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Sample Specification for Medium Voltage Drives

For Voltage Ratings from 4000 to 6900Vac

Part 1

GENERAL
DESCRIPTION

1.01

1.02

A.

This specification describes a complete Adjustable Speed AC Drive (ASD) used to


control the speed of NEMA design B induction motors used in areas where low
harmonic content is desired or mandated.

B.

The ASD manufacturer shall supply the ASD and all necessary controls as herein
specified.

C.

The ASD shall be manufactured by a company with at least fifteen (15) years
experience in the production of this type of equipment.

D.

The ASD manufacturer shall be able to provide start-up service, 24 hour/day


emergency call service, repair work, maintenance and troubleshooting training of
customer personnel.
QUALITY ASSURANCE

E. The ASD manufacturing facility shall be ISO 9001 and ISO 14001 certified.
F. All printed circuit boards shall be completely tested before being assembled into the
complete ASD. The ASD shall be subjected to a functional test and load test.
G. All printed circuit boards shall be conformal coated for environmental protection.
H. The ASD manufacturer shall have an analysis laboratory to evaluate the failure of any
component including but not limited to an entire phase module.
1.03

CODES AND STANDARDS


A. The specified VFD shall be designed and materials shall be furnished in accordance
with the latest revisions of applicable sections of the following Codes and Standards.
International / European Standards for Design and Construction
IEC / EN 60071-1

Insulation coordination - Part 1: Definitions, principles and rules

IEC / EN 60146

Semiconductor Converters

IEC / EN 60664-1

Insulation coordination for equipment within low-voltage


systems - Part 1: Principles, requirements and tests

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IEC / EN 61800-4

Adjustable speed electrical power drive systems Part 4:


General requirements Rating specifications for a.c. power
drive systems above 1 000 V a.c. and not exceeding 35 kV

IEC / EN 61800-5-1

Safety requirements electrical thermal and energy

IEC 62103

Electronic equipment for use in power installations (EN 50178)

International / European Standards for Transformers


IEC 60146-1-3

Semiconductor Converters General requirements and line


commutated converters Part 1-3: Transformers and reactors

IEC 61378-1

Converter transformers Part 1: Transformers for industrial


applications

EMC Standards
CISPR 22 Cl A

Information technology equipment - Radio disturbance


characteristics; Limits and methods of measurement

IEC / EN 61000-2-4

Electromagnetic compatibility (EMC) Part 2-4: Environment


Compatibility levels in industrial plants for low-frequency
conducted disturbances

IEC / EN 61800-3

Adjustable speed electrical power drive systems - Part 3: EMC


requirements and specific test methods

Environmental Standards
IEC / EN 60721-3-1

Classification of environmental conditions Part 3:


Classification of groups of environmental parameters and their
severities Section 1: Storage

IEC / EN 60721-3-2

Classification of environmental conditions Part 3:


Classification of groups of environmental parameters and their
severities Section 2: Transport

IEC / EN 60721-3-3

Classification of environmental conditions Part 3:


Classification of groups of environmental parameters and their
severities Section 3: Stationary use at weather protected
locations

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Effective: 04-01-11
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American Standards

1.04

IEEE 519

Guide for Harmonic Control and Reactive Compensation of


Static Power Converters

IEEE 958

Guide for Application of AC Adjustable Speed Drives on 240013800 V auxiliary systems in electric power generating stations

IEEE 1566

Standard for Performance of Adjustable Speed AC Drives


Rated 375 kW and Larger

IEEE C57.12.00

General Requirements for Liquid-Immersed Distribution Power


and Regulating Transformers

IEEE C57.12.01

General Requirements for Dry-Type Distribution and Power


Transformers

IEEE C57.18.10

Practices and Requirements for Semiconductor Power Rectifier


Transformers

ICS7.1

NEMA Safety standard for construction and guide to selection,


installation and operation of Adjustable Frequency Drive
Systems

QUALIFICATIONS

A.

