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Transcript
General Specification for electrical equipment in large water treatment plants This specification applies to large water treatment plants (200 000 to 1 000 000m3/day, power demand: 5 to 25MVA). Requirements are given for MV switchgear, Ring Main Units, Transformers, LV switchboards, intelligent Motor Centers (multi function Okken), MV Soft Starters, Power Monitoring Equipment, Power Factor Correction, Soft Starters and Variable Speed Drives. (Automatic transfer switches) Last update :2017-05-08 -1- Table of contents: 1. 2. Introduction................................................................................................................................................ 5 General requirements ................................................................................................................................. 5 2.1 Applicable generic standards ............................................................................................................. 5 2.2 Quality and sustainable development ................................................................................................ 6 3. MV switchgear........................................................................................................................................... 7 3.1 General requirements ......................................................................................................................... 7 3.2 Applicable standards .......................................................................................................................... 7 3.3 Rated voltage and short-time withstand current ................................................................................ 7 3.4 Main electrical characteristics ........................................................................................................... 8 3.5 Requirements relative to the design and manufacture of the switchgear .......................................... 9 3.6 Conformity assessment .................................................................................................................... 13 4. Ring Main Unit ........................................................................................................................................ 14 4.1 General requirements ....................................................................................................................... 14 4.2 Applicable standards ........................................................................................................................ 14 4.3 Service conditions ............................................................................................................................ 14 4.4 System Parameters ........................................................................................................................... 15 4.5 Function requirements ..................................................................................................................... 15 4.6 Configuration requirements ............................................................................................................. 15 4.7 Requirements regarding the design and development of switchgear .............................................. 16 4.8 Conformity assessment .................................................................................................................... 21 5. Transformers (cast resin) ......................................................................................................................... 22 5.1 Applicable standards ........................................................................................................................ 22 5.2 Magnetic core .................................................................................................................................. 22 5.3 LV windings .................................................................................................................................... 22 5.4 MV windings ................................................................................................................................... 22 5.5 Accessories and standard equipment ............................................................................................... 24 5.6 Thermal protection........................................................................................................................... 24 5.7 Metal enclosure ................................................................................................................................ 24 5.8 Electrical protection ......................................................................................................................... 25 5.9 Electrical tests .................................................................................................................................. 25 5.10 Climatic and Environmental classifications .................................................................................... 27 5.11 Fire behaviour classification ............................................................................................................ 27 5.12 Technical Data ................................................................................................................................. 27 6. LV Switchboards ..................................................................................................................................... 29 6.1 General requirements ....................................................................................................................... 29 6.2 Applicable standards ........................................................................................................................ 29 6.3 Manufacturer Requirements ............................................................................................................ 29 6.4 Switchboard Assembler requirements ............................................................................................. 29 6.5 Switchboard design requirements .................................................................................................... 29 6.6 Exploitation and maintenance.......................................................................................................... 30 6.7 Project Specifications ...................................................................................................................... 30 7. Intelligent Motor Control Centre ............................................................................................................. 32 7.1 General requirements ....................................................................................................................... 32 7.2 Applicable standards ........................................................................................................................ 32 7.3 Switchboard Manufacturer .............................................................................................................. 32 7.4 Features and certificates .................................................................................................................. 33 7.5 Electrical and mechanical characteristics ........................................................................................ 33 7.6 Switchboard structure ...................................................................................................................... 34 7.7 Derating ........................................................................................................................................... 