sEcTtoN 16262 VARIABLE FREQUENCY DRIVES

PART

I

1.01

SUMMARY

A.

O.5O

- 50 HORSEPOWER

GENERAL

Section includes requirements for: Variable Frequency Drives, VFD, 0.5 to 50 horsepower for control of NEMA Design B squirrel cage induction motors, installed in: Standaloneenclosures. Motor Control Centers. Vendor furnished equipment.

L

a. b. c.

B.

Related Sections: The Contract Documents are complementary; what is called for by one is as binding as if called for by all. lt is the CONTRACTOR's responsibility for scheduling and coordinating the Work of subcontractors, suppliers, and other individuals or entities performing or furnishing any of CONTRACTOR's Work. The following Sections are related to the Work described in this Section. This list of Related Sections is provided for convenience only and is not intended to excuse or othen¡rise diminish the duty of the CONTRACTOR to see that the completed Work complies accurately with the Contract Documents. Section 01300 - Submittals. Section 16050 - General Requirements for ElectricalWork.

1. 2. 3.

a. b.

1.02

REFERENCES

A. B.

1.03

Refer to Section 16050.

National Electrical ManufacturersAssociation (NEMA): 250 - Enclosures for Electrical Equipment (1,000 volts maximum). MGl, Part 31 - Motors with higher peak voltage capability.

1. 2.

C.

lnstitute of Electrical and Electroniqs Engineers (IEEE): 519 - Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems.

D.

Undenryriters' Laboratories (UL):

1.

1. 2.

50 Standards for Enclosures for Electrical Equipment. 5084 Standard for Safety for lndustrial Control Panels.

DEFINITIONS

A.

Refer to Section 16050.

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B.

SpecificDefinitÍons: Point of Common Coupling: the point of common coupling for all harmonic calculation and field measurements for both voltage and current distortions is defined as the closest directly connected panelboard or Motor Control Center bus supplying power to the VFD.

1.

,..04 SYSTEM

A.

DesignRequirements: Each variable frequency drive system consists of all components required to meet the performance, protection, safety, testing and certification criteria of this specification. The VFD system shall: Be a fully integrated packagelnclude all material necessary to interconnect all VFD system elements, even if shípped separately

1.

2.

B.

DESCRIPTION

a. b.

Any modifications to a standard product necessary to meet this specification shall be made only by the VFD manufacturer: Each VFD shall be completely factory pre-wired, assembled and then tested as a complete system by the VFD manufacturer to ensure a properly coordinated, fully integrated drive system. The VFD shall be capable of operating standard NEMA Design B motors. lt is the responsibility of the VFD manufacturer to ensure that the drive will not damage motor insulation due to high carrier frequency, reflected wave, dv/dt or other drive electrical characterístics based upon the installed conditions: Provide equipment necessary to mitigate potential damage to motor insulation. Performance: Operating envelope: Speed and torque requirements: Provide a variable torque or constant torque VFD as required by the driven load. The VFD shall be capable of producing a variable alternating voltage/frequency output to provide contínuous operation over the 40 to 200 percent (25 to 120 herlz) speed range. Currentrequirements: Deliver 100 percent of rated current output on a continuous basis. Variable torque VFD: Minimum 110 percent current overload for 1 minute. Constant torque VFD: Minimum 150 percent current overload for 1 minute. Minimum VFD system efficiency: Ninety-six percent. VFD system efficiency shall be calculated as follows:

1.

2.

a.

C.

1.

a.

b.

2.

1) 2)

1) 2) a) 3) a)

ab.

Efficìency

(%o)

:

Power (Load)

Power

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Power (Load) is the total power measured at the output terminals of the drive system, including VFD, output filters or transformers. Power (Supply) is the total power measured at the input terminals of the VFD including input filters, line reactors, isolatíon transformers, harmonic distortion attenuation equipment and auxiliary equipment (e.9., controls, fans) for complete system operation.

3. 4. 5. 1.05

Total power factor: a. Minimum of 0.96 lagging across the entire speed range. b. At no speed shall the VFD have a leading power factor. Frequency accuracy: a. Minimum of within 0.01 percent. Speed regulation: a. Minimum of within 0.5 percent across the entire speed range.

SUBMITTALS

A.

