General Specification for
electrical equipment
in booster or complex pumping stations
This specification applies to booster or complex pumping stations
(5 to 10 pumps, power demand: 500 to 5000kVA).
Requirements are given for MV switchgear, transformers, iMCC
(advanced Prisma Plus), power monitoring equipment, power
factor correction, soft starters and variable speed drives.
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Table of contents:
1.
2.
Introduction................................................................................................................................................ 4
General requirements ................................................................................................................................. 4
2.1
Applicable generic standards ............................................................................................................. 4
2.2
Quality and sustainable development ................................................................................................ 4
3. MV switchgear........................................................................................................................................... 6
3.1
General requirements ......................................................................................................................... 6
3.2
Applicable standards .......................................................................................................................... 6
3.3
Rated voltage and short-time withstand current ................................................................................ 6
3.4
Main electrical characteristics ........................................................................................................... 6
3.5
Requirements relative to the design and manufacture of the switchgear .......................................... 8
3.6
Conformity assessment .................................................................................................................... 12
4. Transformers (cast resin) ......................................................................................................................... 13
4.1
Applicable standards ........................................................................................................................ 13
4.2
Magnetic core .................................................................................................................................. 13
4.3
LV windings .................................................................................................................................... 13
4.4
MV windings ................................................................................................................................... 13
4.5
Accessories and standard equipment ............................................................................................... 15
4.6
Thermal protection........................................................................................................................... 15
4.7
Metal enclosure ................................................................................................................................ 15
4.8
Electrical protection ......................................................................................................................... 16
4.9
Electrical tests .................................................................................................................................. 16
4.10 Climatic and Environmental classifications .................................................................................... 17
4.11 Fire behaviour classification ............................................................................................................ 17
4.12 Technical Data ................................................................................................................................. 17
5. Intelligent Motor Control Centre ............................................................................................................. 19
5.1
General requirements ....................................................................................................................... 19
5.2
Applicable standards ........................................................................................................................ 19
5.3
Switchboard design .......................................................................................................................... 19
5.4
Switchboard Assembly .................................................................................................................... 20
5.5
Electrical and mechanical characteristics ........................................................................................ 20
5.6
Switchboard structure ...................................................................................................................... 20
5.7
Derating ........................................................................................................................................... 21
5.8
General requirements for intelligent protection device (IPD) ......................................................... 21
5.9
IPD for non-critical motors .............................................................................................................. 22
5.10 IPD for critical motors ..................................................................................................................... 22
6. Soft starters .............................................................................................................................................. 24
6.1
Introduction...................................................................................................................................... 24
6.2
Applicable specific standards .......................................................................................................... 24
6.3
Description of the product ............................................................................................................... 24
6.4
Environment .................................................................................................................................... 25
6.5
Electrical characteristics .................................................................................................................. 25
6.6
Protection functions ......................................................................................................................... 26
6.7
Communication................................................................................................................................ 26
6.8
Main functions ................................................................................................................................. 26
6.9
Supervision ...................................................................................................................................... 27
7. Variable speed drives ............................................................................................................................... 28
7.1
General requirements ....................................................................................................................... 28
7.2
Applicable specific standards .......................................................................................................... 28
7.3
Requirements for the Manufacturer ................................................................................................. 29
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7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
7.12
7.13
Basic requirements for the AC Drives ............................................................................................. 29
AC Drive performance .................................................................................................................... 30
Enclosure and mounting .................................................................................................................. 32
User interface ................................................................................................................................... 32
Communications .............................................................................................................................. 34
Programming terminal ..................................................................................................................... 35
Application programming ................................................................................................................ 36
PC Tools .......................................................................................................................................... 37
Software features ............................................................................................................................. 37
Documents ....................................................................................................................................... 39
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1. Introduction
This specification is applicable to booster or complex pumping stations.
Characteristics:
Number of
pumps
Power demand
(kVA)
5 – 10
500 – 5000
Specificity of water installations are taken into account.
Requirements are given in this document for:
- MV switchgear,
- Transformers,
- Intelligent Motor Control Center (iMCC),
- Variable speed drives,
- Soft starters.
2. General requirements
2.1 Applicable generic standards
Standard
IEC 60038
IEC 60068
IEC 60287-1-1
IEC 60364
IEC 60446
IEC 60479
IEC 60529
IEC 60664
IEC 60721
IEC 60724
IEC 60755
IEC 61000
IEC 61140
IEC 61508
IEC 61557
Title
Standard voltages
Environmental testing
Electric cables - Calculation of the current rating - Current rating equations (100%
load factor) and calculation of losses - General
Electrical installations of buildings
Basic and safety principles for man-machine interface, marking and identification Identification of conductors by colours or numerals
Effects of current on human beings and livestock
Degrees of protection provided by enclosures (IP code)
Insulation coordination for equipment within low-voltage systems
Classification of environmental conditions
Short-circuit temperature limits of electric cables with rated voltages of 1 kV (Um =
1.2 kV) and 3 kV (Um = 3.6 kV)
General requirements for residual current operated protective devices
Electromagnetic compatibility (EMC)
Protection against electric shocks - common aspects for installation and equipment
Functional safety of electrical/electronic/programmable electronic safety-related
systems
Electrical safety in low-voltage distribution systems up to 1000 V AC and 1500 V
DC - Equipment for testing, measuring or monitoring of protective measures
2.2 Quality and sustainable development
The complete electrical equipment including enclosure, circuit breakers, motor starters, major switchgear
components, etc shall be from one single principal manufacturer only. Local assembly / local adaptation by
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only franchised panel builders are allowed however keeping in line with requirements of IEC standards and
ensuring local adaptations done do not affect type testing results of prototype.
If the piece of equipment is to be used in a seismic area, the supplier shall be informed of the specific
acceleration levels required. The supplier shall determine the configuration that is appropriate to the stresses
involved.
The test certificates shall be supplied and refer to IEC, IBC or EDF - Nuclear HN 20-E-53 standards.
The supplier shall be informed of any pollutants, if present (e.g. SO2, H2S) on the site and shall provide
appropriate coating for the conductors, connections and metal elements (mechanisms, frames, casing). The
surface of the copper parts shall be treated to guard against the effects of corrosion. The bolted connections
shall be coated with 30 microns of tin. All friction contact connections shall be coated with 20 microns of
nickel, to prevent wear and tear due to friction.
The supplier shall provide proof of application of a quality procedure complying with standards. This means:
- use of a quality manual approved and signed by a management representative,
- regular updating of this manual so that it reflects the most recent applicable quality control
procedures,
- ISO 9002; 9001 and also ISO 14001certification.
The supplier shall be able to supply the Product Environmental Profile (P.E.P) on the engineer’s request.
An 18-month parts warranty shall be provided on materials and workmanship from the date of delivery or a
24-month warranty as of the date of manufacturing.
The materials used shall be recyclable, non-toxic and flame retardant in compliance with the European
directive ROHS (Restriction Of Hazardous Substances).
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3. MV switchgear
3.1 General requirements
The following specifications apply to modular indoor switchboards comprising factory built, metal-enclosed
switchgear assemblies.
The equipment to be supplied shall consist of modular cubicles satisfying the following criteria:
-
Open-ended design,
Easy to install,
Safe and easy to operate,
Compact design,
Low maintenance.
The supplier shall be able to prove its extensive possess experience in the field of MV switchgear, and has
already supplied equipment of the same type & production process, which has been in operation for at least
three years.
3.2 Applicable standards
The switchgear shall comply with the latest issues of the following specific documents:
Standard
IEC 60044-1
IEC 60044-2
IEC 60044-5
IEC 60044-8
IEC 60265-1
IEC 60282-1
IEC 60470
IEC 62271-100
IEC 62271-102
IEC 62271-105
IEC 62271-200
EN 50263
Title
Instrument transformers; Part 1: Current transformers
Part 2: Inductive voltage transformers
Part 5: Capacitor voltage transformers
Part 8: Electronic current transformers
High-voltage switches - Part 1: Switches for rated voltages above 1 kV and less
than 52 kV
MV fuses
High-voltage alternating current contactors and contactor-based motor-starters
High Voltage alternative current circuit breakers
High voltage alternative current disconnectors and earthing switches
High Voltage alternative current switch-fuse combinations
Alternative current metal-enclosed switchgear and controlgear for rated
voltages above 1 kV and up to and including 52 kV
Electromagnetic compatibility (EMC) - Product standard for measuring relays
and protection equipment
3.3 Rated voltage and short-time withstand current
-
The switchgear shall be suitable for three-phase systems operating at 24 kV / 50 Hz. Operation at
60Hz shall be possible as an alternative.
The rated voltage shall be at least 24 kV
The short-time withstand current shall be 20 kA - 1 s / 24kV or 25 kA - 1 s / 12 kV
Withstand during 2 s and 3 s should be specified upon request if the protection relays can't be set to
achieve clearing times short enough under full short-circuit conditions
3.4 Main electrical characteristics
The hereunder values are for working temperatures from -5° C up to +40° C and for a setting up at an
altitude below 1000 m.
