SECTION 16483 ADJUSTABLE SPEED CONTROLLERS (ASC)
PART 1 GENERAL
1.1 SECTION INCLUDES
A. Detailed design, fabrication, installation, and testing of adjustable speed controller systems as scheduled and as shown on the drawings.
1.2 SUBMITTALS
A. SHOP DRAWINGS: Submit under the provisions of Section 01300. A reviewed set will be returned to the supplier for fabrication. The shop drawings shall include the following:
1. Prior to shop drawing submittal for adjustable speed controller systems, obtain detailed motor load information from equipment manufacturer.
2. Submit system hydraulic analysis including graphs and tabular information for the following:
a. Input horsepower versus flow (minimum design flow to maximum design flow) taking into account pump, AFD and motor efficiencies.
b. System curve versus pump curve at 100 percent speed and in 10 percent increments until minimum pump speed at which pump does not generate enough head to overcome static head is reached. Plots must also show curves of constant hydraulic horsepower to verify non-overloading.
c. Tabulated data shall be calculated at 2 +percent speed increments.
3. Submit harmonic voltage distortion analysis based upon the minimum three phase bolted fault short circuit current available at the point of service. Submittal data shall not relieve supplier of specified performance requirements. Analysis shall include:
a. Calculate percent voltage distortion , with respect to fundamental voltage, for all harmonics up to the 48th.
b. Comparison with IEEE 519 standards for acceptable voltage distortions on such systems.
4. Submit detailed project specific control diagrams for each ASC. Reference P&IDs and HVAC drawings for logic
5. Submit detailed list of any proposed deviations from these specifications.
6. Submit experience certification upon request including Owner name, address, and telephone number for systems of similar size and type.
B. OPERATION AND MAINTENANCE MANUALS: Include as part of the equipment operation and maintenance manual.
C. SPARE PARTS LIST: Provide vendor’s name, address, and phone numbers for spare parts.
1.3 PROJECT RECORD DOCUMENTS
A. Submit project record documents.
B. Submit harmonic distortion analysis test results showing actual field measurements of harmonic distortion.
1.4 DELIVERY, STORAGE AND HANDLING
A. Deliver, store, protect, and handle products according to the written instructions of manufacturer.
1.5 WARRANTY
A. Provide two years of Manufacturer’s warranty covering equipment, software, configuration, and labor from Owner’s Acceptance.
1.6 GENERAL DESIGN REQUIREMENTS
A. This design is based upon the named manufacturer, if substitute equipment is offered, the contractor shall be responsible for all modifications including but not limited to components, interconnection wiring, space requirements, and equipment layout. All modifications shall be subject to approval by Engineer and provided at no additional cost to the Owner.
B. Like components of all systems, although for different service, shall be the end products of a single manufacturer.
C. All MCC-mounted ASC’s on this project shall be of like manufacturer and shall match the manufacturer of the Motor Control Center (MCC), Section 16482.
D. It shall be the responsibility of the Contractor to provide a complete and fully operable adjustable speed controller system for each unit identified elsewhere in the specifications and on the drawings.
1.7 STANDARDS
A. IEEE Standards 519-1992.
B. UL listing/labeling Standard UL508C.
C. CSA
D. EMA ICS 3.1
E. Manufacturer shall be ISO 9001 or ISO 9002 certified.
PART 2 PRODUCTS
2.1 APPROVED MANUFACTURERS
A. Allen-Bradley, 18-pulse, provided in Allen-Bradley Motor Control Centers. (Allen- Bradley, 6-pulse, provided in Allen-Bradley Motor Control Centers if HP is less than 50).
B. Cutler-Hammer, 18-pulse, provided in Cutler-Hammer Motor Control Centers. (Cutler- Hammer, 6-pulse, provided in Cutler-Hammer Motor Control Centers if HP is less than 50).
C. Siemens, 18-pulse, provided in Siemens Motor Control Centers. (Siemens, 6-pulse, provided in Siemens Motor Control Centers if HP is less than 50).
D. Square-D, 18-pulse, provided in Square-D Motor Control Centers. (Square-D, 6-pulse, provided in Square-D Motor Control Centers if HP is less than 50).
2.2 GENERAL
A. Provide adjustable speed controller systems capable of converting the specified voltage, 3-phase, 60 Hz, input power into variable voltage, adjustable frequency, 3-phase output of suitable capacity and waveform to serve as input power to squirrel cage induction motors.
B. Harmonic Distortion:
1. The adjustable speed controller systems shall operate satisfactorily when connected to a bus supplying other solid state power conversion equipment which may be causing up to 10 percent total harmonic voltage distortion and commutation notches up to 36,500 volt microseconds, or when operated from the same bus.