Acceptable manufacturers:
1. ABB ACS 2000 Ultra Low Harmonic (ULH) drive.
2. ASDs that are manufactured by a third party and/or brand labeled shall not be
acceptable.

1.05

SUBMITTALS
A.

The Submittals shall include the following information:


1. Outline Dimensions and Weight.
2. Customer connection and power wiring diagrams.
3. Complete technical product description including a complete list of options
provided.

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Part 2
2.01

DESIGN
DESCRIPTION
A.

The ASD shall be state of the art Voltage Source, 5 level topology utilizing High
Voltage insulated gate bipolar transistor (IGBT) technology.

B.

The ASD shall be an Ultra Low Harmonic Adjustable Speed AC Drive that is
designed to comply with standard IEEE 519-1992 when installed into a system that
already is in compliance with the standard without the use of a multi-pulse
transformer or active filter components.

C.

Reliability

D.

1.

The Mean Time Between Failure (MTBF) of the ASD shall be greater than
40000 hours, demonstrated. All components of the ASD shall be considered for
MTBF calculations.

2.

The calculated Availability of the ASD shall be greater than 99.95%. The
Availability shall be calculated based on the expected downtime due to
corrective and preventive maintenance.

3.

The manufacturer shall list any control or power components that require
recommended maintenance or replacement before 40000 hours of operation.
Information must be available in manufacturer's maintenance manual and
available for submittal.

4.

ASDs, using electrolytic capacitors in the power circuit, will not be accepted.
Foil capacitors with estimated life of 100,000 hours or greater shall be used.

5.

All power semiconductors and passive power components in both the rectifier
and inverter part shall be medium voltage rated components rated 3300 V
minimum. Low voltage components are not acceptable in the power circuit.

6.

In the event of either an input or output power semiconductor failure, the


component or assembly containing that component shall have a mean time to
repair no greater than 30 minutes.

ASD Output Power Quality


1.

Motor cable voltage reflections shall not result in any performance restrictions on
motor side for cable distances up to 1000 ft. It shall be assumed the distance is
less than 1000ft unless otherwise specified on Buyers Datasheet.
The ASD shall not induce greater than 2 % torque pulsations in the motor air gap
in the frequency range up to 100hz.

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E.

Efficiency
1. Overall Efficiency of the ASD system shall include the ASD Isolation Transformer
(if required), ASD and all ASD auxiliaries (such as the cooling system), Power
Factor Correction and Harmonic Filters. The Power Control House building
loads shall not be considered in the ASD System efficiency calculations, but shall
be supplied with the bid, so the Owner can evaluate the ownership costs of the
proposed system.
2. The overall drive system efficiency shall be not less than 96 % at full load, full
speed.

2.02

2.03

HARMONICS
A.

The Ultra Low Harmonic construction of the ASD shall not contribute any significant
harmonics to the system. The ASD shall comply with the limits at or below those
listed in Harmonic Control in Electrical Power Systems, IEEE Std. 519-1992. in the
system that already is in compliance with the standard.

B.

All harmonic management devices must be internal to the ASD enclosure and
supplied as a complete solution.

C.

The ASD shall have an active line supply unit which controls the waveform of the
input current and reduces the low order harmonic current drawn from the power
line. Line currents and voltages shall be nearly sinusoidal.

D.

IGBTs shall be used in the rectifier and inverter circuits. The power structure of the
inverter section shall be suitable for use in the rectifier section in order to minimize
the number of unique spare parts required.

E.

The ASDs design shall not compensate for existing harmonic content in the
distribution system.

F.

The total power factor at the ASD input shall be > 0.95, for the load range of 20 to
100%. The ASD manufacturer shall provide a Power Factor Correction Filter if the
ASD does not meet this requirement.

G.

The ASD including Power Factor Correction and/or Harmonic Filter shall never have
a leading power factor and take into account any interaction with other system
components. ASDs with large capacitance to ground on the input of the drive shall
provide special provisions to maintain power factor above 0.96 throughout the entire
speed range.

