SECTION VARIABLE FREQUENCY DRIVES MEDIUM VOLTAGE

Transcription

1 SECTION VARIABLE FREQUENCY DRIVES MEDIUM VOLTAGE PART 1 GENERAL 1.1 SCOPE A. This Specification defines the requirements for Medium Voltage Variable Frequency Drive Systems (VFD s) for the operation of medium voltage motors. Furnish two 4.16kV (5kV class) 600HP VFD S complete, for installation by others, as described in this specification. B. The supplier shall prepare the bid to be in complete compliance with this specification. Any exception shall be included in the bid with an explanation, clearly indicating the paragraph of this specification to which the exception applies, and concisely stating the reasons. The supplier shall include a copy of this specification section, with addendum updates included, with each paragraph check-marked to indicate specification compliance, or, marked to indicate requested deviations from specification requirements. Check-marks ( ) shall denote full compliance with a paragraph as a whole. If deviations from the specifications are indicated, each deviation shall be underlined and denoted by a number in the margin to the right of the identified paragraph and a detailed explanation of the deviation included. The remaining portions of the paragraph not underlined shall signify compliance on the part of the supplier with the specifications. C. Unless clearly identified as an exception, this specification shall have precedence where there is conflict between bidder s descriptive information and this specification. D. The VFD physical dimensions shall not be larger than that described herein. E. External conduit/cable/wire entry and exit shall be from the top for power, signal and control. F. The supplier shall furnish all tools, equipment, material, supplies, personnel, and perform all installation inspections, start-up, programming and configuration required to test, commission and place into satisfactory operation each VFD furnished under this specification. G. Installation will be by others. H. The existing medium voltage high service pump motors are not invertor duty rated. The VFD supplier shall determine if output filtering is necessary to connect the VFD to the high service pump motors and shall integrate any filtering into the overall VFD enclosure/assembly. Drives Medium Voltage March 2018

2 I. The VFD supplier shall store the drives for up to 6 months after date of manufacture. The VFD supplier shall transport and deliver the equipment to the City of West Palm Beach Water Treatment Plant within two weeks of City request. J. VFD Supplier shall be responsible to provide startup, testing and commissioning of the new equipment after installation has been completed by others. 1.2 RELATED SECTIONS NOT USED 1.3 REFERENCES A. IEEE 519 Guide for Harmonic Control and Reactive Compensation of Static Power Converters B. IEEE 1100 Powering and Grounding Sensitive Electronic Equipment C. National Electrical Manufacturers Association (NEMA) D. NEMA ICS 6 Industrial Control and Systems Enclosures E. NEMA ICS 7 Industrial Control Systems Adjustable Speed Drives F. NFPA 70 National Electrical Code (NEC) G. NFPA 70E Handbook for Electrical Safety in the Workplace H. UL 347A Medium Voltage Power Conversion Equipment 1.4 SUBMITTALS FOR REVIEW/APPROVAL A. The supplier shall submit digital copies of the following information for approval by the City: 1. Dimensional outline and scaled plan arrangement drawings including clearance requirements, foundation details and weights. 2. Electrical schematics, wiring and interconnection drawings. 3. Component list 4. Conduit entry/exit locations 5. Assembly ratings 6. Major component ratings 7. Cable terminal sizes 8. Descriptive bulletins Drives Medium Voltage March 2018

3 9. Product and component data sheets 10. Harmonic analysis B. The VFD manufacturer shall provide overall efficiency data at 25%, 50%, 75% and 100% speed for all components. C. The VFD manufacturer shall provide system total power factor data at 25%, 50%, 75% and 100% load. 1.5 SUBMITTALS OPERATIONS AND MAINTENANCE MANUAL A. The following information shall be submitted for record purposes: 1. Final as-built drawings and information for items listed in Paragraph 1.4 above, and shall incorporate all changes made during the manufacturing process. 2. Wiring diagrams 3. Certified production test reports 4. Installation information, including equipment anchorage provisions 5. Electronic copied of O&M shall be provided. 1.6 QUALIFICATIONS A. The VFD manufacturer shall have ISO 9001 certification. B. The supplier shall be able to provide start-up service, 24-hour/day emergency call service, repair work, maintenance and troubleshooting training of customer personnel. C. The supplier of the assembly shall be the manufacturer of the electromechanical power components used within the assembly, such as bypass contactors when specified. D. The supplier of this equipment shall have produced similar electrical equipment for a minimum period of Five (5) years. E. Eaton SC9000 EP Series is the VFD basis of design for function, quality and physical size. Products that are in compliance with this specification and manufactured by others will be considered only if submittals are accompanied with documentation showing itemized compliance to these specifications; is within the physical size described herein; and demonstrates installation experience similar to the basis VFD supplier, including a list showing details of the installation, application, location, contact name and telephone number of at least four (4) users. Drives Medium Voltage March 2018