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Performance at higher temperature or altitude should be specified upon request.
Rated voltage (kV)
Insulation level
50 Hz / 1 mn (kV rms)
1,2/50µs (kV peak)
7.2
12
17.5
24
Insulation
Isolation
20
23
28
32
38
45
50
60
Insulation
Isolation
60
70
75
85
95
110
125
145
Breaking capacity
Transformer off load (A)
Cables off load (A)
16
31.5
Short–time withstand
current
(kA/1s)
25
20
16
12.5
Maximum breaking capacity
Switch unit (A)
Fuse-switch unit (kA)
Contactor unit with fuses (kA)
Circuit breaker unit (kA)
630 – 1250A
630 – 1250A
630 – 1250A
400 – 630 – 1250A
630 – 800 **
25
25
25
20
20
The making capacity shall be equal to 2.5 times the short-time withstand current.
(**) upon request.
Endurance
Units
Switch unit (*)
Contactor unit with
magnetic holding
Contactor unit with
mechanical latching
Circuit breaker unit
Mechanical endurance
IEC 60265
1000 operations class M1
IEC 60470
300 000 operations
100 000 operations
IEC 62271-100
10 000 operations
Electrical endurance
IEC 60265
100 breaks at In, PF = 0.7 class E3
IEC 60470
100 000 breaks at 320 A
300 000 breaks at 250 A
100 000 breaks at 200 A
IEC 62271-100
40 breaks at 12.5 kA
10 000 breaks at In, PF=0.7
(*) as per recommendation IEC 62271-105, three breaking at PF = 0.2
1730 A / 12 kV
1400 A / 24 kV
2600 A / 5,5 kV
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3.5 Requirements relative to the design and manufacture of the switchgear
Introduction
The equipment shall satisfy the criteria for indoor, metal-enclosed switchgear class LSC2A & Class PI
partitioning in compliance with IEC 62271-200.
The cubicles shall be designed with three compartments housed in a single enclosure:
-
switchgear compartment,
busbar compartment,
connection compartment,
Switchboards
The switchboards shall be made up of separate factory built cubicles housing the switchgear (switchdisconnector and switch enclosures shall be mounted horizontally in the cubicles and the circuit breaker shall
be disconnectable and mounted vertically). The cubicles therefore form a compartmented distribution
switchboard that can be extended if necessary.
The cubicles shall meet the requirements of degree of protection index IP2XC (IP3X available upon
request). The galvanised and electro-galvanised sheet metal and metal fittings shall be painted to provide
protection against corrosion. The epoxy-based paint shall have a thickness of at least 50 microns and shall be
applied to both sides of all sheet metal. The colour shall correspond to the RAL colour range proposed.
The switchboard shall be suitable for mounting above cable trenches, crawl spaces or base structures.
The switchgear and the switchboards shall be designed in such a way that the positions of the various
switchgear devices shall be visible by the operator from the front of the switchboard. It shall also be possible
to operate the switchgear from the front of the switchboard.
The civil works specifications shall be unique for all cubicles making up the MV switchboard. The cubicle
width shall be multiple of 375 mm. In particular, the civil works for the circuit breaker cubicles shall be
identical to the civil works for the switch cubicles.
The manufacturer shall provide an installation drawing to serve as a guide for the civil works.
In accordance with applicable standards, the switchboards shall be designed to prevent access to all live parts
when in operation as well as during maintenance work.
Earthing of metallic parts
The earthing bars of each of the cubicles making up the switchboard shall be interconnected by a set of
busbars, which shall be connectable outside the switchboard and extend over its full width.
The earthing bar shall be designed for connection to the main earthing bar of the substation without
dismantling any of the bars.
Earthing of the power circuit
Cable earthing shall be carried out by an earthing switch able to operate when the switch or disconnector is
open.
A padlocking system shall be provided to lock the earthing switch in either open or closed position. The
position of the earthing switch shall be clearly visible from the front of the cubicle.
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Mechanical interlocking systems shall be provided to prevent incorrect operations such as the closing of the
earthing switch with the switch or disconnector in closed position.
The use of keyed or electric locks to actuate the above mentioned interlocking system shall not be accepted.
Switches
The switches shall use low pressure SF6 gas for current interruption and shall require no maintenance. The
switch enclosure shall be mounted horizontally within the cubicle and the position of the main and earthing
contacts shall be clearly visible from the front of the cubicle. The position indicator shall be placed directly
on the contact-operating shaft. The switch enclosures shall be made of cast epoxy resin.
The switches shall be of the "high operating frequency" type in accordance with clause 3.104 of IEC 602651. They shall have three positions (closed, open and earthed) and shall be fully assembled and tested before
leaving the factory. The relative pressure of the SF6 gas inside the enclosure shall not exceed 0.4 bars (400
hPa).
The pole unit enclosures shall be of the “sealed pressure system” type as defined by IEC 62 271-200 clause
3.118.2, that is with a service life of at least 30 years. No refilling of the gas shall be required over this
period.
Switch pole units requiring maintenance or gas refilling will not be accepted.
The mechanical endurance of the switch operating mechanisms shall ensure at least 1000 operations.
Circuit breakers
The circuit breakers shall be mounted vertically and shall be disconnectable
They shall require only minimum maintenance and shall provide a high level of electrical endurance. The
position of the circuit breaker shall be clearly visible.
Furthermore, the circuit breakers shall be mechanically interlocked with the power circuit disconnector.
The mechanical and electrical endurance shall ensure at least 10,000 operations.
The circuit breakers shall be covered with test reports that are issued by a recognised organisation affiliated
with an international organisation
-
SF6
They shall use SF6 gas as the current interruption medium.
The pole units shall be made of cast epoxy resin and shall be fully assembled and tested before
leaving the factory. The relative pressure of the SF6 gas shall not exceed 2 bars (2000hPa). The pole
units shall be of the “sealed pressure system” type as defined by IEC 62271-100, with a service life
of at least 30 years.
No refilling of the gas shall be required over this period.
Circuit breaker pole units requiring maintenance, inspection or gas refilling will not be accepted.
-
Vacuum
They shall use vacuum as the current interruption medium.
The pole units shall be fully assembled and tested before leaving the factory. The pole units shall be
of the “sealed pressure system” type as defined by IEC 62271-100, with a service life of at least 30
years.
Circuit breaker pole units requiring maintenance, inspection will not be accepted.
Busbars
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The busbar compartment shall be located at the top of the cubicle.
It shall include three parallel-mounted bars without phase separating means. Connections shall be made to
the top pads of the switch or disconnector enclosures. Access to the busbars shall only be possible after
removing a single access panel carrying a symbol warning of the danger of electrical shock. No other busbar
access system will be accepted.
Connections
The HV cable connection pads shall be designed to accept simplified terminations for dry-type cables or to
accept paper-insulated cables impregnated with a non-draining material.
Access to the connection compartment shall only be possible after closing the earthing switch. No other
access mode will be accepted.
Operating mechanisms
The operating mechanisms shall provide in front all the necessary means for operating the switches,
disconnectors and circuit breakers.
-
Load break switch
The operating mechanism box shall include a switch and earthing switch position indicator fixed
directly to the shaft of the moving pole, thereby satisfying the positive break criteria.
This box shall also house the voltage indicators and the mechanical “fuse blown” indicator for fuseswitch combination units.
The box shall be accessible with the cables and busbars live, without isolating the entire switchboard,
and shall be designed for easy installation of padlocks, key locks, auxiliary contacts, releases and the
usual LV accessories.
The front cover of the operating mechanism shall be suitable for the application of all symbols,
mimic diagrams, nameplates and padlocking fixtures required by the function implemented.
All switch and earthing switch operations shall be carried out with an anti-reflex lever and shall be
independent of the action of the operator after charging the operating mechanism springs.
-
Circuit breaker
The operating mechanism box shall include:
o mechanical “open/closed” position indicator,
o “charged/discharged” indicator for the operating mechanisms springs,
o spring charging lever forming an integral part of the operating mechanism; circuit breakers
not satisfying this condition will not be accepted,
o local means for opening and closing the circuit breaker,
o local means for manually discharging the springs.
It shall be possible to add, on site, a motor mechanism for electrical charging of the operating
mechanism as well as the necessary accessories.
LV box
The LV box shall be included in the overall volume of the cubicle. It shall be designed to house the various
LV elements required for the operation of the motor mechanism and auxiliary equipment.
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For specific needs, it shall be possible to enlarge or extend the LV box by adding an enclosure with a door to
the top of the cubicle. The overall height of the cubicles shall not exceed 2225 mm.
In all cases, these volumes shall be accessible with the cables and busbars live, without isolating the entire
switchboard. LV box not satisfying these criteria will not be accepted.
Current transformers
The current transformers shall have the same short-time withstand current and rated voltage as the
switchgear.
It shall be made of cast epoxy resin and must be labelled individually.
The manufacturer shall be in a position to provide type-test reports certified by a recognised organisation
affiliated with an international organisation.
Current transformers not satisfying these criteria will not be accepted.
