SECTION

230514 - VARIABLE-FREQUENCY MOTOR CONTROLLERS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section includes separately enclosed, preassembled, combination VFCs, rated 600 V and less,
for speed control of three-phase, squirrel-cage induction motors.

1.3 DEFINITIONS

A. BAS: Building automation system.

B. CE: Conformite Europeene (European Compliance).

C. CPT: Control power transformer.

D. EMI: Electromagnetic interference.

E. LED: Light-emitting diode.

F. NC: Normally closed.

G. NO: Normally open.

H. OCPD: Overcurrent protective device.

I. PID: Control action, proportional plus integral plus derivative.

J. RFI: Radio-frequency interference.

K. VFC: Variable-frequency motor controller.

1.4 ACTION SUBMITTALS

A. Product Data: For each type and rating of VFC indicated.

1. Include dimensions and finishes for VFCs.
2. Include rated capacities, operating characteristics, electrical characteristics, and
furnished specialties and accessories.

B. Shop Drawings: For each VFC indicated.

1. Include mounting and attachment details.
2. Include details of equipment assemblies. Indicate dimensions, weights, loads, required
clearances, method of field assembly, components, and location and size of each field
connection.
3. Include diagrams for power, signal, and control wiring.

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1.5 INFORMATIONAL SUBMITTALS

A. Coordination Drawings: Floor plans, drawn to scale, showing dimensioned layout on which the
following items are shown and coordinated with each other, using input from installers of the
items involved:
1. Required working clearances and required area above and around VFCs.
2. Show VFC layout and relationships between electrical components and adjacent
structural and mechanical elements.
3. Show support locations, type of support, and weight on each support.
4. Indicate field measurements.

B. Qualification Data: For testing agency.

C. Product Certificates: For each VFC from manufacturer.

A. Harmonic Analysis Report: Provide manufacturer's statement of compliance with IEEE 519 and
manufacturer's harmonic analysis study and report based upon conditions as described in
Section 260573 and 260574. These conditions include but are not limited to the POCC,
harmonic limits, normal power / emergency power modes, cable length, and transformer /
generator data.

B. Source quality-control reports.

C. Field quality-control reports.

D. Sample Warranty: For special warranty.

1.6 CLOSEOUT SUBMITTALS

A. Operation and Maintenance Data: For VFCs to include in emergency, operation, and
maintenance manuals.
1. In addition to items specified in Section 017823 "Operation and Maintenance Data,"
include the following:

a. Manufacturer's written instructions for testing and adjusting thermal-magnetic

circuit breaker and motor-circuit protector trip settings.
b. Manufacturer's written instructions for setting field-adjustable overload relays.
c. Manufacturer's written instructions for testing, adjusting, and reprogramming
microprocessor control modules.
d. Manufacturer's written instructions for setting field-adjustable timers, controls, and
status and alarm points.
e. Load-Current and Overload-Relay Heater List: Compile after motors have been
installed, and arrange to demonstrate that selection of heaters suits actual motor
nameplate, full-load currents.
f. Load-Current and List of Settings of Adjustable Overload Relays: Compile after
motors have been installed, and arrange to demonstrate that switch settings for
motor-running overload protection suit actual motors to be protected.

1.7 QUALITY ASSURANCE

A. Testing Agency Qualifications: Member company of NETA or an NRTL.

1. Testing Agency's Field Supervisor: Currently certified by NETA to supervise on-site
testing.

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1.8 DELIVERY, STORAGE, AND HANDLING

A. If stored in space that is not permanently enclosed and air conditioned, remove loose packing
and flammable materials from inside controllers and install temporary electric heating, with at
least 250 W per controller.

B. Product Selection for Restricted Space: Drawings indicate maximum dimensions for VFCs,
including clearances between VFCs, and adjacent surfaces and other items.

