July 22, 1994

Contract #TW0592

**SPECIAL** **SPECIFICATION**

**SECTION 16921-S**

**[VARIABLE FREQUENCY DRIVE FOR VARIABLE]{.underline}**

**[TORQUE PUMP OR FAN ALTERNATING CURRENT MOTORS]{.underline}**

[Page]{.underline}

[PART 1 - GENERAL]{.underline}

1.01 Description of Work 2

1.02 References 2

1.03 Submittals 2

1.04 Quality Assurance 3

1.05 Warranty 3

[PART 2 - PRODUCTS]{.underline}

2.01 General 3

2.02 VFD Supplied With A New Pump or Fan System 4

2.03 VFD Supplied For An Existing Pump or Fan System 4

2.04 VFD Maximum Voltage & Current Harmonic Distortion 5

2.05 Design Features 5

2.06 Protective Features 7

2.07 Diagnostic Fault Indicators 7

2.08 VFD Environmental and Service Conditions 8

2.09 Spare Parts 8

2.10 VFD Motor Requirements 8

[PART 3 - EXECUTION]{.underline}

3.01 Examination 9

3.02 Preparation 9

3.03 Installation 9

3.04 Field Quality Control 9

**SPECIAL** **SPECIFICATION**

**SECTION 16921-S**

**[VARIABLE FREQUENCY DRIVE FOR VARIABLE]{.underline}**

**[TORQUE PUMP OR FAN ALTERNATING CURRENT MOTORS]{.underline}**

[PART 1 - GENERAL]{.underline}

1.01 [Description of Work]{.underline}

A. The Contractor shall furnish and install a complete Variable
Frequency Drive (VFD) System as described in this specification and as
detailed on the construction drawings. The VFD will be used to control
the speed of a variable torque, pump or fan alternating current (A.C.)
motor.

B. The Contractor shall be responsible for the installation, field
testing, and startup of the equipment covered by this specification.

1.02 [REFERENCES]{.underline}

> The requirements of the most current versions of the codes, standards,
> and other documents referenced in this document are to be considered
> as part of this specification. In the event of a conflict between this
> specification and referenced documents or between several referenced
> documents, the more stringent requirement shall be followed.

A. Construction drawings included with this contract.

B. Sandia National Laboratories (SNL) standard specifications.

1\. Section 01300 \-- Descriptive submittals.

2\. Section 16001 \-- Electrical work.

3\. Mechanical Specifications issued with this contract.

C. The following codes and standards are referenced:

> NEMA \-- National Electrical Manufacturers\' Association
>
> NEC \-- National Electrical Code NFPA-70
>
> IEEE \-- Institute of Electrical and Electronic Engineers
>
> UL \-- Underwriters Laboratories
>
> ANSI \-- American National Standards Institute

1.03 [Submittals]{.underline}

A. The submittal requirements of the SNL Standard Specification, Section
01300 shall be followed.

B. The Contractor shall submit the final documentation for the VFD
installation as described in Section 3.03 of this specification.

C. Final Drawings: The VFD supplier shall furnish one set of
\"as-built\" reproducible drawings on black on white mylar 22 X 34 inch
(56 X 85 cm) size showing dimensions, details, wiring diagrams and
interconnections. All wiring on all systems shall be included on these
drawings. Drawings shall be of sufficiently high quality drafting and
reproduction to permit microfilming. Internal wiring diagrams shall be
laid out such that terminal blocks for external connections have
sufficient room, a minimum of one and one-half inch, for showing cables
for external connections. In addition to the above specific design
drawings, the VFD supplier shall furnish complete sets of their standard
drawings showing control schematics, transistor schematics, wiring,
outline dimensions, mounting details, and equipment weight.

D. Instruction Books and Spare Parts List: VFD supplier shall furnish
copies of all instruction books, spare parts lists, and special
bulletins covering on-site storage.

E. Filter Requirements: The VFD supplier shall provide documentation
from the VFD manufacturer per Section 2.05 M to meet the maximum noise
requirements per Section 2.04.

1.04 [QUALITY ASSURANCE]{.underline}

A. The VFD manufacturer shall have a minimum of five years in designing
and manufacturing VFDs of the horsepower, range, and technology
specified herein.

B. The Contractor shall arrange and pay for the services of the VFD
manufacturers\' service engineer to train SNL\'s personnel in proper
operation and maintenance of the VFD system. Provide a minimum of two
(2) normal eight-hour working days on-site instruction unless otherwise
noted.

1.05 [Warranty]{.underline}

> If any defect in apparatus supplied, or failure to comply with this
> specification shall appear within the period of one (1) year from the
> date of commercial operation, not to exceed 42 months from shipment,
> the VFD shall be immediately repaired. The Contractor shall correct,
> without delay and at his own expense, the defects or failure of
> compliance by repairing the defective parts, by supplying a
> non-defective replacements, or by correcting a defective or deficient
> design.

[PART 2 - PRODUCTS]{.underline}

2.01 [General]{.underline}

A. The VFD shall be U.L. listed.

B. The VFD shall comply with the latest applicable standards of:

1\. ANSI.

2\. IEEE.

