RFP-76161

Design and Construction of the Third Set of Locks

SECTION 26 29 23 – VARIABLE FREQUENCY DRIVE

1.01 SUMMARY:

A. Basic Function: This specification shall apply to gates operating motor mechanism and
any other systems that the Contractor’s design requires a Variable Frequency Drive
(VFD).

B. Scope of Work: Variable A17frequency drives A17 shall be installed whenever the
operation of motors required variable speed applications. This specification covers the
complete labor, materials, and equipment required to place into operation a VFD system,
and covers all components of the engineered system. For the gates particular application,
it may be required that two VFD’s work in parallel in order to equalize load sharing and
match the speed, and increase reliability.
A16
1.02 REFERENCES: A16

A. American National Standards Institute (ANSI) Standards:

958 –03 Guide for the Application of AC Adjustable-speed

Drives on 2,400 and 13,800V Auxiliary Systems in
Electric Power Generating Stations

C57.110 – 04 Recommended Practice for Establishing Transformer

Capability when Supplying Non-sinusoidal Load
Currents

C57.16 – 01 Standard requirements, Terminology, and Test Code for

Dry-Type Air-Core Series-Connected Reactors

18 – 02 Standard for Shunt Power Capacitors

P1036 – 06 Guide for Application of Shunt Power Capacitors

B. Institute of Electrical and Electronics Engineer (IEEE) Standard:

519 – 04 Recommended Practice and Requirements for Harmonic

Control in Electrical Systems

C. National Fire Protection Association (NFPA) Publications:

70 – 08 National Electrical Code

D. National Electrical Manufacturers Association (NEMA) Publications:

ICS 61800-4 - 04 Adjustable Speed Electrical Power Drive Systems Part

4: General Requirements Rating Specifications for AC
Power Drive Systems Above 1,000VAC and not
exceeding 35kV

November 2008 1 of 12
Amendment No. 19
Volume II – Employer’s Requirements
Part 2 – Supplemental Requirements RFP-76161
Section 26 29 23 – Variable Frequency Drive Design and Construction of the Third Set of Locks

ICS 6 – 06 Industrial Control and Systems Enclosures

ICS 7 – 06 Industrial Control and Systems: Adjustable-Speed

Drives

250 – 03 Enclosures for Electrical Equipment (1000 volts

maximum)

E. Underwriters Laboratories Inc. (UL) Standards for Safety:

1283 – 2005 UL Standard for Safety for Electromagnetic Interference

Filters
A7
1.03 REQUIREMENTS:A7

A. The drivers will be installed in an air conditioned room, but they shall be able to perform
in the normal ambient conditions of Panama. VFD system shall be capable of continuous
operation without derating in an average ambient temperature of 40°C at sea level and a
humidity environment of 95% non-condensing.
A7
B. Performance:A7

1. Torque: VFD shall meet the following speed and torque requirements:
a. Continuous system operation output over a speed range as required for
the application.
b. Operating any standard AC motor over the specified speed range.
c. Momentary overload of 120% of rated motor current for one minute out
of any ten minutes.
d. Produce full rated torque at any speed in the operating range (constant
torque capability).
e. Transient over-torque of 130% of nominal motor torque for one minute
of any ten minutes.
f. Breaking torque capacity to be determined by gate operation
requirements, but in no case shall be less than 30% of motor torque.
g. No speed sensor shall be required
h. Continuous operation with 30% voltage sag or power loss of 3 cycles or
less on the input power line.
i. The VFD converter section shall be 18 or 12 pulse as required in
paragraph 1.04 D.