1.9 WARRANTY

A. Special Warranty: Manufacturer agrees to repair or replace VFCs that fail in materials or
workmanship within specified warranty period.
1. Warranty Period: Five years from date of Substantial Completion.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Basis-of-Design Product: Subject to compliance with requirements, provide product indicated

on Drawings or comparable product by one of the following:
1. ABB Inc.
2. Danfoss Inc; Danfoss Drives Div.
3. Eaton Electrical Sector; Eaton Corporation; Cutler-Hammer Business Unit.
4. Fuji Electric.
5. Siemens Energy & Automation, Inc.
6. Yaskawa Electric America, Inc.
7. Trane
8. Emerson

2.2 SYSTEM DESCRIPTION

A. General Requirements for VFCs:

1. VFCs and Accessories: Listed and labeled as defined in NFPA 70, by a qualified testing
agency, and marked for intended location and application.
2. Comply with NEMA ICS 7, NEMA ICS 61800-2, and UL 508C.

B. Application: Constant torque and variable torque.

C. VFC Description: Variable-frequency motor controller, consisting of power converter that

employs pulse-width-modulated inverter, factory built and tested in an enclosure, with integral
disconnecting means and overcurrent and overload protection; listed and labeled by an NRTL
as a complete unit; arranged to provide self-protection, protection, and variable-speed control of
one or more three-phase induction motors by adjusting output voltage and frequency.
1. Units suitable for operation of NEMA MG 1, Design A and Design B motors, as defined
by NEMA MG 1, Section IV, Part 30, "Application Considerations for Constant Speed
Motors Used on a Sinusoidal Bus with Harmonic Content and General Purpose Motors
Used with Adjustable-Voltage or Adjustable-Frequency Controls or Both."
2. Units suitable for operation of inverter-duty motors as defined by NEMA MG 1,
Section IV, Part 31, "Definite-Purpose Inverter-Fed Polyphase Motors."
3. Listed and labeled for integrated short-circuit current (withstand) rating by an NRTL
acceptable to authorities having jurisdiction.

D. Design and Rating: Match load type, such as fans, blowers, and pumps; and type of connection
used between motor and load such as direct or through a power-transmission connection.

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E. Output Rating: Three phase; 10 to 60 Hz, with voltage proportional to frequency throughout
voltage range; maximum voltage equals input voltage.

F. Unit Operating Requirements:

1. Input AC Voltage Tolerance: Plus 10 and minus 10 percent of VFC input voltage rating.
2. Input AC Voltage Unbalance: Not exceeding 5 percent.
3. Input Frequency Tolerance: Plus or minus 3 percent of VFC frequency rating.
4. Minimum Efficiency: 96 percent at 60 Hz, full load.
5. Minimum Displacement Primary-Side Power Factor: 96 percent under any load or speed
condition.
6. Ambient Temperature Rating: Not less than 32 deg F and not exceeding 104 deg F.
7. Humidity Rating: Less than 95 percent (noncondensing).
8. Altitude Rating: Not exceeding 3300 feet.
9. Vibration Withstand: Comply with NEMA ICS 61800-2.
10. Overload Capability: 1.1 times the base load current for 60 seconds; minimum of 1.8
times the base load current for three seconds.
11. Starting Torque: Minimum 100 percent of rated torque from 3 to 60 Hz.
12. Speed Regulation: Plus or minus 5 percent.
13. Output Carrier Frequency: Selectable; 0.5 to 15 kHz.
14. Stop Modes: Programmable; includes fast, free-wheel, and dc injection braking.

G. Inverter Logic: Microprocessor based, 32 bit, isolated from all power circuits.

H. Isolated Control Interface: Allows VFCs to follow remote-control signal over a minimum 40:1
speed range.
1. Signal: Electrical.

I. Internal Adjustability Capabilities:

1. Minimum Speed: 5 to 25 percent of maximum rpm.
2. Maximum Speed: 80 to 100 percent of maximum rpm.
3. Acceleration: 0.1 to 999.9 seconds.
4. Deceleration: 0.1 to 999.9 seconds.
5. Current Limit: 30 to minimum of 150 percent of maximum rating.