4 1.7 REGULATORY REQUIREMENTS A. The VFD shall meet the following: 1. ANSI / NEMA Standards 2. UL (certified) 1.8 DELIVERY, STORAGE AND HANDLING A. The Supplier shall coordinate with the City for delivery of each VFD furnished under this specification. One (1) copy of VFD manufacturer delivery, storage and handling instructions shall be included with the equipment at time of shipment. 1.9 OPERATION AND MAINTENANCE MANUALS A. Equipment operation and maintenance manuals shall be provided with each VFD shipped, and shall include instruction leaflets and instruction bulletins for the complete assembly and each major component. PART 2 PRODUCTS 2.1 MANUFACTURERS A. The listing of specific manufacturers below does not imply acceptance of their products that do not meet the specified ratings, features, dimensions and functions described in the drawings and specified herein. Manufacturers listed below are not relieved from meeting these specifications in their entirety. Products in compliance with the specification and manufactured by others not named will be considered only if submittals are accompanied with documentation showing itemized compliance to the drawings, specifications, physical size requirements and experience specific to the basis of design VFD. B. Medium voltage VFDs shall be manufactured by: 1. Eaton (Preferred) 2. Yaskawa 3. Siemens 4. Approved equal 2.2 SYSTEM DESCRIPTION A. The system shall consist of the following main components: one medium voltage variable frequency drive (VFD), fused isolation switch, isolation contactor, drive isolation/phase shifting transformers with minimum 24 pulse rectification, DC bus pre-charge circuit, and output harmonic filter as necessary. All above items are to be integrated in one VFD enclosure not to exceed 102 W x 50 D x 102 H. Drives Medium Voltage March 2018

5 B. The integrated dedicated fused contactor with isolation switch shall be rated to protect the VFD from specified short-circuit levels. The minimum interrupting rating of the input contactor shall be 400A and 800A. The VFD enclosure doors shall be interlocked to prevent opening when main power is available. C. The DC bus capacitors shall be charged before application of main power to limit inrush current to the main rectifier/converter bridge devices by use of a DC bus pre-charge circuit. When the proper DC bus voltage is attained, the main contactor shall be closed and the pre-charge circuit shall be turned off. D. Use of electrolytic capacitors in the drive assembly is not acceptable. E. The requirements of IEEE 519 shall be met at the input terminals of the VFD without an input filter. The harmonic current distortion shall not exceed the limits listed in table 10.3 of IEEE 519 at the input terminals. The harmonic voltage distortion shall not exceed the limits listed in table 11.1 of IEEE 519 at the input terminals. F. Drive shall operate with a +/-10 % input voltage variation. G. The VFD shall be rated for 60kV BIL and 50kA short circuit. H. Auxiliary power 480V, 3-phase, 50/60 Hz shall be provided internal to the integrated Drive. External auxiliary supply voltage sources will not be acceptable. I. The drive will be suitable for the pump motor(s) rated 4160V, 3-phase, 60 Hz, 600 HP, 900 rpm, 81 FLA. J. For variable torque applications the overload capacity shall be 110% of rated current for 1 minute repeated every 10 minutes. For constant torque applications the overload capacity shall be 150% of rated current for 1 minute repeated every 10 minutes. K. The VFD shall be suitable for use with a new or an existing standard squirrel cage motor with 1.0 service factor and standard medium-voltage insulation. 2.3 INVERTER DESIGN A. The VFD inverter shall be of the pulse width modulated (PWM) neutral point clamp (NPC) type. The output devices shall be insulated gate bipolar transistors (IGBT s) with a voltage rating of 6500V for 4160V outputs. Use of lower voltage rated devices is unacceptable. The inverter shall be individual three-phase power pole inverter up to 3500hp and two in parallel for up to 6000hp capable. B. The VFD inverter shall be constructed using six individual power poles installed on a roll-in/roll-out inverter. All power components associated with the power pole shall be encapsulated. All inverter mounted printed circuit boards shall be conformal coated. Drives Medium Voltage March 2018

6 C. Drive shall be capable of running with an inverter with larger devices to minimize the number of spare inverters that will be stocked at the customer site. D. Oil filled power capacitors must be used, electrolytic devices are not acceptable. E. The VFD inverter shall be cooled using heat pipe technology and dedicated cooling fans. 2.4 INTEGRATED INPUT ISOLATION TRANSFORMER AND RECTIFIER A. The VFD shall contain an incoming input isolation transformer with 4160V primary voltage integrated in the VFD enclosure to provide power conversion from the line voltage to the required VFD voltage and to isolate the line from harmonics and common mode voltages. The transformer shall conform to ANSI/IEEE C57 standards. B. The transformer shall contain 12 three phase secondary windings that provide the proper phase shifting to develop a 24-pulse rectification to reduce harmonic currents and voltages reflected to the primary power system. Anything less than 24-pulse is not acceptable. Transformer shall have a 220 degree C insulation rating. C. The transformer and rectifier shall be an integral part of the VFD assembly along with primary isolation switch, power fuses, and input vacuum contactor eliminating the need for separate components, field installation, or wiring. D. The rectifier shall be a diode bridge design with fast acting current limiting semiconductor fuses to protect the bridge. E. The transformer shall be designed to withstand a short circuit. It shall maintain electromagnetic symmetry when only one secondary winding is in short circuit in order to minimize the resulting short circuit forces. The transformer shall be capable of thermally withstanding a short circuit for 2 seconds. F. Transformers shall be of a high efficiency type with full load losses of no greater than 2%. G. Suitable vibration dampers shall be provided with the transformer and its enclosure in order to attenuate mechanical resonance and to reduce the operational sound level. H. The transformer shall include electrostatic shielding between the windings to carry high frequency capacitive currents to ground. I. Transformer designs shall be open type mounted J. The transformer shall be of the air-cooled type and be forced ventilated. K. Only rectifier grade K-factor transformers shall be utilized, with K-Factor of 6 for diode rectifiers. VFD manufacturers providing SCR type rectifiers shall include K Drives Medium Voltage March 2018