2. Individual or simultaneous operation of the adjustable speed controller systems shall not add more than 5 percent total harmonic voltage distortion to the normal bus, nor more than 10 percent while operating from the standby generator in accordance with IEEE 519, 1992.
3. Maximum total and individual harmonic current distortion limits for each odd harmonic shall not exceed those set forth by IEEE 519, 1992.
4. If harmonic filters are needed to meet these requirements, then the speed controller supplier shall provide and be responsible for the design and manufacture of the filters. The need for filters shall be identified by the Contractor in the Shop Drawings.
C. Reflected Wave/Harmonics:
1. If the distance between the speed controller and the driven equipment requires cable terminators, they should be furnished by the speed controller supplier and installed by the contractor. The need for cable terminator(s) or reflected wave traps, shall be identified in the Shop Drawings.
2.3 ADJUSTABLE FREQUENCY DRIVE
A. Environmental
1. Altitude: 3,300 feet without derating.
2. Humidity: 5 to 95 percent, non-condensing.
3. Temperature: 32 to 104 degrees Fahrenheit.
B. Electrical
1. Input voltage tolerance: 10 percent of rated voltage.
2. Rated voltage: as shown on drawings and scheduled.
3. Input frequency: 48 to 62 Hertz.
4. Displacement power factor: 0.95, provide inductor on units 5 hp and smaller.
5. Efficiency at rated current and nominal voltage: 97.5 percent.
6. Maximum short circuit current: 5000 A rms at 600 volts.
C. Control
1. Method: Sine coded PWM with programmable carrier frequency.
2. Output voltage: 0 to rated voltage.
3. Output frequency: 0 to 400 Hz.
4. Volts per Hertz ratio: fully programmable.
5. Frequency regulation:
a. Analog input: 0.4 percent of maximum.
b. Digital input: 0.01 percent of maximum.
6. DC Boost:
a. Fan mode: two selectable.
b. Auto mode: eight selectable with independent.
c. Fixed mode: selectable with independent acceleration and run boosts.
7. Acceleration/deceleration: two independently programmable times, adjustable from 0 to 600 seconds in 0.1 second increments.
8. Intermittent overload capability.
a. Constant torque: 150 percent of output for one minute.
b. Variable torque: 115 percent of output for one minute.
9. Proactive current limit:
a. Constant torque: 20 to 160 percent of rated output.
b. Variable torque: 20 to 115 percent of rated output.
c. Inverse time overload: Class 20 protection with speed sensitive response, adjustable from 20 to 115 percent of rated current in 3 speed ranges.
D. Protective features.
1. Detection and trip:
a. Undervoltage.
b. Overvoltage.
c. Overcurrent.
d. Overtemperature.
e. External signal.
f. Output short circuit.
g. Ground fault.
2. Overcurrent stall.
3. Overvoltage stall.
4. Six alarms.
E. Signal interface:
1. Drive fault contact.
2. Drive run contact.
3. Drive alarm contact.
4. Programmable output contact.
5. Potentiometer input.
6. 0-10 VDC analog input.
7. 4-20 mA analog input.
8. 4-20 mA signal loss response.
9. Analog output, selectable.
10. Analog input conversion.
11. Pulse train input.
12. Encoder feedback closed loop speed control.
F. Programmable Parameters:
1. Dual acceleration/deceleration profiles.
2. Three skip frequencies.
3. DC injection braking.
4. Dynamic braking.
5. Slip compensation.
6. Negative slip compensation.
7. Selectable fault reset tries and time.
8. Electronic thermal overload.
9. S-curve acceleration/deceleration profile.
10. Standard and custom volts-per-hertz curves.
11. Traverse function.
12. Proactive current limit.
13. Four event fault memory.
14. Flying start.
15. Automatic DC boost.
16. Seven preset speeds.
17. Phase lock loop.
G. Human Interface Module- Keypad
1. Display faults in English language:
a. Power fault.
b. Control fault.
c. Logic fault.
d. Software fault.
e. Protective fault.
2. Settings and indication
a. Adjustable Speed/Constant Speed Selection (systems with bypass)
b. Bypass Run Indication (systems with bypass)
c. Manual/Automatic Selection
d. Manual Pushbutton Start/Stop
e. Speed Indication
f. Speed Setpoint Indication
g. Inverter Failure Indication
h. Inverter Run Indication
i. Manual Speed Control
j. Alarm/Cutout Reset Switch
k. Output Current Indication (each phase)
l. Output Voltage Indication (each phase)
m. Output Frequency Indication (each phase)
n. Output Kilowatts Indication (each phase)
o. Drive Temperature Indication
p. Motor RPM Indication
3. Allow control of speed controller with start-stop function keys and digital speed potentiometers.
4. Allow programming of all programmable parameters.
5. Door mounted on front of enclosure. ASCs furnished as part of a motor control center (MCC), shall include an HMI keypad on cubicle door of the MCC. Provide required interface cable for either situation.