Low Power Current Transformer (LPCT)
The LPCT is a magnetic sensor which provides a voltage output that represents the primary current, and
shall meet the characteristic of the switchgear.
It shall be in accordance to IEC 60044-8, and shall be made of cast epoxy resin and must be labelled
individually.
It shall be easily installed, and shall have direct connection (plugging) to protection relay.
LPCT not satisfying these criteria will not be accepted.
Voltage transformers
The voltage transformers shall be made of cast epoxy resin and must be labelled individually.
Depending on the needs, they shall be of the phase-to-phase or phase-to-earth type. They shall be protected
by MV fuses or by circuit breakers on the power circuit.
The manufacturer shall be in a position to provide type-test reports certified by a recognised organisation
affiliated with an international organisation
Voltage transformers not satisfying these criteria will not be accepted.
LV auxiliaries
The LV cables shall be class 2 type with a 2000 V insulation level.
They shall be marked at each end for easy verification during maintenance or servicing work.
The cable cross-sections shall not be less than 2.5 mm2 for circuits carrying high currents, or 1 mm2 for other
circuits.
Control and monitoring
All the relays, instruments and meters shall be incorporated in the LV box located at the top of the cubicle.
The relays shall be of the “integrated unit” type, meeting all protection and automatic control needs.
If necessary, they shall be able to communicate:
-
using standardised protocols,
adapting to a wide range of power supply voltages,
with the possibility of being disconnected while live without any danger to installation,
storing the information in memory in the event of an auxiliary power failure.
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The manufacturer shall provide proof that he has already supplied equipment of the same type and same
make and that this equipment has been in operation for at least three years.
3.6 Conformity assessment
Declarations of Conformity shall be provided for the various components of the switchgear. Additional
information shall be provided, as for instance test reports, on the main performances listed below:
-
impulse dielectric tests,
power frequency dielectric tests,
temperature-rise tests,
short-time withstand current tests,
mechanical operating tests,
verification of the degree of protection,
verification of electromagnetic compatibility.
In addition, for the switches and circuit breakers, the rated making and breaking capacities shall be
substantiated by a test report.
For the earthing switch, the making capacity, the short-time withstand current and the corresponding peak
value shall be substantiated by a test report.
The routine tests carried out by the manufacturer shall be substantiated by a test report signed by the
manufacturer's quality control department.
The report shall cover the following aspects:
-
conformity with drawings and diagrams,
power frequency tests,
manual operating mechanism tests,
functional tests of LV auxiliaries and relays.
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4. Transformers (cast resin)
This specification applies to MV/LV transformers meeting the following general requirements:
-
Three-phase transformers of cast resin type,
Class F insulation system with natural (AN) cooling,
Indoor installation,
If required: forced cooling (AF) to increase the rated power up to 40%.
4.1 Applicable standards
These transformers shall be in compliance with the following standards :
Standard
IEC 60076
IEC 60076-2
IEC 60076-3
IEC 60076-4
IEC 60076-5
IEC 60076-10
IEC 60076-11
IEC 60905
EN HD 464-S1
EN HD 538-1-S1
Title
Power transformers; Part 1: General
Part 2: Temperature rise
Part 3: Insulation levels, dielectric tests and external clearances in air
Part 4: Guide to the lightning impulse and switching impulse testing - Power
transformers and reactors
Part 5: Ability to withstand short circuit
Part 10: Determination of sound levels
Part 11: Dry-type transformers
Loading guide for dry-type power transformers
Dry-type power transformers (cancelled: June 2003)
Three-phase dry-type distribution transformers 50 Hz, from 100
to 2500 kVA with highest voltage for equipment not exceeding 24 kV
4.2 Magnetic core
This shall be made from laminations of grain oriented silicon steel, insulated with mineral oxide and shall be
protected against corrosion with a coat of varnish.
In order to reduce the power consumption due to transformer no-load losses, the magnetic core shall be
stacked using overlapping-interlocking technology, with at least 6 overlaps.
In order to reduce the noise produced by the magnetic core, it shall be equipped with noise-damping devices.
4.3 LV windings
The LV winding shall be produced using aluminium or copper foils (according to the manufacturer’s
preference); this foil shall be insulated between each layer using a heat-reactivated class F pre-impregnated
epoxy resin film
The ends of the windings shall be protected and insulated using a class F insulating material, covered with
heat reactivated epoxy resin
The whole winding assembly shall be polymerised throughout by being autoclaved for 2 hours at 130°C.
4.4 MV windings
They shall be separated from the LV windings to give an air gap between the MV and LV circuits in order to
avoid depositing of dust on the spacers placed in the radical electrical field and to make maintenance easier.
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These shall be independent of the LV windings and shall be made of aluminium or copper wire or foil
(according to the manufacturer's preference) with class F insulation.
The MV windings shall be vacuum cast in a class F fireproof epoxy resin casting system composed of :
- an epoxy resin
- an anhydride hardener with a flexibilising additive
- a flame-retardant filler.
The flame-retardant filler shall be thoroughly mixed with the resin and hardener. It shall be composed of
trihydrated alumina powder (or aluminium hydroxide) or other flame-retardant products to be specified,
either mixed with silica or not.
The casting system shall be of class F. The interior and exterior of the windings shall be reinforced with a
combination of glass fibre to provide thermal shock withstand
MV winding support spacers
These shall provide sufficient support in transport, operation and during bolted short circuit conditions as
well as in the case of an earthquake.
These spacers shall be circular in shape for easy cleaning. They shall give an extended tracking line to give
better dielectric withstand under humid or high dust conditions.
These spacers shall include an elastomer cushion that shall allow it to absorb expansion according to load
conditions. This elastomer cushion shall be incorporated in the spacer to prevent it being deteriorated by air
or UV.
MV connections
The MV connections shall be made from above on the top of the connection bars. Each bar shall be drilled
with a 13 mm hole ready for connection of cable lugs on terminal plates.
The MV connection bars shall be in rigid copper bars protected by heat shrinkable tubing.
MV connections in cables are not allowed, in order to avoid all risk of contact, due to cables flapping.
The MV connections shall be in copper.
LV connections
The LV connections shall be made from above onto bars located at the top of the coils on the opposite side
to the MV connections.
Connection of the LV neutral shall be directly made to the LV terminals between the LV phase bars.
The LV connection bars shall be in copper or in tinned aluminium (according to preference of the
manufacturer).
The output from each LV winding shall comprise a tin-plated aluminium or copper connection terminal,
enabling all connections to be made without using a contact interface (grease, by-metallic strip).
These shall be assembled according to current practices, notably using spring washers under the fixings and
nuts.
Devices in the 630 to 2500 kVA range shall be easy to connect using factory-built electrical ducting through
an optional interface. Stress withstand in the instance of a bolted short circuit on the connector shall be
guaranteed by the manufacturer.
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MV tapping
The tapping which act on the highest voltage adapting the transformer to the real supply voltage value, shall
be off-circuit bolted links.
Tapping with connection cables are not allowed.
These bolted links shall be attached to the MV coils.
4.5 Accessories and standard equipment
These transformers shall be equipped with :
- Four flat bi-directional rollers
- Lifting lugs
- Haulage holes on the underbase
- Two earthling terminals
- One rating plate
- One "Danger Electricity" warning label (T 10 warning)
- One routine test certificate
- One instruction manual for installation, commissioning and maintenance in English.
4.6 Thermal protection
These transformers shall be equipped with a thermal protection device which shall comprise two sets of
three PTC sensors, one sensor for "Alarm 1", one for "Alarm 2" per phase, installed in the coils of the
transformer. They shall be placed in a tube to enable them to be replaced if ever necessary.
An electronic converter with two independent monitoring circuits equipped with a changeover switch, one
for "Alarm 1" the other for "Alarm 2". The position of the relays shall be indicated by different coloured
indicator lights. A third indicator light shall indicate the presence of voltage.
These three indicator lights shall be on the front of the converter. The electronic converter shall be installed
away from the transformer.
A plug-in terminal block for connection of the PTC sensors to the electronic converter.
The PTC sensors shall be supplied assembled and wired to the terminal block fixed on the upper part of the
transformer. The converter shall be supplied loose with the transformer, packaged complete with its wiring
diagram.
4.7 Metal enclosure
On request, these transformers shall be equipped with a metal enclosure for indoor installation comprising an
integral IP 31 (except the base which may be IP 21) metal enclosure, that can be dismantled on request, with:
-
An anti-corrosion protection in the manufacturer's standard colour
Lifting lugs enabling the transformer and enclosure assembly to be handled.
A bolted access panel on the enclosure front to allow access to the MV connections and to the
tapping. This shall be fitted with handles, it shall have one "Danger Electricity" warning label (T 10
warning), a rating plate and a visible braid for earthling.
Blanked off holes for fitting Ronis ELP 1 or alternatively Profalux P1 type key locks on the bolted
access panel to enable it to be locked.
Two un-drilled gland plates on the roof : one on the MV side, one on the LV side (drilling and cable
gland not supplied).