J. Self-Protection and Reliability Features:

1. Surge Suppression: Factory installed as an integral part of the VFC, complying with
UL 1449 SPD, Type 1 or Type 2.
2. Loss of Input Signal Protection: Selectable response strategy, including speed default to
a percent of the most recent speed, a preset speed, or stop; with alarm.
3. Under- and overvoltage trips.
4. Inverter overcurrent trips.
5. VFC and Motor-Overload/Overtemperature Protection: Microprocessor-based thermal
protection system for monitoring VFCs and motor thermal characteristics, and for
providing VFC overtemperature and motor-overload alarm and trip; settings selectable
via the keypad.
6. Critical frequency rejection, with three selectable, adjustable deadbands.
7. Instantaneous line-to-line and line-to-ground overcurrent trips.
8. Loss-of-phase protection.
9. Reverse-phase protection.
10. Short-circuit protection.
11. Motor-overtemperature fault.

K. Automatic Reset/Restart: Attempt three restarts after drive fault or on return of power after an
interruption and before shutting down for manual reset or fault correction; adjustable delay time
between restart attempts.

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L. Bidirectional Autospeed Search: Capable of starting VFC into rotating loads spinning in either
direction and returning motor to set speed in proper direction, without causing damage to drive,
motor, or load.

M. Torque Boost: Automatically varies starting and continuous torque to at least 1.5 times the
minimum torque to ensure high-starting torque and increased torque at slow speeds.

N. Motor Temperature Compensation at Slow Speeds: Adjustable current fall-back based on

output frequency for temperature protection of self-cooled, fan-ventilated motors at slow
speeds.

O. Integral Input Disconnecting Means and OCPD: UL 489, molded-case switch, with power fuse
block and current-limiting fuses or NEMA KS 1, nonfusible switch, with power fuse block and
current-limiting fuses with pad-lockable, door-mounted handle mechanism.
1. Disconnect Rating: Not less than 115 percent of NFPA 70 motor full-load current rating
or VFC input current rating, whichever is larger.
2. Auxiliary Contacts: NO or NC, arranged to activate before switch blades open.

2.3 CONTROLS AND INDICATION

A. Panel-Mounted Operator Station: Manufacturer's standard front-accessible, sealed keypad and

plain-English-language digital display; allows complete programming, program copying,
operating, monitoring, and diagnostic capability.
1. Keypad: In addition to required programming and control keys, include keys for HAND,
OFF, and AUTO modes.
2. Security Access: Provide electronic security access to controls through identification and
password with at least three levels of access: View only; view and operate; and view,
operate, and service.

a. Control Authority: Supports at least four conditions: Off, local manual control at
VFC, local automatic control at VFC, and automatic control through a remote
source.

B. Historical Logging Information and Displays:

1. Real-time clock with current time and date.
2. Running log of total power versus time.
3. Total run time.
4. Fault log, maintaining last four faults with time and date stamp for each.

C. Indicating Devices: Digital display and additional readout devices as required, mounted flush in
VFC door and connected to display VFC parameters including, but not limited to:
1. Output frequency (Hz).
2. Motor speed (rpm).
3. Motor status (running, stop, fault).
4. Motor current (amperes).
5. Motor torque (percent).
6. Fault or alarming status (code).
7. PID feedback signal (percent).
8. DC-link voltage (V dc).
9. Set point frequency (Hz).
10. Motor output voltage (V ac).