Furnish submittals in accordance with Sections 01300 and 16050: 1. Custom prepared by the VFD manufacturer and specific for the equipment furnished.

B.

Product Data: 1. Manufacturer of the VFD. 2. Manufacturer of all components of the VFD. 3. Dimensions: a. Height. b. width. c. Depth. 4. Weight. 5. Nameplate Schedule. 6. Billof material. 7. Ratings: a. Voltage. b. Phase. c. Current. d. lnterrupting rating. e. Momentary current rating. 8. List of recommended spare parts. 9. Catalog Cut sheets for major components. 10. Design Data: a. Efficiency and power factor values. b. Certification that the drive is sized for the full nameplate motor horsepower and current of the driven load at the installed altitude and ambient temperature. c. Certification that based upon VFD design, cable length to motor, and motor dielectric insulation levelthat the VFD will not damage motor insulation due to carrier frequency, reflected wave, dv/dt, or other VFD produced characteristics. d. Certification that all electronic circuits and printed circuit boards are conformally coated.

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C.

Shop Drawings: Complete plan and elevation drawings showing: All dimensions. Panel, sub-panel and component layout indexed to the Bill of Material. ConduitconnectionsBlock diagram showing the basic control and protection systems specifying the protection, control, trip and alarm functions, the reference signals and commands and the auxiliary devices. Complete schematic, wiring and interconnection diagrams showing connections to both internal and external devices: lnclude terminal number and wire numbers. Complete single-line and 3-line diagrams including, but not limited to, circuit breakers, motor circuit protectors, contactors, instrument transformers, meters, relays, timers, control devices, and other equipment comprising the complete system: Clearly indicate device electrical ratings on the drawings.

1.

2.

a. b. c.

3. 4.

a.

a.

D.

lnstallation lnstructions: The written instructions must detail the complete installation of the VFD including moving, and setting into place. Provide anchorage instructions and requirements for the VFD based on the seismic requirements at the project site as indicated in Section 16050: Stamped by a Professional Engineer registered in the State of Texas.

1. 2.

a.

E.

Operation and Maíntenance Manuals: Spare parts list with supplier names and part numbers. Start-up and commissioning instructions and data. Operating Manuals: Submit operating instructions and a maintenance manual presenting full details for care and maintenance of each model of VFD provided under this contract. Operatinglnstructions: Written descriptions detailing the operational functions of all controls on the front panel. Maintenance Manual: Furnish maintenance manuals with instructions covering all details pertainíng to care and maintenance of all equipment as well as identifying all parts. Manuals include, but are not limited to the following: Adjustment and test instructions covering the steps involved in the initial test, adjustment and start-up procedures. Detailed control instructions which outline the purpose and operation of every control device used in normal operation. All schematic wiring and external diagrams: Furnish drawings in a reduced 11 inch by 17 inch format that are fully legible at that size.

1. 2. 3. 4. 5.

a.

a. a. b.

F.

1) 2) 3)

a)

Test Reports.

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1,06

G.

Manufacturer's Field Reports: 1. Certification letter from the VFD manufacturer that the VFD(s) has been inspected and installed in accordance with the manufacturer's requirements. 2. Report listing the setting of all VFD adjustable parameters and their values after start-up.

H.

Record Documents: 1. Certifíed record documents of equipment with information listed above.

QUAL¡TY ASSURANCE

A. B.

1.07

Refer to Section 16050. Ship the VFDs and associated equipment to the job site on a dedicated vehicle that will allow the CONTRACTOR to utilize on site off loading equipment: 1. VFDs shall be delivered to the site preassembled and wired. 2. Furnish temporary equipment heaters within the VFD to prevent condensation from forming.

PROJECT OR SITE CONDITIONS

A. I.O9

Qualifications: 1. Any third party certification, safety or protection requirements shall be applied to the VFD system as a whole. Certification or protection of system elements or individual components by themselves is not acceptable2. VFD Systems shall be UL listed and labeled. 3. Variable Frequency Drives shall be manufactured by the VFD manufacturer at its own facility which shall have a quality assurance program that is certified ín conformance with ISO 9001.

DELIVERY, STORAGE, AND HANDLING

A. B.

1.08

Refer to Section 16050.