7 12 transformers for variable torque applications and K 20 for constant torque applications. 2.5 RELIABILITY A. The manufacturer shall list any control or power components that require recommended maintenance or replacement before 50,000 hours of operation. Information must be available in the manufacturer's maintenance manual and available for submittal. B. All components of the VFD shall be considered for MTBF calculations using Failure in Time (FIT) analysis. C. The Mean Time Between Failure (MTBF) of the current carrying devices of the VFD shall be 98,000 hours or greater D. The VFD shall be capable of continuous operation ( ride-through ) in the event of a power loss of up to 5 cycles. E. The VFD shall be able to safely operate, without tripping, with up to 30% voltage sag on the rated input voltage. F. All power semiconductors and passive power components in both the rectifier and inverter sections shall be medium voltage rated components. Low voltage components are not acceptable in the power sections. 2.6 INPUT POWER QUALITY A. The VFD total harmonic voltage distortion (THD) contribution at the input terminals shall not exceed the 5% THD limit recommended for General Systems as listed in Table 11.1of IEEE 519, throughout the speed range. B. The VFD fundamental power factor shall be > The total power factor at the VFD input shall be > 0.95, for the load range of 20 to 100%. The VFD manufacturer shall provide a power factor correction filter if the VFD does not meet this requirement. The VFD including power factor correction and/or harmonic filter shall never have a leading power factor. C. For any VFD employing capacitors on the input side, such capacitors shall be rated 12.47kV or higher to avoid harmonic transient resonance. 2.7 OUTPUT POWER QUALITY A. Output waveform switching transients and harmonic content shall have a negligible contribution to motor heating, acoustical noise in the motor, torsional stress in the power train, and motor insulation. B. Common mode voltages on the VFD output shall be isolated from the motor. Drives Medium Voltage March 2018

8 C. Motor cable voltage reflections and the resulting restrictions on motor cable length shall be taken into consideration and the drive shall be properly applied to the motor. 2.8 CONTROL FUNCTIONS A. The VFD control circuit shall be as shown in the attached drawings. B. Frequently accessed VFD programmable parameters shall be adjustable from a digital operator keypad located on the front of the VFD. The VFD s shall have a three line alphanumeric programmable display with status indicators. Keypads must use plain English words for parameters, status, and diagnostic messages. Keypads that are difficult to read or understand are not acceptable, particularly those that use alphanumeric codes and tables. Keypads shall be adjustable for contrast with large characters easily visible in normal ambient light. The keypad shall have copy/paste capability. C. Upon initial power up of the VFD, the keypad shall display a start up guide that will sequence all the necessary parameter adjustments for general start up. D. Standard advanced programming and trouble-shooting functions shall be available by using a personal computer s RS-232 port and Windows based software. In addition the software shall permit control and monitoring via the VFD s RS232 port. The manufacturer shall supply the required software. An easily understood instruction manual and software help screens shall also be provided. The computer software shall be used for modifying the drive setup and reviewing diagnostic and trend information as outlined in this section. E. The operator shall be able to scroll through the keypad menu to choose between the following: 1. Monitor 2. Operate 3. Parameter setup 4. Actual parameter values 5. Active faults 6. Fault history 7. LCD contrast adjustment 8. Information to indicate the standard software and optional features software loaded. F. The following setups and adjustments, at a minimum, are to be available: Drives Medium Voltage March 2018

9 1. Start command from keypad, remote or communications port 2. Speed command from keypad, remote or communications port 3. Motor direction selection 4. Maximum and minimum speed limits 5. Acceleration and deceleration times, two settable ranges 6. Critical (skip) frequency avoidance 7. Torque limit 8. Multiple attempt restart function 9. Multiple preset speeds adjustment 10. Catch a spinning motor start or normal start selection 11. Programmable analog output 12. DC brake current magnitude and time 13. PID process controller 2.9 CONTROL SYSTEM INTERFACES A. The VFD shall have the following system interfaces: 1. Inputs A minimum of six (6) programmable digital inputs, two (2) Analog inputs and serial communications interface shall be provided with the following available as a minimum: a. Remote start/stop b. Remote preset speeds c. Remote external trip d. Remote fault reset e. Local Hand-Off-Remote Switch in HAND position (local control) f. Remote speed command, 4-20 ma input g. Potentiometer and 1-10Vdc speed reference interface h. RS232 programming and operation interface port Serial communications port Drives Medium Voltage March 2018