34 Last update :2017-05-08 -2- 7.8 Requirements for the Intelligent Motor Protection Relay (IMPR) .................................................. 35 7.9 IMPR for non-critical motors .......................................................................................................... 35 7.10 IMPR for critical motors .................................................................................................................. 36 8. MV Soft Starters ...................................................................................................................................... 40 8.1 General requirements ....................................................................................................................... 40 8.2 Applicable standards ........................................................................................................................ 40 8.3 Line fuses ......................................................................................................................................... 41 8.4 Motor Controller Assembly ............................................................................................................. 41 8.5 Ratings ............................................................................................................................................. 42 8.6 Components ..................................................................................................................................... 43 8.7 Power and earth busbar (Motor Control Centre Construction Only) .............................................. 44 8.8 Wiring / Terminations...................................................................................................................... 44 8.9 Motor protection .............................................................................................................................. 44 8.10 Metering ........................................................................................................................................... 45 8.11 Controllers ....................................................................................................................................... 45 8.12 Mechanically latched contactor ....................................................................................................... 51 8.13 Incoming Line sections to MCC ...................................................................................................... 51 8.14 Manufacturing.................................................................................................................................. 52 8.15 Factory finishing .............................................................................................................................. 52 9. Power monitoring equipment .................................................................................................................. 53 9.1 General requirements ....................................................................................................................... 53 9.2 Applicable standards ........................................................................................................................ 53 9.3 Technical characteristics .................................................................................................................. 54 9.4 Commissioning the system and training .......................................................................................... 54 9.5 Medium or Low Voltage Metering Units ........................................................................................ 54 9.6 High performance metering unit ...................................................................................................... 55 9.7 Medium Voltage protection relays .................................................................................................. 60 9.8 Low Voltage protection unit ............................................................................................................ 62 9.9 Ethernet server ................................................................................................................................. 62 9.10 Electrical data for the user ............................................................................................................... 64 9.11 MV, LV, and MCC equipment ........................................................................................................ 65 9.12 e-Services ......................................................................................................................................... 66 10. MV Power Factor Correction .............................................................................................................. 67 10.1 General requirements ....................................................................................................................... 67 10.2 Applicable standards ........................................................................................................................ 67 10.3 Technical characteristics .................................................................................................................. 67 10.4 Electrical characteristics .................................................................................................................. 67 10.5 Operating conditions ........................................................................................................................ 70 10.6 Factory tests ..................................................................................................................................... 70 10.7 Documents ....................................................................................................................................... 70 11. Soft starters .......................................................................................................................................... 71 11.1 Introduction...................................................................................................................................... 71 11.2 Applicable specific standards .......................................................................................................... 71 11.3 Description of the product ............................................................................................................... 71 11.4 Environment .................................................................................................................................... 72 11.5 Electrical characteristics .................................................................................................................. 72 11.6 Protection functions ......................................................................................................................... 73 11.7 Communication................................................................................................................................ 73 11.8 Main functions ................................................................................................................................. 73 11.9 Supervision ...................................................................................................................................... 74 12. Variable speed drives ........................................................................................................................... 75 Last update :2017-05-08 -3- 12.1 General requirements ....................................................................................................................... 