3\. NEMA.

C. The VFD shall be of a fixed Direct Current (D.C.) bus type with a
full wave input diode bridge. The VFD shall convert three-phase, 60 Hz,
input power to three-phase adjustable voltage, adjustable frequency
output power using Pulse Width Modulation (PWM) switching techniques.

D. The VFD shall be manufactured by Toshiba, Reliance Electric, Emerson
Industrial Controls, Allen Bradley, or Westinghouse Electric Corporation
or an approved equal.

2.03 [VFD Supplied For An Existing Pump or Fan System]{.underline}

A. The VFD manufacturer shall submit a letter stating that the use of
their VFD is compatible with and properly sized for the existing pump or
fan motor and that it will meet all the requirements of this
specification.

B. If the contractor provides a VFD other than what was called out on
the construction drawings, the contractor shall submit the follow­ing:

1\. Submit a harmonic study showing how the substituted VFD meets the
line noise limits as specified per Section 2.04 of this specification.
Sandia will provide the power system data required to perform the
harmonic study.

2.04 [VFD Maximum Voltage & Current Harmonic Distortion]{.underline}

A. The harmonic voltage distortion shall not exceed the distortion
limits at the point of common coupling (PCC) as recommended and defined
by IEEE-519-1992 \"Recommended Practices and Requirements for Harmonic
Control in Electric Power Systems\". The harmonic voltage distortion
shall be limited to 3% of fundamental for an individual frequency
harmonic and a total harmonic voltage distortion (THVD) to 5% at the PCC
without a major parallel resonance of the injected harmonic frequencies.
Existing harmonics shall be taken into account when preparing study.

B. The harmonic current distortion shall not exceed the distortion
limits at PCC as defined in IEEE-519-1992, Table 10.2.

2.05 [Design Features]{.underline}

As a minimum, the VFD shall have the following design feature
requirements:

A. Automatic Restart: The VFD shall be equipped such that upon
restoration of input power the VFD will automatically restart and
accelerate to the speed set by the remote speed reference signal.

B. [Speed Controls]{.underline}:

1\. The process follower shall be designed to accept a 3-15 psi
pneumatic isolated speed reference signal, unless otherwise specified on
the construction drawings.

2\. The VFD shall have an independent minimum frequency speed adjustment
that is adjustable from 0-100% speed.

3\. The VFD shall have an independent maximum frequency speed adjustment
that is adjustable from 0-100% speed.

4\. The VFD shall have a selectable V/Hz adjustment.

5\. The VFD shall have independent acceleration and deceleration
adjustments that is adjustable over a minimum range of 2-120 seconds.

6\. The VFD shall have a minimum of three selectable output fre­quency
ranges.

7\. The VFD, as a minimum, shall have two selectable stopping modes:
coast and ramp to stop.

8\. The VFD shall have bi-directional autospeed search for starting into
rotating loads in both directions and for returning the motor to the
desired speed in the proper rotational direction.

9\. Upon loss of the speed reference signal, the VFD shall operate at
the preset minimum speed in order not to cause problems with the pump or
fan system.

C. The VFD should have an [overload capability]{.underline} of 120% for
60 seconds and 110% continuous. Refer to construction drawings for motor
size.

D. [A D.C. bus discharge indicator]{.underline} shall be incorporated
within the VFD control system.

E. A [heat sink]{.underline} over temperature protector should be
incorporated within the VFD controller.

F. The VFD shall contain separate terminal strips for input and output
wire connections.

G. The VFD controller shall contain the following door mounted switches:

1\. Hand-Off-Auto switch with the following features:

\"Hand\" - fan/pump enabled

\"Off\" - fan/pump disabled

\"Auto\" - remote stop/start enabled

2\. A switch with the following functions:

Position 1 - Manual speed control

Position 2 - Auto speed control

H. The VFD shall have a door-mounted output load ammeter, voltmeter, and
speed indication.

I. The VFD shall be supplied in a louvered NEMA 12, gasketed enclosure
containing louvers with air filters, and fans as required for heat
dissipation.

J. [The maximum acoustical noise levels]{.underline} for sound
originating in VFD equipment shall not exceed 9 decibels above the room
abient noise level where the VFD equipment will be located. The room
ambient noise level will be specified in the Mechanical Section of the
contract specifications or drawings.

K. [The efficiency]{.underline} of the total VFD system shall be no less
than 96.5% at full load when operating at full speed, and no less than
95% when operating at half speed.

L. If electrical line noise filters or line reactors are required to
meet the maximum allowable noise requirements per Section 2.04, they
shall be as recommended by the VFD manufacturer.

M. [The VFD shall be capable of power loss]{.underline} ride through to
prevent shut­down during power losses for a minimum of three cycles.

> An input power disconnect switch shall provide a positive
> disconnecting means between the controller and all phases of the
> incoming AC line. This disconnect shall mount inside the controller
> enclosure and include a mounting bracket and through-the-door
> interlocking handle with provisions for padlocking. The switch shall
> be a thermal magnetic, molded case circuit breaker. The circuit
> breaker shall be sized to interrupt 25,000 amperes (symmetrical) fault
> current unless otherwise noted.