D. Control Signal Interfaces:

1. Electric Input Signal Interface:

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a. A minimum of two programmable analog inputs: 0- to 10-V dc, 4- to 20-mA dc, or

operator-selectable "x"- to "y"-mA dc.
b. A minimum of six multifunction programmable digital inputs.
2. Remote Signal Inputs: Capability to accept any of the following speed-setting input
signals from the BAS or other control systems:

a. 0- to 10-V dc.
b. 4- to 20-mA dc.
c. Potentiometer using up/down digital inputs.
d. Fixed frequencies using digital inputs.
3. Output Signal Interface: A minimum of one programmable analog output signal(s) ( 4- to
20-mA dc), which can be configured for any of the following:

a. Output frequency (Hz).

b. Output current (load).
c. DC-link voltage (V dc).
d. Motor torque (percent).
e. Motor speed (rpm).
f. Set point frequency (Hz).
4. Remote Indication Interface: A minimum of two programmable dry-circuit relay outputs
(120-V ac, 1 A) for remote indication of the following:

a. Motor running.
b. Set point speed reached.
c. Fault and warning indication (overtemperature or overcurrent).
d. PID high- or low-speed limits reached.

E. BAS Interface: Factory-installed hardware and software shall interface with BAS to monitor,
control, display, and record data for use in processing reports. VFC settings shall be retained
within VFC's nonvolatile memory.
1. Communication Interface: Comply with ASHRAE 135. Communication shall interface
with BAS to remotely control and monitor lighting from a BAS operator workstation.
Control features and monitoring points displayed locally at lighting panel shall be
available through the BAS.

2.4 LINE CONDITIONING AND FILTERING

A. Input Line Conditioning: Based on the manufacturer's harmonic analysis study and report,
provide input filtering, as required, to limit total demand (harmonic current) distortion and total
harmonic voltage demand at the defined point of common coupling to meet IEEE 519
recommendations.

B. The VFD shall have internal 5% equivalent impedance to reduce the harmonics to the power
line and to add protection from AC line transients. The 5% impedance may be from dual
(positive and negative DC bus) reactors, or 5% AC line reactors. VFD’s with only one DC
reactor shall add an AC line reactor.

C. Output Filtering: Verify voltage does not exceed motor pulse withstand capability.

2.5 BYPASS SYSTEMS

A. Bypass Operation: Safely transfers motor between power converter output and bypass circuit,
manually, automatically, or both. Selector switches set modes and indicator lights indicate
mode selected. Unit is capable of stable operation (starting, stopping, and running) with motor
completely disconnected from power converter.

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B. Bypass Mode: Manual operation only; requires local operator selection at VFC. Transfer
between power converter and bypass contactor, and retransfer shall only be allowed with the
motor at zero speed.

2.6 OPTIONAL FEATURES

A. Sleep Function: Senses a minimal deviation of a feedback signal and stops the motor. On an
increase in speed-command signal deviation, VFC resumes normal operation.

B. Motor Preheat Function: Preheats motor when idle to prevent moisture accumulation in the
motor.

C. Remote digital operator kit.

D. Communication Port: RS-232 port, USB 2.0 port, or equivalent connection capable of
connecting a printer and a notebook computer.

2.7 ENCLOSURES

A. VFC Enclosures: NEMA 250, to comply with environmental conditions at installed location.

B. Plenum Rating: UL 1995; NRTL certification label on enclosure, clearly identifying VFC as
"Plenum Rated."

2.8 ACCESSORIES

A. General Requirements for Control-Circuit and Pilot Devices: NEMA ICS 5; factory installed in
VFC enclosure cover unless otherwise indicated.
1. Push Buttons: Covered.
2. Pilot Lights: Push to test.
3. Selector Switches: Rotary type.

B. Control Relays: Auxiliary and adjustable solid-state time-delay relays.

C. Phase-Failure, Phase-Reversal, and Undervoltage and Overvoltage Relays: Solid-state

sensing circuit with isolated output contacts for hard-wired connections. Provide adjustable
undervoltage, overvoltage, and time-delay settings.
1. Current Transformers: Continuous current rating, basic impulse insulating level (BIL)
rating, burden, and accuracy class suitable for connected circuitry. Comply with
IEEE C57.13.

