**CONSTRUCTION STANDARD SPECIFICATION**

**SECTION 16269**

**[VARIABLE FREQUENCY CONTROLLERS]{.underline}**

### Page

PART 1 - GENERAL

[1.01 Summary 2](#__RefHeading___Toc23238617)

[1.02 References 2](#__RefHeading___Toc23238618)

[1.03 Definitions 3](#__RefHeading___Toc23238619)

[1.04 Submittals 3](#__RefHeading___Toc23238620)

[1.05 Quality Assurance 4](#__RefHeading___Toc23238621)

[1.06 Storage 4](#__RefHeading___Toc23238622)

[1.07 Warranty 4](#__RefHeading___Toc23238623)

[1.08 Maintenance 4](#__RefHeading___Toc23238624)

PART 2 - PRODUCTS

[2.01 Manufacturers 5](#__RefHeading___Toc23238626)

[2.02 Manufactured Units 5](#__RefHeading___Toc23238627)

[2.03 Components 10](#__RefHeading___Toc23238628)

[2.04 Source Quality Control 10](#__RefHeading___Toc23238629)

[2.05 Technical Support 11](#__RefHeading___Toc23238630)

[2.06 Test And Inspection Equipment 11](#__RefHeading___Toc23238631)

PART 3 - EXECUTION

[3.01 Examination 11](#__RefHeading___Toc23238633)

[3.02 Installation 12](#__RefHeading___Toc23238634)

[3.03 Field Quality Control 12](#__RefHeading___Toc23238635)

**CONSTRUCTION STANDARD SPECIFICATION**

**SECTION 16269**

**[VARIABLE FREQUENCY CONTROLLERS]{.underline}**

[PART 1 - GENERAL]{.underline}

1.  []{#__RefHeading___Toc23238617 .anchor}Summary

    A.  Furnish and install a complete Variable Frequency Controller
        (VFC) system as described in this Section, and as detailed on
        Drawings. VFCs will be used to control speed of three-phase
        variable torque pump or fan alternating current (AC) induction
        motors.

    B.  Related sections: refer to the following sections for related
        work:

        1.  Section 01330, "Submittal Procedures"

        2.  Section 01700, "Closeout Procedures"

        3.  Section 13943, "Facilities Control Systems"

        4.  Section 15994, "Mechanical Systems Demonstrations"

        5.  Section 16001, " Electrical Work"

2.  []{#__RefHeading___Toc23238618 .anchor}References

    A.  Institute of Electrical and Electronics Engineers (IEEE)

> 519 Recommended Practices and Requirements for Harmonic Control in
> Electrical Power Systems

A.  National Electrical Manufacturers Association (NEMA)

> 250 Enclosures for Electrical Equipment (1000 Volts Maximum)
>
> ICS 2-222 Overload Relay Class Designation
>
> MG 1 Motors and Generators

B.  National Fire Protection Association (NFPA)

> 70 National Electrical Code (NEC)

C.  International Electro-technical Commission (IEC)

> 947-4-1 Low-voltage switchgear and Controlgear, Part 4-1: Contactors
> and Motor Starters

3.  []{#__RefHeading___Toc23238619 .anchor}Definitions

> FCS: Facilities Control System
>
> FLN(P1): Floor Level Network (Protocol 1)
>
> IGBT: Integrated gate bipolar transistor
>
> PI: Proportional - Integral control action
>
> PWM: Pulse-width modulated
>
> SDR: Sandia Delegated Representative
>
> VFC: Variable frequency controller

4.  []{#__RefHeading___Toc23238620 .anchor}Submittals

    A.  Equipment Submittals: Submit in accordance with conditions of
        Contract and Section 01330, "Submittal Procedures," except as
        noted herein.

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    A.  Product Data: For each type of VFC, provide dimensions; mounting
        arrangements; location for conduit entries; shipping and
        operating weights; and manufacturer\'s technical data on
        features, performance, electrical ratings, characteristics, and
        finishes.

    B.  Shop Drawings: For each VFC:

        1.  Include dimensioned plans, elevations, sections, and
            details, including required clearances and service space
            around equipment. Show tabulations of installed devices,
            equipment features, and ratings. Include the following:

            a.  Each installed unit\'s type and details.

            b.  Nameplate legends.

            c.  Short-circuit current ratings of integrated unit.

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        1.  Wiring Diagrams: Provide three (3) complete sets of VFC
            supplier's standard drawings showing schematics and wiring
            for each type of VFC.