10 2. Outputs Programmable relay outputs with one (1) set of Form C contacts for each, selectable with the following available at minimum: a. Fault b. Run c. Two (2) spare programmable relay outputs. 3. Programmable analog 4-20ma DC output signal, selectable with the following available at minimum: a. Speed Out b. Two (2) spare programmable 4-20ma DC outputs. B. Monitoring and Displays 1. The VFD display shall be a LCD type capable of displaying three (3) lines of text and the following thirteen (13) status indicators: a. Run b. Forward c. Reverse d. Stop e. Ready f. Alarm g. Fault h. I/O terminal i. Keypad j. Bus/Comm k. Local (LED) l. Remote (LED) m. Fault (LED) 2. The VFD keypad shall be capable of displaying the following monitoring functions at a minimum: Drives Medium Voltage March 2018

11 a. Output frequency b. Frequency reference c. Motor speed d. Motor current e. Motor torque f. Motor power g. Motor voltage h. Dc-bus voltage i. Unit temperature j. Calculated motor temperature k. Voltage level of analog input l. Current level of analog input m. Digital inputs status n. Digital and relay outputs status o. Analog out C. Operator Interfaces 1. Selector switches and push buttons shall be 30mm heavy-duty type and match the NEMA rating of VFD enclosure. Legend plates shall be scribed and provided by the manufacturer. The VFD shall include the following operator control devices interfaces at minimum: a. Local/Off/Remote Selector Switch b. Start Push Button c. Stop Push Button d. Reset Push Button e. Speed Control Potentiometer 2. Pilot indicating lights shall be 30mm LED, heavy duty, and push-to-test type. The VFD shall include the following pilot lights at minimum: a. Call to Run Drives Medium Voltage March 2018

12 b. Running c. VFD Fault d. VFD Over Temperature e. Incomplete Sequence f. Low Flow g. Low Vacuum h. Discharge Valve Fully Open D. Control Interfaces: 1. The following signals shall be available to plant SCADA. Output and input signals shall be dry contact closures with contacts rated 120V, 5A minimum. Analog signals shall be 4-20 ma. a. From Plant SCADA 1. Start/Stop Command(dry contact input) 2. Speed Command (4-20 ma DC input) b. To Plant SCADA 1. Running (dry contact output) 2. VFD Fault (dry contact output) 3. VFD Overtemperature (dry contact output) 4. Low Flow (dry contact output) 5. In Hand (dry contact output) 6. In Remote (dry contact output) 7. Discharge Valve Opened (dry contact output) 8. Discharge Valve Closed (dry contact output) 9. Incomplete Sequence (dry contact output) 10. Speed Indication (4-20 ma output) 2. The following Discrete Input/Output Signals shall be interfaced with VFD control logic: Drives Medium Voltage March 2018

13 a. Existing emergency stop push button station (dry contact input) b. Existing pump primed pressure switch (dry contact input) c. Existing high discharge pressure switch (dry contact input) d. Existing low discharge flow switch (dry contact input) e. Existing low discharge flow switch (120VAC instrument power) f. Existing discharge valve open limit switch (dry contact input) g. Existing discharge valve closed limit switch (dry contact input) h. Existing discharge valve open command (dry contact output) i. Existing discharge valve close command (dry contact output) j. Pump winding temperature monitor (RTD inputs). Total of three, one per winding PROTECTIVE FUNCTIONS A. The VFD shall include the following protective features at minimum: 1. Over current 2. Over voltage 3. Inverter fault 4. Under voltage 5. Input phase loss 6. Output phase loss 7. Under temperature 8. Over temperature 9. Motor stalled 10. Motor over temperature 11. Motor under load 12. Logic voltage failure 13. Microprocessor failure Drives Medium Voltage March 2018

14 14. The VFD shall provide ground fault protection during power-up, starting, and running. VFD s with no ground fault protection during running are not acceptable. B. Diagnostic Features 1. Fault History 2. Record and log faults 3. Indicate the most recent first, and store up to 30 faults. 4. An Emergency-stop (E-Stop) shall be provided on the VFD door in addition to inputs for customer supplied E-Stop command. C. Control Power Transformers (CPT s) 1. A control power transformer (CPT) shall be provided with UPS within the enclosure. 2. The kilovolt-ampere rating of the CPT shall be determined by the manufacturer and shall have a minimum of 25% spare capacity. 3. The CPT secondary voltage shall be 120 Vac. 4. The CPT primary shall be fused with current limiting fuses with an interrupting rating no less than 50,000 amperes. 5. The CPT secondary shall be fused and have one terminal grounded INTEGRATED MAIN POWER TOP BUS A. If required by the manufacturer, a top mounted bus may be an integral part of the VFD design to be configured as a part of the integrated VFD assembly. B. All bus bars shall be copper tin-plated. Bus shall be rated for minimum 400A continuous current. C. Bus bars shall be braced to withstand short circuit currents at a minimum of 50k AIC INTEGRATED INPUT ISOLATION SWITCH A. Each AFD shall include a fused manually operated isolation 5kV switch with visible blades, current limiting power fuses, and a removable vacuum contactor to feed the isolation/phase shifting transformer. These components shall be provided to safely isolate the drive from the power source. The vacuum contactor shall carry the same ratings as full voltage vacuum contactors designed for MV motor starting duty. The fault rating of the vacuum contactor shall be a minimum of 8500A. Drives Medium Voltage March 2018