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-
One plate at the right MV side on the bottom of the enclosure for the MV cables for connections
from the bottom
as an option, a MV cable clamping system shall be provided when the cables are coming from the
bottom
4.8 Electrical protection
Protection relay
The installation shall have a protection relay to protect the transformer from:
- overload,
- short circuits (internal or external),
- earth faults,
- overflow.
MV surge arresters
Phase-earth surge arresters shall be implemented in the following cases:
- If the lightning impact level Nk is greater than 25 (necessarily),
- In case of occasional switching (less than 10 operations a year) of a transformer with a weak load, or
during a magnetisation period (necessarily),
- If the substation is supplied by a network including overhead parts, then a cable which is longer than
20 m (highly recommended)
RC filters (repetitive switching operations)
If the installation is likely to be subjected to repetitive switching operations (e.g. connected with a process),
it shall be protected from the resulting surges by fitting an RC damping filter between the phases and the
earth.
This RC filter shall be placed as close as possible to the transformer’s primary terminals, either in a separate
metal enclosure or, preferably, inside the metal enclosure of the transformer
The filter shall consist of three 50 ohm resistors (of the RWST type), and three 0.25 µF capacitors, insulation
level 24 kV.
4.9 Electrical tests
Routine tests
These tests shall be carried out on all the transformers after the manufacturing, enabling an official test
certificate to be produced for each one :
- Measurement of winding resistance
- Measurement of the transformation ratio and vector group
- Measurement of impedance voltage and load loss
- Measurement of no load loss and no load current
- Applied voltage dielectric test
- Induced voltage dielectric test
- Measurement of partial discharges.
For measurement of the partial discharges, the acceptance criterion shall be:
- partial discharges less than or equal to 10 pC at 1.30 Un.
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Type tests or special tests
As options, these tests shall be performed with the manufacturer's agreement:
- Lightning impulse test (see IEC 60076-3)
- Short-circuit test (see IEC 60076-5)
- Noise level measurements (see IEC 60076-10).
- Temperature rise test (see IEC 60076-11),
4.10
Climatic and Environmental classifications
These transformers shall be of climatic class C2 and of environmental class E2 as defined in EN HD 464-S1.
These classes shall be indicated on the rating plate.
The manufacturer shall produce a test report from an official laboratory for a transformer of the same design
as those produced.
The tests shall have been performed in accordance with appendix ZA and ZB of EN HD 464 S1.
4.11
Fire behaviour classification
These transformers shall be of class F1 as defined in EN HD 464-S1. This class shall be indicated on the
rating plate.
The manufacturer shall produce a test report from an official laboratory on a transformer of the same design
as those produced and on the same transformer which have initially passed the here above Climatic and
Environmental tests. This test shall be performed in accordance with appendix ZC of EN HD 464-S1.
4.12
Technical Data
For each requested transformer, the supplier shall give the following data :
Rated power……………………………………………………………………..
Cooling…………………………………………………………………………..
Quantity………………………………………………………………………….
Rated frequency………………………………………………………………….
Rated primary voltage……………………………………………………………
Rated primary insulation level……………………………………………………
Applied voltage to industrial frequency …………………………………………
Basic Insulation Level (BIL) or impulse…………………………………………
Off-circuit tapping………………………………………………………………..
Secondary voltage at no load
between phases………
phase to neutral………
Rated secondary insulation level…………………………………………………..
Applied secondary voltage to industrial frequency……………………………….
Vector group……………………………………………………………………….
Last update :2016-03-10
kVA
Hz
kV
kV
kV
kV
%
V
V
kV
kV
- 17 -
No load losses……………………………………………………………………..
W
Load losses at 75° C………………………………………………………………
W
Load losses at 120° C……………………………………………………………..
W
Rated impedance voltage at 120° C………………………………………………
%
Acoustic power Lw(A)………………………………………………………….. dB(A)
Acoustic pressure at 1 metre Lp(A)…………………………………………….. dB(A)
Maximum ambient temperature………………………………………………….
Daily average ambient temperature………………………………………………
Yearly average ambient temperature……………………………………………..
Maximum altitude………………………………………………………………..
°C
°C
°C
m
MV winding temperature class……………………………………………………
F
LV winding temperature class…………………………………………………….
F
Temperature of insulation system………………………………………………… 155°C
Enclosure………………………………………………………………………….. YES / NO
Protection degree…………………………………………………………………. IP 31
Length…………………………………………………………………………….
Width……………………………………………………………………………..
Height…………………………………………………………………………….
Total weight………………………………………………………………………
Measurement circuit supply voltage for the thermal protection electronic
converter
DC / AC
Last update :2016-03-10
mm
mm
mm
kg
V
- 18 -
5. Intelligent Motor Control Centre
5.1 General requirements
This specification describes the requirements for the low voltage intelligent motor control centre (iMCC).
The iMCC is the equipment that provides comprehensive protection on motors by intelligent protection
devices (IPD) inside the MCC switchboard. The iMCC offer described here provides the solution to protect
the motors up to 37kW.
The iMCC shall also bundle the bus communication with the most common protocols found in industrial
networks (different possible options: Modbus SL / Modbus Ethernet / Profibus DP / DeviceNet).
The iMCC shall be an equipment offer labelled with the brand name of an international company (iMCC
designer), which owns the complete intellectual property of the iMCC switchboard and intelligent devices
used in this offer. The iMCC shall provide the flexibility to choose different solutions in motor protection
and monitoring functions according to the requirements of critical motors and non-critical motors and related
loads.
The iMCC original designer shall be a worldwide well-known leader in electrical distribution and
automation; it shall have a rich experience in project execution, including switchboard design,
manufacturing, installation, and commissioning in-house or by licensed partners; it has the capability to
provide training, technical support and service at a worldwide level. The know-how on both the switchboard
and the protective devices shall guarantee the availability and the reliability of the equipment.
5.2 Applicable standards
The iMCC offer shall comply with the related national and international standards, including, but not limited
to:
Standard
IEC 60439-1
IEC 60721-3-3
IEC 60947
AS 3439-1
Title
Low-voltage switchgear and controlgear assemblies; part 1: type-tested and
partially type-tested assemblies
Classification of environmental conditions - Part 3: Classification of groups of
environmental parameters and their severities; section 3: Stationary use at
weather protected locations
Low-voltage switchgear and controlgear
Low-voltage switchgear and controlgear assemblies - Type- tested and partially
type-tested assemblies
5.3 Switchboard design
The switchboard type-test certificates shall be originated by a worldwide known third-party
certification organization such as ASEFA. The Switchboard supplier shall provide a copy of the first
page of theses seven certificates on request.
Hereafter the detail of those 7 type tests:
No. 1 - temperature rise limits
No. 2 - dielectric properties
No. 3 - short-circuit withstand
No. 4 - protective circuit effectiveness
No. 5 - clearances and creepage distances
No. 6 - mechanical operation
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No. 7 - degree of protection
The selected switchgear and controlgear brands shall be equal to the ones mentioned in the type tests reports
of the equipment. All switchgear used in the switchboard shall be of the same manufacturer to allow
better interoperability and installation.
5.4 Switchboard Assembly
To complete the conformity to the standard, the switchboard assembler shall achieve three others tests after
the complete assembly.
Hereafter are the 3 routine tests performed by the assembler:
No. 8 - general inspection
No. 9 - insulation / dielectric test
No. 10 - protection measures.
Thanks to the full achievement of those 3 routine tests, the Switchboard operators have the insurance that the
equipment is in conformance with the electrical drawings and to the manufacturer rules.
A copy of these routines tests fully completed by the assembler shall be presented within or close to the
switchboard in its operation site.
5.5 Electrical and mechanical characteristics
-
Rated insulation voltage:
Rated operational voltage:
Rated current of main busbar:
Short current withstand strength:
Different available options:
- Form:
- IP & IK:
- Cable Entry:
- Access:
1000 Vac
up to 690 Vac
up to 3200A
up to 85kA/1s, 176kA peak.
Form 1/2/3/4
IP30/31/IK08, IP55/IK10
Top / bottom
Front / rear
5.6 Switchboard structure
Busbar
To facilitate the connections and cable access, the main busbar shall be installed at the top of the columns,
with the design allowing for front or back cables’ connection, via the top or bottom plates. All these
interfacing possibilities shall remain available even with no busbar position change.
The main busbar shall be made of copper bars spliced at each column level in order to achieve simplicity and
flexibility in transportation, installation and maintenance. Sliding fishplates shall be used to make the
connection of the copper bars between columns.
Functional units (FU)
The functional units shall be modular and designed for installation one on top of the other. Mounting
shall be of fixed type and Form shall be 4a. Functional units shall be separated from each other by an
isolating plate and a front plate shall be used to protect people from direct access to live parts of a functional
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unit, and only the rotary handle of components and HMI (button, lamp, etc…) shall be accessible. A
transparent door shall be used to cover all the functional units, while the maintenance staff can see the
status (run, stop, trip) of motor starters.
When rapid replacement of functional units is essential, mounting shall be of disconnectable type and Form
shall be 2. In any case, fixed and disconnectable mounting shall never be mixed in the same section.