2. Input Harmonics: VFD’s shall comply with the latest edition of IEEE 519 for
total harmonic voltage and current distortion calculation and measurement and
meet the following distortion limits:

2 of 12 November 2008
Amendment No. 19
 Volume II – Employer’s Requirements
RFP-76161 Part 2 – Supplemental Requirements
Design and Construction of the Third Set of Locks Section 26 29 23 – Variable Frequency Drive

a. Voltage Harmonics: Individual or simultaneous operation of the VFD’s

shall not add more than 3% total harmonic voltage distortion while
operating from the utility source and measured at the point of common
coupling at any motor load and speed.
b. Current Harmonics: Maximum allowable total harmonic current
distortion limits for each VFD shall not exceed 5% as calculated and
measured at the point of common coupling at any motor load and speed.
A17
c. The existing network source data is available as an Aspen data base,
made available by the Employer to all Tenderers, to be used in all
required studies and for determining the harmonic response of the
existing network. A17

C. Serviceability / Maintainability

1. Access: VFD system should be designed for easy access. All maintenance, part
replacement and/or installation shall be able to be done from access doors.

2. Modularity: Modular designed components for rack-out accessibility for ease of

maintenance and to minimize repair downtime.

D. Capacities: Capacities of equipment and material shall be not less than those indicated
on these specifications.

E. Modularity: VFD System shall be modular type system with easy access or replacement
of the different modules or elements.

F. Corrosion Resistance: All interior and exterior ferrous metal shall be cleaned and
painted with corrosion protective coating system as per ANSI C57.12.29 and Section
09 96 00 (Corrosion Control Coatings).

G. Installation: VFD Systems shall be installed as per manufacturer’s recommendation.

H. Standard Products: Materials and equipment submitted for approval shall be standard
cataloged products of concerns regularly engaged in the commercial production of these
products and shall be the latest standard design that conforms to the specifications.

I. Marking: Internal equipment wiring marking shall be as per Section 26 05 53

(Identification for Electrical Systems).
A7
1.04 DESIGN CRITERIA/SYSTEM DESCRIPTION AND PERFORMANCE:A7

A. Each VFD system shall consist of all system components required to meet the
performance, protection, safety, testing, and certification criteria of this specification.
These components shall be part of an integral motor control system: VFD, motor,
harmonic filter and power factor correction unit, isolation transformer, VFD
converter/DC-link/inverter, and output filter.

B. The Contractor will be allowed to design the gate control system in medium voltage
(12kV). This will requires a medium voltage VFD and a medium voltage motor. If

November 2008 3 of 12
Amendment No. 19
Volume II – Employer’s Requirements
Part 2 – Supplemental Requirements RFP-76161
Section 26 29 23 – Variable Frequency Drive Design and Construction of the Third Set of Locks

Contractor decides to use medium voltage system, IEEE 958 standard shall be followed
in addition to the requirements of these specifications.

C. The VFD system as defined above shall be completely factory pre-wired, assembled and
tested (with the motor) as complete packages by the VFD manufacturer, to assure a
properly coordinated and fully integrated drive system.

D. The VFD converter section shall be of at least eighteen pulse type for motors sized above
200 HP, and twelve pulse type for motors sized 200 HP or less. Harmonic filters shall be
tuned to avoid resonance problems.

E. Metering: Power quality metering system shall be permanent installed in the VFD
system to continuously monitor the quality of the input and output electrical power. The
power quality meter data shall include the following:
1. Input and output voltage, current, (per phase and average rms value)
2. Input and output frequency, Power factor
3. Input and output kW, kVAR; input kWh and kVARh
4. Input and output harmonic demand distortion in current and voltage
5. THD (average of three phases) for current and voltage
6. Drive efficiency
7. Motor: Speed (in RPM and/or %), flux (%), torque (%)
8. Elapse time meter

F. Standard Motor Compatibility:

1. VFD system shall provide an output waveform that will allow utilization of
standard squirrel cage motors with 1.15 service factor, without need of any
special insulation or de-rating. Motor life expectancy should not be
compromised in any way by operation with the VFD system. The VFD must
provide motor overload protection in any operating condition.

2. To avoid motor heating, VFD output current waveform, as measured at the

motor, shall be inherently sinusoidal at all speeds, with a total harmonic current
distortion not exceeding 3% referenced to the output current fundamental at any
operating point in the range between 10% and 100% speed at any motor load.

3. VFD shall inherently protect existing motors from high-voltage, resonance wave
and δv/δt stress; independent of cable length to motor. The VFD system shall be
designed to produce no standing waves or over-voltage conditions based on a
cable length of at least 1000 ft (~300 m). If the VFD requires an output filter or
isolation transformers or any other device in order to meet the requirement of the
IEEE 519, it shall be an integral part of the VFD system and included within the
enclosure.