RATINGS
A.

The ASD shall be rated to operate from 3-phase power at +10/-10% of rated voltage.
The under voltage trip level shall be a minimum 25% under the nominal voltage.

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B.

The ASD shall be rated to operate at the following environmental operating


conditions: ambient temperature 5 to 40C continuous. ASDs that can only operate at
40 C intermittently (during a 24 hour period) are not acceptable and must be
oversized. Altitude 0 to 6500 feet (2000 meters) above sea level without derating,
less than 95% humidity, non-condensing.

C.

The ASD shall be rated to operate from input power from 48 Hz to 63 Hz.

D.

Output voltage and current ratings shall match the adjustable frequency operating
requirements of standard IEC and NEMA design A or NEMA design B motors.

E.

The normal duty overload current capacity shall be 110% of rated current for one (1)
minute out of ten (10) minutes.

F.

The heavy duty overload current capacity shall be 150% of rated current for one (1)
minute out of ten (10) minutes.

G.

The area classification for the ASD shall be non-hazardous.

H.

The ASD shall be protected from vibration with maximum sinusoidal displacement of
0.3 mm (29 Hz) and maximum acceleration of 1 m/s2 (2200 Hz).

CONSTRUCTION

2.04

A.

All models shall provide a complete, ready-to-install solution. Medium voltage input
power cabling entering and exiting the ASD enclosure shall be a 3 in 3 out
configuration. External cabling to an isolation transformer is unacceptable unless
specifically requested.

B.

Construction shall be robust such that all power semiconductors are shipped
completely assembled and installed in the drive cabinet. Separate shipping of power
semiconductor phase modules is not acceptable

C.

The latest, high voltage IGBT power technology shall be used. This technology shall
be used for all power and voltage ranges offered by the manufacturer. The use of
Low Voltage IGBTs or Medium Voltage SGCTs is unacceptable.

D.

The ASD shall offer microprocessor based control logic that is isolated from power
circuitry.

E.

The ASD shall use the same main control board for all ratings.

F.

Control connections shall remain consistent for all power ratings.

G.

The ASD shall employ a PWM controlled AC to DC rectifier (commonly referred to as


an active supply unit or active front end). The ASD shall not require a multi-pulse
transformer in order to meet IEEE 519 standards. If an input harmonic filter is

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required to meet IEEE 519 it shall be factory mounted and wired within the ASD
enclosure.
H.
I.

The ASD shall be offered in NEMA Type 1/IP21 enclosures.


ASD shall be of free-standing construction and shall include the following standard
features:
1.
2.

The phase modules in the cabinet shall be of a modular construction for quick
removal and replacement.
Phase modules shall be of modular construction with bus stab connections to
ensure fast and easy handling.

J.

The ASD enclosure doors with access to power semiconductor parts shall include an
mechanical interlocking system with a safety grounding switch. The enclosure doors
can be opened only if the safety ground switch connects all DC buses to ground, to
ensure all stored ASD and motor energy is discharged. Grounding of any power
circuit via a resistor is not acceptable.

K.

ASD enclosure panels with access to medium voltage parts other than power
semiconductors shall require a tool for entry. All panels shall have appropriate
warnings.

L.

All painted surfaces shall have an ANSI 61 grey exterior finish unless otherwise
specified on Buyers Datasheet. Interior surfaces shall be bright (unpainted)
galvanized steel.

M.

The enclosure must be designed to avoid harmonic and inductive heating and
eliminate radio frequency interference

N.

Cooling fans of air cooled ASDs shall have the option for a redundant fan with
automatic switch-over, if specified in Buyers Datasheet. Periodical cycling between
active and stand-by fans shall be initiated automatically. Loss of redundancy shall
issue an alarm.

O.

ASD noise level shall be less than 85 dB(A) at 1 meter distance for air cooled ASDs.
OPERATOR INTERFACE

2.05

A.