75 12.2 Applicable specific standards .......................................................................................................... 75 12.3 Requirements for the Manufacturer ................................................................................................. 76 12.4 Basic requirements for the AC Drives ............................................................................................. 76 12.5 AC Drive performance .................................................................................................................... 77 12.6 Enclosure and mounting .................................................................................................................. 79 12.7 User interface ................................................................................................................................... 79 12.8 Communications .............................................................................................................................. 81 12.9 Programming terminal ..................................................................................................................... 82 12.10 Application programming ............................................................................................................ 83 12.11 PC Tools ...................................................................................................................................... 84 12.12 Software features ......................................................................................................................... 84 12.13 Documents ................................................................................................................................... 86 13. Automatic transfer switches ................................................................................................................ 87 13.1 General requirements ....................................................................................................................... 87 13.2 Applicable standards ........................................................................................................................ 87 13.3 Electrical characteristics .................................................................................................................. 87 13.4 Construction, operation and environment........................................................................................ 87 13.5 Endurance ........................................................................................................................................ 88 13.6 Auxiliaries........................................................................................................................................ 88 Last update :2017-05-08 -4- 1. Introduction This specification is applicable to large water treatment plants. Characteristics: Number of motors (typical) Power demand (MVA) 700 5 - 25 Specificity of water installations are taken into account. Requirements are given in this document for: - MV switchgear, - Ring Main Unit, - Transformers, - LV switchboards, - intelligent Motor Control Centers (multi function Okken), - MV Soft Starters - Power Monitoring Equipment, - Power Factor Correction, - Soft Starters, - Variable Speed Drives, 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 Last update :2017-05-08 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 -5- 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 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). Last update :2017-05-08 -6- 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 Last update :2017-05-08 -7- 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. 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 Last update :2017-05-08 -8- 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. Last update :2017-05-08 -9- 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. Last update :2017-05-08 - 10 - Busbars 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. Last update :2017-05-08 - 11 - 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. 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, Last update :2017-05-08 - 12 - - 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. 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. Last update :2017-05-08 - 13 - 4. Ring Main Unit 4.1 General requirements These specifications apply to factory-built, RMU type, metal-enclosed indoor switchgears. The equipment to be supplied shall come in the form of a compact switchboard and shall meet the following requirements : - Easy to install - Safe and easy to operate - Compact - Low maintenance The supplier shall be capable of proving that he has a broad experience in the area of MV switchgears and shall provide proof that he has already supplied equipment of the equivalent type and brand which has been in operation for at least three years. Upon the request, units shall be available either in standard compact range or in extensible versions. Details for extensibility design shall be provided including the basic principle and operations. Extensibility shall be easily possible on site by the customer, without SF6 handling , without any particular floor preparation and specific tools. When assembled, extensible units shall respect integral insulation and insensitivity to environment. 4.2 Applicable standards In order to be accepted, the switchgear shall comply with the requirements stated in the latest editions of the following recommendations, standard and specifications : Standard IEC 60137 IEC 60265-1 IEC 61958 IEC 62271-100 IEC 62271-102 IEC 62271-105 IEC 62271-200 DIN 42600 Title Insulated bushings for alternating voltages above 1000 V High-voltage switches - Part 1: Switches for rated voltages above 1 kV and less than 52 kV High-voltage prefabricated switchgear and controlgear assemblies - Voltage presence indicating systems 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 Instrument transformers for 50 Hz, Um 0,6 to 52 kV 4.3 Service conditions Maximum altitude Maximum air temperature Minimum air temperature 1000 meters above sea level + 40 ° C - 25 ° C Manufacturer shall declare whether RMU is able to operate in air temperature higher than + 40 °C and if current derating is necessary. The RMU shall be capable of: - operation in electrically exposed locations, - exposition to high relative humidity and ambient air pollution, - installation in either concrete indoor substations or in compact metal substations and kiosks with an IP54 rating. Last update :2017-05-08 - 14 - Manufacturer shall give all details regarding its solution for free-standing outdoor installations when requested. 