15 2.13 HARMONIC FILTERS AND POWER FACTOR CORRECTION A. Power factor correction equipment shall be provided, if necessary, to maintain a constant input power factor of 0.95 lagging throughout the entire load range. B. Filters shall be contained and mounted in the VFD enclosure. Freestanding filters will not be acceptable. C. Capacitors, if used, shall be environmentally safe. Discharge resistors and a method of shorting the phases shall be provided. D. Inductors may be air or iron core. Inductors shall have Class F insulation with Class B temperature rise. E. There shall be annunciation of output filter failure MEDIUM VOLTAGE FUSES A. Construction 1. The following features shall be included on every current limiting fuse: a. High purity, graded silica-sand filler with pure silver (.999 fine) elements encased in a glass-epoxy casing 2. The following features shall be included on every boric acid expulsion fuse unit: B. Main devices Maximum Design kv a. Fuse refill shall be hermetically sealed to prevent water ingress b. Fuse casing shall be glass-epoxy 1. CLE Type Fuses a. 5 kv and 8.3 kv fuses, through 450E shall be 3 inches in diameter and shall be 17-7/8 inches in length 2. Type CLE Current Limiting Fuses General Purpose, Indoor, Indicating Used On Transformers, Load Interrupters, Feeder Circuit Protection Current Rating Interrupting Rating RMS Sym. Amps Suitable For Use E, 15E, 20E, 25E 50,000 Indoor, In Enclosure E, 15E, 20E, 25E, 30E 63,000 In Enclosure E, 50E, 65E, 80E, 100E, 125E 50,000 Indoor, In Enclosure Drives Medium Voltage March 2018

16 Maximum Design kv Current Rating Interrupting Rating RMS Sym. Amps Suitable For Use E, 175E, 200E, 250E, 300E, 400E, 450E 63,000 Indoor/ Outdoor, E, 750E 40,000 Indoor, In Enclosure , ,500 Indoor, In Enclosure E, 20E, 25E 50,000 Indoor, In Enclosure 2.15 EFFICIENCY A. Overall efficiency of the VFD shall include the drive isolation transformer, VFD and all VFD auxiliaries, output filter, power factor correction and harmonic filter. B. VFD system efficiency calculations shall be in accordance with IEEE 995. C. The overall efficiency shall be not less than 96% at full load, full speed MOTOR PROTECTION RELAYS A. EMR-3000 Motor Protection Relay 1. Furnish each VFD with a definite purpose microprocessor-based Motor Protective Relay (MPR) for protection, control and monitoring of the motors. The MPR shall be Eaton type EMR The MPR shall meet UL 1053, CUL and CSA standards. 2. True rms current into the motor shall be constantly monitored, and by means of a protective algorithm, separated into positive and negative sequence components. These components shall be used to determine the heating effects on the stator and rotor of the motor to provide maximum motor protection and utilization. The protective algorithm shall provide faster trip times for higher temperatures providing maximum motor protection and shall operate with a longer trip time for lower temperatures allowing maximum motor utilization. The MPR shall provide the following protective functions: a. Adjustable current unbalance protection (IEEE Device 46 adjustable in percent unbalance) b. Motor running time overcurrent protection (IEEE Device 49/51) c. Adjustable instantaneous overcurrent protection (IEEE Device 50) with adjustable start delay in one-cycle increments d. Zero sequence ground fault protection (IEEE Device 50/51G) with adjustable start delay and run delay in 0.01 sec increments e. Lockout relay (IEEE Device 86) Drives Medium Voltage March 2018

17 f. Auxiliary over temperature protection for RTD. 3. Only the following settings shall be needed to define the motor thermal protection curve: a. Motor full-load amperes (FLA) b. Locked rotor current in percent of FLA c. Locked rotor stall time in seconds d. Ultimate trip current based on motor service factor 4. The following control functions shall be provided by internal solid-state based timers or relays: a. Limitation on number of starts per time period in minutes (IEEE Device 66) b. Programmable transition relay based on current and/or time c. Time between starts d. Number of cold starts 5. The MPR shall have a real-time clock for time tagging of events, operations, and history. The relay shall have quick and easy access to monitored values, view settings, motor history and motor log records. The relay shall monitor and display the following: a. Motor currents: Average current (Iave), individual phase and ground current in primary amperes and percent of full load and percent phase unbalance. b. Motor RTD: Individual winding, motor bearing, load bearing and auxiliary temperatures. c. Motor: Percent I2t (thermal accumulation), time until next start can occur, remaining number of starts, and time left on oldest start. d. Sequence Currents 6. The MPR shall be capable of accommodating external current transformers with ranges from 1 to 50,000 Amps primary and 1 or 5 Amps secondary. Provide three (3) current transformers sized per manufacturer s recommendations based on motor full-load amperes and service factor. Where ground fault protection is specified, it shall be from an independent measuring circuit that utilizes either a separate zero sequence current transformer (50/51G) or residual scheme utilizing the three-phase current Drives Medium Voltage March 2018