4 of 12 November 2008
Amendment No. 19
 Volume II – Employer’s Requirements
RFP-76161 Part 2 – Supplemental Requirements
Design and Construction of the Third Set of Locks Section 26 29 23 – Variable Frequency Drive

4. All internal firing signals and other communications (which link operational
controls with power components such as status and diagnostic signals) must meet
noise immunity and safety requirements as defined by standard UL 1283.

5. VFD system shall maintain a 0.90 minimum true power factor at any speed.
Power factor correction and/or harmonic filter shall never have leading power
factor. Power factor correction unit shall include short circuit protection, power
factor correction capacitors, and series harmonic de-coupling reactors, all
integrated into VFD system and mounted within the same enclosure.

6. Sleeve type wire marker tags or other acceptable means of permanent

identification shall be applied to power and control wiring. Individual labels
shall be provided for all major components of the VFD system

7. Redundant cooling system shall be provided with automatic switchover in the

event of a failure, for enhanced reliability. Drive must have ability to detect
failed operation of the cooling system. During normal operation, the system
must periodically cycle between the two systems (main & stand-by) to “exercise”
them. Contractor shall coordinate VFD’s heat dissipation with the design of the
HVAC system.

8. Enclosure: Provide enclosures conforming to NEMA 250, NEMA ICS 7 and

NEMA ICS 6. All VFD system components including transformer shall be
mounted and wired by the VFD system manufacturer in a grounded enclosure
meeting the following requirements without exception:
a. VFD system shall be NEMA-1. Units shall have washable filter media
covering all air inlets. Inlet air filters shall be corrosion-free media.
Filters shall be easy replaceable while the equipment is in operation
without exposing maintenance personnel to any of the power
components. Cabinet color shall be ANSI 61 Gray. Paint procedures
and materials shall be manufacturer’s system designed and proven for
resistance to chemical attack in industrial powerhouse environment.
b. Cabinets and doors shall be fabricated using heavy gauge steel
conforming to NEMA ICS 6, for sturdy construction and dimensional
integrity to assure long-term fit and function. All doors shall be gasketed
to provide environmental protection and secure fits.
c. Enclosures must be designed to avoid harmonic and inductive heating
effects. The enclosure must be designed to protect the equipment from
any outside interference; and enclosed, and shielded to eliminate any
radio frequency interference.
d. Main grounding consisting of copper bus bars in the enclosure base.
Corrosion resistant grounding pads shall be provided on two locations,
one at each end of the enclosure. A copper ground bus shall be provided
for grounding of control circuits.
e. All control wiring shall be physically separated from the power wiring.
All wiring shall be tagged with permanent labels at each termination,
junction box, and device. Labels shall correspond to the schematic and
wiring diagrams.

November 2008 5 of 12
Amendment No. 19
Volume II – Employer’s Requirements
Part 2 – Supplemental Requirements RFP-76161
Section 26 29 23 – Variable Frequency Drive Design and Construction of the Third Set of Locks

9. Power Component Protection:

a. VFD system shall include distribution class surge arrestors to protect the
system against voltage surges.
b. The VFD system shall include short circuit protection on the input to the
converter rectifier devices to protect the system from any potentially
harmful fault currents.
c. Protective Features and Circuits:
1) The controller shall include the following alarms and protective
features:
a) Instantaneous over-current and over-voltage
b) Under-voltage, reverse phase, and power loss
c) Volts/Hertz
d) Over-temperature
e) Motor inverse time overload
f) Provisions for 6 motor stator windings RTD’s for motor
temperature monitoring to provide trip and alarm.

2) The VFD system shall be protected from damage due to the

following:
a) Single-phase fault or three-phase short circuit on VFD
system output terminals
b) Failure to commutate inverter electronic switching
device due to severe overload or other conditions
c) Loss of input power due to opening of VFD input
disconnect device or utility power failure during VFD
operation
d) Loss of one (1) phase of input power
e) Motor regeneration due to backspin or loss of VFD input
power

3) The VFD shall be able to withstand the following fault

conditions without damage to the power circuit components:
a) Failure to connect a motor to the VFD output.
b) VFD output open circuit that may occur during
operation.