Each ASD shall be equipped with a front mounted operator control panel consisting of
a back lighted alphanumeric display and a keypad with the functions:
1. Run/Stop command
2. Local/Remote command
3. Speed Increase/Decrease command
4. Menu navigation and parameter selection

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B.

All parameter names, fault messages, warnings and other information shall be
displayed.

C.

During normal operation, the speed reference, and run/stop forward/reverse and
local/remote status shall be displayed. At least 2 additional user selectable values
shall be available for display including the following values as a minimum:
1. Motor speed, current and power
2. Output frequency, voltage and torque
3. DC bus voltage
4. Cooling air pressure drop
5. Values of analog input and output signals
6. Status of discrete inputs and outputs.

D.

Password protection shall be available for prevention of unauthorized parameter


access.

E.

The keypad shall be used for local control, for setting all parameters, and for stepping
through the displays and menus.

F.

G.
An intelligent start-up assistant shall be provided as standard. The Start-up
routine will guide the user through all necessary adjustments to optimize operation.
PROTECTIVE FEATURES

2.06

A.

The buyer will provide a dedicated circuit breaker or vacuum contactor (hereto called
Input Isolation Device); rated to protect the ASD at specified short-circuit levels. The
Input Isolation Device shall be controlled by the ASD.

B.

The ASD shall have short circuit detection capability at the gate unit level to allow for
short circuit current to be switched off at the semiconductor level within 25 micro
seconds.

C.

At least 40 time tagged fault messages shall be stored in the ASDs fault history.

D.

An Emergency Off pushbutton shall be provided on the ASD door. The Emergency Off
pushbutton will trip the upstream MCB and the motor will coast to stop.

E.

A discrete (binary) input for Process-stop shall be provided. The reaction upon
activation of this input shall be either a ramp or coast to stop, selectable by the user.

F.

An automatic restart function shall attempt to restart the ASD after various internal
fault conditions. An adjustable time-out setting shall be provided. The user shall have
the option of employing this feature or disabling it.

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G.

H.

The following motor protection functions shall be available at the ASD.


1.

Motor winding or motor lead phase-to-phase short.

2.

Motor ground fault protection.

3.

Motor phase loss protection.

4.

Stall protection shall be programmable to provide a warning or fault the ASD after
the motor has operated above a programmed torque level for a programmed time
limit.

5.

Motor overload (= overcurrent) protection shall be programmable to provide a


warning or stop the ASD, applying at least three time dependent thresholds. The
ASD shall provide electronic motor overload protection.

The following ASD protective functions shall be available.


1. Overtemperature and pressure drop monitoring
2. Loss of cooling (fan) failure
3. ASD internal fault detection
4. Protection against input phase loss.
5. Surge arrestors for phase to phase and phase to ground line voltage transient
protection.
6. The ASD shall provide input phase loss and line under voltage protection.
7. A power loss ride through feature shall allow the ASD to remain fully operational
after losing power as long as kinetic energy can be recovered from the rotating
mass of the motor and load.
8. For each programmed warning and fault protection function, the ASD shall display
a message in complete English words or Standard English abbreviations. The five
(5) most recent fault messages and times shall be stored in the ASDs fault
history.
CONTROL INPUTS AND OUTPUTS

2.07

A.

Buyer shall provide 380 to 600V auxiliary power. The ASD shall transform auxiliary
power for the control section. Control power to be defined on customer one line
diagram.

B.

Discrete Inputs
1.

A minimum of ten (10) discrete inputs shall be provided. Inputs shall be


independently programmable with function selections (run/stop, hand-off-auto,
etc).

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2.

3.

C.

Discrete Outputs
1.

D.

E.

F.

Discrete (binary) inputs shall be designed for 24 VDC. Discrete input functions
shall include Run/Stop, Increase/Decrease, Disable Local (to prevent
unauthorized operation from the local panel) and Remote Reset.
Additional (binary) inputs for transformer monitoring (oil pressure / temperature /
level alarm and trip) shall be available.