    C.  Operations and Maintenance Data: Provide three (3) copies of
        instruction books, operating manuals, comprehensive trouble
        shooting guide, spare parts list and special bulletins covering
        on-site storage.

    D.  Manufacturer\'s field service report: Provide three (3) copies
        of the field test reports as specified in Part 3.

    E.  Load-Current and Overload-Relay Heater List: Compile after
        motors have been installed and arrange to demonstrate that
        selection of heaters are sized for actual motor nameplate
        full-load currents.

    F.  If VFC is derated, submit derating calculations.

    G.  

5.  []{#__RefHeading___Toc23238621 .anchor}Quality Assurance

    A.  Manufacturer's Qualifications: Minimum of five years experience
        in design and manufacture of VFCs of horsepower, range, and be
        knowledgeable in the latest technology specified on Contract
        Drawings and in this Section.

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    A.  Source Limitations: Obtain VFCs of a single type through one
        source from a single manufacturer.

    B.  Electrical components, devices and accessories shall be labeled
        and listed as defined in NFPA 70, Article 100, for intended use.

6.  []{#__RefHeading___Toc23238622 .anchor}Storage

    A.  Store VFCs indoors in clean, dry space with uniform temperature
        to prevent condensation.

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    A.  Protect VFCs from exposure to dirt, fumes, water, corrosive
        substances, and physical damage.

7.  []{#__RefHeading___Toc23238623 .anchor}Warranty

    A.  Provide manufacturer's warranty certificate upon acceptance of
        VFC system that shall include the following as a minimum:

        1.  If defect in supplied apparatus appears, or failure to
            comply with this Section is identified within period of
            two (2) years from date of manufacturer's certified
            start-up, not to exceed 30 months from shipment, response to
            repair or replacement of VFC shall be within a
            forty-eight (48) hour period.

        2.  Contractor shall, without delay and at Contractor's own
            expense, correct defects or failure of compliance by
            repairing defective parts, supplying non-defective
            replacement parts, or correcting defective or deficient
            design by any other means recommended by VFC manufacturer
            and accepted by SDR.

8.  []{#__RefHeading___Toc23238624 .anchor}Maintenance

    A.  Furnish extra materials described below that match products
        installed. Package with protective covering for storage, and
        identify with labels describing contents.

        1.  Furnish one spare fuse for every five installed, but not
            less than one set of three of each type and rating.

        2.  Furnish two spare indicating lights of each type installed.

        3.  Furnish one set of spare fans and filters for each size and
            type of filter installed in the VFC.

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    A.  Provide written certification from VFC supplier that spare
        printed circuit boards of each type utilized in VFC are readily
        available to SNL from VFC manufacturer within 24 hours of order.
        Describe each part and/or module and list stock number(s) of
        such parts.

        [PART 2 - PRODUCTS]{.underline}

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1.  []{#__RefHeading___Toc23238626 .anchor}Manufacturers

    A.  Subject to compliance with requirements, provide products by one
        of the following:

        1.  ABB Power Distribution

        2.  Danfoss Graham

2.  []{#__RefHeading___Toc23238627 .anchor}Manufactured Units

    A.  Description: The VFC shall convert the input AC main power to an
        adjustable frequency and voltage as defined in the following
        sections. The VFC shall use insulated gate bipolar transistors
        (IGBT) in the inverter section with a Pulse Width Modulated
        (PWM) output and arranged to provide variable speed of a NEMA MG
        1, Design B, 3-phase, high efficiency induction motor by
        adjusting output voltage, current and frequency. The VFC shall
        be listed and labeled as a complete unit and shall include all
        accessories and requirements as described in this section.

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    A.  The VFC shall be rated as shown on drawings. As a minimum the
        full load output current of the drive shall be equal to the
        equivalent motor horsepower as listed by NEC.

    B.  Unit Operating Requirements:

        1.  Input ac voltage tolerance of 200 volts AC ±10 percent or
            460 volts AC ±10 percent, as specified in contract
            documents.