10. Data Displays: As a minimum, the following door mounted digital display
indications shall be supplied:
a. Speed demand in percent
b. Input and output current in amperes

6 of 12 November 2008
Amendment No. 19
 Volume II – Employer’s Requirements
RFP-76161 Part 2 – Supplemental Requirements
Design and Construction of the Third Set of Locks Section 26 29 23 – Variable Frequency Drive

c. Input and output Frequency in hertz

d. Input and output voltage
e. Total 3-phase kW output
f. Peak and Average demand of following, peak values shall be kept until
manually reset: Kilowatts, kVA, Volts, Amperes, Power Factor.
g. Kilowatt hour accumulated
h. Elapsed time running meter

11. Diagnostics & Fault Recording:

a. The control logic section shall be fully digital and may not require analog
adjustment pots or fixed selector resistors.

b. Fault log data storage memory shall be stored in non-volatile memory.

c. Shall include a comprehensive microprocessor based digital diagnostic

system, which monitors its own control functions and displays faults and
operating conditions.

d. A “EVENT LOG” shall record and store, the last three fault events.
Each event record shall include the following control variables at an
adjustable time rate of 5 samples per cycle; for the 125msec immediately
preceding a fault trip and 250msec following such trip:
1) VFD mode (manual/auto/inhibited/tripped/etc.)
2) Speed demand
3) VFD output frequency
4) Demand (output) Amps
5) Feedback (motor) Amps
6) VFD output volts
7) Type of fault:
8) Drive inhibit (On/Off)
9) The fault log record shall be accessible via a communication
link. If special software is required to download and display
data, it shall be included in the proposal.
A7
G. Protection Characteristics:A7

1. In the event of a ground fault, the VFD shall be capable of annunciating a ground
fault condition, and continue safely operating due to the condition of working in
an ungrounded system. There shall not be risk of fire or electric shock because
of the ground fault.

2. The failure of any power-switching device (SCR, GTO, diode, IGBT, IGCT, etc.)
shall not prevent continued VFD operation. In the event of a device failure, the

November 2008 7 of 12
Amendment No. 19
Volume II – Employer’s Requirements
Part 2 – Supplemental Requirements RFP-76161
Section 26 29 23 – Variable Frequency Drive Design and Construction of the Third Set of Locks

VFD shall annunciate and identify the specific location of the failed device and
trip the unit.

3. The VFD system shall have the user selectable option of programming up to
three speed avoidance bands. This gives the user the ability to block out and
prevent operation at any undesirable speed, such as one that may be coincident
with a mechanical resonance condition.
A7
H. Programming & Communications:A7

1. User Input/Keypad: User shall be allowed to do all programming of the VFD

through a local display interface. Monitoring and alarms shall be also available
in this interface.

2. Ethernet communications:
a. The VFD shall have network communication capability to allow remote
control, programming and status monitoring. The supplier shall also
provide the software that makes possible the remote control,
programming and status monitoring of the system.
b. Provisions for local computer connection must be provided.
c. An Ethernet link shall be provided.
d. At least Modbus communication protocol must be provided.

3. Input Isolation Transformer: If required, it could be dry-type or oil type.

Transformer shall comply with the standards C57.110 and C57.16; in addition to
Sections 26 12 19 (Pad Mounted Liquid Filled Medium Voltage Transformer) or
26 22 00 (Dry Type Transformers).

4. DC Link Inductors: DC link inductors if required shall be air core to prevent

saturation. Maximum temperature rise shall not exceed 115°C with minimum
220°C insulation and over-temperature protection. The inductors shall be
integral to the VFD system lineup. Inductors shall meet IEEE C57.16
requirements and be designed to prevent saturation under maximum fault current
conditions.

5. DC Link Capacitors: Shall comply with the requirements specified on ANSI

18, ANSI P1036, and Section 26 60 00 (Dynamic VAR Compensator).