18 transformers (50/51N). For zero sequence ground fault protection, provide a 50/5-ampere zero sequence transformer 7. Four user-programmable discrete inputs shall be provided for external control or trip functions. Programmable input functions shall be included for shutdown based on external contacts for incomplete sequence of operation and remote trip, remote reset, differential trip, motor stop, reset disable, zero speed switch or emergency override 8. The unit shall draw its power from a control power transformer located in the starter. The MPR shall be suitable for 60 Hz. 9. The device shall have separate one Form C (NO/NC) and two (NO) contacts. All contacts shall have ratings of 10 amperes at 115/240 VAC or 30 VDC resistive. All the relays output contacts shall be programmable to operate from any internal protection function or from a discrete input signal such as differential trip or remote trip. All contacts shall be programmable to function in either a normally de-energized (non-fail-safe) or energized (failsafe) operation. 10. The device shall have 1 analog output contact 11. The relay shall be capable of monitoring electrical current, receiving commands from remote sources either by contact closures or digital data, and giving commands by means of contact closure to the motor starters and other devices under its control. The MPR shall be capable of displaying information by alphanumeric display to the operator or by digital communication signals to a remote location a. The combination relay and operator panel shall be mounted on the door of the starter. Specific data entry to suit the actual motor application shall be programmed into the device by means of the operator panel pushbuttons. b. Entered data shall be stored in non-volatile memory so as not to require battery backup. Non-volatile memory shall be capable of storing all setup information even after power failure, all monitored information at the time of a trip, and cause of trip even after power failure. Access to all programmed set points shall be restricted by means of a secured and sealed access cover. c. The MPR shall have a user-selectable emergency override feature to reset I2t thermal accumulation and deactivate start inhibit timers for emergency starting of the motor. d. The emergency override feature shall be capable of being activated from an access-restricted button, communications or via a contact input into the MPR. Drives Medium Voltage March 2018

19 e. The MPR shall provide a programmable control function for reduced voltage applications for the transition from reduced to full-voltage starting. The transition shall be programmable based on current, time, current and time, or, current or time. 12. The MPR shall provide the following data logging and display capability for history including the date and time from when the history was last reset and counting began. The history shall include: a. Resettable motor history for operational counter, runtime, highest starting and running currents, highest percent phase unbalance, maximum winding, bearing and load RTD temperature, and number of emergency overrides. b. Resettable trip history for number of trips for ground faults, overloads, instantaneous overcurrent, JAM, underload, phase unbalance, RTDs, phase reversal, incomplete sequence, remote differential, communication, starts exceeded, time between starts, and transition. c. Resettable alarm history for number of alarms, for ground faults, overloads, JAM, underload, phase unbalance, RTDs, starts exceeded. d. A permanent history record which cannot be reset shall include local trips, run time and operations count. e. A log book including a chronological list of events or operations as detected by the MPR, such as, starts, stops, setting change, emergency override, trips, alarms or changes in the state of discrete inputs. f. An event log providing detailed information on trips and alarms including phase and ground currents, percent phase unbalance, maximum RTD temperatures and cause of trip or alarm. g. A start log providing information on the five most recent starts including maximum phase and ground starting current, maximum percent unbalance, time from start to transition, current at transition, and time from start to run to trip. h. A USB front communication port for programing and interrogation of the relay via personal or laptop computer i. Communication ports shall have the ability to transmit all information contained in the relay such as currents, set points, cause of trip, magnitude of trip current, and open-close trip status over the connected network. 13. The MPR shall provide trip coil monitor 14. The MPR shall provide load profiling Drives Medium Voltage March 2018

20 15. The MPR shall provide waveform capture (6000 cycles total) 16. The MPR shall be fully programmable through the face of the relay. In addition a means to be able to program the MPR through a front communication port need to be provided. 17. The MPR shall be provided with removable terminal blocks, including the CT terminals. The CT terminals shall be short circuited, when pulled out AUXILIARY DEVICES A. Provide fixed mounted potential transformers, fused-type, of the quantity and ratings required for proper operation of the motor protection relay. Relays shall be rated 4200V primary to 120V secondary (ratio 35:1). B. Provide window-type current transformers for phase and ground measurements for proper operation of the motor protection relay. Each phase CT ratio shall be nominal 100:5A and the current transformer shall be 5kV class. Ground current transformer shall be a single unit measuring all three phases with a nominal ratio of 50:5. The ground current transformer shall be 5kV class. Current transformer accuracy shall be suitable for the connected burden. C. Provide an auxiliary control power transformer of the quantity and kva rating as required for specified motor control logic. Nominal motor control voltage shall be 120V single phase. D. Furnish each potential transformer and control power transformer with appropriate primary fusing as required by the VFD manufacturer. Furnish appropriate secondary fusing on the control power transformer used for motor control circuits. E. Furnish appropriate device power transformers for internal use voltages other than 120VAC for controls. Furnish VFD complete with appropriate 480V transformers for cooling fans, or other similar devices, that require other than 120V power for operation ENVIRONMENTAL CONDITIONS A. The VFD shall operate in an ambient temperature range of 0 C to 40 C (32 F to 104 F) with a relative humidity of up to 95% (non-condensing), unless specified otherwise. B. The equipment shall be capable of being stored in an environment with an ambient temperature range of -40 C to 70 C. C. The equipment shall operate at altitudes from 0 to 1000m (3,300 ft.) above sea level, without de-rating. For applications above 1000m, the maximum ambient temperature and Basic Impulse Levels (BIL) of the controllers shall be de-rated as necessary, and vacuum contactors shall be compensated for operation at the specified altitude. Drives Medium Voltage March 2018