        2.  Input frequency tolerance of 60 Hz, ±2 Hz.

        3.  Capable of driving full load, under the following
            conditions, without derating:

            a.  Ambient Temperature: 0 to 40 deg C

            b.  Humidity: Less than 90 percent (non-condensing)

            c.  Altitude: 5500 feet (1.7 km)

        4.  Minimum Efficiency: 96 percent at 60 Hz, full load

        5.  Minimum Displacement Primary-Side Power Factor: 96 percent

        6.  Overload Capability: 1.1 times the base load current for 60
            seconds; 2.0 times the base load current for 3 seconds

        7.  Starting Torque: 100 percent of rated torque or as indicated

        8.  Speed Regulation: ±1 percent

        9.  Isolated control interface to allow controller to follow
            control signal over an 11:1 speed range

    C.  Internal Adjustability Capabilities:

        1.  Minimum Speed: 0 to 100 percent of maximum rpm

        2.  Maximum Speed: 100 percent of maximum rpm

        3.  Acceleration: .1 to 1800 seconds

        4.  Deceleration: 1800 to .1 seconds

        5.  Current Limit: 50 to a minimum of 110 percent of maximum
            rating

    D.  Protection and Reliability Features: The VFC shall include the
        following:

        1.  The VFC including main breaker and bypass shall have an
            integrated withstand rating of no less than 100,000 amperes
            (symmetrical) and must be listed with UL or an equivalent
            test laboratory, unless noted otherwise in Contract
            documents.

        2.  Input transient protection by means of surge suppressors.

        3.  Upon power-up the VFC shall automatically test for valid
            operation of memory, loss of analog reference input, loss of
            communication, dynamic brake failure, DC to DC power supply,
            control power and the pre-charge circuit.

        4.  Under and over voltage trips, inverter over temperature,
            overload, and overcurrent trips.

        5.  Motor Overload Relay: Adjustable and capable of NEMA 250,
            Class 10 performance.

        6.  The VFC shall be capable of starting into a rotating load
            (forward or reverse) and accelerate or decelerate to set
            point without safety tripping or component damage (flying
            start).

        7.  The VFC shall be capable of DC injection braking at start to
            stop a reverse spinning motor prior to ramp.

        8.  The VFC shall be equipped with an automatic extended power
            ride-through circuit, which will utilize the inertia of the
            load to keep the drive powered. Typical control power
            ride-through for a fan load shall be a minimum of 200
            milliseconds.

        9.  If the input reference power (4-20mA or 0-10V) is lost, this
            shall cause a warning to be issued and the user shall have
            the option of pre-selecting either (1) stopping and
            displaying the fault, (2) running at a programmable preset
            speed, (3) hold the VFC speed based on the last good
            reference received. The VFC shall be programmable to signal
            this condition via a keypad warning, relay output or over
            the serial communication link.

        10. The VFC shall be capable of sensing a loss of load (broken
            belt or no water in pump) and signal the loss of load
            condition.

        11. Instantaneous line-to-line and line-to-ground overcurrent
            trips.

        12. Loss-of-phase protection.

        13. Reverse-phase protection.

        14. Short-circuit protection.

        15. Motor over temperature fault.

    E.  Automatic Reset and Restart: To attempt three restarts after
        controller fault or on return of power after an interruption and
        before shutting down for manual reset or fault correction.
        Bi-directional auto-speed search shall be capable of starting
        into rotating loads spinning in either direction and returning
        motor to set speed in proper direction, without damage to
        controller, motor, or load.

    F.  Input Line Conditioning: Provide input line conditioning
        equipment as required per Part 2.04.

    G.  Status Lights: Door-mounted light indicators shall indicate:
        Power On, Run and Fault. The detailed information on the type of
        fault and other operating information on the VFC shall be
        annunciated on keypad display.

    H.  Panel Mounted VFC Controller: A panel mounted VFC controller or
        electromechanical hand-off-auto switch shall allow for selection
        between "Hand", "Auto" and "Off". When "Hand" is selected motor
        speed shall be controlled via the panel mounted VFC controller.
        When "Auto" is selected motor speed shall be controlled via an
        external speed reference signal from either the FLN(P1) and/or a
        hardwired connection. The VFC shall incorporate "bumpless
        transfer" of speed reference when switching between "Hand" and
        "Auto" or between "Auto" and "Hand". When "Off" is selected the
        VFC shall stop, regardless of prior control selection.

    I.  Indicating Devices: Meters or digital readout devices and
        selector switch, mounted flush in controller door and connected
        to indicate the following controller parameters:

        1.  Output frequency (Hz)

        2.  Motor speed (rpm)

        3.  Motor status (running, stop, fault)

        4.  Motor current (amperes)

        5.  Motor torque (percent)

        6.  Fault or alarming status (code)

        7.  PI feedback signal (percent)

        8.  DC-link voltage (VDC)

        9.  Set-point frequency (Hz)

        10. Motor output voltage (V)

    J.  Control Signal Interface: Provide the VFC with the following
        unless otherwise specified on contract drawings:

        1.  Electrical Input Signal Interface: A minimum of 2 analog
            inputs 4-20 mA (24 VDC) and 4 programmable digital inputs.