Minimum of four (4) freely programmable digital outputs shall be provided.


Selections shall include:
a) Operating conditions such as ASD ready, ASD running, reversed and at
set speed
b) General warning and fault conditions
c) Relay contacts shall be rated to switch 6 Amps at 24 VDC or 115/230
VAC...

Analog Inputs
1.

Minimum of two (2) analog inputs shall be provided:


a) Resolution of analog inputs must be at least 10 bit total resolution

2.

Analog inputs shall be programmable for either voltage or current, (0-10V, or 020mA). Analog input signals processing functions shall include scaling
adjustments and adjustable filtering. Analog signal functions shall include speed
and torque reference signals.

3.

Two (2) analog inputs shall be programmable to form a reference by addition,


subtraction, multiplication, minimum selection or maximum selection.

Analog Outputs
1.

Minimum of two (2) analog outputs configurable for either voltage or current shall
be provided.

2.

Outputs shall be independently programmable to provide signals proportional to


output function selections including output speed, frequency, voltage, current and
power.

RTD Inputs
1. If transformer winding temperature and/or motor winding and bearing temperature
supervision are required, the drive shall provide an option for a minimum of 5
inputs. A Motor Protection Relay shall not be required for adequate protection.

G.

Interface to Upstream Disconnect


1.

Two (2) outputs and three (3) inputs shall be provided for interfacing to an
upstream disconnect device.

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Effective: 04-01-11
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2.08

SERIAL COMMUNICATIONS
A.

If specified in Buyers Datasheet, serial field bus communication interface modules


shall be provided.

B.

The ASD shall be capable of communicating with other ASDs or controllers via a
serial communications link. A variety of communications interface modules for the
typical overriding control systems shall be available.
1. Interface modules shall be available for a wide selection of protocols including but
not limited to:
a)
b)
c)
d)

Modbus
Ethernet IP
DeviceNet
Profibus

2. I/O shall be accessible through the serial communications adapter. Serial


communication capabilities shall include, but not be limited to:
a) Run-Stop control
b) Speed Adjustment
c) Accel/Decel time adjustments
3. The ASD shall have the capability of allowing the overriding controller to monitor
feedback such as process variable feedback, output speed/frequency, current (in
amps), % torque, power (kW), kilowatt hours, operating hours, relay outputs, and
diagnostic warning and fault information.
4. A connection shall also be provided for personal computer interface. Software
shall be available for ASD setup, diagnostic analysis, monitoring and control.
2.09

CONTROL FUNCTIONS AND ADJUSTMENTS


A.

Output frequency shall be adjustable between 0 Hz and 75 Hz. Operation above


motor nameplate shall require programming changes to prevent inadvertent highspeed operation.

B.

Stop mode selections shall include coast to stop and ramp to stop.

C.

The ASD shall be capable of controlling deceleration of a load without generating an


overvoltage fault caused by excessive regenerated energy. Overvoltage control on
deceleration shall extend the ramp time beyond the programmed value to keep the
amount of regenerated energy below the point that causes overvoltage trip.

D.

The ASD shall run with a sensorless control algorithm with static speed error of less
than 0.2% and open loop torque step rise time of less than 10 milliseconds.

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E.

The ASD shall be capable of starting into a rotating load (flying start) regardless of
motor direction. It should then accelerate or decelerate to the active reference without
tripping on fault or causing component damage.

F.

The ASD shall provide an automatic current limit feature to control motor currents
during startup and provide a soft start torque profile for the motor-load combination.
Current and torque limit adjustments shall be provided to limit the maximum ASD
output current and the maximum torque produced by the motor.

G.

The ASD shall accept a start/stop command and speed reference from a local ASD
panel, or from a remote panel.

H.

Speed control functions shall include:


a.
Adjustable min/max speed limits.
b.
Three sets of critical speed lockout adjustments.
c.
A built-in PID controller to control a process variable such as pressure, flow or
fluid level.

