PowerFlex 400 AC Drive Guide Specification Adjustable Frequency Drives with Bypass 3.0 50HP @ 208V AC 3.0 350HP @ 480V AC PART 1 GENERAL 1.01 Quality Assurance A. The manufacturer shall have minimum 5 years experience in the design and manufacture of Variable Frequency Drives (VFDs). B. The VFD and all associated bypass equipment shall be UL Listed according to UL 508C Power Conversion Equipment. As verification, a UL label shall be attached on the enclosure. C. The VFD shall be UL approved for mounting in plenums and compartments handling conditioned air. D. The VFD shall be designed, constructed and tested in accordance with UL, CSA, NEMA, and NEC standards. E. Every power converter shall be tested with an AC induction motor while loaded and temperature cycled within an environment chamber. 1.02 Submittals A. [ ] submittal packages shall be furnished for Engineers approval prior to factory assembly of AC drives. B. Submittals shall include: 1. Outline Drawings 2. Schematic Drawings 3. Interconnect Drawings PART 2 PRODUCT 2.01 Manufacturers A. The VFD shall be provided by Rockwell Automation, or prior approved equal. B. Substitutions must be submitted in writing three (3) weeks prior to original bid date with supporting documentation demonstrating that the alternative manufacturer meets all aspects of the specification herein. 2.02 General Requirements A. The VFD shall convert the input AC main power to an adjustable frequency and voltage as defined in the following sections. B. The VFD shall be listed and labeled as a complete unit and shall include all accessories and requirements as described in this section. 2.03 Environmental Ratings A. Storage ambient temperature range: -40 to 85 C (-40 to 185 F). B. Ambient temperature operating range: -10 to 40 C (14 to 104 F). C. Relative humidity range: 5% to 95%, non-condensing. D. Operating elevation: 1000 Meters (3,300ft). E. Shock: 15G peak for 11ms duration. F. Vibration: 0.152 mm (0.006 inches) displacement, 1G peak. G. Seismic: The AC drive shall meet the seismic requirements of the 2003 International Building Code as specified by AC156.
2.04 Motor Data A. The AC drive shall be sized to operate the following AC motor: 1. Motor horsepower [ ]. 2. Motor full load ampere [ ]. 3. Motor rpm will be [900] [1200] [1800] [3600] at 60Hz. 4. Motor voltage will be [208] [460] VAC. 5. Motor service factor will be [1.00] [1.15] [1.25]. 2.05 Application Data A. The AC drive shall be sized to operate a variable torque load. B. The speed range shall be from a minimum speed of 1.0 Hz to a maximum speed of 60 Hz. 2.06 Construction A. The VFD shall be enclosed in an NEMA/UL [ Type 1] [ Type 12] [ Type 3R] [ Type 4] enclosure. B. Conduit knockouts shall be provided for bottom cable entry. C. All VFD bypass packages shall be wall mountable. 2.07 Ratings A. The VFD shall be designed to operate from an input voltage of [208V AC ±10%] [480V AC ±10%]. B. AC frequency: 60Hz ±5% C. Current overload rating: 110% of rated current for 60 seconds. D. Starting torque: 150% at 1 Hz. E. Speed regulation: 2%. 2.08 Protection A. The VFD shall be protected against short circuits, between output phases and to ground. B. The VFD shall have under-voltage and over-voltage protection. C. The VFD shall provide class 10 motor overload protection investigated by UL, to comply with N.E.C. Article 430. D. The VFD shall be able to sense a loss of load and signal a fault. E. If the input analog reference 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 programmable preset speed, or (3) running at min or max frequency. F. Upon VFD fault, drive shall store the DC bus voltage, out current and output frequency in readable parameters. 2.09 Integral Functions A. Process PID Control: 1. PID regulator shall be standard in the VFD. This allows a pressure or flow signal to be connected to the VFD for closed loop control. 2. The PID setpoint shall be adjustable from the Programming Terminal, Analog Inputs or Communication Networks. B. Skip Frequencies / Bands: 1. The VFD shall have at minimum (3) programmable set points that lock out continuous operation at frequencies, which may produce mechanical resonance. 2. The setpoints shall have an adjustable bandwidth. C. Flying Start: 1. The VFD shall be capable of determining the speed and direction of a spinning motor and adjust its output to pick-up the motor at the rotating speed. D. Start At Power Up: 1. The VFD shall have a programmable restart function to automatically restart the equipment after restoration of power after an outage. 2. A maintained 2-wire start input shall be necessary for this function. E. Sleep / Wake Mode: Page 2 of 5
1. The VFD shall have the capability to use an analog input or PID output as a start stop command. This input can be a separate input or also used as the speed reference. Signal level below the sleep level acts as a Stop Command and a signal level above the Wake level acts as a Start Command. 2. Sleep / Wake time and level shall be programmable. F. Auto Restart 1. The VFD shall have the capability to attempt (9) restarts following a fault condition before locking out and requiring manual intervention. 2. The time between restarts shall be adjustable. 2.10 Programming Terminal A. The VFD shall include an integral programming terminal. B. The programming terminal shall have at minimum a 2 line by 16 character LCD display with LED backlight. C. Digital speed control buttons shall be provided. Potentiometers are not acceptable. D. Programmable Hand-Off-Auto buttons shall be provided to toggle both start and frequency control or only the frequency control to and from the programming terminal. E. Text support in multiple languages, including but not limited to English, German, French, Italian, Spanish, Portuguese and Dutch. 2.11 Control Interface A. Analog Inputs: 1. (1) Optically isolated analog input (-10 to 10V or 0 to 20mA), user selectable. 2. (1) Non-isolated analog input (0 to 10V or 0 to 20mA), user selectable. 