Hz components heat load generated when operating at 100 percent load.

Provide 60 Hz convenience receptacles.

NOTE: Ensure that the 400 Hz distribution system is properly coordinated including the ratings of the power cables, ground cables, circuit breakers, transformers, filters, rectifiers, and control equipment. When replacing a motor generator set with a solid state converter ensure that the existing feeder’s circuit protective devices will operate properly without damage to electrical devices including the solid state converter.

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.

SECTION 26 35 43 Page 5

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 1159 (2009) Recommended Practice on Monitoring

Electric Power Quality

IEEE 519 (1992; R 1993; Errata 2004) Recommended

Practices and Requirements for Harmonic Control in Electrical Power Systems

IEEE C2 (2012; Errata 2012; INT 1-4 2012) National

Electrical Safety Code

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) Recommended Practice on

Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60947-4-1 (2012; ED 3.1) Low-voltage Switchgear and

Controlgear, Part 4-1: Contactors and Motor Starters - Electromechanical Contactor and Motor Starters

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2008) Enclosures for Electrical Equipment

(1000 Volts Maximum)

NEMA ST 20 (1992; R 1997) Standard for Dry-Type

Transformers for General Applications

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2011; Errata 2 2012) National Electrical

Code

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE AS5756/6 (2004) Cable, 3-Phase Power, Electric

Portable, Multiconductor, 90 Degree C, 600V, Ozone Resistant, Split Phase

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-STD-1399-300 (2008; Rev B) Electric Power, Alternating

Current

MIL-STD-461 (2007; Rev F) Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

SECTION 26 35 43 Page 6

MIL-STD-705 Military Standard Generator Set, Engine

Driven Methods of Test and Instructions

UNDERWRITERS LABORATORIES (UL)

UL 1012 (2010; Reprint Jan 2012) Power Units

Other than Class 2

UL 1449 (2006; Reprint Jul 2012) Surge Protective Device s

UL 489 (2013) Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit- Breaker Enclosures

UL 506 (2008; Reprint Oct 2012) Specialty

Transformer s

1.2 GENERAL REQUIREMENTS

Section 26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS, applies to this section with addition and modifications specified herein.

1.3 SUBMITTALS

** NOTE: Review Submittal Description (SD) definitions in Section 01 33 00 SUBMITTAL PROCEDURES and edit the following list to reflect only the submittals required for the project.

The Guide Specification technical editors have designated those items that require Government approval, due to their complexity or criticality, with a "G". Generally, other submittal items can be reviewed by the Contractor's Quality Control System. Only add a “G” to an item, if the submittal is sufficiently important or complex in context of the project.

For submittals requiring Government approval on Army projects, a code of up to three characters within the submittal tags may be used following the "G" designation to indicate the approving authority. Codes for Army projects using the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO" for District Office (Engineering Division or other organization in the District Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project Office. Codes following the "G" typically are not used for Navy, Air Force and NASA projects.

Choose the first bracketed item for Navy, Air Force and NASA projects, or choose the second bracketed item for Army projects.

SECTION 26 35 43 Page 7

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are [for Contractor Quality Control approval.][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

Frequency converter drawings [G]

SD-03 Product Data

Frequency converter [G] Power cable assembly [G] Control Panel [G]

SD-06 Test Reports

Work Plan [G] Routine Factory Test Plan [G] Special Factory Test Plan [G] Performance Test Plan [G] Test Schedule [G] Routine Factory Tests [G] Special Factory Tests [G]

SD-07 Certificates

Qualifications of manufacturer [G] UL Listing [G]

SD-09 Manufacturer's Field Reports

Initial Inspection and Tests [G] Performance Tests [G] Training Syllabus [G]

SD-10 Operation and Maintenance Data

Frequency converter, Data Package 5[G] Preliminary Operation and Maintenance Manuals, Data Package 5[G] Control Panel, Data Package 5[G]

SECTION 26 35 43 Page 8

1.4 QUALITY ASSURANCE

1.4.1 Frequency Converter Drawings

Furnish scaled drawings of enclosure outline including front, top, side views, and overall dimensions. Provide external power and control wiring and cable connections. Provide single line, schematic, and wiring diagrams. Drawings shall include details of input and output circuit breakers, contactors, rectifiers, surge protectors, and control devices.

Drawings shall include conduit entry and exit locations.

1.4.2 Qualifications of Manufacturer

NOTE: The experience clause in this section has been approved by a Level I Contracting Officer in accordance with the requirements of Naval Facilities Acquisition Supplement (NFAS). NFAS can be found at the following link:

https://portal.navfac.navy.mil/portal/page/portal/navfac/navfac_forbusinesses This clause may be used without further approval or request for waiver.

Submit a certification that the manufacturer has a minimum of two (2) years' experience in the design, manufacturing, and testing of 400 Hz solid state frequency converters at the same or equivalent KVA and voltage ratings for direct connection to Patriot System electrical loads.