4.4 System Parameters Network Rated Voltage System Frequency Lightning Impulse withstand Voltage Phase to phase, phase to earth Across the isolating distance Power Frequency withstand voltage Rated Normal Current Line switch Transformer feeder Branch circuit breaker feeder Rated Short time current withstand ( 1 sec ) Rated Short circuit making capacity of line switches and earthing switches Number of operations at rated short circuit current on line switches, earthing switches and CB Rated load interrupting current Line switch Rated cable charging interrupting current Line switch Rated magnetizing interrupting current Line switch Number of mechanical operations Line switches and earthing switches Switch-fuse combination Circuit breaker Number of electrical operations at full loop current Number of operations at rated short circuit current on circuit breaker Three phase - Three wires 12 - 17,5 - 24 kV 50/60 Hz 95 - 125 kV 110 - 145 kV 28 - 38 - 50 kV rms - 1 min. 400/630 A 200 A 630 A 12,5 - 16 - 20 - 25 kA 31,5 - 40 - 50 - 62,5 kA peak at Rated Voltage 5 closing operations 400 - 630 A rms 30 A 16 A 1000 O/C 1000 O/C 2000 O/C 100 O/C 3 breaking operations 4.5 Function requirements The following functions shall be available : - Line switch (Line) - Branch circuit breaker feeder (BranchCB) - Transformer protection feeder by Circuit Breaker (TransfoCB) - Transformer protection feeder by fuse (Fuse) - Bus isolation by load break switch - Bus isolation by circuit breaker - Direct cable connection to busbars - MV Metering 4.6 Configuration requirements The following configurations shall be available : Standard compact range : Last update :2017-05-08 - 15 - (FU: Functional Unit) 1 FU: Line - BranchCB - TransfoCB 2 FU: Line/Line - Branch CB/Line - TransfoCB/Line - Fuse/Line 3 FU: Line/Line/Line - Line/BranchCB/Line - Line/TransfoCB/Line - Line/Fuse/Line 4 FU: Line/Line/Line/Line - Line/Line/BranchCB/Line – Line/Line/TransfoCB/Line Line/Line/Fuse/Line - Branch CB/Line/Branch CB/Line – TransfoCB/Line/TransfoCB/Line Fuse/Line/Fuse/Line Extensible range : 1 FU: Line - BranchCB - TransfoCB - Fuse - Bus sectionnalizer by load break switch Bus sectionnalizer by load break switch - Direct cable connection to bus bars - MV Metering 2 FU: Line/Line 3 FU: Line/Line/Line - Line/BranchCB/Line - Line/TransfoCB/Line - Line/Fuse/Line 4 FU: Line/Line/Line/Line - Line/Line/BranchCB/Line – Line/Line/TransfoCB/Line Line/Line/Fuse/Line - BranchCB/Line/Branch CB/Line – TransfoCB/Line/TransfoCB/Line Fuse/Line/Fuse/Line 4.7 Requirements regarding the design and development of switchgear Introduction The RMU shall meet the criteria for compact, metal-enclosed indoor switchgear in accordance with IEC 62271-200 : - Switchgear classification : PM class - Loss of service continuity class : LSC2A It shall include, within the same metal enclosure, the number of MV functional units required for connection, power supply and protection of transformers, i.e. - 2 or 3 "network" switch disconnectors, 1 or 2 "transformer protection" feeders, earthing switches. Disconnectors and circuit-breakers shall be maintenance-free, with breaking in low pressure SF6 gas. The position of the power contacts and earthing contacts shall be clearly visible on the front of the switchboard. The position indicator shall have 3 positions, open-disconnected, closed and earthed, and will be constructed in such a way that natural interlocking prevents unauthorized operations. The switches shall be fully mounted and inspected in the factory. Switchboards The switchgear and busbar shall all be contained in a stainless steel enclosure filled with SF6 at 0.2 bar (200 hPa) relative pressure to ensure the insulation and breaking functions. Sealed for life, the enclosure shall meet the "sealed pressure system" criterion in compliance with IEC 62271-100 standard. In addition, manufacturer shall confirm that maximum leakage rate is lower than 0,1 % / year. It shall provide full insulation, making the switchgear insensitive to the environment (temporary flooding, high humidity...), with an IPX7 protection index. Thus assembled, the active parts of the switchgear shall be maintenance-free and the switchboard shall be low-maintenance. The switchboards shall have an IP3X protection index. Last update :2017-05-08 - 16 - The tank shall be made of at least 2 mm AISI 304 unpainted stainless steel and be able to withstand an accidental internal overpressure of at least 3 bars (3000 hPA) The switchboards shall be suitable for mounting on a trench, utilities space or base. Each switchboard shall be identified by an appropriately sized label which clearly indicates the functional units and their electrical characteristics. The switchgear and switchboards shall be designed so that the position of the different devices is visible to the operator on the front of the switchboard and operations are visible as well. In accordance with the standards in effect, the switchboards shall be designed so as to prevent access to all live parts during operation without the use of tools. Dielectric medium SF6 gas is the preferred dielectric medium for MV RMUs. Oil filled switchgear will not be considered. It is preferable to fit an absorption material in the tank to absorb the moisture from the SF6 gas and to regenerate the SF6 gas following arc interruption. Earthing of metallic parts There shall be continuity between the metallic parts of the switchboard and cables so that there is no electric field pattern in the surrounding air, thereby ensuring the safety of people. The substation frames shall be connected to the main earth busbar without dismantling any busbars. Earthing of the main circuit The earthing switch can only be operated when the switch is open. The earthing switch shall be fitted with its own operating mechanism and manual closing shall be driven by a fast-acting mechanism, independent of operator action. The moving contacts of the earthing switch shall be visible in the closed position through transparent covers. Mechanical interlocking systems shall prevent access to the operating shaft to avoid all operator errors such as closing the earthing switch when the switch is closed. "Network" disconnectors The switches shall be of the "increased operating frequency" in accordance with IEC 60265-1 § 3.104 standard. Manual opening and closing will be driven by a fast-acting mechanism, independent of operator action. Each switch can be fitted with an electrical operating mechanism in a specially reserved location, without any modification of the operating mechanism and without de-energizing the switchboard. The switch and earthing switch operating mechanism shall have a mechanical endurance of at least 1000 operations. Last update :2017-05-08 - 17 - "Branch circuit-breaker" feeders An operating mechanism can be used to manually close the circuit breaker and charge the mechanism in a single movement. It shall be fitted with a local system for manual tripping by an integrated push button. There will be no automatic re-closing. The circuit breaker shall be associated with an integrated protection unit that will operate without any auxiliary power supply and shall include: - Three toroid transformers incorporated in the transformer tee-off bushings, - An electronic relay, - A low energy release, - A "fast-on" test receptacle for protection testing (with or without CB tripping) The protection system will ensure circuit breaker tripping as of a minimum operating current (Is) which is the rated current of the underground network to be protected and may be set to following ratings from 8 to 600 A Electrical characteristics of the circuit-breaker function shall be at least greater than following values - rated current: 630 A - short-circuit breaking capacity: 25 kA / 12kV 21 kA / 17,5 kV 20 kA / 24 kV "Transformer protection" feeders by circuit-breakers An operating mechanism can be used to manually close the circuit breaker and charge the mechanism in a single movement. It shall be fitted with a local system for manual tripping by an integrated push button. There will be no automatic reclosing. The circuit breaker shall be associated with an integrated protection unit that will operate without any auxiliary power supply and shall include: - Three toroid transformers incorporated in the transformer tee-off bushings, - An electronic relay, - A low energy release, - A "fast-on" test receptacle for protection testing (with or without CB tripping) The protection system will ensure circuit breaker tripping as of a minimum operating current (Is) which is the rated current of the transformer being protected and may be set to following ratings from 8 to 200A. Phase to phase protection shall be able to work from 1.2 times the minimum operating current Is. As an option, ground fault protection shall also be provided. Electrical characteristics of the circuit-breaker function