3. Analog I/O must have 10 bit resolution or better. 4. Both analog inputs and outputs should be able to be used simultaneously in either voltage or current modes or a combination of each. B. Analog Outputs: 1. (2) Analog outputs (0 to 10V or 0 to 20mA), user selectable. 2. Analog I/O must have 8 bit resolution or better. 3. Both analog outputs should be able to be used simultaneously in either voltage or current modes or a combination of each. C. Digital Inputs: 1. (7) Digital inputs (24V DC), user programmable. 2. Inputs must be configurable as sink or source. 3. The VFD shall have a dedicated digital input for a Purge function. The Purge input shall override all Stop commands over the network as well as (1) Customer Interlock. 4. The VFD shall have (2) dedicated digital inputs for Customer Interlocks: a. One interlock will not record a fault and permit running after external condition is met. Purge input will override this interlock. b. One interlock will cause a drive fault and require control system to reset prior to returning to ready condition. This input will always be active even during Purge. D. Relay Outputs: 1. (2) Relay outputs, form C (1 N.O. and 1 N.C.), user programmable. 2. Both relays must be programmable for a minimum of 16 different combinations including Drive Ready, At Frequency, Motor Running, Motor Overload, Above Frequency, Above Current and others. E. Digital Optocoupler Output: 1. User programmable with normally open or normally closed configuration. 2. Digital Optocoupler Output must be programmable for a minimum of 16 different combinations including Drive Ready, At Frequency, Motor Running, Motor Overload, Above Frequency, Above Current and others. 2.12 Internal Adjustments A. Acceleration time shall be adjustable from 0.1 to 600 seconds. Page 3 of 5
B. Deceleration time shall be adjustable from 0.1 to 600 seconds. C. (4) preset speeds shall be provided. D. VFD shall have an adjustable PWM frequency to allow tuning the VFD to the motor. 2.13 Communication A. The VFD shall have an RS-485 port as standard. B. The following protocols should be integral to the drive and selectable via a parameter without any field programming to download software prior to operation: 1. Modbus RTU. 2. Metasys N2. 3. Siemens P1-FLN C. Optional protocols such as LonWorks, BACnet, ControlNet, PROFIBUS, EtherNet and DeviceNet shall be available. 2.14 Bypass Package A. Door-interlocked Main Input Disconnect shall mount within the standard NEMA/UL TYPE 1 enclosure for positive power disconnect of the VFD. It shall have the capability for door padlocking. B. Input line fuses shall provide protection for the input rectification circuit using Class J fuses. The series interrupting rating of the VFD and fuses shall be a minimum of 100,000 AIC. C. A complete three contactor bypass shall be provided to allow the motor to be safely transferred from VFD output to the AC line or from the AC line to the VFD, while the motor is at zero speed. The contactor bypass shall be electrically interlocked. The contactors shall be IEC rated and have the following functionality: 1. Drive Input Contactor shall open and close input to the drive. 2. Drive Output Contactor shall open and close the connection between the drive and motor. 3. Bypass Contactor shall open and close the connection to line start the motor. D. A three-position Drive/Drive Test/Bypass switch on the bypass operator interface shall have the following functionality: 1. In Drive Mode, the drive input contactor and the drive output contactor shall be closed to allow operation of the motor by the drive. 2. In Drive Test Mode, the drive input contactor shall be closed to keep the power on to the drive. The drive output contactor and bypass contactor shall remain open. This shall enable the user to test the drive before running the motor. A jumper shall be added to test the drive while the motor is running in bypass and must be field installed to alert operators of this condition. 3. In Bypass Mode, the drive input and the drive output contactor will be open to isolate the drive. The bypass contactor will be closed to allow the motor to run directly from the AC line. E. Bypass motor overload protection shall be provided by bimetallic Class 20 overload relay. F. A three-position Hand/Off/Auto switch on the bypass operator interface shall allow the user to: 1. Transfer the control source (Start/Stop) to the drive keypad in Hand Mode. 2. Stop the motor in Off Mode. 3. Transfer the control source (Start/Stop) to the drive s terminal block in Auto Mode G. The operator interface on the bypass option box shall have the following indicating LEDs: 1. Ready (green) 2. Interlock Open (yellow) 3. Bypass Run (green) 4. Bypass Trip (red) 5. Purge (yellow) 6. Drive output enable (green) PART 3 EXECUTION Page 4 of 5
3.01 Installation A. Installation shall be in compliance with manufacturer s instructions, drawings and recommendations. B. Installation shall be the responsibility of the mechanical contractor. 3.02 Start-up A. Certified factory start-up shall be provided for each VFD provided. B. Service engineers shall be employed by the manufacturer or be certified by the manufacturer and provide startup services including physical inspection of drive and connected wiring and final adjustments to meet specified performance requirements. 3.03 Warranty A. Warranty shall be 24 months from the date of certified start-up, not to exceed 30 months from the date of shipment 3.04 Product Support A. Factory trained application engineering and service personnel that are familiar with the VFD products offered shall be locally available. B. A 24 hour, 365 day technical support line shall be available. www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444 Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Publication 23C-SR001C-EN-P- December 2006 Copyright 2004 Rockwell Automation, Inc.. All rights reserved. Printed in USA. Page 5 of 5