The certification shall state that the manufacturer is experienced in manufacturing and testing solid state converters of an equivalent or greater KVA rating. Experience in manufacturing motor generator sets does not qualify as equivalent. Experience in manufacturing portable engine-driven 400-hertz power units do not qualify as equivalent. The manufacturer shall be experienced in producing units for installation in permanent buildings in environmentally closed spaces or in weatherproof enclosures as applicable. The manufacturer shall also document that converters are designed for connection to non-linear loads typically encountered in the aircraft, weapon systems and shipbuilding industries. The manufacturer shall furnish documented experience with converters in various environmental conditions including exterior flight line, hangar, and environmentally enclosed spaces within buildings.

1.4.3 Work Plan

Submit a written schedule of dates of routine and special factory tests, installation, field tests, and operator training for the converter system.

Furnish a list of instrumentation equipment for factory and field test reports.

1.4.4 Routine Factory Test Plan

Submit 7 copies of test plans and procedures at least [21] calendar days prior to the tests being conducted. Provide detailed description of test procedures, including test equipment and setups, to be used to ensure

SECTION 26 35 43 Page 9 the converters meet the performance specification and explain the test methods to be used. As a minimum, the test procedures shall include the tests required under the paragraph entitled "Routine Factory Tests."

1.4.5 Special Factory Test Plan

Submit 7 copies of test plans and procedures with the Routine Factory Test Plan. Provide detailed description of test procedures, including test equipment and setups, used to ensure the converter meets the performance specification and explain the test methods used. As a minimum, the test procedures shall include the tests required under the paragraph entitled "Special Factory Tests."

1.4.6 Performance Test Plan

Submit 7 copies of test plans and procedures at least [15] calendar days prior to the start of field tests. Provide detailed description and dates and times scheduled for performance of tests, and detailed description of test procedures, including test equipment (list make and model and provide functional description of the test instruments and accessories) and setups of the tests to be conducted to ensure the converter meets the performance specification. Explain the test methods to be used. As a minimum, the test procedures shall include the tests required under the paragraph entitled "Field Quality Control."Test reports shall include power quality measurement data collected in accordance with IEEE 1159.

1.4.7 UL Listing

Submit with the initial submittal to verify qualification of manufacturer.

Frequency converter shall be identified with a UL or nationally recognized testing laboratory (NRTL) label prior to shipping.

1.4.7.1 Currently Listed Products

Submit UL or NRTL certification or UL file number for the actual frequency converter to be shipped.

1.4.7.2 Proposed Listed Products

Submit UL or NRTL certification or UL file number for same or similar rating or product size range of like design unit.

1.4.8 Routine Factory Tests Report

Submit within [45] calendar days after completion of tests. Receive approval of test prior to shipping unit. Certify tests were conducted on each converter in accordance with the requirements set forth in paragraph entitled "Routine Factory Tests" and certify converter satisfactorily operated within specified limits. Report shall include copies of the test procedures, test data, and results.

1.4.9 Special Factory Tests Report

Certify tests were conducted on a converter of the same design, construction and kVA and voltage rating to be provided and in accordance with the requirements set forth in paragraph entitled "Special Factory Test" and certify converter operated without malfunctioning within specified limits. Report shall include copies of the test procedures, test

SECTION 26 35 43 Page 10 data and results.

1.4.10 Performance Tests Report

Submit report of test results as specified by paragraph entitled "Field Quality Control" within [15] calendar days after completion of tests.

Certify tests were conducted on each converter in accordance with the paragraph entitled "Field Quality Control" and certify converter satisfactorily operated within specified limits. Report shall include copies of the test procedures, test data, and results.

1.5 MAINTENANCE

1.5.1 Operation and Maintenance Manuals

Submit frequency converter operation and maintenance manuals in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA.

1.5.1.1 Additions to Operation and Maintenance Manuals

In addition to requirements of Data Package 5, include the following on the actual frequency converter provided:

a. A "one-line diagram" from service entrance to 400 Hz utilization panel or point.

b. A weatherproof, tear-resistant plastic data sheet with operating instructions for each unit including startup, shutdown procedures.

c. Routine and field acceptance test reports.

d. UL or NRTL certification or UL file number.

1.5.1.2 Preliminary Operation and Maintenance Manuals

Prior to scheduling Field Performance Tests, 2 copies of a Preliminary Operation and Maintenance Manual must be submitted to and approved by the Contracting Officer.

1.5.1.3 Extra Material

Furnish recommended manufacturer's spare parts list and schedule of prices for each type of converter and other equipment specified in this section.

This list shall include the following:

a. Power semi-conductors

b. Power filter capacitors

c. Plug-in logic cards

d. Output switching modules

SECTION 26 35 43 Page 11

e. Fuses

f. Indicator lamp/LED

[g. Ventilation system filters]

PART 2 PRODUCTS

2.1 FREQUENCY CONVERTER

Provide frequency converters consisting of modular construction solid-state components for [60] to 400 Hz conversion, input/output devices, and ancillary control devices. Frequency converter shall be a standard product of the manufacturer and shall be the manufacturer's latest design that complies with the specification requirements. The 400 Hz frequency converters provided under this contract shall be products of the same manufacturer. The unit shall have a calculated MTBF exceeding [13128] hours as calculated when the converter is provided with yearly servicing and maintenance. The converter shall be UL or third party listed to comply with UL 1012. Circuit breakers operating at 400 Hz shall be designed and UL tested for 60 Hz operation and derated for 400 Hz operation. The converter shall use a minimum 12 pulse or active input rectification circuit. Provide startup and shutdown instructions posted on the front of the unit using engraved plastic plate. Provide a plastic encapsulated schematic diagram attached to the inside of the unit in clear view of maintenance personnel.