shall be at least greater than following values - rated current: 200A - short-circuit breaking capacity: 25 kA / 12kV 21 kA / 17,5 kV 20 kA / 24 kV Last update :2017-05-08 - 18 - "Transformer protection" feeders by fuse-switches combination An operating mechanism can be used to manually close the switch and charge the mechanism in a single movement. It shall be fitted with a local system for manual tripping by an integrated push button. Fuses shall be installed in 3 individual sealed chambers metalized on the outside and disconnectable. They shall be mounted in series with the switch with the following operating mode : blowing of a fuse releases a striker pin which causes three-phase opening of the switch and prevents re-closing. MV Metering MV Metering shall be carried out by a factory assembled type tested air insulated cubicle. This unit shall be totally closed, without any ventilation. A 16kA 1s internal arc withstand is required. Connection with adjacent cells will be direct through bus bar and MV cables shall not be used. Voltage Transformers (VTs) and Current Transformers (CTs) from the manufacturer or type DIN 42600 shall be accepted. VTs could be plugged upstream or downstream of CTs and a fuse protection shall be possible. The following configuration shall be available : - 2 VTs phase-phase, 2 VTs phase-earth, 3 VTs phase-earth - 2 or 3 CTs RMU bushings and Cable terminations It is preferable to have all bushings accessible from the front of the RMU. Bushing along the sides or the rear of the RMU are not acceptable. The bushing shall be conveniently located for working with cables specified, and allow for the termination of these cables for the 400 A plug-in or 630 A M16 bolted connectors on line switch, and for the 200 A plugin connectors on transformer protection feeder. A non ferromagnetic cable clamp arrangement shall be provided for all network cables terminated on the RMU. Padlocking facilities Circuit breakers, fuse-switches combination, switches and earthing switches can be locked in the open or closed position by 1 to 3 locks. Voltage indicators and phase comparators Each function shall be equipped with a voltage indicator box on the front of the device to indicate whether or not there is voltage in the cables. The capacitive dividers will supply low voltage power to the lamps. Three inlets can be used to check the synchronisation of phases. Fault Passage Indicators Load break switch functions shall be equipped with a fault passage indicator (FPI), in order to detect and localise easily the faulty part of the network. The latter FPI shall segregate the short circuit and earth faults, shall indicate permanently the phase-perphase load currents, and shall easily actuate a remote indication lamp. Last update :2017-05-08 - 19 - The FPI fault detection core function shall be self-powered without help external power supply or built-in batteries. Safety of people Any accidental overpressure inside the sealed chamber will be limited by the opening of a pressure limiting device in the lower part of the enclosure. Gas will be released to the rear of the switchboard away from the operator. Manufacturer shall provide type test report to prove compliance with IEC 62271-200 Annex A, Internal arc classification class AFL with 20kA 1s for the SF6 enclosure. Operating lever An anti-reflex mechanism on the operating lever shall prevent any attempts to reopen immediately after closing of the switch or earthing switch. All manual operations will be carried out on the front of the switchboard. The effort exerted on the lever by the operator shall not be more than 250 N for the switch and for the circuit breaker. Front plate The front plate shall have an IP3X degree of protection. The front shall include a clear mimic diagram which indicates the different functions. The position indicators shall give a true reflection of the position of the main contacts. They shall be clearly visible to the operator. The lever operating direction shall be clearly indicated in the mimic diagram. The manufacturer's plate shall include the switchboard's main electrical characteristics. Cable insulation testing It shall be possible to test the core or the sheath insulation of the network cables while the RMU remains energized at rated voltage. It shall be preferable to carry out the phase by phase testing through a built-in facility without necessity to have an access to cable compartment. The maximum test voltage shall be less than 42 kV DC for 10 minutes. Remote control of the RMU A limited number of applications for remote operation of the RMU are required. Remote operation of the RMU line switches shall be possible using motors fitted to the operating mechanism. Fuse-switches combination does not need to be motorised. It shall be possible to fit the motors either directly in manufacturing plant or on site when required. Installation on site shall be possible with the RMU fully energised and manufacturer shall provide detailed instructions for installation to the control mechanism. Auxiliary contacts for remote indication of switch status are also required. The fitting of the motors to the mechanism shall not in any way impede or interfere with the manual operation of the switches. An auxiliary contact to prevent motorised operation of the mechanism while the operating handle is inserted into the operating point shall also be provided The tenderer may wish to advise of options and cost for remote control units of the RMU and MV network control system. Last update :2017-05-08 - 20 - Dimensions The overall dimensions shall not be greater than the followings (in mm) : Width Compact standard range 2 functions 3 functions 4 functions Extensible range 3 functions extensible on right side 4 functions extensible on right side 1 function double-ext. module 850 1200 1650 Height Depth 1150 720 1220 1650 540 Finishing The device shall be fully designed for use in a hot, humid atmosphere and shall be low-maintenance. Manufacturer shall provide type test report to prove salt fog withstand for at least 200 hours on operating mechanism. All metallic parts shall have rust protection. Two lifting rings shall be installed on the top of the switchboards for handling. 4.8 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 withstand test, Temperature-rise test, Short-time withstand current test, Mechanical operation test, Checking of degree of protection, Switch, circuit breaker, earthing switch making capacity, Switch, circuit breaker breaking capacity Internal arc withstand, Checking of partial discharge on complete unit 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, - Measurement of closing and opening speeds, - Measurement of operating torque, - Checking of filling pressure, Last update :2017-05-08 - 21 - - Checking of gas-tightness, Checking of partial discharges on individual components, Dielectric testing and main circuit resistance measurement. 5. 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%. 5.1 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 5.2 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. 5.3 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. 5.4 MV windings Last update :2017-05-08 - 22 - 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. 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. Last update :2017-05-08 - 23 - 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. 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. 5.5 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. 5.6 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. 5.7 Metal enclosure As an option, 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 as an option, 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. Last update :2017-05-08 - 24 - - 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). 