VILLARROYA DE LA SIERRA

1.0 GENERAL

This Specification describes the requirements for the 400V Variable Frequency Drive Controllers (VFD). The 400V Variable Frequency Drive Controllers shall be designed and provided in accordance with this Specification and the attached data sheets. The proposed Manufacturers installation requirements should be complied by the Manufacturers as part of the Contract including shielded power cables (if required), enclosure for VFD’s, earthing requirements, etc to achieve EMC Compatible installation. All details shall be furnished as part of the submittal.

All equipment shall be designed, manufactured and tested in accordance with the latest edition of the applicable:

NFPA 70 IEC 146

EN Standard / CE marked for EMC directives:

Emissions Immunity

EN 50081-1 EN 50082-1

EN 50081-2 EN 50082-2

EN 55011 Class A IEC 801-1, 2, 3, 4, 5, 6, 8 EN 55011 Class B EN 50178

EN 60204-1

The manufacturer shall furnish the product as listed and classified by underwriter’s laboratories as suitable for the purpose specified and indicated.

The VFD product line shall be capable of operating normally in an environment with an ambient temperature range of 0 °C to 50 °C with a relative humidity of up to 95%

(non-condensing). The enclosed current rating shall be derated by 10% for each 5 °C above 50 °C not exceeding 60 °C.

The product line shall be capable of being shipped and stored in an environment with an ambient temperature range of 0 °C to 65 °C.

The nominal operating altitude shall be less than 1000 m above sea level.

Ship controllers in convenient sections crated and protected, bearing in mind the hazards of transportation.

All necessary bus connections, wire jumpers, bolts, nuts, etc. shall be suitably packed and identified to facilitate field assembly.

2.0 SPECIFICATIONS

2.1 The variable speed drive controllers’ technical requirements shall be in accordance with the data sheets. Seller shall be responsible for ensuring that under all operating conditions:

- The controllers and their characteristics shall be compatible with their respective driven production motor and the plant control system. Seller shall obtain speed (frequency) range required and maximum frequency permitted for each type of controller from the load equipment supplier.

- The VFD shall be suitable for use with high efficiency Design B, 400 V motors.

- The total harmonic distortion (THD) voltage in the plant electrical and local DEWA systems shall not exceed 5% and no individual harmonic shall exceed 3% during normal plant operation.

- Computerised harmonic analysis studies to IEEE Standard 519; copies of the studies shall be provided with the proposal.

- The VFD shall be fully digital pulse width modulated type (PWM) using latest generation IGBT’s with isolating contactors and line reactors.

2.2 The VFD controllers shall be suitable for operation on 400 Volt ±15%, 3 phase, 50 Hz input power supply and 0-400 Volt, 3 phase, 0.5 to 400 Hz output. No transformer shall be used on either the input or output of the VFD.

2.3 Each controller shall comprise:

- Enclosure with filters and gaskets construction, mounted on steel sills.

- Incoming supply terminals complete with cable lugs.

- Padlockable line disconnect switch with bolt on HRC fuses in each phase.

- 110% overload capacity above motor service factor demand (115%) for 30 minutes.

- Short circuit and current limit protection.

- Surge (TVSS) protection.

- Stop/Start contactor to ensure when the motor is not running, no voltage is present on the motor power terminals.

- Wireways with removable gland plates.

- Incoming power system isolation transformer, if required, with thermal sensing in each phase, and filters to limit on the plant 400V bus THD to 5%; no single harmonic to be more than 3%.

- Drive operation man machine interface (MMI) keyboard.

- Stepless non reversing minimum and maximum motor speed adjustments,

- “Drive Ready” with remote signal.

- Stop and start pushbuttons via keypad, in remote mode.

- Speed control: Local/Remote/Automatic via keypad.

- Motor speed indication via LED display.

- Motor On/Off indication via LED display.

- Emergency stop pushbutton, local at controller and local to plant.

- Drive status and failure diagnostic feature via LED display. Feature to log, time and date the last 30 fault conditions.

- Indication of output to drive current on each phase.

- Isolated I/O control signals.

- Motor multi-function protection, providing short circuit (51), overvoltage (59), undervoltage (27), thermal (49), stalling (49S) and phase unbalance (46) protections, complete with ground fault (51G) protection device to trip the incoming supply.

- Bolted and shrouded bolted type terminals for terminating load cables.

- Weidmuller or Wieland type terminal blocks shall be provided to connection of external wiring and cables.

- Interposing relays as required.

- 110V AC control voltage or manufacturers standard.

- Microprocessor based electronic self-diagnostics and fault detection system.

- Each cubicle shall be provided with a earthing bus, complete with two connectors for connecting to the plant earthing system. Drilled holes shall be provided for connecting cable earth conductor.

- VFD controllers shall be provided with a lamacoid engraved nameplate, minimum size 150mm x 75mm, engraving details to be provided by Purchaser.

- The VFD shall have built-in ventilation fan and dust filter. The controller to be remote mounted at front door for manual adjustments and monitoring of parameters.

- The VFD shall have thermal cut-off provision for the motor over temperature.

In “Man” mode, two modes shall be functional: Local or Remote. In “Local” mode, motor shall be started from Start/Stop pushbuttons via controller’s keypad. In “Remote” mode, motor shall be started from pushbutton station located near motor (if required).

2.4 Performance

The VFD shall have the following features as a minimum:

- Minimum efficiency of 97% at maximum load and speed.

- Minimum line side displacement power factor of 0.95 to 1.0 logging at all speeds and loads.

- Adjustable motor frequency of 0 to 400 Hz.

- Separately adjustable acceleration and deceleration ramps from 0 to 999 seconds.

- Rotating motor restart feature.

- Capable of running without a motor connected for set-up and testing.

- Skip frequency reject point to prevent operating of the equipment at a resonant speed.

- Ride through for power outage of at least 2 seconds duration - Load loss detection

- Overload protection - Auto economizer

- The flying start feature operable with or without encoder feedback 2.5 Discrete Operation

Inputs - Start - Stop Outputs

- Ready to start - Running

- VFD general fault alarm status

- VFD Auto and Man/Local/Remote operation status 2.6 Analog Operation

Inputs

- Speed control signal Outputs

- Speed signal feedback - Phase currents (percent) - Frequency (percent) 2.7 Verification of Interface

- Vendor shall demonstrate functional testing and operational verification of the control interface with the Building Management System via Modbus, Bacnet, LON, or equal as required.

3.0 INSPECTIONS AND FACTORY TEST

Controllers shall be inspected at all stage of manufacture in accordance with the Seller’s Quality Assurance Program and shall be completely assembled in the works. Seller shall provide a production schedule, which shall give details of the production processes. Seller shall provide a QA

Manual, which shall detail the inspections, testing to referenced standards, and burn in at full load at an ambient of 50 °C, for a minimum of 8 hours. All deficiencies shall be corrected before shipment.

All metal surfaces that are to be painted or coated shall be cleaned to an equal of a commercial finish as defined in the Steel Structures Painting Council’s manual - SSPC-SP6-63, modified to exclude wet sandblasting and painted to manufacturer’s standard finish. Internal surfaces shall be painted white.

Nameplates shall be provided for each VFD controller.

SECTION 6