D. Supplemental Digital Meters:

1. Elapsed-time meter.
2. Kilowatt meter.
3. Kilowatt-hour meter.

E. Breather and drain assemblies, to maintain interior pressure and release condensation in
NEMA 250, Type 4 and Type 4X enclosures installed outdoors or in unconditioned interior
spaces subject to humidity and temperature swings.

F. Space heaters, with NC auxiliary contacts, to mitigate condensation in NEMA 250, Type 3R and
Type 4X enclosures installed outdoors or in unconditioned interior spaces subject to humidity
and temperature swings.

G. Cooling Fan and Exhaust System: For NEMA 250, Type 1; UL 508 component recognized:
Supply fan, with composite intake and exhaust grills; 120-V ac; obtained from integral CPT.

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H. Sun shields installed on fronts, sides, and tops of enclosures installed outdoors and subject to
direct and extended sun exposure.

2.9 SOURCE QUALITY CONTROL

A. Testing: Test and inspect VFCs according to requirements in NEMA ICS 61800-2.
1. Test each VFC while connected to a motor that is comparable to that for which the VFC
is rated.
2. Verification of Performance: Rate VFCs according to operation of functions and features
specified.

B. VFCs will be considered defective if they do not pass tests and inspections.

C. Prepare test and inspection reports.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine areas, surfaces, and substrates to receive VFCs, with Installer present, for compliance
with requirements for installation tolerances, and other conditions affecting performance of the
Work.

B. Examine VFC before installation. Reject VFCs that are wet, moisture damaged, or mold
damaged.

C. Examine roughing-in for conduit systems to verify actual locations of conduit connections before
VFC installation.

D. Prepare written report, endorsed by Installer, listing conditions detrimental to performance of the
Work

E. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 INSTALLATION

A. Wall-Mounting Controllers: Install with tops at uniform height and with disconnect operating
handles not higher than 79 inches above finished floor, unless otherwise indicated, and by
bolting units to wall or mounting on lightweight structural-steel channels bolted to wall. For
controllers not on walls, provide freestanding racks complying with Section 260529 "Hangers
and Supports for Electrical Systems."

B. Floor-Mounting Controllers: Install VFCs on 4-inch nominal thickness concrete base. Comply
with requirements for concrete base specified in Section 033000 "Cast-in-Place Concrete."
1. Install dowel rods to connect concrete base to concrete floor. Unless otherwise
indicated, install dowel rods on 18-inch centers around the full perimeter of concrete
base.
2. For supported equipment, install epoxy-coated anchor bolts that extend through concrete
base and anchor into structural concrete floor.
3. Place and secure anchorage devices. Use setting drawings, templates, diagrams,
instructions, and directions furnished with items to be embedded.
4. Install anchor bolts to elevations required for proper attachment to supported equipment.

C. Temporary Lifting Provisions: Remove temporary lifting eyes, channels, and brackets and
temporary blocking of moving parts from enclosures and components.

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D. Install fuses in each fusible-switch VFC.

E. Install fuses in control circuits if not factory installed. Comply with requirements in
Section 262813 "Fuses."

F. Install heaters in thermal-overload relays. Select heaters based on actual nameplate full-load
amperes after motors are installed.

G. Install, connect, and fuse thermal-protector monitoring relays furnished with motor-driven
equipment.

H. Comply with NECA 1.

I. Utilize metal type of conduit (refer to division 26) for line, load and control wiring. Do not mix
line, load, and control wiring in the same conduit.

3.3 CONTROL WIRING INSTALLATION

A. Install wiring between VFCs and remote devices and facility's central-control system. Comply
with requirements in Section 260519 "Low Voltage Electrical Power Conductors and Cables."