2.1.1 Electrical Characteristics

2.1.1.1 Input Voltage

NOTE: For units 15 kVA and below the input voltage should be 208 volts and for units over 15 kVA the preferred input voltage is 480 volts. Using input voltage other than 480 volts will increase the cost and weight and decrease the efficiency of the converter. The input voltage shall be shown on the construction drawings.

[480/277] V, three phase, four wire, grounded, [60] Hz. Converter shall provide rated output voltage when input voltage is varied plus or minus [10] percent. Input neutral currents shall not exceed [21] percent of any individual phase current at no load and at full load.

SECTION 26 35 43 Page 12

2.1.1.2 Input Power Factor

Between 0.8 lagging and unity, under all conditions of steady state line and load variations specified herein.

2.1.1.3 Surge Protection

NOTE: Select Location Category C for outdoor locations only.

The converter shall be capable of sustaining an input surge described in and tested in accordance with UL 1449, and IEEE C62.41.1 and IEEE C62.41.2, Location Category [B], and continue to operate with no alarms within the specified tolerance.

2.1.1.4 Inrush Current

The inrush current shall not exceed 100 percent of the rated full load input current. Inrush current limitation is based on a frequency converter that does not require a transformer at the input to the unit. Should the contractor choose to provide a frequency converter with a transformer at the input to the unit, the contractor shall be responsible for increasing the size of the upstream feeder breaker(s) and increasing the size of conductors and raceways in accordance with NFPA 70.

2.1.1.5 Input Current Distortion

NOTE: Where total connected frequency converter load is a small percentage (less than 40 percent) of the total connected facility load, use 12 percent THD and 8 percent individual. For large frequency converters (i.e. 312 kVA or larger) or where total connected frequency converter load is a significant percentage of the total connected facility load, use 5 percent THD and 3 percent individual. For installation in shipboard environments, use 5 percent THD and 3 percent individual.

Input current THD shall not exceed [12] percent of the fundamental with nominal input voltage at full load. Individual harmonic content shall not exceed [8]-percent of the fundamental.

2.1.1.6 Output Voltage

SECTION 26 35 43 Page 13

[120/208 V, 3 phase 4 wire, 400 Hz, grounded]system.

[Adjustable to plus or minus 10 percent of the rated voltage.] The limits overvoltage and undervoltage shall be [as defined in MIL-STD-704] power] [plus or minus [1] percent]. The phase rotation of the output voltage shall be clockwise sequence of [A-B-C].

2.1.1.7 Power Output

[187.5 ] kVA at 0.8 power factor lagging.

And

[75 ] kVA at 0.8 power factor lagging.

2.1.1.8 Load Range

Operate into a linear load with a power factor between 0.5 lagging and 0.8 leading and into a non-linear load with not less than 15 percent current THD, composed of not less than 6 percent of the 3rd harmonic and not less than 7 percent of the 5th harmonic.

2.1.1.9 Efficiency

NOTE: Use the table below to fill in the kVA and minimum efficiency.

Minimum Percent Efficiency

Rating (kVA) 50 Percent Load 100 Percent Load

5 - 14 80 90

15 - 39 86 90

39 - 99 87 91

100 - up 89 92

Adding EMI filtering for units with power rating larger than 15 kVA, will reduce the efficiency of the unit. If EMI filtering is specified for units with power rating larger than 15 kVA, reduce minimum efficiency by 2 percent.

SECTION 26 35 43 Page 14

The [187.5 and 75] kVA units shall have a minimum efficiency of [80] at 50 percent load and [83] at 100 percent load. For a frequency converter that requires a transformer at the input to the unit, reduce the specified efficiencies by 2 percent.

2.1.1.10 No Load Input Losses

NOTE: Above 30 kVA, use 7 percent, below 30 kVA, use 9 percent.

The frequency converter shall have no-load input losses no greater than [9] percent of the output kW rating. For a frequency converter that requires a transformer at the input to the unit, increase the specified no load input losses by 2 percent.

2.1.1.11 Overload/Overcurrent

Satisfactory overload/overcurrent operating time is based on no more than one overload in any 4 consecutive hours of operation:

Percent of Full Load

Satisfactory Operating Time

110 percent 120 minutes

125 percent 25 minutes

150 percent 5 minutes

300 percent 1 seconds

After minimum operating time is achieved, unit shall interrupt output power. Unit shall be capable of sustaining the overload/overcurrent without damage until the protective device interrupts the overload/overcurrent.