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 5.8 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. 5.9 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. Last update :2017-05-08 - 25 - For measurement of the partial discharges, the acceptance criterion shall be: - partial discharges less than or equal to 10 pC at 1.30 Un. Last update :2017-05-08 - 26 - 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), 5.10 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. 5.11 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. 5.12 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 :2017-05-08 kVA Hz kV kV kV kV % V V kV kV - 27 - 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 :2017-05-08 mm mm mm kg V - 28 - 6. LV Switchboards 6.1 General requirements This document describes the general rules to guarantee the maximum level of quality and performances for a Low Voltage Switchboard. To guarantee the installation consistency during the switchboard life cycle, the installation systems and the devices shall be supplied by the same manufacturer. 6.2 Applicable standards Standard IEC 60439-1 IEC 62208 Title Low-voltage switchgear and controlgear assemblies; part 1: type-tested and partially type-tested assemblies Empty enclosures for low-voltage switchgear and controlgear assemblies. General requirements 6.3 Manufacturer Requirements In order to comply to IEC 60439-1, the Switchboard shall pass successfully seven tests in the most critical configurations: 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 No. 7 - degree of protection The Switchboard supplier shall provide a copy of the first page of theses seven certificates. 6.4 Switchboard Assembler requirements To complete the conformity to the standard, the switchboard assembler shall perform three others tests after the complete assembly. Hereafter are the 3 type tests performed by the assembler : No. 8 - general inspection No. 9 - insulation / dielectric test No. 10 - protection measures. A copy of these routines tests fully completed by the assembler shall be present within or close to the switchboard on its exploitation site. 6.5 Switchboard design requirements To guarantee the thermal withstand and announced performances, as well as to distinguish easily inside the assembly the function of each switchgear or control gear, all devices must be installed onto mounting plates specifically designed for each of them. For safety reasons, when the switchboard is power on with door opened, all busbars have to be covered by barriers, onto the whole perimeter of the busbar zone. To achieve this requirement, the switchboard specification must comply with the partitioning rules at the minimum level of form 2. Last update :2017-05-08 - 29 - Vertical distribution system must be designed to allow connection by front access only (no nuts) and all along the height. To supply electricity inside the assembly, install distribution blocks using spring terminal technology (IPxxB compliant) must be settled in upstream of modular devices. In order to facilitate the access for maintenance, the assembly’s covering panels must be dismountable on all surfaces for any IP degree. 6.6 Exploitation and maintenance Due to the continual evolution of the electrical needs for buildings, facilities or infrastructures, the distribution switchboards shall be made to follow these evolutions : - The switchboard offer shall include dedicated components affording the adjunction of one or several enclosures & cubicles on the exploitation site, In order to facilitate the current maintenance, e.g. infra red measurement, the devices zone has to be accessible in one operation, The final customer shall have the possibility to obtain spare parts ten years after the commercialization ending of the switchboard offer, For maintenance needs, the cubicle extraction and reintegration in the switchboard environment shall be made without any operation onto the adjacent cubicles. 6.7 Project Specifications Besides the specifications detailed above, hereunder are the environmental, mechanical and electrical characteristics to fill in to achieve the full definition of a complete assembly. Environmental Altitude……………………… < 2000m Ambient temperature……….. 25°C Climatic ambience………….. T2 Other : Value = Relative humidity…………… 80% (35°C) Other : Value = Last update :2017-05-08 Other 35°C : Value = 45°C 55°C - 30 - Electrical Type of Voltage…………………… AC DC Frequency…………………………. 50 Hz 60 Hz Nominal Voltage rate……………… 220V 400V other : Value = Nominal Current rate……………… Value = A Nominal Apparent Power…………. Value = VA Short circuit withstand…………….. Value = kA Earth Schematics………………. T.T I.T T.N.C T.N.S Protection degree (extern)………… IP30 IP31 IP43 IP55 Protection degree (intern)…………. A B C D Protection degree against impact… IK07 IK08 IK10 Level of partitioning…………….. Form 1 Form 2a Form 3a Form 4a Form 2b Form 3b Form 4b Mechanical Envelop colour……………………. Value = RAL Handle locking type………………. Last update :2017-05-08 Key n° 405 Other : Value = - 31 - 7. Intelligent Motor Control Centre 7.1 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 integrating intelligent motor protection relays (IMPR) or intelligent protection devices (IPD) inside the MCC switchboard. The iMCC shall also bundle the bus communication with the most common protocols found in industrial networks (different possible options: Modbus SL / Modbus TCP / 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 be a complete range, which provides 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. 7.2 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 IEC 61641 AS 3439-1 EDF HN 20-E-53 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 Enclosed low-voltage switchgear and controlgear assemblies – Guide for testing under conditions of arcing due to internal fault Low-voltage switchgear and controlgear assemblies - Type- tested and partially type-tested assemblies Spécification d'essai de tenue aux séismes des matériels électriques classés de sûreté des centrales nucléaires - Essai bi-axial par accélérogrammes 7.3 Switchboard Manufacturer The switchboard manufacturer could be the equipment plant of the iMCC original designer or a panel builder with a formal license from the iMCC original designer. All switchgear used in the switchboard shall be of the same manufacturer to allow better interoperability and installation. Last update :2017-05-08 - 32 - 7.4 Features and certificates Type tests The switchboard type-test certificates shall be originated by a worldwide known third-party certification organization such as ASEFA, or KEMA. The supplier shall be able to provide several certificates (not only one) as an option during the project. These certificates shall either reflect the switchboard characteristics or allow understanding on how these characteristics are reached. In this second case, the manufacturer shall be able to show design tables (such as derating or co-ordination tables) formally originated from the iMCC original designer. The selected switchgear and controlgear brands shall be equal to the ones mentioned in the type tests reports of the equipment. Internal arc features The switchboard shall be designed to minimize the risks of occurrence of an internal arc, and whenever such an arc appears it shall prevent its propagation and its effect on operators and material/equipment surrounding the switchboard. It shall be in conformance with the requirements of the IEC 61641 technical report and of AS 3439-1. EMC features The switchboard shall meet the EMC conformity requirements. It shall be designed for use in a type A environment in accordance with IEC 60439-1. In particular, the design of the functional units shall