21 2.19 ENCLOSURES A. Indoor enclosures shall be NEMA 1A with gasket and filters. B. The VFD shall require front access only. Designs requiring rear or side access are not acceptable. C. The VFD enclosure doors shall include an interlocking system with the isolation switch. D. A safety grounding device shall be provided for grounding the positive, and negative buses to ensure all stored VFD energy is discharged. E. Enclosures encompassing all components required for a single VFD assembly from input fused disconnect switch to output filters (if necessary) shall be configurable a continuous line-up or control gear assembly. Multiple line-ups, or control gear assemblies, shall be capable of side-by-side installation to make a continuous line-up of multiple VFDS if practicable. F. The drive isolation transformer, fused input contactor, isolation switch, ac precharge circuit contactor, output filter if required, and input harmonic filter and power factor correction filter if required shall be factory mounted wired by the manufacturer and integrated into the VFD enclosure, complete. G. All painted surfaces shall be ANSI 61 Gray. H. The enclosure must be designed to avoid harmonic and inductive heating and eliminate radio frequency interference. I. The VFD enclosure shall comply with UL 347 standards suitable for installation in an indoor, unclassified area. J. All enclosure openings exceeding 0.25 inch (6 mm) in, width shall be provided with screens to prevent the entrance of snakes, rodents, etc. The maximum screen mesh opening width shall be 0.25 inch (6 mm). K. Air filters shall be of a reusable type that can be easily cleaned. All doors or front panels will be fully gasketed. Air exhaust from cooling fans will be at the top of the enclosure and direct exhaust airflow away from personnel in front of the equipment. L. The VFD shall be designed for harsh environments, including encapsulated power components. All exposed copper components shall be tin-plated or epoxy-coated. All printed circuit cards shall be conformal coated COOLING A. A loss of cooling fault shutdown shall be furnished with forced-cooled equipment. In the event of clogged filters or fan failure, the drive will shut down safely without electronic component failure. The fault shall be integrated into the Drives Medium Voltage March 2018

22 overall VFD fault output signal with the keypad displaying the loss of cooling fault for ready diagnosis. B. Fan motors shall be protected by an input circuit breaker. Metal squirrel cage ball bearing 460V three phase fan motors with 50,000 hour life are to be used in the drive design. Plastic muffin fans are not acceptable. As specified on the data sheet, fan power will be obtained from the primary 2400/4160V power through a 480V, 3-phase, 60 Hz internal auxiliary power supply. In the event of a fault or opening of the main contactor feeding the drive, the fans will continue to run for a time to allow for sufficient cooling of the drive. Convection cooling in the case of fault or main contactor opening is unacceptable as a method to ensure proper cooling of the drive. C. The VFD shall have internal fans to ensure proper operation in the above referenced ambient. Where available, furnish additional redundant fan(s) to ensure operation in the event of primary fan failure. Where redundant fans are not available, the cooling provided by additional fans shall produce enough CFM to operate the VFD at 100% of full load. D. Furnish appropriate motor controls integral to the VFD assembly for the cooling fans SPACE HEATERS A. AC Motor Space Heaters: Existing AC motor space heaters are powered out of a local panelboard. No provisions for motor space heaters are required NAMEPLATES A. Nameplates shall be 2-inch high x 2-1/2 inch wide, laminated black with white core. B. Unit nameplate and device marker lettering shall be 3/16-inch high FINISH A. The finish for internal and external parts shall consist of a coat of ANSI 61 (gray) thermosetting, polyester, powder paint applied electrostatically to pre-cleaned phosphatized steel and aluminum surfaces. PART 3 EXECUTION 3.1 FACTORY TESTING A. The VFD System shall undergo standard manufacturing testing. B. Each VFD shall be factory load tested with an induction motor on a dynamometer or M-G test stand for a minimum of 8 hours at rated ambient temperature (40-deg C standard) and rated load with VFD system at full voltage. Resistive or Inductive load-bank testing shall not be acceptable Drives Medium Voltage March 2018

23 1. Constant torque VFD s shall be tested at 100% rated load for 9 minutes, 150% rated load for 1 minute. This cycle will continue throughout the 8-hour test. 2. Variable torque VFD s shall be tested at 100% rated load for 9 minutes, 110% rated load for 1 minute. This cycle will continue throughout the 8-hour test. C. The manufacturer shall provide three (3) certified copies of factory test reports. 3.2 FIELD QUALITY CONTROL A. The City will schedule an on-site meeting between supplier and installer to coordinate the following: 1. The start-up and commissioning plan 2. The start-up and commissioning schedule 3. The VFD s installation requirements. B. The VFD supplier shall provide the services of a manufacturer s employed field service Engineer for the start-up of each VFD after it is installed according to the manufacturer s recommendations. Functional testing, commissioning and first parameter adjusting shall be carried out by the manufacturer s employed field service Engineer. (No third-party representatives will be permitted). C. Testing, final parameter adjustment and performance tests shall be carried out by the manufacturers employed field service Engineer with the City present. D. After commissioning the manufacturer s employed field service Engineer shall review the City s operating procedures and provide (2) two hours of basic handson maintenance and operation training to the City s personnel. E. Typical commissioning will be up to (3) consecutive eight-hour work-days per VFD. Rate schedule for commissioning, travel to the jobsite and living expenses during the period of work shall be included with the supplier s bid proposal. F. Microsoft Windows based software shall be provided for VFD commissioning, parameter setup, fault log viewing, diagnostic analysis, and monitoring and control. The software shall provide real time graphical displays of VFD performance. G. The supplier shall provide three (3) copies of the manufacturer s field startup report. H. The VFD manufacturer shall certify in writing that the equipment has been installed, adjusted and tested in accordance with the manufacturer s recommendations. Drives Medium Voltage March 2018