The design of functional units shall meet the requirement to achieve high stacking density, especially for the
motors up to 15kW. It shall have the capability to install up to 30 functional units in one section.
5.7 Derating
To ensure that all components work in appropriate conditions, the influence of ambient temperature
and switchboard IP shall be taken into account in the design of the switchboard. To ensure the
reliability, the switchboard manufacturer shall be able to provide, when requested, the design table with IP
and ambient temperature, formally originated from the iMCC original manufacturer showing the current
value allowed for the dedicated components under a certain combination of ambient temperature, IP degree
and voltage.
5.8 General requirements for intelligent protection device (IPD)
Intelligent protection device (IPD) provides comprehensive functions in motor protection and monitoring,
and it shall be able to provide different functions mix according to the application requirements of critical
motors and non-critical ones. It is acceptable to use the thermal relay the other motors, but the IPD and
thermal relay used in the offer shall be from the same supplier.
For motors with ratings up to 15 kW the IPD shall be an “all-in-one” device; i.e., it shall include the
breaking, isolation, control and protection functions, ensuring Total Coordination.
For motors with ratings higher than 15 kW, a three-product architecture, i.e., circuit breaker + contactor +
protection is acceptable as far as Coordination Type 2 is ensured.
IPD supplier
The supplier shall have a local representative office with qualified support staff to provide training, technical
support and service.
Communication
The IPD shall provide the communication ports for the connection to the communication network. It shall be
easily integrated into the communication architecture with remote information access.
It shall be an open communications system, which means that it shall be possibly directly connected to
the main industrial network protocols, listed below:
- ModBus SL
- ModBus / Ethernet
- Profibus DP
- DeviceNet
The IPD shall embed the relevant network protocol in built-in (native) mode.
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Configuration
The IPD supplier shall provide a user-friendly software running in a Windows environment to ease the IPD
configuration. The software shall have menus and icons for easy access to the data required, guided
navigation to go through all the data of the same function in one screen and with a file management system.
5.9 IPD for non-critical motors
Protection
The IPD shall provide the following protections and alarm settings:




Short-circuit trip
Thermal overload trip, tripping class 10 or 20
Over current trip
Phase loss trip
Measuring
The IPD shall provide measurement on average current of motor
Monitoring
The IPD shall provide monitoring on motor status, including:
 Ready/Run/Fault status
 Fault differentiation
5.10
IPD for critical motors
Protection
For critical motors, the IPD shall provide the additional following protections:







Thermal overload trip, with selectable tripping class 5, 10, 15, 20, 25,30
Under current trip
Jam trip
Imbalance trip
Long start trip
Internal fault trip
Communication loss trip
Measuring
The IPD shall provide measurement on motor current, including:





3 phase current
Average current
Thermal capacity
Phase imbalance
Earth leakage current
All the measurement values shall be able to be transmitted to supervision system through communication
network.
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Monitoring
The IPD shall provide monitoring on motor status, including:




Starting count
Running hours
Fault count and identification
Last 5 faults history log
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6. Soft starters
6.1 Introduction
The specified soft starters shall be used for starting and stopping IEC or NEMA type three-phase
asynchronous squirrel-cage motors. The following stopping modes shall be available: freewheel, braking or
deceleration.
The starter shall be sized to operate with the following motor data: Power (kW or HP), continuous current
(A) and rated voltage (V).
6.2 Applicable specific standards
The electronic starter shall be developed and qualified in compliance with the following international
standards:
Standard
IEC 60146
IEC 60439
IEC 60715
IEC 60947-4-2
EN 50178
Title
Semiconductor converters; general requirements and line commutated converters
Low-voltage switchgear and controlgear assemblies
Dimensions of low-voltage switchgear and controlgear. Standardized mounting on
rails for mechanical support of electrical devices in switchgear and controlgear
installations
Low-voltage switchgear and controlgear - Part 4-2 Contactors and motor-starters AC semiconductor motor controllers and starters
Electronic equipment for use in power installations
The electronic starter shall have "CE" marking.
6.3 Description of the product
The operating principle of the starter shall not be based simply on limitation of the motor current during the
transient phases or on a voltage ramp but on control of motor torque. The starter shall provide a torque ramp
during the acceleration phase. Therefore, it shall be able to control the torque throughout the starting period
and if needed, supply a constant motor torque throughout the acceleration phase.
To avoid water hammer, pump deceleration shall take place on a torque ramp.
Starters with all ratings shall have the same control board.
All the starters shall be equipped with a means of measuring real motor current in order to guarantee motor
protection.
The power terminals for connection to the electrical distribution system shall be located at the top of the
starter and the motor connection terminals at the bottom (feed-through wiring).
Starters with all ratings shall have terminals for connection of the starter shorting contactor. Current
measurements shall be saved when the starter is shorted by the contactor.
The starter shall have a separate control power supply.
The logic and analog order control terminal block shall be disconnectable.
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6.4 Environment
The starter shall be operative without derating with ambient temperature between –10 and + 40°C and with
derating of 2% per °C above 40°C, up to 60°C.
The storage temperature shall be between -25°C and + 70°C.
The maximum altitude shall be 1000 meters (i.e. 3300 feet) without derating. A 2.2% derating per 100
meters shall be applied above 1000m.
The supplier shall indicate a starter noise level, not exceeding 65dBA.
For starters equipped with cooling fans, the fans shall not run continuously. They shall start up automatically
according to the heat sink temperature.
The starters shall be designed to operate with ambient pollution degree 3, according to IEC 60664-1 (or IEC
60947-4-2).
The supplier shall indicate the starter wiring diagrams.
The supplier shall provide the association tables for circuit breakers, fuses, contactors and starters to ensure
type 1 or type 2 coordination.
6.5 Electrical characteristics
As regards electromagnetic compatibility, the starter shall be compliant with class A for conducted and
radiated emissions, described in the product standard IEC 60947-4-2, for all the standard starter functions.
Class B shall be obtained with additional accessories and only concerns starters with rated current of no
more than 170 A.
The starter shall be certified according to UL 508 and CSA " Industrial Control Equipment".
The starter utilization category shall be AC 53a according to IEC 60947-4-2.
The supplier shall be capable of proposing one or more ranges of starters to cover 208 to 690V distribution
systems (208V–15% to 690V +10%).
The starter current range shall be between 17 and 1200 A.
The starter shall adapt automatically to the 50 or 60 Hz power frequency with a tolerance of +/-5%. By
configuration, it shall be capable of operating at a power frequency that may vary by +/- 20%.
The starter shall have at least four insulated 24V logic inputs.
The starter shall have at least three relays with normally-open contacts. Maximum switching capacity on
inductive loads: 1.8 A with 230 V AC and 30 V DC. Minimum switching capacity 10 mA for 6 V DC.
The starter shall have at least two 24 V logic outputs.
The starter shall include one analog output with a 0 - 20 mA or 4 - 20 mA signal. The signal shall be
scalable.
The starter shall have its own 24 V power supply for the logic inputs/outputs.
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The supplier shall propose a starter selection table for 2 types of sizing:
- Sizing 1 :
From cold status (S1 motor duty): 1 start at 3 In for 46 seconds.
For cycle type operation (motor duty S4), with a duty factor of 50 % and 10 starts per hour or a
thermally equivalent cycle: 1 start at 3 In for 23 seconds.
- Sizing 2 :
From cold status (S1 motor duty): 1 start at 4 In for 48 seconds
For cycle type operation (S4 motor duty), with a duty factor of 50% and 5 starts per hour, or a
thermally equivalent cycle: 1 start at 4 In for 25 seconds.
6.6 Protection functions
The starter shall include management of PTC sensors.
The starter shall continuously calculate motor temperature rise according to the real current measured (the
current shall be measured and not estimated). Several thermal protection classes shall be proposed according
to IEC60947-4-2 standard: classes 10A, 10, 20, 30 as well as intermediate classes, one less than class 10A,
one between classes 10 and 20 and one between classes 20 and 30. Thermal protection calculation shall
continue even when the starter is not powered.
The starter shall be protected against thermal overloads.
The starter shall detect underloads based on motor torque information. The detection pick-up value and the
authorized underload duration shall be adjustable. This protection function shall trigger a fault on the starter
or simply trigger an alarm type indication on a logic output.
The starter shall detect overloads based on motor current information. The detection pick-up value and the
authorized overload duration shall be adjustable. The overload duration shall be adjusted as of 0.1 second.
This protection function shall trigger a fault on the starter or simply trigger an alarm type indication on a
logic output.
The starter shall have protection against distribution system phase inversion, and loss of distribution system
or motor phase(s).
The starter shall take into account the management of external faults: when the contact is open, the starter
goes into fault status.
The protection functions shall be maintained even when the starter is shorted by a contactor.
6.7 Communication
The starter shall include a multi-point serial link for direct connection to a Modbus bus.
It shall be possible for the starter to be connected to the Ethernet network and to other optional
communication networks and buses.