ensure that the sensitive circuits are isolated from the power conductors. Seismic features The switchboard shall have the capability to withstand seismic conditions. When the switchboard is to be used in a seismic area, the manufacturer shall determine the switchboard configuration according to seismic information provided by customer, which is appropriate to the stresses involved. The seismic test shall be done in compliance with the UBC (Uniform Building Code) and CBC (California Building Code) regulations. The manufacturer shall be able to provide information on seismic zone (1 to 4) and installation level which the equipment is conforming to. The test certificates shall be supplied with the switchboard and refer to the relevant standard (IEC, IBC or EDF HN 20-E-53). Corrosive atmosphere features The switchboard shall have the ability to withstand corrosion due to Sulphur Dioxide (SO2) and Hydrogen Sulphide (H2S) with necessary adaptations recommended by the iMCC original designer. Inside the equipment, the appropriate coating shall be done on conductors (busbars, connections) and metal elements (mechanisms, frames, casing). Also, the electrical and electronic equipment shall show a compliance class relevant to the above pollutants. The manufacturer shall consider the power circuits’ conductivity depending on the types of coatings used on these circuits. As an option, the manufacturer shall be able to show the iMCC original designer specifications regarding the above-mentioned facts. 7.5 Electrical and mechanical characteristics - Rated insulation voltage: Rated operational voltage: Rated current of main busbar: Rated current of distribution busbar: Last update :2017-05-08 1000 Vac up to 690 Vac up to 6300A up to 4000A - 33 - - Short current withstand strength: Internal arc withstand (switchboard and column) Internal arc withstand (functional unit) Different available options: - Form: - IP: - Cable Entry: - Access: up to 150 kA 1s 100 kA 0.3 s 80 kA 0.3 s Form 3b/4 IP 31/41/54 Top / bottom Front / rear 7.6 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) To ease operation and maintenance, functional units shall be full withdrawable (WWW) for critical motor starters. For non-critical motor starters, disconnectable (WFD) FUs are acceptable. For distribution feeders, full withdrawable or plug-in type functional units could be accepted. It is essential to install the motor starter FU and distribution feeder FU in one column. To facilitate upgrading, all the functional units with same size (up to 630A) shall be interchangeable. There shall be clear position indicators of the drawer, which indicate the connected, test and disconnected position. The drawer shall provide an effective mechanical latch to prevent incorrect operation to avoid unexpected position changing from one position to another. The drawers shall have the feasibility to be locked by padlock to prevent unauthorized insertion/withdrawal or OPEN / CLOSE operation. In the case that two drawers are of the same dimensions there shall be, as an option, a mechanical mean to prevent unwanted interchangeability of these drawers. Software-only means shall not be accepted. The system used to connect between the functional units and the distribution busbar shall not cause any wear or tear on the distribution busbar during plugging-in / drawing out. The size of drawers (full withdrawable FU) shall be optimised to achieve a high stacking density of the switchboard. The switchboard shall have the capability to accommodate 24 drawers of 9kW with bus communication. 7.7 Derating To ensure that all components work in appropriate conditions, the influence of the 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 derating table of starters, formally originated from the iMCC original manufacturer showing the current value Last update :2017-05-08 - 34 - allowed for the dedicated components under a certain combination of ambient temperature, IP degree and voltage. 7.8 Requirements for the Intelligent Motor Protection Relay (IMPR) IMPR supplier The supplier shall have a local representative office with qualified support staff to provide training, technical support and service. Communication The IMPR shall provide the communication port 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 IMPR shall embed the relevant network protocol in built-in (native) mode. Configuration The IMPR supplier shall provide a user-friendly software running in a Windows environment to ease the IMPR on-relay 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. 7.9 IMPR for non-critical motors It is acceptable to use an intelligent motor protection device, including circuit breaker, contactor sensing and processing unit in a single component. However, all the IMPR used in the iMCC shall be from the same manufacturer. Protection The IMPR shall provide the following protections and alarm settings: Thermal overload trip, with selectable tripping class 5, 10, 15, 20, 25,30 Over current trip Under current trip Jam trip Phase imbalance trip Long start trip Internal fault trip Measuring The IMPR shall provide measurement on motor current, including: 3 phase current Average current Last update :2017-05-08 - 35 - Thermal capacity Phase imbalance Monitoring The IMPR shall provide monitoring on motor status, including: Starting count Running hours Fault count and identification Last 5 faults history log 7.10 IMPR for critical motors Protection For critical motors, the IMPR shall provide additional protection on the following faults with alarm setting: Current phase imbalance Current phase loss Current phase reversal Ground current Voltage phase imbalance Voltage phase loss Voltage phase reversal Under voltage Over voltage Under power Overpower Under power factor Over power factor IMPR shall support direct motor thermal protection by supporting temperature sensor (PTC Binary or PTC Analogue or NTC Analogue) input. IMPR shall provide “Rapid cycle lockout” mechanism to prevent inadequate motor start. IMPR shall support “Voltage load shedding” to set up motor re-starting sequence when power voltage is unstable. The thermal overload trip curve shall be selectable between inverse (I²t) or definite time (I;t) curve. For variable speed drives, auxiliary fan cooling application shall also be proposed according to specifications from the iMCC original designer. It shall include Ground Fault Protection internally, and it shall be possible to use an external toroid CT to do it, without any additional module or device. Metering The IMPR shall provide the following measurements, statistics and diagnostic functions to implement different applications and carry out commissioning and maintenance. Measurement Line current Last update :2017-05-08 - 36 - Average line current Current phase imbalance Ground fault current Thermal capacity level Motor internal temperature (sensor input) Frequency Line-to-Line voltage Line voltage imbalance Active power Reactive power Active power consumption Reactive power consumption Statistics Protection fault counts Protection warning counts Diagnostic fault counts Motor control function counts Fault history Diagnostics Internal watchdog results Controller internal temperature Temperature sensor connections Current connections Voltage connections Control commands (start, stop, run, check back and stop check back) Control configuration checksum Communication loss Motor States Operating time Motor starts per hour Maximum current of last start Last start time Time to trip Time to reset The manufacturer shall be able to propose at least one solution with direct current sensing (without current transformer) up to 100 A. For motors bigger than 100 A, external current transformers shall be provided. Monitoring The IMPR shall provide