24 I. The supplier shall provide three (3) copies of the manufacturer s representative s certification. 3.3 TRAINING A. The supplier shall provide two (2) training sessions for twelve (12) City representative(s) across two (2) shifts at the City s Water Treatment Plant at dates and times to be determined by the City. B. The training session shall be conducted by the manufacturer (no third-party representatives will be permitted) and include instruction on assembly, troubleshooting, and other major components. 3.4 DELIVERY, STORAGE AND HANDLING A. Equipment shall be handled and delivered in accordance with manufacturer s instructions. One (1) copy of these instructions shall be included with the equipment at time of shipment. 3.5 OPERATION AND MAINTENANCE MANUALS A. Equipment operation and maintenance manuals shall be provided with each assembly shipped, and shall include instruction leaflets and instruction bulletins for the complete assembly and each major component. 3.6 FIELD ADJUSTMENTS A. VFD parameters shall be programmed by VFD manufacturer s field representative. B. Program RTD Module shall be programmed by VFD manufacturer s field representative. C. Configuration and programming of the motor protection relay shall occur at the time of start-up and testing by the manufacturer s field representative. Parameters will be provided by the City to the manufacturer s field representative at the time of start-up and commissioning. 3.7 FIELD TESTING A. Field testing shall be performed by a manufacturer employed and trained Engineering Services Field Service Engineer and shall include the following as a minimum: 1. Sight Inspection 2. Power-Off Checklist 3. Power Up (Control Assembly only) checklist Drives Medium Voltage March 2018

25 4. Full Voltage Main Power-Up No Load Testing 5. Full Load Testing. 6. Configuration/programming. 7. Commissioning. 3.8 MAINTENANCE / WARRANTY SERVICE A. Warranty to commence upon delivery of the VFDS to the City s Water Treatment Plant. The length of the warranty shall be five (5) years from the date of manufacture, and shall include all parts, labor, field services and travel time. 3.9 SPARE PARTS A. The VFD manufacturer shall provide a complete list of recommended spare parts for the VFD. B. The VFD manufacturer shall provide local support for renewal parts and stock spares. C. As a minimum, the VFD manufacturer shall include these spare parts as part of the bid: % spares of each type of medium voltage fuse % spares of each type of low voltage fuse. 3. Inverter power components, which shall be interchangeable between output phases shall be provided. A minimum of one complete phase is required. 4. Special tools for testing or maintaining equipment. 5. All spare parts shall be properly marked and packaged for long-term storage. All printed circuit boards shall be provided in separate anti-static containers. END OF SECTION Drives Medium Voltage March 2018

26 APPENDIX DRAWINGS E-01 EAST HIGH SERVICE PUMP BUILDING MODIFIED ELECTRICAL PLAN AND VFD ONE LINE DIAGRAM E-02 SCHEMATIC DIAGRAMS Drives Medium Voltage March 2018

27 WATER TREATMENT PLANT HIGH SERVICE PUMP VFD REPLACEMENT EAST HIGH SERVICE PUMP BUILDING MODIFIED ELECTRICAL PLAN AND VFD ONE LINE DIAGRAM PROJECT # SCALE: DESIGNED BY: DRAWN BY: CHECKED BY: DATE: CAD FILE: A.L.C B.K.H J.W.K MARCH 2018 WP09-E01 SEALED: AMY L. CHAMPAGNE BAKER FL. P.E NO. DATE BY R E V I S I O N S DESCRIPTION Engineering Services ENGINEERING SERVICES DEPARTMENT * ENGINEERING SERVICES DIVISION * 401 CLEMATIS ST., 4TH FLOOR * WPB, FL * PH. (561) * FAX: (561) SHEET 1 E-01 OF 2

28 WATER TREATMENT PLANT HIGH SERVICE PUMP VFD REPLACEMENT SCHEMATIC DIAGRAM PROJECT # SCALE: DESIGNED BY: DRAWN BY: CHECKED BY: DATE: CAD FILE: A.L.C B.K.H J.W.K MARCH 2018 WP09-E02 SEALED: AMY L. CHAMPAGNE BAKER FL. P.E NO. DATE BY R E V I S I O N S DESCRIPTION Engineering Services ENGINEERING SERVICES DEPARTMENT * ENGINEERING SERVICES DIVISION * 401 CLEMATIS ST., 4TH FLOOR * WPB, FL * PH. (561) * FAX: (561) SHEET 2 E-02 OF 2