2.1.1.12 Short Circuit

When [a bolted line-to-ground fault,] a bolted line-to-line fault, or a bolted three phase fault is applied to the unit, unit shall be capable of sustaining the short circuit current without damage until the protective device interrupts the fault.

2.1.1.13 Output Voltage THD

a. Balanced load:

(1) Output voltage THD: Not to exceed [2] percent line-to-line and line-to-neutral for linear loads as specified in the paragraph entitled "Load Range".

(2) Output voltage THD: Not to exceed [2] percent line-to-line and line-to-neutral for non-linear loads as specified in the paragraph entitled "Load Range".

(3) Maximum single harmonic distortion: Not to exceed [2]

SECTION 26 35 43 Page 15 percent of the fundamental at the nominal voltage for linear loads as specified in the paragraph entitled "Load Range".

(4) Maximum single harmonic distortion: Not to exceed [3] percent of the fundamental at the nominal voltage for non-linear loads

b. Unbalanced load: Output voltage THD not to exceed 4 percent, line-to-neutral with 15 percent unbalanced linear load.

2.1.1.14 Output Voltage Amplitude Modulation

Output voltage amplitude modulation shall not exceed 1/2 percent of nominal voltage at no load to full load.

2.1.1.15 Frequency Stability

Provide a high frequency crystal clock to control output frequency of the 400 Hz converter within plus or minus 0.5 percent for all operating conditions, including maximum and minimum specified input voltages, ambient temperature and relative humidity. The frequency regulation shall operate independent of supply frequency and load changes.

2.1.1.16 Phase Angle Regulation

Displacement angle between adjacent voltage phases shall be 120 degrees plus or minus 2 degrees with balanced load and plus or minus 4 degrees with three phase 15 percent unbalanced load. A 15 percent unbalanced load is defined as:

a. Phase A at full rated single phase load.

b. Phase B at 85 percent of Phase A.

c. Phase C at 85 percent of Phase A.

2.1.1.17 Transient Output Voltage Recovery

[In accordance with MIL-STD-704.]

2.1.2 Environmental Rating

The converter shall operate satisfactorily from no load to rated full load under the following conditions:

a. Ambient temperatures ranging from 0 degrees C to 55 degrees C. b.

Relative humidity from [0 to 95] percent non-condensing.

c. Ambient pressures from sea level to [915] meters [3,000]

SECTION 26 35 43 Page 16

[3,000] feet.

2.1.3 Monitoring and Control Panel

Provide converter with a control panel that is equipped with the following controls, indicators, instrumentation, data logging, diagnostics, and alarm functions.

2.1.3.1 Controls

a. Start/toggle switch

b. Lamp/light emitting diode (LED) test - A push-to-test button or switch to test indicator lamps/LEDs.

[c. Alarm silence - A switch that shall disable the audible alarm.]

d. Alarm reset - A pushbutton to silence audible alarms.

e. Emergency power off - A separate pushbutton for emergency power off.

[f. Circuit breaker.]

[g. Output contractor ON/OFF]

[h. Output voltage adjust.]

2.1.3.2 Indicators

a. Input power available - Lamp/LED to indicate that the supply voltage is available.

b. Output power On/Off - Lamp/LED to indicate that the converter output voltage is available.

c. System alarm - Lamp/LED to indicate that a fault has been detected.

This indicator shall be latched in the "ON" position whenever an alarm condition described in paragraph entitled, "Alarm Annunciator," is detected and shall remain "ON" until the alarm reset pushbutton is pressed.

d. Indicating lamp/LED to indicate that the alarm silence switch is in the disable position.

e. Audible alarm.

[f. Output contactor "ON".]

2.1.3.3 [Digital Instrumentation

SECTION 26 35 43 Page 17

Provide true rms, plus/minus one percent accuracy, microprocessor-based meter with a simultaneous three-line LCD display. Meter shall display elapsed time (in hours). Meter shall display a selected [output phase-to-neutral voltage,] output phase-to-phase voltage, output phase current, [output neutral current,] and output frequency.

] 2.1.3.4 [Instrumentation

a. Elapsed time meters (in hours).

b. Output voltmeter selector switch having three [phase-to-phase positions for monitoring outputs in accordance with [phase to neutral positions for monitoring wye voltage outputs in accordance with MIL-STD-704] and one "OFF" position.

c. Output ammeter selector switch having three phase positions and one

"OFF" position.

d. Output frequency meter, 395 to 405 HZ scale, having a 400 HZ center with an ON-OFF switch.

] 2.1.3.5 Alarm Annunciator

The unit shall be capable of detecting the following abnormal conditions, sounding an audible alarm and illuminating individual indicator lamp/LEDs that are clearly identified:

a. Input overvoltage.

b. Input undervoltage.

c. Output undervoltage.

d. Output overvoltage.

e. Output overload.

f. System alarm.

g. Control logic failure.

h. Overtemperature.

i. Logic power supply failure.

2.1.4 Input/Output Devices

Provide fully-rated, three-pole, UL approved devices for control of [60] Hz input and 400 Hz output from the converter. Devices and cables

SECTION 26 35 43 Page 18 operating at 400 Hz shall be derated in accordance with IEEE 519.