Refer to Section 16050.

SEQUENCING

AB.

Submit equipment for review.

C. D.

Conduct Factory Acceptance Test.

E.

Following approved submittal, conduct internal factory test to ensure that all systems and equipment are functional and submit Certified Test Results for ENGINEER's review.

Ship equipment to project site after successful completion of Factory Acceptance Test. lnstall equípment in the field.

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1.10

F.

Submit manufacturer's certification that all equipment has been properly installed and is fully functional for ENGINEER's review.

G. H. l.

Conduct field acceptance test and submit results for ENGINEER's review.

Refer to Section 16050.

The VFD manufacturer shall be responsible for start up of the VFDs in the presence of the equipment suppliers, CONTRACTOR, ENGINEER and OWNER.

COMMISSIONING

A.

1.14

Refer to Section 16050.

SYSTEM START UP

A. B. 1.13

Refer to Section 16050.

WARRANTY

A. 1.12

Formally energize, start-up and commíssion equipment.

SCHEDULING

A. 1.11

Conduct OWNER's Training Sessions.

After start-up and training has been completed, the VFDs shall be commissioned by the VFD manufacturer: 1. The VFDs shall operate the driven load without failure under normal operating conditions for a period of 30 days: 2. Any failures shall be repaired by the VFD manufacturer. 3. Following repair, the commissioning period shall be restarted. Commissioning shall only be complete once an uninterrupted 30 day period has been completed.

MAINTENANCE

A.

Spare Parts: 1. As a minimum, the following spare parts shall be furnished: a. One set of all power and controlfuses for each VFD. b. One complete main control key pad for each type and rated size of VFD. c. One spare fan for each VFD unit. d. Two sets of ventilation filters for each VFD unit (if applicable in VFD cabinet louvers). e. Any special dedicated tools for emergency service and troubleshooting. f. One set of thyristors or power electronics for each type and rated size of VFD. g. All hardware and software required for configuration, maintenance, troubleshooting and inquiry of all drive parameters.

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PART2 2.01

MANUFACTURERS

A.

2.02

PRODUGTS

One of the following or equal: 1. Eaton/Cutler-Hammer. 2. Allen-Bradley. 3. Toshiba. 4. Siemens-Robicon. 5. Schneider Electric/Square D. 6. General Electric.

EQUIPMENT

A.

General: 1. Sinusoidal Pulse Width Modulated, (PWM) Type Drive. a. Six-pulse insulated gate bipolar transistor, (IGBT), power section. b. Microprocessor based controls. c. Line and load reactors. d. lnput isolation contactors.

B.

Ratings:

C.

1.

Voltage: a. lnput Voltage: 480 volts within 10 percent, 3-phase, 60 hertz.

OperationalFeatures: 1. ProtectiveFeatures: a. Provide the following minimum protective features: 1) Motor overload protection. 2) lnstantaneousovercurrent. 3) lnstantaneousovervoltage. 4) Undervoltage. 5) Power unit overtemperature. 6) Phase loss. 7) VFD output short circuit. 2. Control Mode: a. Operation in either a constant volts/hertz or sensorless vector mode: 1) Control mode selectable using the programming keypad. 3. Frequency Control: a. Minimum of 3 selectable skip frequencies with adjustable bandwidths. b. Programmable minimumfrequencyc. Programmablemaximumfrequency. 4. Acceleration/Deceleration: a. Separately adjustable acceleration and deceleration rates: 1) Each rate acljustable from 0.01 to 3,600 seconds. 5. Spinning Load: a. The VFD shall be capable of determining the speed and direction of a spinning load, "catch" the load and accelerate or decelerate it without damage to the load.

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6.

7. 8.

Programmable Loss of Signal: Upon loss of speed reference the vfd shall be programmable to either: Stop. Maintain current speed. Default to pre-selected speed. Power lnterrupt Ride-Through: The VFD shall be capable of continuous operation in the event of a power loss of five cycles or less. lnputs/Outputs: Analog lnputs: Minimum of 2 programmable analog inputs, configurable as either 0-10 volts or 4-20 mA. Analog Outputs: Minimum of 2 programmable 4-2O mA isolated analog outputs. Discrete lnputs: Minimum of 7 programmable discrete inputs. Discrete Outputs: Minimum of 3 programmable discrete form C relay outputs. Additionallnputs/Outputs:

a.