2.06 [Protective Features]{.underline}

A. The VFD shall be designed to be self protecting from electrical
damage due to normal transients and surges in the incoming power line,
grounding or disconnection of its output power, and any interruption in
or run away of the incoming speed reference signal. Protection is
defined as a normal shutdown with no component damage. The available
fault current at the VFD will be 25,000 amperes, unless otherwise noted.

B. As a minimum, the VFD shall have the following protective features:

1\. Ground fault protection.

2\. Short circuit protection.

3\. Overload protection of VFD unit.

4\. Separate motor overload relay with reset button extending through
door.

5\. A minimum current limit adjustable (output of drive) from 60-100%.

6\. Current limited stall prevention.

7\. Current limiting D.C. bus fuse.

8\. D.C. bus under voltage.

9\. D.C. bus over voltage.

10\. Loss of input phase protection.

11\. Over frequency protection.

12\. Over temperature protection.

2.07 [Diagnostic Fault Indicators]{.underline}

A. The VFD shall have a self-diagnostic check for fault conditions.
Faults shall be displayed on the front panel.

B. As a minimum, the following faults shall be displayed:

1\. Overcurrent.

2\. Short circuit.

3\. Ground fault.

4\. Overload.

5\. Overvoltage.

6\. Undervoltage.

7\. Overtemperature.

8\. Control function error.

2.08 [VFD Environmental and Service Conditions]{.underline}

The VFD shall be designed to operate within the following environmental
or service conditions:

A. Ambient service temperature: 0oC to 40oC.

B. Humidity: non-condensing to 90%.

C. Altitude: 5,500 feet (1,676 m).

D. Input Voltage: The input voltage will be specified on the
construction drawings and will either be 200 VAC [+]{.underline} 10% or
460 VAC [+]{.underline} 10%.

E. Input Frequency: 60 Hertz [+]{.underline} 2%.

2.09 [Spare Parts]{.underline}

> Unless otherwise specified, the Contractor shall provide spare parts
> as recommended by the VFD manufacturer. As a minimum, the spare parts
> should include the following:

A. One spare for each type of printed circuit card.

B. One set of fuses for each fuse size.

C. One power transistor for each transistor rating supplied.

2.10 [VFD Motor Requirements]{.underline}

A. New pump or fan motors operated from a VFD system shall meet the
following requirements:

1\. Shall conform to the latest applicable requirements of NEMA, IEEE,
ANSI, and NEC standards.

2\. Shall be designed for continuous duty operation, NEMA Design B.

3\. Shall have a service factor of 1.15.

4\. Shall be furnished with Class F insulation.

5\. Shall be energy efficient and meet NEMA S484E efficiency standard.

B. For existing pump or fan motors to be operated from a VFD system;
Sandia will provide nameplate information on an attached sheet or it
will be shown on the construction drawings. See Section 2.03 for VFD
manufacturer\'s requirements.

[PART 3 - EXECUTION]{.underline}

3.01 [EXAMINATION]{.underline}

> The Contractor shall examine areas and conditions under which the VFD
> system is to be installed and notify the SDR in writing of those
> conditions detrimental to proper completion of the work. Work shall
> not proceed until unsatisfactory conditions have been corrected in a
> manner acceptable to the SDR.

3.02 [PREPARATION]{.underline}

> The Contractor shall provide indoor storage for the VFD to meet
> service conditions in Section 2.08 A and B.

3.03 [INSTALLATION]{.underline}

A. Construction work shall be performed in a thorough and conscientious
manner in accordance with the specifications, construction drawings, and
the requirements of the referenced codes and standards of Section 1.02.

B. Installation of the VFD and accessory items shall be made in
accordance with the manufacturer\'s written installation instructions
and per SNL\'s standard specification 16001 - Electrical Work.

3.04 [Field QUALITY CONTROL]{.underline}

A. The Contractor shall arrange and pay for the services of the VFD
manufacturers\' service engineer to test, checkout, and start up the VFD
system.

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

C. The Contractor shall demonstrate trouble free, stable operation for
conditions of starting, full load, three-quarter load, half load,
one-quarter load, no load, and intermediate loads.

D. Tests shall include 100 hours of operation under load to demonstrate
adequacy of equipment under thermal and voltage stresses, and that
harmonic and other interferences do not adversely affect the electrical
instrumentation and communication system.

E. Sandia will test the VFD at the point of common coupling, at no
charge to the Contractor, before and after it is installed with a
Dranetz Model 658 power analyzer. The power analyzer is capable of
measuring total harmonic voltage and current distortion. If the harmonic
voltage and current distortion limits, as defined in section 2.04 of
this specification, are exceeded, the Contractor agrees to furnish and
install, at no cost to Sandia, any devices necessary to reduce the
distortion to acceptable limits.

F. The VFD manufacturer\'s service engineer shall prepare final written
documents of installation and inspection tests made in the field,
complete with meter readings and recordings, where applicable, and these
documents shall be submitted to the SDR for approval.

G. Test Reports: VFD supplier shall furnish copies of each test report
as required by this specification.

END OF SECTION