The communication system shall provide access to starter control, settings and supervision.
6.8 Main functions
The starter shall be capable of starting and decelerating several motors in a cascade arrangement.
A second set of motor parameters shall be switched to by a logic input.
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In order to protect the motor against condensation during extended stop periods, the starter shall have a
preheating function that does not cause motor rotation. The preheating current shall be adjustable.
The starter shall manage the shorting contactor: closing of the shorting contactor at the end of starting and
opening of the contactor when a stop request is made. This function shall be compatible with freewheel,
braked and deceleration type stops.
The starter shall be able to control the line contactor. The contactor shall close when a start order is given
and open at the end of motor stopping.
Access to the settings shall be lockable by a code. The monitoring parameters shall remain accessible.
6.9 Supervision
The starter shall have a standard dialogue screen and programming keys. A remote programming terminal
shall be proposed as an option.
The following information shall be accessible on the dialogue screen:
- Motor current
- Motor torque
- Motor thermal state
- Power factor
- Power
- Current status (acceleration, deceleration, …).
- Starting operating time.
- Type of last fault.
The following information shall be accessible on the analog output:
- Motor current
- Motor torque
- Motor thermal state
- Power factor
- Active power
The starter shall have, as an option, advanced dialogue solutions such as:
- software workshop for PC to prepare, store, download and print settings
- console with display of parameters in plain text
For these tools, at least five languages will be available: French, English, German, Italian, Spanish.
Last update :2016-03-10
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7. Variable speed drives
7.1 General requirements
This part of the specification describes the general requirements for the Variable Speed Drives, herein
referred to as AC Drives, for use with standard IEC or NEMA squirrel cage or Wound Rotor AC motors and
synchronous motors with permanent magnets. The nominal values, the standard documents and the drive’s
minimum performance are defined in this document. The AC Drive does not include motor in this
specification.
To avoid any mismatch between the motor and its control equipment, the AC Drive shall be capable of auto
adjustment by automatic measurement of the motor parameters without motor rotation.
7.2 Applicable specific standards
The AC Drive shall comply with National and International standards and the recommendations for
electrical industrial control devices (IEC, EN, UL, NFC, VDE), and particularly the dedicated standards
listed below:
Standard
IEC 60068-2-3
IEC 60068-2-6
IEC 60068-2-27
IEC 60146
IEC 60204-1
IEC 60721-3-3
IEC 60947
IEC 61508-1
IEC 61800-3
IEC 61800-5-1
IEC 61800-5-2
EN 13849-1
EN 50178
Title
Environmental testing; Part 2-3: Tests - Test Ca: Damp heat, steady state
Part 2-6: Tests - Test Fc: Vibration (sinusoidal)
Part 2-27: Tests - Test Ea and guidance: Shock
Semiconductor convertors; general requirements and line commutated convertors
Safety of machinery - Electrical equipment of machines - Part 1: General
requirements
Classification of environmental conditions - Part 3-3: Classification of groups of
environmental parameters and their severities - Stationary use at weather
protected locations
Low-voltage switchgear and controlgear
Functional safety of electrical/electronic/programmable electronic safety-related
systems - Part 1: General requirements
Adjustable speed Electrical Power Drive Systems; Part 3: EMC requirements and
specific test methods
Part 5-1: Safety requirements - Electrical, thermal and energy
Part 5-2: Safety requirements - Functional
Safety of machinery - Safety related parts of control systems - Part 1: general
principles for design.
Electronic equipment for use in power installations
The AC Drives shall be :
- CE marked, conforming to European Low Voltage (73/23/CEE and 93/68/CEE) and EMC
(89/336/CEE) Directives,
- UL marked according to UL 508C,
- CSA marked according to CSA 22.2 N14-05.
In the Russian market (or in the ex-soviet countries such as Ukraine, Baltic countries) the AC Drive shall
have a GOST.
The supplied AC Drives shall carry the C-Tick mark indicating that they comply with the essential
requirements of the relevant Australian directives
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7.3 Requirements for the Manufacturer
Experience:
The Frequency Converter Manufacturer shall have adequate experience in frequency converter
manufacturing and have adequate business volume in order to provide credibility in his commitments and a
capability of long term support.
Local support:
The Supplier shall have a permanent representative office with a trained and skilled support staff, in the
country where the goods are delivered, in order to prove his commitment for local support and to provide a
channel for communication. The local representatives shall be easily accessible and shall be able to arrive at
the site within 24 to 48 hour notice.
The engineers employed by the Supplier’s regional office shall be certified by the Manufacturer and provide
start-up service including physical inspection of the drive, connected wiring and final adjustments, to ensure
that the AC Drive meets the required performance.
The Supplier shall be able to give basic drives training to the Customer’s engineers, preferably on the site
but anyway, in the country where the customer’s site is. The training shall, as a minimum, include system
concepts and basic troubleshooting. The Supplier shall also be capable of solving most AC Drive problems
quickly.
The Manufacturer shall be able to offer commissioning of the drive to be done by the local office.
The most common spare parts like fuses, IGBTs as well as main control- and I/O-boards shall be available in
48 hours from the notification through a regional service centre of the Supplier. The more rarely used spare
parts should be available in maximum 5 days on site.
7.4 Basic requirements for the AC Drives
The AC Drive shall be of the most modern design, yet user friendly and be simple to install, commission and
maintain.
The AC Drive shall be a digitally controlled device, using, at least, the Pulse Width Modulation (PWM) with
flux vector control open loop, with speed control mode, and a safety function (see chapter "Safety"). It shall
have IGBTs in the inverter section of the throughout the power range, and it shall have the following
minimum specifications.
Operating conditions:
Rated Input Voltage
Rated Input Frequency
Fundamental Power Factor
Efficiency
Output Voltage
Output Frequency Range
Last update :2016-03-10
200V -15% 240V +10%, three-phase, or
380V -15% 480V +10%, three-phase, or
200V -15% 240V+10%, single-phase
(ONLY up to 5.5kW, 7.5 HP)
48 - 63Hz
For use with generators, the AC Drive shall
operate from 40 to 72 Hz.
0.97 or better at nominal load
 98 % at nominal load
0 - UN, three-phase
0 to 1600 Hz up to 37kW (50HP), adjustable
0 to 500 Hz above 37kW (50HP), adjustable
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Acceleration/Deceleration Time
Overload capability (Constant Torque)
Operating ambient Temperature
Storage ambient Temperature
Maximum operating altitude
Max. Relative Humidity (IEC 60068-2-3)
Max. Corrosion Level of the Cooling Air
Chemical Gases
Solid Particles
Max. Vibration Level (IEC 60068-2-6)
2 to 13 Hz
13 to 200 Hz
Max. Ambient Pollution degree
according to IEC 61800-5-1
according to UL 508C
Main Protections
0.01 – 999.9s, adjustable, linear, with S, with
U or customised shapes
110% or 120% of nominal current for 1min
in every 5 min,
-10°C up to 50 °C
for higher temperatures, see below
-25°C up to 70 °C
1000 m without derating
1000…3000m: current derating of 1% per
additional 100 m.
Limited to 2000 m for the “Corner
Grounded” distribution network
5…95 %, without condensation and dripping
water
IEC 60721-3-3, class 3C1. In option,
conformal coating shall be requested to
comply with IEC 60721-3-3 Class 3C2
IEC 60721-3-3, class 3S2
1.5 mm, peak to peak
1 m/s2
Degree 2, up to 15 kW (20 HP)
Degree 3, above 15 kW (20HP)
- overcurrent
- short circuit between phases
- short circuit between phase and ground
- input phase loss
- output phase loss
- motor overload
- over-voltage
- under-voltage
- over-speed
- IGBT over-temperature
- heat sink over-temperature
- other internal faults.
The AC Drive shall be able to give a 100 % output current continuously in the above specified conditions. In
order to ensure that the drive can provide the required output current in the specified ambient conditions, the
Manufacturer shall inform the required derating, if the ambient temperature given in the project specification
is higher than 50 °C or if the installation altitude is more than 1000 m above the sea level. The derating
factor shall be specified so that neither the lifetime of the AC Drive nor the unit’s performance, overload
capability included, nor the reliability of the AC Drive shall suffer.
7.5 AC Drive performance
Control modes:
-
Motor control type:
o Quadratic kN²
o Energy saving
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-
o Sensor-less (SVC) voltage vector control for AC motors for multiple motors supply
o Sensor-less (SVC) current vector control for AC motors for a single motor supply
o Volt per hertz 2 or 5 points for AC motors
Speed range in the motor quadrant: 1:100 in sensor-less vector control
Overtorque capability: at least 130% of the rated motor torque (typical value) during 60s
Speed accuracy:  10% of the nominal slip of the motor in sensor-less vector control
Torque control accuracy:  15% in sensor-less vector control for AC motors
Current at standstill: 100% of the nominal peak current up to 75kW, 80% of the nominal peak
current above to 75kW
Protections
-
-
-
Circuit breaker coordination and short circuit protection shall eliminate the need for current-limiting
and semiconductor fuses. Manufacture who require the use of semiconductor or current limiting
fuses shall not be approved.