1) 2) 3)

a. a.

1)

b. 1) c. 1) d. 1) e. 1) Fonruard starVstop. 2) Emergency stop. 3) Potentiometer 3-wire input. Diagnostics: 9. a. Store a minimum of 4 fault conditions in non-volatile memory on a first in-first out basis. b. Operational parameters stored at the time of a the fault: 1) Operatingfrequency. 2) Drive status3) Powermode. c. Fault memory accessible via RS-232, RS-422 or RS-485. 10. Automatic Restart: a. User selectable automatic restart feature allowing the VFD to restart following a momentary power failure or other VFD fault: 1) Programmable for up to nine restart attempts. 2) Adjustable time delay between restart attempts. 2.O3

COMPONENTS

A.

Enclosure: NEMA 12. Provide cooling devices required to maintain the VFD within the Manufacturer's specified temperature limits for the project conditions: Provide cooling device failure alarm.

1. 2.

a.

B. C.

Power Disconnect: Flange mounted motor circuit protector, MCP. Lockable in the OFF position.

1. 2.

Reactors: 3 percent input and 3 percent output line reactors.

1-

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D.

Keypad: Provide each VFD with a keypad for programming and control. KeypadRequirements: Password security to protect drive parameters. Mounted on the door of the VFD. Back-Lit LCD: Minimum of 2 lines with a minimum of 16 characters per line. Programming and display features language: English. Capable of displaying the following parameters: Speed (percent). Output current (Amperes). Output frequency (Hertz). lnput voltage. Output voltage. Total 3-phase kilowatt. Kilowatt hour meter. Elapsed run time meter. Revolutions per minute. 10) Direct current bus voltage. Provide the VFD with controJs as indicated on the Drawings.

1. 2.

a. b. c. 1) d. e. 1) 2) 3) 4) 5) 6) 7) 8) 9)

3.

2.04

E.

Control Power Transformer: Furnish a control power transformer mounted and wired inside the VFD enclosure. With primary and secondary fusing. Sized to power all VFD controls and options as well as any external devices indicated on the Drawings including the motor winding heater.

F.

VFD lnput Contactor: Provide the VFD with a contactor between the incomíng power and the VFD: Provide with all circuitry to control the contactor: On motor start, close the input contactor. After the motor is stopped, open the input contactor.

1-

a-

1) 2)

ACCESSORIES

A.

B.

2.05

1. 2. 3.

Metal Oxide Varistors: Provide protection for the VFD against: Line Transients: 5,000 volt peak minimum. Line to Ground Transients: 7,000 peak minimum.

1-

a. b.

Conformal Coating: Provide conformal coating material applied to electronic circuitry and printed circuit boards to act as a protection against moisture, dust, temperature extremes, and chemicals such as HzS and chlorine.

1.

FINISHES

A.

Enclosure finish shall be manufacturer's standard.

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2.06

SOURCE QUALITY CONTROL

A.

Variable frequency drives, factory testing: 1. General: a. lncoming inspection of components and raw materials based on strategic supplier base and experience. b. All variable frequency drives furnÍshed under this section shall be tested and inspected as specified below. Testing of variable frequency drives based on sampling plans is not allowed. c. The testing procedures specified are the minimum acceptable requirements. The manufacturer may perform additional tests at it's discretion. 2. Failure of any component during testing requires repair of the faulted component and complete retest. 3. Testing Sequence: a. Submit a detailed test procedure for the VFD factory test: 1) A mÍnimum of 8 weeks in advance of the proposed testing date. 2) No tests shall be performed until the test procedure is reviewed and accepted by the ENG¡NEER. 4. Component Tests: a. Preliminaryinspection: 1) Verify that all components are correct. 2) Verify that all connections are properly torqued. b. Printed Circuit Boards: 1) Test for correct component placement and value and complete board functionaltest to ensure proper performance with specified tolerances. 2) Heat cycle test for 48 hours at 60 degrees Celsius. 3) Apply control power to microprocessors, printed circuit boards, diagnostic boards, and similar devices including software to test for proper operation, sequencing, logic, and diagnostics. 4) Test operation of all analog and discrete inputs and outputs. c. Wiring: 1) Control and power wiring continuity verified point-to-point. 2) Hi-pot power and controlwiring at manufacturer's recommended levels. 3) Verify ground bond resistance. d. Load Testing: f ) No load testing in accordance with the manufacturer's standard factory test procedure. 2) Full Load Testing: a) Test each VFD and a representative motor with the system logic and a dynamometer load to simulate field operation conditions at 25 percent, 50 percent, and 100 percentfull load current. b) Load test each VFD at an ambient temperature of 40 degrees Celsius. c) Monitor and record temperature rÍse: (1) lf temperature ríse exceeds the rated value, repair or replace the VFD and re-test. d) Once temperature rise stops continue to operate the VFD for a minimum of 4 hours.