B. Bundle, train, and support wiring in enclosures.

C. Connect selector switches and other automatic-control devices where applicable.

1. Connect selector switches to bypass only those manual- and automatic-control devices
that have no safety functions when switches are in manual-control position.
2. Connect selector switches with control circuit in both manual and automatic positions for
safety-type control devices such as low- and high-pressure cutouts, high-temperature
cutouts, and motor-overload protectors.

3.4 IDENTIFICATION

A. Identify VFCs, components, and control wiring. Comply with requirements for identification
specified in Section 260553 "Identification for Electrical Systems."
1. Identify field-installed conductors, interconnecting wiring, and components; provide
warning signs.
2. Label each VFC with engraved nameplate.
3. Label each enclosure-mounted control and pilot device.

B. Operating Instructions: Frame printed operating instructions for VFCs, including control
sequences and emergency procedures. Fabricate frame of finished metal, and cover
instructions with clear acrylic plastic. Mount on front of VFC units.

3.5 FIELD QUALITY CONTROL

A. Manufacturer's Field Service: Engage a factory-authorized service representative to test and

inspect components, assemblies, and equipment installations, including connections.

B. Acceptance Testing Preparation:

1. Test insulation resistance for each VFC element, bus, component, connecting supply,
feeder, and control circuit.
2. Test continuity of each circuit.

C. Tests and Inspections:

1. Inspect VFC, wiring, components, connections, and equipment installation. Test and
adjust controllers, components, and equipment.

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2. Test insulation resistance for each VFC element, component, connecting motor supply,
feeder, and control circuits.
3. Test continuity of each circuit.
4. Verify that voltages at VFC locations are within 10 percent of motor nameplate rated
voltages. If outside this range for any motor, notify Architect before starting the motor(s).
5. Test each motor for proper phase rotation.
6. Perform tests according to the Inspection and Test Procedures for Adjustable Speed
Drives stated in NETA Acceptance Testing Specification. Certify compliance with test
parameters.
7. Correct malfunctioning units on-site, where possible, and retest to demonstrate
compliance; otherwise, replace with new units and retest.
8. Test and adjust controls, remote monitoring, and safeties. Replace damaged and
malfunctioning controls and equipment.

D. VFCs will be considered defective if they do not pass tests and inspections.

E. Prepare test and inspection reports, including a certified report that identifies the VFC and
describes scanning results. Include notation of deficiencies detected, remedial action taken,
and observations made after remedial action.

3.6 STARTUP SERVICE

A. Engage a factory-authorized service representative to perform startup service.

1. Complete installation and startup checks according to manufacturer's written instructions.

3.7 ADJUSTING

A. Program microprocessors for required operational sequences, status indications, alarms, event
recording, and display features. Clear events memory after final acceptance testing and prior to
Substantial Completion.

B. Set field-adjustable switches, auxiliary relays, time-delay relays, timers, and overload-relay
pickup and trip ranges.

C. Adjust the trip settings of instantaneous-only circuit breakers and thermal-magnetic circuit
breakers with adjustable, instantaneous trip elements. Initially adjust to 6 times the motor
nameplate full-load amperes and attempt to start motors several times, allowing for motor cool-
down between starts. If tripping occurs on motor inrush, adjust settings in increments until
motors start without tripping. Do not exceed 8 times the motor full-load amperes (or 11 times
for NEMA Premium Efficient motors if required). Where these maximum settings do not allow
starting of a motor, notify Architect before increasing settings.

D. Set the taps on reduced-voltage autotransformer controllers.

E. Set field-adjustable circuit-breaker trip ranges

F. Set field-adjustable pressure switches.

3.8 PROTECTION

A. Temporary Heating: Apply temporary heat to maintain temperature according to manufacturer's

written instructions until controllers are ready to be energized and placed into service.

B. Replace VFCs whose interiors have been exposed to water or other liquids prior to Substantial
Completion.

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3.9 DEMONSTRATION

A. Engage a factory-authorized service representative to train Owner's maintenance personnel to

adjust, operate, reprogram, and maintain VFCs.

END OF SECTION 230514

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