2.1.4.1 Circuit Breaker

Conform to requirements of UL 489. Breaker operating at 400 Hz shall be derated for 400 Hz operation.

2.1.4.2 Input Circuit Breaker

Provide converter with a UL listed input circuit breaker as an integral part of the converter. Breaker shall be operable from the front of the converter. Breaker shall have a short-circuit current rating of [630] amperes symmetrical minimum.

2.1.4.3 Output Contactor

Provide converter output with an automatic magnetically-held contactor with interlock circuit. Output contactor shall be of sufficient capacity to handle rated load, overload, and available short circuit current.

Contactor shall open when any circuit identified in the paragraph entitled "Protective Control" causes the system to shut down. Output contactor shall be electrically interlocked with ON/OFF circuitry so that when the frequency converter is shut down, the contactor shall open immediately and remain open. [Conform to the requirements of IEC 60947-4-1.]

2.1.4.4 [Output Circuit Breaker

Provide converter output with a non-automatic manual circuit breaker with appropriate frame size and a shunt trip coil derated for 400 Hz operation.

Circuit breaker shall be tripped by the unit's OFF circuit [local or remotely activated] and when any circuit identified in the paragraph entitled "Protective Control" causes the system to shut down. Output breaker shall be operable from the front of the unit.

SECTION 26 35 43 Page 19

2.1.5 Protective Controls

Provide circuitry for the following protective controls.

a. Input undervoltage.

b. Input overvoltage.

c. Loss of phase.

d. Loss of input power.

e. Door interlock - When any access door is opened, the interlock circuitry shall open the [60]Hz input device and 400 Hz output device and not allow the input or output device to close.For maintenance purposes, provide a bypass switch to defeat the interlock circuitry.

f. Output overvoltage - Protect by tripping output devices for instantaneous overvoltage of 30 percent or more and for 10 to 30 percent overvoltage lasting more than 0.25 second.

g. Output undervoltage - Protect by preventing the closing of the output disconnect until the output voltage is 95 percent of the rated output.

If, after closing, the voltage decreases to below 90 percent for longer than 5 seconds, provide relaying to trip output devices utilizing a field-adjustable time-delayed circuit with a range of 4 to 10 seconds.

h. Output frequency - Protect by tripping output devices for frequency change in excess of plus or minus 5 percent of the rated output frequency (400 HZ).

i. Output overload.

j. Converter overtemperature protection.

SECTION 26 35 43 Page 20

2.1.6 [DELETED]

2.1.7 [DELETED]

2.1.8 [DELETED]

2.1.9 [DELETED]

2.1.10 [Built-In Test Equipment

Frequency converter shall include built-in test equipment which monitors both primary circuits and protection circuits of the unit. Provide visual indication to assist diagnosis of unit failures to a modular level.

Provide visual indication of converter status using cabinet mounted light emitting diodes.

2.1.11 [Magnetic Devices

Provide Class 180 power magnetic transformer and inductors in accordance with NEMA ST 20 and UL 506. The limits of Class 180 shall not be exceeded at the maximum specified ambient temperature and at 100 percent load.

2.1.12 Acoustical Noise

NOTE: The following table serves as a guide for establishing the maximum allowable sound pressure level for each kVA rating. The designer should take into consideration that converters are inherently noisy when locating the unit. Do not modify these values unless required by the location of the frequency converter and new values have been confirmed by manufacturer as attainable. If values different than shown below are used, include acoustical noise test in Special Factory Tests.

Maximum Allowable

Rating (kVA) Acoustical Noise (dBa)

5 - 14 65

15 - 39 65

40 - 99 68

100 - 249 72

250 - up 72

Maximum continuous acoustical noise level shall be [72] dBa (A weighted scale).

SECTION 26 35 43 Page 21

2.1.13 Assembly Construction

Provide enclosures suitable for [indoor NEMA Type 1] environments in accordance with NEMA 250. Arrange to provide required [louvers,] cooling air, entry and exit provisions for equipment within enclosures. Construct unit(s) so that components, with the exception of control and monitoring components, are totally enclosed within the enclosure. Electronic circuits including power circuits shall be modular construction readily accessible for maintenance, repair and module replacement from the exterior of the enclosure. [For units installed outdoors or in corrosive environments, electronic circuits shall be enclosed in a sealed electronics compartment that is not provided with direct cooling ventilation or forced air cooling. ] Provide permanent identification tags for wiring. Uniquely identify each wire. Use the same identification system in the wiring diagrams in the Operation and Maintenance Manual. Provide each enclosure with a finish coat over a substrate which has been provided with a rust inhibiting treatment. [Provide two finish coats for outdoor enclosures.] Color shall be the manufacturer's standard color.

2.1.14 Nameplates

As specified in Section 26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND

METHODS.

SECTION 26 35 43 Page 22

2.2 POWER CABLE ASSEMBLY

INPUT Cable The unit shall provide appropriate hardware terminations for quantity one (1)-conductor (3 phase and ground), lugged, and properly sized input cables.