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PART

3

3.01

!NSTALLATION

A. B. C.

3.02

EXECUTION

Refer to Sectíon '16050. lnstall the VFD per the manufacturer's guidelines and submitted installation instruction to meet the seismic requirements at the project site. General: 1. Furnish all cables, conduit, lugs, bolts, expansion anchors, sealants, and other accessories needed to complete the installation of the VFD (free-standing or withîn motor control center). 2. Assemble and install the VFD in the locations and with the layouts shown on the Drawings. 3. Perform work in accordance with manufacturer's instructions and shop drawings. 4. Furnish components and equipment as required to complete the installation. 5. Replace any hardware lost or damaged during the installation or handling to provide a complete installation. 6. lnstallfree-standing enclosures on 3-112inch raised concrete house keeping pad: a. Provide structural leveling channels in accordance with the manufacturer's recommendations to provide proper alignment of the units. b. Weld and/or bolt the VFD frame to the leveling channels. 7. Provide openings in top or bottom of the VFD (free-standing or within motor control center) enclosure for conduit only, no additional openings will be allowed: a. lmproperly cut holes will require that the entire panel be replaced: 1) No hole closers or patches will be allowed. L Bundle circuits together and terminate in each unit: a. Tie wÍth nylon wire ties. b. Label all wires at each end with wire numbers shown on the approved control drawings. c. All connections to and from the VFD (free-standing or within motor control center) enclosure must be made via terminal blocks.

FIELD QUALIW CONTROL

A. B.

Refer to Section 16050. Provide the services of a VFD manufacturer representative for startup assistance and trainíng: 1. lnspection and Field Adjustment: a. Supervise the following and submit written certification that the equipment and controls have been properly installed, aligned, adjusted, and readied for operation. 2. Start-Up Field Testing: a. Provide technical direction for testing, checkout, and startup of the variable frequency drive equipment in the field.

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b. 3.03

Under no circumstances are any portions of the drive system to be energized without authorization from the manufacturer's representative.

ADJUSTING

A. B.

Make all adjustments as necessary and recommended by the manufacturer, ENGINEER, or testing firm. Provide the services of a VFD manufacturer factory technician to make all drive parameters and protective device settings: Protective device settings provided by the VFD manufacturer in accordance with the manufacturer of the driven equipment requirements. Provide documentation of VFD settings included but not limited to: Minirnum speed. Maximum speed. Skip speeds. Current limit. Acceleration time. f Deceleration time.

1. 2.

a. b. c. d. e. .

3.04 CLEANING

A. 3.05

Refer to Section 16050.

DEMONSTATION AND TRA¡NING

A. B. C.

Refer to Section 16050. Demonstrate the operation to the ENGINEER's and OWNER's satisfaction. Training: Provide instruction of the OWNER's operation and maintenance staff on the operation and maintenance of the VFD. Separate classes are required for the operations staff and maintenance staff: Operations staff training shall consist of two identical training sessions, each consisting of 1 session per day for two days, with each session lasting 4 hours for a total class time of I hours: The sessions shall be scheduled with the OWNER to ensure all operators have the opportunity to attend. Maintenance staff trainíng shall consist of 1 session per day for one day with each session lasting for 8 hours, for a total class time of I hours. lnstruction shall occur at the OWNER's facility and shall utilize the actual VFDs installed at the site.

1. 2.

a.

1)

b. c.

3.06

PROTEGTION

A.

Refer to Section 16050. END OF SECTION

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