6. Harmonic Filters: If required they shall meet Section 26 60 00 (Dynamic VAR

Compensator).
A7
1.05 SUBMITTALS:A7

A. Before Manufacture:

1. Certification: Electrical materials shall be new and listed by the Underwriters

Laboratories, Inc., wherever standards have been established by that agency.

8 of 12 November 2008
Amendment No. 19
 Volume II – Employer’s Requirements
RFP-76161 Part 2 – Supplemental Requirements
Design and Construction of the Third Set of Locks Section 26 29 23 – Variable Frequency Drive

2. Drawings and Descriptive Literature: The Contractor shall submit to the

Employer’s Representative for review before manufacturing, copies of drawings
and literature describing the equipment to be furnished and including, but not
limited to, the following items:
a. Preliminary A17dimensions and weights A17
b. General performance information: Voltage, current, efficiency, speed
range, torque range, over-current and overload allowances, THD of the
system at every speed and load conditions.
3. Proven Technology: Proof of actual operation of a similar system for a
minimum of three years in service.

B. Before Shipment:

1. Final manufacturing Drawings: After the VFD have been manufactured, and
before installation, the Contractor shall submit copies of each final drawing, and
shall include all authorized changes made during the course of manufacture.
A16
2. Reserved. A16

3. Factory Test Reports: Submit certified factory test reports of all factory tests
performed by the manufacturer, including tests required by the applicable
standards. Results of factory tests performed shall be certified by the
manufacturer, or an approved testing laboratory, and submitted following
successful completion of the tests.

4. Installation Manuals and Field Test Procedures: Submit copies of installation

manuals and field test procedures for the variable frequency driver and related
subsystems. The manufacturer's pass/fail criteria for field tests shall be included.

5. Field Test Plan: Submit a proposed field test plan, prior to testing equipment
and subsystems. No field test shall be performed until the test plan has been
reviewed by the Employer’s Representative. The test plan shall consist of
complete field test procedures, including tests to be performed, qualifications of
personnel performing the testing, test equipment required, and tolerance limits.
After completion of field testing, submit Certified Field Test Reports.

C. Before Taking Over:

1. Equipment List: Shall provide an electronic database of all installed VFD with
the following information:
a. Unit Identification (name or number)
b. Manufacturer & Serial Number
c. Voltages primary/secondary
d. kVA rating
e. Location
f. Enclosure type

November 2008 9 of 12
Amendment No. 19
Volume II – Employer’s Requirements
Part 2 – Supplemental Requirements RFP-76161
Section 26 29 23 – Variable Frequency Drive Design and Construction of the Third Set of Locks

2. Final Documentation: The following documentation shall be provided:

a. Start-up and commissioning instructions data
b. Complete set of “as-built” drawings
c. Operation and maintenance manual
A16
d. Reserved. A16
e. Equipment dimensions, including stub-up locations
A7
1.06 QUALITY ASSURANCE:A7

A. Any third party certification, safety or protection requirements shall be applied to the
VFD system as a whole. Certification of system elements or individual components by
themselves is not acceptable.

B. VFD’s shall be manufactured, assembled, tested and provided with a UL label.

C. Variable frequency drives shall be manufactured on a facility, which has a quality

assurance program that is certified at least in conformance with ISO Standard 9001 and
UL.

D. Experience: The equipment offered shall have the best performance available from
currently proven technology.

E. A factory test shall be performed at the VFD manufacturer’s facility certifying that
efficiencies have been met. If efficiencies submitted are not achieved the equipment will
not be accepted.
A7
F. Factory Testing:A7

1. Subassembly Tests:
a. Printed circuit boards shall be visually inspected and functionally tested.
All boards must be tested individually prior to assembly to minimize any
impact faulty boards may have on delivery schedules and system
reliability. Each board shall be load and temperature cycled from no
load to full load and from ambient to +60°C during a 24-hour burn-in
test. Any boards that exhibit drift during the test must be replaced with
boards that have successfully completed the burn-in without drift.
b. Power assemblies shall be visually inspected and then HIPOT tested.
Complete diagnostics and logic shall be tested. The complete power
conversion circuit shall be thoroughly tested at 100% load for a
minimum of 10 minutes and then tested for one minute at momentary
overload rating.