I.

2.10

Five (5) programmable critical frequency lockout ranges shall be provided to prevent
the ASD from operating the load continuously at an unstable speed.

DATALOGGING
A. The ASD shall have optional data logging capability that will monitor and store all
information with respect to system events and system alerts, as well as information about
the ASD.
1.

Data logging shall be independent from ASD control.

2.

All events/alerts related to ASD operating data should be stored by the data
logging system for later analysis.

3.

Data logging system should on an event ASD basis monitor ASD operation and
performance.

4.

Data logging system should allow optionally to trend long term operating
performance of the ASD

5.

Data logging system should monitor and register all changes to the ASD
configuration and monitor consequent performance

B. The data logging system should contain supporting information with respect to trouble
shooting, tuning, and VSD set-up parameters
1.

Optionally system should provide Preventive Maintenance information and


monitor the Preventive Maintenance schedule over time.

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C. The data logging system has to be equipped to enable remote access.


1.

3.01

The data logging system should be equipped with remote access functionality
enabling remote troubleshooting and performance analysis by Supplier experts
(data transfer, remote collaboration, automated notifications etc.).

EMERGENCY OFF FUNCTION


A.

Enclosed ASD shall be provided with input emergency off function:


Emergency off command by the operator shall separate the ASD from the AC line
by opening an upstream line contactor / line circuit breaker.

1.

EXECUTION

4.01

TESTING
A.

The ASD equipment shall undergo standard routine testing in accordance to applicable
standards.

B.

Each ASD shall be factory load tested. This test shall include a full current test and a
light load test with an induction motor on a dynamometer test stand.

C.

If requested in Buyers Datasheet, a factory acceptance test or factory inspection visit


for Buyers representative shall be scheduled upon award of contract.

4.02

SPARE PARTS
A.

The ASD manufacturer shall provide a complete list of spare parts for the ASD.

B.

The ASD manufacturer shall provide local support for renewal parts.

C.

As a minimum, the ASD manufacturer shall include these spare parts as a separate line
item on the bid:

4.03

1.

100% spares of each type of medium voltage fuse.

2.

100% spares of each type of low voltage fuse.

3.

Spare filter material

PREPARATION FOR SHIPMENT


A.

Equipment shall be individually crated and tagged with proper identification of the
assembly to which it belongs.

B.

Materials, including detailed wiring diagrams and instructions for reassembling


shipping sections and making bus connections at shipping splits shall be provided.

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C.

4.04

Terminal strips shall be provided for all interconnecting wiring at shipping splits. Each
wire terminal shall be identified with permanent wire markers.
INSTALLATION

A.

4.05

The ASD manufacturer shall provide adequate drawings and instruction material to
facilitate installation of the ASD by qualified electrical and mechanical personnel
employed by others.
START-UP

A.

B.

C.

4.06

The Bidder shall be able to provide commissioning services and basic hands-on
maintenance and operation training on site by an engineer certified by the VFD
Manufacturer.
The Bidder shall provide daily rates for all services.
Microsoft Windows based software shall be provided for ASD commissioning,
parameters setup, fault log viewing, diagnostic analysis, monitoring and control. The
software shall provide real time graphical displays of ASD performance.
PRODUCT SUPPORT

A.

Factory trained application engineering and service personnel that are thoroughly
familiar with the ASD products offered shall be locally available at both the specifying
and installation locations.

B.

A 24/365 technical support line shall be available on a toll-free-line.

4.07

WARRANTY
A.

All equipment furnished under this section shall be warranted by the installing
Contractor and the equipment manufacturer(s) for a minimum period of 12 months
after completion of start-up or 18 months after shipment, whichever occurs first.

B.

With a certified start-up, warranty shall be 24 months from the date of start-up, not to
exceed 30 months from the date of shipment. The warranty shall include all parts,
labor, travel time, and expenses.

C.

There shall be 24/365 support available on a toll-free-line.

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