H. Constant or variable torque. Coordinate with the specification of the driven equipment.
2.4 OVERCURRENT PROTECTION
A. Provide thermal magnetic main circuit breaker of scheduled ampacity.
B. UL short circuit withstand rating shall be 42,000A minimum.
C. Provide a through-the-door circuit breaker operator, which is interlocked with the door mechanism and is lockable in the off position. Provide an interlock defeat mechanism which allows authorized personnel to enter the enclosure while circuit breaker is in the on position.
2.5 PILOT CONTROL DEVICES
A. Provide the following front of panel mounted pilot devices:
1. Human interface Module.
2. Reset pushbutton.
B. Provide the following interface signals, prewired to terminal block for connections to SCADA system:
1. Remote START input. (maintained or momentary as shown on P&IDs)
2. Remote TRIP input.
3. Controller ON output.
4. Controller in REMOTE control output.
5. Controller FAILED output.
6. Remote 4-20 mA speed demand input.
7. 4-20 mA speed indication output.
C. Provide the following interface signals, prewired to terminal block for connection to field mounted devices:
1. Input connections from field mounted HOA switches.
2. Input connections from all other devices shown on P&IDs.
2.6 ADDITIONAL REQUIREMENTS
A. The ASCs shall have an efficiency that exceeds 97% at 100% speed and load. The efficiency shall exceed 80% at 50% speed and load.
B. The ASCs shall maintain the line side displacement power factor no less then 0.95 regardless of speed and load.
C. The ASCs shall have a one minute overload current rating of 110% for Variable Torque Drives.
D. The ASCs shall have a one minute overload current rating of 150% for Constant Torque Drives.
E. The ASCs shall be able to start into a spinning motor. Each ASC shall be able to determine the motor speed in any direction and resume operation without tripping. If the motor is spinning in the reverse direction, the AFD shall start into the motor in the reverse direction, bring the motor to a controlled stop, and then accelerate the motor to the setpoint speed.
F. The ASCs shall have fully adjustable acceleration and deceleration controls.
G. The ASCs shall provide automatic phase rebalance to rebalance 3 phase load currents upset by voltage unbalance.
H. Provide all internal control logic circuitry as shown on P&IDs and/or HVAC drawings.
2.7 ENCLOSURE
A. Refer to electrical plans for enclosure type (i.e. wall-mounted or integral with MCC).
PART 3 EXECUTION
3.1 INSTALLATION
A. Installation by Others in accordance with written instructions from manufacturer in location shown on drawings.
B. Protect panels while construction is underway.
C. Clean panels and touch up paint when construction is complete.
D. Adjust overload devices.
E. Adjust all programmable controller features, including but not limited to auto restart parameters. The controller system must automatically restart after a power fail condition.
F. Provide engraved nameplates. Use equipment tag names shown on the plans. Refer to Section 16482.
G. Provide typed label inside each unit identifying motors served, nameplate horsepower, full load current, code letter, service factor, voltage/phase rating, and overload setting.
H. Provide typed label inside each unit identifying configured valves for all programmable drive parameters.
3.2 QUALITY CONTROL AND TESTING
A. Inspect and test each unit in accordance with NEMA ICS. 2, Division 16, and Vendor Manuals.
B. Prior to each drive application startup, all equipment shall be inspected for proper alignment and proper connection.
C. Short commercial tests shall be made, including no-load current at rated voltage, full load current, and locked rotor current.
D. Provide test of motor cables prior to energizing each new ASC. ASC manufacturer to provide test procedure.
E. Provide a pre-service test operation of the drive and motor in all normal modes of operation to test start, stop, jog, run, acceleration, and deceleration in local and remote modes.
F. Provide certified copies of test reports on each drive, to the Engineer for review.
3.3 TRAINING
A. The Contractor shall provide a training session for up to 4 Owner’s representatives for 2 normal workdays with a maximum of 2 trips at a job site location determined by the Owner. Training and instruction time shall be in addition to that required for start-up services.
B. The training shall be conducted by the manufacturer’s qualified representative.
C. The training program shall consist of the following:
1. Instructions on the proper operation of the equipment.
2. Instructions on the proper maintenance of the equipment.
END OF SECTION
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