The AC Drive shall have a coordinated short circuit rating designed to UL 508C and NEMA ICS 7.1
and listed on the nameplate. The AC Drive shall not create a hazard in the event of a short circuit at
any point within the AC Drive when it is connected to a power source as specified on the nameplate
and protected as specified in the instruction bulletin.
Upon power-up the AC Drive shall automatically test for valid operation of memory, option module,
loss of analogue reference input, loss of communication, dynamic brake failure, DC to DC power
supply, control power and the pre-charge circuit.
The Power Converter shall be protected against short circuits of the logic and analogue outputs.
The AC drive shall have a minimum AC undervoltage power loss ride-through of 200 ms. The AC
Drive shall have the user-defined option of frequency fold-back to allow motor torque production to
continue to increase the duration of the power loss ride-through.
The AC drive shall have a selectable ride-through function that will allow the logic to maintain
control for a minimum of one second without faulting.
The deceleration mode of the AC drive shall be programmable for normal and fault conditions. The
stop modes shall include freewheel stop, fast stop, DC injection braking and as fast as possible.
Upon loss of the analogue process follower reference signal, the AC Drive shall fault and/or operate
at a user-defined speed set by a software programmed speed settings or last speed.
The AC Drive shall integrate a protection against IGBT chips over temperature that is different to the
heat sink overheat protection.
The AC drive shall have solid state thermal protection that is UL Listed and meets UL 508C as a
Class 20 overload protection and meets IEC 60947. The minimum adjustment range shall be from
0.25 to 1.36 times the current output of the AC Drive. The motor thermal state shall be memorized
and shall decrease following the motor rating even when the power is OFF.
The AC Drive should be able to protect the motor when PTC probes are connected.
The AC drive shall be able to limit the motor voltage surge at twice the DC bus voltage
The AC drive shall display all faults in plain text and help screens shall be available to guide the user
in the troubleshooting. Codes are not acceptable.
Safety
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The AC drive shall be integrated directly in the safety chain complying with EN 13849-1category 3,
and with IEC 61508-1 SIL2.
The AC drive shall integrate the “Power Removal” safety function which prohibits unintended
equipment operation. The motor no longer produces torque.
This safety function shall comply with standard for safety of machinery EN 13849-1, category 3 ;
standard for functional safety IEC 61508, SIL2 capability (safety control-signalling applied to
processes and systems)
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The “Power Removal” safety function shall have a redundant electronic architecture (1) that shall be
monitored continuously by a diagnostics function.
This SIL2 and category 3 level of safety function shall be certified as conforming to these standards
by a certification body under a program of voluntary certification.
The Power removal function shall comply with the definition of the product standard IEC 61800-5-2
for both stop functions, Safe Torque Off (“STO”) and Safe Stop 1 (“SS1”)
The AC drive manufacturer shall provide the certified schematics and the list of devices in order to
comply with IEC 60204-1 stopping category 0 and 1.
7.6 Enclosure and mounting
Open style
Mounting type:
- side by side
- vertical position  10°
- When mounted in an enclosure, the AC Drive shall have an IP54 / NEMA 12 power section in order
to evacuate the heat outside the enclosure
Protection degree available: IP20/ UL Type 1, or IP21/ UL Type 1, or IP54/ UL Type 12
Packaged style (cubicle)
Power range : from 110kW to 630kW 380/480V
Protection degree : IP54 for the enclosure
Panel design specifications:
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Standards:
Cabinet access:
Cable entry and exit:
Colour, front:
Transportation:
IEC 60439-1, VDE660 Part 500.
From front
Bottom entry as standard
RAL 7032
horizontal
Standard equipment of the enclosure
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UL Type 1/ IP20
Interrupter and fuses
Programming graphic terminal: IP65 on front face of enclosure
The Programming terminal of the AC Drive shall be accessible for programming and control with the
main door closed.
The whole assembly shall be implemented with a strict consideration of the Electromagnetic
Compatibility and Regulations as described further in this specification.
7.7 User interface
General
The user interface shall be identical throughout the power range to avoid confusion amongst the users and
need for training in several different units.
Inputs and outputs
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At least, the following standard Inputs and Outputs shall be provided, to be used in interface with the control
system:
Analogue Inputs
Analogue Output
Logic inputs
Safety input
Relay Outputs
Reaction time
1 x Programmable differential voltage input + 10V
1 x Programmable current input 0(4) - 20mA
1 x Programmable voltage input 0 – 10V
1 x Programmable analogue outputs 0(4) - 20mA or 0 – 10V
6 x Programmable logic Inputs isolated from the mains
(One of these inputs could be used for PTC probe)
All logic inputs may be used either in sink or source
One input dedicated to the Power removal safety function
In option, digital inputs may be used with 115V control supply
2 x Programmable Digital outputs with a changeover dry contact
2ms  0.5ms (except for the relays)
All the control terminals shall be clearly marked.
It shall be possible to extend the number of inputs / outputs of the AC Drive up to :
- 14 logic inputs
- 4 analogue inputs
- 3 analogue outputs
- 2 logic outputs (open collector)
- 4 relays
At least, it shall be possible to assign the following functions to the I/Os:
Analogue input
Speed reference
Summing reference
Subtracting reference
Multiplying reference
Torque reference
Torque limitation
PID feedback
Manual PID reference
PID speed reference
Forced local
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Analogue outputs
Motor current
Motor frequency
Motor torque (signed or unsigned)
Motor power
Motor voltage
Output frequency (signed or unsigned)
PID error
PID feedback
PID output
PID reference
Ramp output
Signed ramp
Torque reference (signed or unsigned)
Drive thermal state
Motor thermal state
Torque limitation
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Logic input
Relay or logic outputs (open collector)
Run
Forward
Reverse
Jog
Preset speeds
Reference switching
Ramp switching
Fault reset
Fault inhibition
PID regulation mode (auto)
PID speed regulation mode (manu)
PID integral reset
Preset PID reference
Sleep/wake-up
Activate sleep mode by flow detection
Torque limitation activation
Analogue torque limitation activation
Torque reference sign
Torque /speed control switching
Brake contact feedback
Command switching
Parameter sets selection
Fast stop
DC injection
Freewheel stop
+ speed
- speed
External fault
Pre Fluxing
Forced local
Current limitation activation
Output contactor feedback
Reference memorisation
Auto-tuning
Flow limit
Forced operation
Under load detection
Overload detection
Limiting low speed operating time
Switching frequency, noise reduction
Ready
Drive running
Frequency reference attained
Current attained
High speed attained
Drive fault
Frequency threshold attained
Torque sign
Motor thermal state attained
Drive thermal state attained
Torque or current limitation attained
Brake control
Output contactor command
Input contactor command
Current present
Power removed
Alarm Groups
Alarm (load slipping, 4-20mA loss, brake
control, external fault, PTC, PID error, PID
feedback, IGBT temperature, Under-voltage,
torque control, drive temperature, braking
resistor)
Active configuration
Active parameter set
Active channel
In braking
DC bus charged
DC bus charging
7.8 Communications
The AC drive shall integrate as standard 2 Modbus ports and 1 CanOpen port.
The AC drive shall have the capability for internal mounted communication card.
The following protocols shall be the minimum available :
Dedicated for Industry
- Ethernet TCP/IP
- Modbus Plus
- FIPIO
- Profibus DP
- DeviceNet
- InterBus-S
Dedicated for HVAC building
- LonWorks
- BACnet
- METASYS N2
- APOGEE FLN
The AC drive shall be piloted following :
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Drivecom profile (CANopen CiA DSP 402)
I/O profile where the command is as simple as the wired logic
ODVA profile for DeviceNet network only
The speed or torque command and reference shall come from different possible control sources :
- I/O terminals
- Communication network
- Programmable card
- Remote graphic display terminal
The AC Drive shall be able to switch these control sources according to the application requirements.
The AC drive shall integrate its own programmable communication scanner to always provide periodic
variable exchange.
The control section of AC drive shall be supplied separately if necessary with 24V DC, to keep the network
communication always available even if the power supply is OFF.
The AC drive behaviour shall be programmable on communication fault
Advanced monitoring and diagnostic functions shall be available through the programming terminal., with
monitoring of :
- The communication scanner
- Command words sent by the different sources
- Command words taken by the AC drive
- 4 words which addresses are selectable
7.9 Programming terminal
The AC drive shall have a detachable keypad with a back lit 8-line, with a minimum of 23-character
alphanumeric operating display for programming and controlling purposes. An IP54 or IP65 remote
mounting shall be possible at a distance of 10m. The programming shall be able to operate in a multi-point
connection. The displayed messages shall be in user friendly, descriptive text in multiple languages,
including English, German, French, Italian, Spanish and Chinese. It shall be possible to replace 5 languages
by other ones by a simple download. Coded messages are not acceptable.
Using a shuttle button shall carry out the navigation in the menu and the parameter setting.
Parameter setting shall be easily accessible and user friendly with actual text messages and actual setting
range.