        2.  Remote Speed Control Signal Inputs: Shall be able to accept
            one or more of the following types of speed control input
            signals from the FCS system; which shall be specified in the
            contract documents:

            a.  0 to 10 V dc

            b.  4-20 mA (24 VDC)

            c.  0 to 15 psig

            d.  Potentiometer using up/down digital inputs

        3.  Additional Control Capabilities

            a.  Remote start-stop capabilities utilizing one of the
                above digital inputs.

            b.  PI control capabilities utilizing one of the analog
                inputs as the control variable, or the control variable
                monitored by the FLN(P1) connection.

        4.  Output Signal Interface: A minimum of 1 analog output signal
            (0/4-20 mA), which can be programmed to any of the
            following:

            a.  Output frequency (Hz)

            b.  Output current (load)

            c.  Motor torque (percent)

            d.  Motor speed (rpm)

            e.  Set-point frequency (Hz)

            f.  Control variable value

    K.  Communications: The VFC shall include an interface device that
        accepts control signals via SNL's Protocol 1 (P1) network
        communication connection to Siemens (Landis Division) Series 600
        Modular Building Controller (MBC). Communication link shall meet
        the following requirements:

        1.  VFC shall have the ability to function on Siemens (Landis
            Division) system 600 P1 Network as a floor level network
            (FLN) device.

        2.  As a minimum, the VFC shall be able to perform the following
            tasks via the P1 network:

            a.  Monitor drive frequency output

            b.  Monitor drive speed

            c.  Monitor drive current

            d.  Monitor drive torque

            e.  Monitor drive power

            f.  Monitor drive temperature

            g.  Monitor drive kWh

            h.  Monitor drive run time

            i.  Monitor control variable

            j.  Control drive start/stop capabilities

            k.  Control drive speed determined by System 600 control
                strategy

        3.  Gateway-type protocol translation shall not be accepted.

    L.  Input Power Disconnect: The VFC shall include a main power
        circuit breaker disconnecting device that opens all phases of
        incoming AC line. The disconnect shall provide positive shutdown
        of the input power to both VFC and bypass circuitry.

        1.  Disconnect shall be thermal magnetic, molded case circuit
            breaker.

        2.  Mount circuit breaker inside controller enclosure, and
            include mounting bracket and through-the-door interlocking
            handle with provisions for padlocking.

        3.  A mechanical interlock shall prevent an operator from
            opening VFC drive door when the disconnect is in the "ON"
            position. Another mechanical interlock shall prevent
            operator from placing the disconnect in the "ON" position
            while the VFC drive door is open.

    M.  Electronic Bypass: When specified on Contract Drawings, the VFC
        shall include an electronic bypass that meets the following
        requirements:

        1.  Include circuitry necessary to safely transfer motor from
            VFC to power line, or from power line to VFC while motor is
            at zero speed.

        2.  Include a three pole bypass contactor.

        3.  Provide motor overload protection in both "Controller" and
            "Bypass" mode.

        4.  A readily visible indicator shall be provided to indicate
            the tripped position of the overload.

        5.  Refer to following schematic for typical VFC Bypass one-line
            diagram:

3.  []{#__RefHeading___Toc23238628 .anchor}Components

    A.  Enclose the VFC in a Type 12 enclosure per NEMA 250, unless
        noted otherwise on Drawings.

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    A.  Louvers that are required for appropriate heat dissipation shall
        include air filters.

    B.  Do not mount VFC in motor control center (MCC).

    C.  Cooling fans shall be located and installed so that they are
        readily accessible and easily replaced.

    D.  Finish: Manufacturer's standard paint applied to factory
        assembled and tested VFCs before shipping.

4.  []{#__RefHeading___Toc23238629 .anchor}Source Quality Control

    A.  Perform a harmonic analysis study in accordance with the latest
        version of IEEE 519 unless otherwise specified in contract
        documents.

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    A.  The harmonic distortion at the PCC shall be predicted through
        computer modeling of the distribution system and connected AC
        drives. SNL will provide power system data required to perform
        harmonic analysis study.