2. System Level Tests:

a. The system shall be given preliminary checks including verification of
electrical connections and ground connections; power and control wiring

10 of 12 November 2008
Amendment No. 19
 Volume II – Employer’s Requirements
RFP-76161 Part 2 – Supplemental Requirements
Design and Construction of the Third Set of Locks Section 26 29 23 – Variable Frequency Drive

shall be resistance-checked point-to-point. E-prom and EE-prom shall be

checked for correct revision level. Visual check shall be performed to
verify: degree of protection for cabinets, input isolation is lockable in the
off-position, marking of terminals and wiring, space availability for cable
termination, accessibility of components and ease of maintenance and
repair. The VFD system shall be fully checked against the approved
drawings for compliance and correct physical dimensions.
b. Power circuit and all control circuits shall be HIPOT tested to ground.
c. All control voltage levels shall be checked and verified.
d. A no load test shall be performed on the system. Drive is to be
connected to an unloaded motor. Output voltage shall be calibrated. All
logic and interlocks including customer logic and instrumentation shall
be tested.
e. Drive shall be given a full power test at rated current and rated voltage
(simultaneously) for a minimum of four hours on a dynamometer or
reactor load. This test shall be performed as an integrated system
including all supplied: input switchgear, input transformer, input filter,
power section and output filter. The VFD manufacturer shall perform
the factory system test to verify that total system efficiency, power factor
and harmonic distortion limits are met as specified. System shall not be
shipped unless specified performance criteria are met. Certified test data
of all tests conducted shall be provided with final documentation.
f. Employer reserves the right to witness factory tests at no extra cost.
Employer will cover all travel expenses of their representatives. A
projected test schedule and a copy of proposed test procedures shall be
provided at least one month in advance of test date. Employer shall be
given at least three-week notice or confirmation of actual test date(s).
A7
G. Start-Up:A7

1. VFD system manufacturer shall provide the commissioning services of a factory

technician as necessary to supervise/inspect installation, test and start-up all
equipment A17provided. All A17 equipment required for testing, start-up and
performance verification shall be provided by the start-up technician.

2. Verification of VFD input harmonic voltage and current distortion limits

specified must be verified as part of the final acceptance and it shall comply with
the IEEE 519 for the all speed range regardless of the load.

H. VFD System Efficiency: Guaranteed minimum total VFD system efficiency (ηsys)
shall be a minimum 95% at full load and minimum 93% at 50% load at any speed.
Efficiency evaluation shall include input transformer, harmonic filter and power factor
correction (if applicable), VFD converter, and output filter, as indicated below. Auxiliary
controls, such as internal VFD control boards, cooling fans, shall be included in all loss
and efficiency calculations.

The VFD efficiency is: ηsys = ηVFD x ηxfmr x ηpfc x ηharm x ηfilter x ηothers

November 2008 11 of 12
Amendment No. 19
Volume II – Employer’s Requirements
Part 2 – Supplemental Requirements RFP-76161
Section 26 29 23 – Variable Frequency Drive Design and Construction of the Third Set of Locks

Converter/Inverter (VFD) ηVFD

A17
Input transformer ηxfmr
Power factor correction ηpfc
Input harmonic filter 7 ηharm
Output filter ηfilter A1
Others (fans, control, auxiliary’s equipments) ηothers

Note: space heaters, lighting and other not operational loads shall not be included.

I. Training: VFD system supplier shall provide on site training for customer’s operations,
maintenance and service personnel (3 days training for 15 people). The training shall
include classroom discussion on the theory of operation of the equipment, as well as
maintenance and service methods for the purchased equipment. Topics covered shall
include safety, hardware layout and functions, power & control wiring, diagnostic
indicators, keypad/display interface, software mapping, programming, setup,
configuration, control loop tuning, operational indicators, faults, diagnostic tools,
troubleshooting, and preventive maintenance. Hands-on training shall be on the same
equipment provided.

END OF SECTION

12 of 12 November 2008
Amendment No. 19