Visibility and protection shall be selected for each parameter. Password protection shall be provided to avoid
unauthorized tampering with the set parameters.
The programming terminal shall offer the possibility of memorizing and downloading 4 configurations of
the AC drives to save time during the commissioning and to avoid mistakes.
Direct access to the 10 last modifications shall be provided.
Four programmable function keys shall be available for short cuts, application functions.
Monitoring shall be possible up to a distance of 5 meters by using digital values and/or bar graph. Dedicated
functions shall be provided such as I/O map, Communication map.
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The programming terminal shall be able to display the commercial reference of the AC drive and options,
the software version, the serial number.
The user shall be able to customize the interface :
- Creation of a user menu
- Customization of 15 parameters : name, scaling, unit
- Integration of bitmaps
The programming terminal shall integrate a Simply Start menu for fast and easy commissioning.
Direct keypad entry shall be provided to observe the following actual parameters. Any two of the following
parameters or actual values shall be selected to be always displayed.
- Input Voltage
- Input Frequency
- Output Voltage
- Output Frequency
- DC Bus Voltage
- Output Power
- Output Torque
- Output Current
- Motor Speed
The following parameters shall always be displayed during normal operation.
- Drive Status
- Command source (terminal, keypad, …)
The AC Drive shall have self-diagnostic properties to display faults and warnings as they occur and be able
to store at least 8 last faults into the fault memory. The fault memory shall be accessible by PC maintenance
tools.
The following drive control functions at least shall be available from the keypad:
- Run
- Stop
- Local / Remote selection.
- Forward/Reverse (if function enabled)
- Accelerate
- Decelerate
- Parameter setting
- Scrolling & Viewing through Actual values
7.10
Application programming
The AC Drive shall be designed for both simple and the most complicated applications, yet it shall be user
friendly. The AC Drive shall have built-in application macros available for selection of pre-programmed
control configurations, and shall be able to store at least two customer modified macro-configurations. It
shall be possible to reset the parameter settings back to the original macro settings through the keypad. The
parameter readouts shall be in text format and not coded.
Multi-pump applications:
The AC Drive Supplier shall incorporate all the application function for managing pumping installations as
sleeping , wake-up, friction loss compensation, low or no flow detection, under-load detection, overload
detection , PID regulator with preset PID references, night and day algorithm, pressure boost mode, pipe file
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algorithm, staging and de-staging algorithm, cavitation protection, over pressure protection, low water level
protection, pipe burst and pipe blockage protection, cycling protection.
The drive shall be able to manage main communication protocols and multi-pump card application at the
same time.
Multi-pump cards feature their own I/O. They shall manage I/O on the drive as well as those on I/O
extension cards. They shall also make use of drive parameters such as those for speed, current, torque, etc.
The AC drive shall incorporate dedicated menu link to multi-pump application through a graphic keypad.
7.11
PC Tools
The AC Drive Supplier shall have a Windows® based PC software available for monitoring and controlling
the AC Drives, and the software shall be offered as an option. The software shall be supplied with the
necessary hardware and a provision for connecting a PC with the AC Drives. It shall be possible to set and
modify parameters, control the drive, read actual values and make trend analysis using the software.
7.12
Software features
Power loss ridethrough
Multi-motor or multiconfiguration
Multi-parameters
Oscilloscope
Service message
Diagnostic functions
Flying start
Pre-fluxing
Current/speed limiting
Operations on
reference signals
Line contactor
command
Restart
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The drive shall have a power loss ride-through capability. This means that the
drive controls shall stay alive during a power loss by means of the energy stored
in the load. The ride through time shall be longer when the kinetic energy of the
load is higher.
The AC drive shall have 3 configurations, which can be activated remotely,
allowing it to adapt to:
- 2 or 3 different motors or mechanisms in multi-motor mode. Each motor
shall be protected thermally by the AC Drive
- 2 or 3 configurations for the same motor in multi-configuration mode.
The AC Drive shall integrate and shall be able to switch 3 sets of 15 parameters
when the motor is running.
The drive shall be able to store a total of 4000 points for one up to four channels.
Trigger, time base, and channels shall be fully programmable by using the PC
software, with display of the channels with zoom functions.
The drive shall be able to store 5 lines of 23 characters in order to display a
message to the user or the maintenance people.
The drive shall integrate test procedure to check the motor connection and the
power components. Motor connection shall be tested at each run command.
The drive shall have a built-in Flying Start feature. This feature will allow a
Motor unit which is still rotating, to be reaccelerated up to the reference speed
without first stopping it. The Flying Start feature shall be operative regardless of
the rotation direction of the motor
The AC Drive shall have a built-in pre-fluxing function, minimizing the response
time at start-up.
In case the acceleration or deceleration ramps are too fast for the drive capacity,
the drive shall be able to automatically adapt the ramp to prevent tripping. Also,
in case of transient overload the drive shall automatically reduce speed to prevent
an over-current trip.
Operations shall be possible so that speed reference signals can be summed,
subtracted or multiplied.
The AC Drive shall be able to manage a line contactor depending on the Run
command it receives
In the event of a fault trip due to overvoltage, overcurrent or loss of analogue
signal, the AC drive shall be programmable to attempt an automatic restart. For
safety reasons, the maximum number of attempts shall be within a selectable
time. If the fault does not clear after the attempts, the drive shall lock out.
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PID-regulator
Sleeping , wake-up
Set point ramping
Activate sleep mode by
flow detection
Friction loss
compensation
Low or no flow
detection
Flow limitation
Under-load and
overload detection
Forced operation
Limited operating time
Night and day
algorithm
Pressure boost mode
Staging and de-staging
algorithm
Cavitation protection
Pipe fill algorithm
Over pressure
protection
Low water level
protection
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The AC Drive shall have a built-in PID-controller for control of the customer
process. Others functions such as Preset PID reference, automatic/manual,
predictive speed shall be available.
The AC drive shall have sleeping and wake-up function in addition to PID
regulator to avoid extended operation at too low speeds. It stops the motor
following a period of reduced speed operation. This duration and this speed can
be adjusted. It restarts the motor if the error or the PID feedback exceeds an
adjustable threshold.
On transition from any state into PID control, the reference is ramped from the
current feedback level to the required set point. This prevents an unwanted initial
large error.
This function shall be used in application where zero flow cannot be detected by
sleep function alone.
This function shall be used if a flow meter is installed. The flow compensation
algorithm automatically adjusts the pressure set point to compensate for losses
due to increasing flow.
The AC drive shall avoid operation when there is no fluid or if the conduits are
blocked.
The AC drive shall be able to limit the flow of a fluid using a flow sensor
assigned to an analogue input.
The AC drive shall have an under-load and overload protection. Under load is
detected when the motor is in steady state and the torque is below the set underload limit. Overload is detected when the motor is in steady state and the current
is above the set overload threshold
The AC drive shall have a forced operation mode. In combination with the
function inhibiting faults, this function allows the run command to be forced in a
defined direction and the reference to be forced to a configured value
In multi-pump operation, the AC drive shall ensure an even distribution of
operating times of each pump and thus limit pump wear.
The AC drive shall be able to switch from night time operation (fixed speed
between two pressure set points) to day time operation (normal lead pump) in
case of excessive demand, and back.
For long supply lines or high rise buildings, it shall be required to boost the
pressure at regular intervals.
This algorithm shall be implemented for smooth pick up and drop off for fixed
speed pumps, based on speed, pressure, PID error or any combination of these.
The AC drive shall have a Cavitation protection algorithm for the lead pump.
Cavitation is detected by high pump speed and low motor current. When
cavitation is detected, a temporary shutdown will occur. All fixed speed pumps
will then stop sequentially at approximately 2 second intervals. The AC drive
status will display WAIT and the top line of the display will flash CAVITATION
On initial start-up, pipes may be empty. Starting PID control under these
conditions would result in the PID ramping up, due to a low feedback. The AC
drive shall include an algorithm to run the system at a preset speed until a start
pressure is reached, and then transfer into PID control.
The AC drive shall have an analogue pressure feedback signal. It can be
monitored and used to protect against high pressure condition.
A Minimum Pressure Protection shall be activated if the feedback pressure drops
below the Minimum Pressure Fault level. This is typically the case when a burst
pipe simulates a high demand.
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7.13
Documents
Documents to be provided to customer:
Manuals
Drawings
Quality assurance
On request:
Environmental
aspect
These must contain instructions on how to install, commission and program
the AC Drive, instructions for maintenance and for trouble shooting
Dimension drawings, control connection diagram, CAD drawings
Quality Plan, Test reports
The AC Drive Manufacturer shall also present documents to prove that
impact on environment has been taken into account during all the life cycle
of the product (manufacturing, distribution, use, end of life), the software
used to measure impact shall be E.I.M.E. or equivalent
A detailed description and other directions to ensure the EMC Compatibility during the installation of the
AC Drive and associated field cables and connections, shall be given by the Supplier to comply with the
EMC Directives. The Contractor shall follow the directions during installation, in order to achieve
attenuation of the RFI.
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