Shielded Output Cabling The unit shall provide appropriate hardware terminations for 4 CONDUCTOR (3ph/neutral, shielded, lugged, output cables sized to insure no voltage drop occurs.

2.3 [DELETED]

2.4 SOURCE QUALITY CONTROL

2.4.1 Converter Test Schedule

The Government reserves the right to witness tests. Provide frequency converter test schedule for tests to be performed at the manufacturer's test facility. Submit required test schedule and location, and notify the Contracting Officer 30 calendar days before scheduled test date. Notify Contracting Officer 15 calendar days in advance of changes to scheduled date.

Test Instrument Calibration.

a. The manufacturer shall have a calibration program which assures that all applicable test instruments are maintained within rated accuracy.

b. The accuracy shall be directly traceable to the National Institute of Standards and Technology.

c. Instrument calibration frequency schedule shall not exceed 12 months for both test floor instruments and leased specialty equipment.

d. Dated calibration labels shall be visible on all test

e. Calibrating standard shall be of higher accuracy than that of the instrument tested.

f. Keep up-to-date records that indicate dates and test results of instruments calibrated or tested. For instruments calibrated by the manufacturer on a routine basis, in lieu of third party calibration, include the following:

(1) Maintain up-to-date instrument calibration instructions and procedures for each test instrument.

(2) Identify the third party/laboratory calibrated instrument to verify that calibrating standard is met.

2.4.2 Routine Factory Tests

SECTION 26 35 43 Page 23

*** NOTE: Coordinate line drop compensation option with power cable assembly requirements.

Routine tests shall be performed by the manufacturer on each of the actual frequency converter(s) prepared for this project to ensure that the design performance is maintained in production. Submit test reports, by serial number and receive approval before delivery of equipment to the project site.

For tests which require full load, use 1.0 power factor unless otherwise noted. All measurements shall be true RMS measurements.

Measurements shall be obtained in accordance with IEEE 1159. Tests shall include the following:

a. Input current and power factor: Operate converter at low, nominal and high input voltage at full load. Measure and record input voltage, input power factor and input current in each phase [and neutral if the neutral conductor is connected to the converter input.]

b. Output voltage, output voltage THD, output current, output power factor, and voltage regulation: Operate converter at nominal input voltage for:

(1) 50 percent of rated capacity with 0.8 lagging power factor linear load.

(2) 100 percent of rated capacity with 0.5 lagging power factor,

0.8 lagging power factor, 1.0 power factor, and 0.8 leading power factor linear loads.

(3) 50 percent of rated capacity with the non-linear load

(4) 100 percent of rated capacity at low and high input voltage.

(5) 100 percent of rated capacity with the non-linear load as specified in the paragraph entitled "Load Range".

Operate for not less than 10 minutes at each test condition in (1), (2), and (3) and (4) above and not less than 30 minutes at test condition in (5) above. Monitor and record output voltage, output voltage THD, output current, output current waveform, output power factor and frequency at the beginning and end of each test condition. Monitor and record output voltage single harmonic distortion for each test condition in (2) and (5) above at the beginning and end of each test condition. Verify output remains within specified regulation limits.

c. Efficiency: Operate at nominal input voltage at half load and full load at 1.0 power factor. Measure and record input voltage, input current, input power factor, output voltage, output current, and

SECTION 26 35 43 Page 24 output power factor. Calculate the unit efficiency.

d. No load losses: Operate at no load and nominal input voltage. Measure and record input voltage, input current, input power, input power factor, and output voltage.

e. Burn-in Test: Before delivery, burn-in all units [under full load conditions for at least [24] hours] [by cycling units [6] hours "ON" under full load conditions and [3] hours "OFF" at no load conditions for at least [4] complete "ON" cycles.] Burn-in test shall be performed with the converter enclosure doors closed and all ventilation in the final operating condition.

f. Include harmonic frequency spectrum analysis depicting Harmonic Order and Harmonic Magnitude at the unit's input and output terminals during full load THD test in test reports.

2.4.3 Special Factory Tests (Design Tests)

*** NOTE: Delete acoustical noise test unless frequency converter is installed in special locations such as test laboratories or other confined spaces.

Submit special factory test (design test) reports (complete with test data, explanations, formulas, and results), in the same submittal package as the catalog data and drawings for [each of] the specified frequency converter(s). Tests shall be certified and signed by a registered professional engineer. Tests shall be on file based on a production model of converters of the same design, construction and kVA rating provided.

As an option, the manufacturer shall test [1] unit[s] at the same time scheduled for routine tests, of each rating and size converter to assure compliance with the specification. For all tests which require full load, use 1.0 power factor unless otherwise noted. The tests shall include the following:

a. Surge protection: Apply input surges in accordance with IEEE C62.41.1 and C62.41.2, Location Category [B] and monitor output.

Conduct a minimum of three consecutive successful tests on each unit listed. Confirm there is no interruption to 400 Hz output power and voltage stays within specified regulation tolerances.