    B.  Do not exceed harmonic voltage and current distortion limits at
        point of common coupling (PCC) for general system applications,
        as recommended and defined by IEEE 519, unless specified
        otherwise in contract drawings.

    C.  If the calculations determine that the harmonic distortion
        levels are higher than the voltage and current specified, the
        drive manufacturer shall provide either line reactors, isolation
        transformers, multi-pulse drives or trap filters to meet the
        intent of IEEE 519.

    D.  The harmonic analysis report shall be part of the submittal
        approval process.

5.  []{#__RefHeading___Toc23238630 .anchor}Technical Support

    A.  Provide written certification from VFC manufacturer stating the
        availability of technical support for minimum of five (5) years
        from start-up.

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    A.  Provide technical support on the following basis:

        1.  Respond within 24 hours for diagnosis and repair the
            problem.

6.  []{#__RefHeading___Toc23238631 .anchor}Test And Inspection Equipment

    A.  Manufacturer shall inform SNL through their bid submittal, if
        VFC or VFC system provided requires any special tools or
        equipment to test, analyze or maintain system, and include
        additional price list for said equipment.

        [PART 3 - EXECUTION]{.underline}

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1.  []{#__RefHeading___Toc23238633 .anchor}Examination

    A.  Examine areas and conditions under which VFCs are to be
        installed for compliance with requirements, installation
        tolerances, and other conditions affecting performance and
        provide SDR with written notification of conditions detrimental
        to proper completion of work.

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    A.  Proceed with installation only after unsatisfactory conditions
        have been corrected in manner acceptable to SDR.

2.  []{#__RefHeading___Toc23238634 .anchor}Installation

    A.  Anchor each VFC assembly arranged and sized according to
        manufacturer\'s written instructions. Attach by bolting.

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    A.  Coordinate mounting and anchoring of VFCs with drawing details.

    B.  Install warning label on VFC indicating that load is subject to
        automatic restart upon power restoration.

3.  []{#__RefHeading___Toc23238635 .anchor}Field Quality Control

    A.  Provide services: The Contractor shall engage a qualified VFC
        manufacturer's service engineer to perform the following:

        1.  Test, checkout, and start up VFC system as required under
            "Field Quality Control" Article.

        2.  Select features of each VFC to coordinate with ratings
            characteristics of supply circuit and motor; required
            control sequence; and duty cycle of motor, drive and load.

        3.  Train Sandia National Laboratories' (SNL) personnel in
            proper operation and maintenance of VFC system.

        4.  Contractor shall coordinate testing, checkout, start-up, and
            training functions with SNL Maintenance organization.

        5.  Notify SDR a minimum of two weeks prior to scheduled test,
            checkout, and start-up.

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    A.  Do not energize any portion of VFC system without authorization
        from VFC manufacturer\'s representative and SDR.

    B.  Demonstrate trouble-free, stable operation for the 0 to 100%
        speed range.

    C.  Correct malfunctioning units on-site where possible and retest
        to demonstrate compliance; otherwise replace new units and
        retest.

    D.  SNL will test VFC with a Dranetz power quality analyzer at point
        of common coupling, at no charge to Contractor, before and after
        installation.

        1.  If harmonic voltage and current distortion exceed limits
            specified in Part 2, Contractor shall furnish and install,
            at no cost to SNL, devices necessary to reduce distortion to
            acceptable limits.

    E.  VFC manufacturer\'s service engineer shall prepare final written
        documents of installation and inspection tests made in field,
        complete with meter readings and recordings, where applicable,
        and submit to SDR for approval. Data collected from these tests
        shall include:

        1.  Incoming voltages from each phase leg to neutral, and from
            phase to phase

        2.  External process signal and its source

        3.  Set-Up Parameters: Comply with SNL's written instructions

            a.  Acceleration time to full motor speed in seconds

            b.  Deceleration time from full motor speed in seconds

            c.  Second acceleration/deceleration as applicable

            d.  Maximum speed in hertz and RPM

            e.  Minimum speed in hertz and RPM

        4.  Operational Parameters

            a.  Line current for each phase at inverter at full load

            b.  Line current for each phase at bypass in bypass mode

            c.  Load current for each phase at full load

            d.  Load current for each phase at bypass in bypass mode

        5.  Ambient temperature during test

        6.  DC bus voltage

        7.  Frequency output at 100% reference signal

        8.  Name of person completing test and start-up procedure

        9.  Date start-up completed

END OF SECTION