Surge protection tests shall be applicable on all frequency converter units utilizing same surge protection device by manufacturer and part number regardless of frequency converter kVA size.

b. Inrush current: After applying power to the converter, conduct a minimum of three inrush current tests at full load. Provide copies of waveform and THD analysis in test report.

c. Input current distortion: Operate at nominal input voltage at full load. Measure and record the input current THD for the current in each phase.d. Overload/overcurrent: Operate at nominal input voltage with loads listed below:

SECTION 26 35 43 Page 25

d. Overload/overcurrent: Operate at nominal input voltage with loads listed below:

200 percent 20 sec

Monitor output to confirm there is no 400 Hz power interruption. After minimum operating time is achieved, unit shall interrupt output power.

e. Short-circuit: Apply a [bolted line-to-ground,] bolted line-to-line, and bolted three phase fault directly to the output terminals of the unit. Conduct a minimum of three consecutive successful tests on each unit. Provide unit capable of carrying the fault current until the integral system protective devices interrupts the fault with no damage to the unit. Provide waveforms of short circuit current during short circuit tests.

f. Output voltage THD: Operate at nominal input voltage at full load with balanced and 15 percent unbalanced load. A 15 percent unbalanced load is defined as follows:

(1) Phase A at full rated single phase load.

(2) Phase B at 85 percent of Phase A

(3) Phase C at 85 percent of Phase A

Measure and record the output voltage THD for the line-to-neutral voltage of each phase.

g. Phase angle regulation: Operate at full load with balanced and 15 percent unbalanced loads. Measure and record displacement angle between adjacent output voltage phases. A 15 percent unbalanced load is defined as follows:

(1) Phase A at full rated single phase load.

(2) Phase B at 85 percent of Phase A.

(3) Phase C at 85 percent of Phase A.

h. Transient recovery: Operate at the following load steps: 0 to 100 percent, 0 to 50 percent, 100 to 0 percent and 50 to 0 percent.

Measure and record recovery time and output voltage deviation limits.

Provide recordings or display of output voltage during transient recovery test.

[i. Acoustical noise: Operate at no load, 50 percent and 100 percent of full load. Measure continuous steady sound pressure level 1525 mm 5 feet horizontally from the center of each side of the converter at a point 1525 mm 5 feet above the floor. Decibels (dB) are referenced to 20 micropascal.]

SECTION 26 35 43 Page 26

[j. Electromagnetic interference (EMI) test: [EMI test shall meet the requirements of MIL-STD-461D, Part 9, for Class C2 equipment.] [Certified test results on units of the same design shall be acceptable.]]

SECTION 26 35 43 Page 27

PART 3 EXECUTION

3.1 INSTALLATION

Install products to operate at 400 Hz in the same manner as specified in other sections of this specification for products operating at [60] Hz, unless indicated or specified otherwise. Conform to the requirements of NFPA 70 and IEEE C2 and to manufacturer's instructions and recommendations.

3.1.1 Equipment

3.1.1.1 Floor Mounted

Provide proper floor mounting channels and install in accordance with the manufacturer's drawings and instructions and as indicated. Align, level, and bolt or weld units to channels to allow easy withdrawal or insertion of removable components and to permit proper operation and maintenance of

] 3.1.2 Grounding

NOTE: Insert appropriate Section number and title in the blanks below using format per UFC 1-300-02.

In accordance with NFPA 70 and as specified in [Section 26 20 00 INTERIOR

DISTRIBUTION SYSTEM] [26 20 00].

3.1.3 Wiring and Conduit

NOTE: Conductors, circuit breakers, and devices operating at 400 Hz shall be derated as follows:

Circuit Breakers

Derating Factor

E Frame (100 A) 0.87

F Frame (225 A) 0.85

J Frame (600 A) 0.82

SECTION 26 35 43 Page 28

Circuit Breakers

Derating Factor

K Frame (1200 A) 0.74

Cable

AWG Derating Factor

#2 0.9877

#1 0.9675

#1/0 0.9481

#2/1 0.9167

#3/0 0.8831

#4/0 0.8483

3.1.3.1 Building Wiring

NOTE: Insert appropriate Section number and title in the blank below using format per UFC 1-300-02.

Provide Type XHHW or THHN with stranded copper conductors wiring for 400 Hz circuits. Provide wiring for 400 Hz circuits in non-magnetic conduit, aluminum or PVC. Provide wiring and conduit for 60 Hz circuits as specified in Section 26 20 00, INTERIOR DISTRIBUTION SYSTEM [26 20 00].

3.1.3.2 Conduit

Use aluminum conduit for exposed feeders. Do not install aluminum conduit underground or encased in concrete. Use aluminum fittings and boxes with aluminum conduit. For underground or concrete encasement use PVC.

] 3.1.4 Manufacturer's Representative

The manufacturer's representative shall place the system in operation and make necessary adjustments to ensure optimum operation of the equipment.

The manufacturer's representative shall have at least 2 years of practical experience in the installation and testing of 400 Hz solid state frequency converters.

3.2 FIELD QUALITY CONTROL

3.2.1 Instruments

Provide test instruments capable of measuring and recording or displaying

SECTION 26 35 43 Page 30 test data at a higher resolution and greater accuracy than specified for the converter's performance. The test instruments used in the field tests shall have current valid calibration stickers issued by an approved calibration laboratory. Verify calibration and adjustments of converter instruments provided prior to field tests. Instruments shall be calibrated for 400 Hz operation when measuring 400 Hz signals.

3.2.2 Performance of Acceptance Checks and Tests

Perform field tests and conduct inspections. Provide labor, equipment tests instruments, and incidentals required for the tests including load banks, except the Government will furnish electricity. For all electrical load tests, use 1.0 power factor.

Perform in accordance with the manufacturer's recommendations and include the following visual and mechanical inspections and electrical tests.

3.2.3 Initial Inspection and Tests

a. Compare equipment nameplate information with specifications and approved shop drawings.

b. Inspect physical and mechanical condition.

c. Inspect all bolted electrical connections for high resistance using low-resistance ohmmeter, verifying tightness of accessible bolted electrical connections by calibrated torque-wrench method, or performing thermographic survey.

d. Perform specific inspections and mechanical tests as recommended by manufacturer.

e. Verify correct equipment grounding.

f. Perform resistance measurements through all bolted connections with low-resistance ohmmeter, if applicable.

3.2.4 Performance Tests

Conduct converter performance tests under the supervision of the manufacturer's representative. Successfully complete the preliminary operation, control and protective devices check prior to performing load and transient tests. If the converter fails to operate within the specified limits during any of the performance tests the Contractor shall discontinue the test and shall make necessary repairs to correct the failure and restart testing of the converter.

3.2.4.1 Preliminary Operation

Inspect the converter and make adjustments necessary to assure proper operation in accordance with the manufacturer's instructions. Operate frequency converter at 0, 25, 50, 75, and 100 percent of rated full load.

Measure and record the output voltage, current, frequency, and THD at each load. Calculate output voltage regulation. Verify converter is operating within specified limits at each load level.

3.2.4.2 Control and Protective Device Checks

Operate each control, switch, input/output device that is capable of being

SECTION 26 35 43 Page 31 operated manually a minimum of three times, demonstrating satisfactory operation each time. Perform operation test on each protective device to ensure that devices functions properly. After each operation measure and record the converter output frequency, voltage and current. Verify converter is operating within specified limits.

3.2.4.3 Load Test

Operate each unit continuously a minimum of 2 hours at 100 percent rated load. Measure and record the converter output frequency, voltage and current. Verify converter is operating within specified limits. Load test shall be performed with the converter doors closed [and the load connected to the converter with specified power cable assembly].

3.2.4.4 Transient Tests

Transient recovery: Operate at the following load steps: 0 to 100 percent, 0 to 50 percent, 100 to 0 percent, and 50 to 0 percent. Provide recordings or displays of voltage and frequency during each transient test, and indicate on the recordings and displays the time intervals and acceptable limits for voltage and frequency. Repeat each transient test three times; record the results of each test. Verify converter is operating within specified limits.

3.2.4.5 Harmonic Distortion Tests

Perform output voltage harmonic distortion tests at the output of the converter terminals at 0 percent load and 100 percent load at unity power factor. The Contractor shall provide test equipment and instrumentation required for the tests. Tests shall be conducted with a distortion analyzer with test leads within 3 feet of the frequency converter's output terminals. Test data shall include total harmonic distortion amplitudes of all individual harmonics presented in a spectrum analysis format up to the 37th order.

3.2.4.6 Line Drop Test

Conduct line drop tests on each converter with the load connected to the converter with the specified power cable assemblies. Operate each converter at no load, 50 percent and 100 percent of the rated capacity. No adjustments to the frequency converter shall be allowed between load tests.

Monitor and record output voltage at the load end of the cable. Verify specified performance of the line drop compensation.

3.2.5 Grounding System

Inspect ground system for compliance with contract plans and specifications.

3.2.6 Follow-up Verification

Upon completion of acceptance checks and tests, the Contractor shall show by demonstration in service that circuits and devices are in good operating

SECTION 26 35 43 Page 32 condition and properly performing the intended function. As an exception to requirements stated elsewhere in the contract, the Contracting Officer shall be given 5 working days advance notice of the dates and times of checking and testing.

3.3 DEMONSTRATION

3.3.1 Instructing Government Personnel

Provide field training to Government personnel on the operation and maintenance of the converter provided. Provide field training 2 weeks prior to the scheduled date for field acceptance tests. As a minimum the training shall include [2] hours of instruction on the theory of operation and [4] hours on the repair and maintenance of the converters.

The instructor shall be approved by the manufacturer of the unit provided.

Submit training syllabus including each topic of training and a brief outline of each topic to the Contracting Officer at least 4 weeks prior to training for approval. Training shall be approved by the Contracting Officer at least 2 weeks in advance. The Government may record, video and audio, the training sessions and use these recordings to train personnel on the operation and maintenance of the converter system.

Provide two copies of video or audio tapes, if used in the training sessions, to the Contracting Officer.

-- End of Section --