the monitoring and diagnostic functions of the following: Diagnostic Run command check Stop command check Run check back Stop check back Last update :2017-05-08 - 37 - Wiring / configuration faults PTC connection CT reversal Voltage phase reversal Current phase reversal Voltage phase loss Phase configuration Internal faults Stack overflow Watchdog ROM checksum EEROM CPU Internal Temperature Motor temperature sensor PTC Binary Thermal overload Definite Inverse Thermal Current Long Start Jam Current Phase Imbalance Current Phase Loss Over current Undercurrent Internal Ground Current External Ground Current Voltage Over voltage Under voltage Voltage phase Imbalance Power Under power Overpower Under Power Factor Over Power Factor Operating modes IMPR shall support the following motor operating modes: DOL (Independent) Star-Delta (Two steps) Two directions (Reverse) Two-speed Last update :2017-05-08 - 38 - Custom Mode (via programming) Programming The IMPR shall provide a “Custom mode”, allowing control logic customised by the end user. Last update :2017-05-08 - 39 - 8. MV Soft Starters 8.1 General requirements The Contractor shall furnish and install the medium voltage controllers as specified herein and as shown on the contract drawings. Medium voltage motor control equipment shall be compatible with the medium voltage primary equipment. The manufacturer of this equipment shall be a company specializing in medium voltage metal-enclosed motor controller with at least five years documented experience. The manufacturer of the motor controller shall be the same as the manufacturer of the circuit breaker switchboard. The manufacturer of this equipment shall have produced similar electrical equipment for a minimum period of five (5) years. When requested by the Engineer, an acceptable list of installations with similar equipment shall be provided demonstrating compliance with this requirement. Certificates shall be available as an option. Certificates issued/supported by independent testing laboratories are preferred. Components installed within the assembly shall be type tested in accordance with the applicable IEC standards. Certificates obtained from the component Manufacturers shall be made available at the request of the Principal. 8.2 Applicable standards Medium voltage controllers shall be designed, manufactured, assembled and tested in accordance with the following standards: Standard IEC 60044-1 IEC 60044-2 IEC 60044-8 IEC 60255 IEC 60282-1 IEC 60470 IEC 60694 IEC 61958 IEC 62271-102 IEC 62271-200 IBC 2000 NEMA ICS 31993 (R2000) Part 1 & 2 UL 347 EEMAC G14-1 ANSI C37.20.7 (2007) Last update :2017-05-08 Title Instrument transformers; Part 1: current transformers Part 2: voltage transformers Part 8: low power current transducers Measurement relay and protection unit High voltage fuses: limiting fuses High voltage alternating current contactors and contactor based motor starter Commons specifications for high-voltage switchgear and controlgear standards High-voltage prefabricated switchgear and controlgear assemblies - Voltage presence indicating systems Alternating current disconnectors and earthing switches Ac metal-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV International Building Code: Structural/Seismic Design Manual Industrial Control and Systems: Medium Voltage Controllers Rated 2001 to 7200 Volts AC UL Standard for Safety, High Voltage Industrial Control Equipment Electrical Equipment Manufacturers Association of Canada: Procedure For Testing The Resistance Of Metal Clad Switchgear Under Conditions Of Arcing Due To An Internal Fault IEEE guide for testing metal-enclosed switchgear rated up to 38 kV for internal arcing faults - 40 - 8.3 Line fuses Current limiting fuses shall be of suitable manufacture to ensure the coordination and the integrity of the system. The blown fuse indicator shall be an "Extended Travel” type with a minimum of 25mm of travel. Fuses shall have a 50,000 Amperes interrupting rating. Fuses shall be non-disconnect type with provisions for removal and replacement from the front of the motor controller. As an option, the Medium Voltage Motor Controllers shall be equipped with an optional Fuselogic blown fuse protection system to automatically open the contactor, when a fuse interrupts. The system shall also prevent single phasing conditions by blocking the closing of the contactor when a fuse is blown or if a fuse is not installed. 8.4 Motor Controller Assembly Controllers to be supplied in modular one-high, one controller per structure construction. Stacked or tiered controllers are not acceptable. The equipment shall be factory-assembled (except for necessary shipping splits) and operationally checked. The width of a standard motor starter shall be 375 mm. The width of an enclosure with an integrated power factor correction capacitor shall be 750 mm. The enclosure rating shall be IP3X as standard, and IP4X as an option. The motor controller shall be of indoor construction with different possibilities: - consist of a single section - be a multiple section line-up - be close coupled to MetalClad Switchgear The medium voltage motor controller assembly shall be partitioned into the following distinct compartments: - Busbar compartment - Low Voltage compartment - Load compartment containing the fuses, contactor, instrument transformers, and customer cable terminations and cable-earthing switch. Disconnector and contactor assemblies, including current limiting fuses, shall be of the component-tocomponent type. There shall be no bolted connections between the contactor finger assembly and the customer load terminals. The equipment shall be designed for front accessibility only to allow installation against a wall. Standard rear access shall be provided. A viewing window shall be provided as standard to permit verification from the rear of the enclosure that an operator is accessing the proper cubicle by ensuring that the appropriate front door is open. Cable entry or exit shall be either bottom, top, or bottom and top. As an option, the enclosure shall be Internal Arc Class as defined in Annex A of IEC 62271-200. As an option, a tunnel shall be provided to divert the hot gasses. The tunnel height shall be 440mm. (Required when ceiling height is 2 meters or less above the top of the equipment, or if top cable entry or exit is not available. In establishing the requirements for the enclosure design, consideration shall be given to such relevant factors as controlled access, tamper resistance, protection from ingress of rodents and insects. Last update :2017-05-08 - 41 - Motor controller shall not require ventilation openings to aid in cooling of the associated components. Flexible power conductors shall interconnect the main contactor with the motor load terminals. Flexible power conductor terminals shall be of the swage 360º radial cold-fused compression type connections. These connections shall be maintenance free, never requiring torque. The motor controller shall be low maintenance designed to reduce the requirement for annual/ periodic maintenance of the equipment. Equipment with scheduled maintenance intervals of one or more years is preferred. A low voltage compartment to accommodate control circuit terminal blocks, control components and metering equipment. The low voltage compartment shall be located at the top of each vertical section. The interior of the Low Voltage compartment shall be painted white. Shipping splits shall be a maximum of 5 sections (1875 mm) to minimize the number of overlapped main bus joints and on site labour. 8.5 Ratings Maximum System Voltage: Power frequency: Optional System voltages available: Main Busbar Capacity available: Altitude: 7.2kV 50/60Hz 2.4 - 3.3 - 4.16 - 6.6kV 630 – 1250 – 2500 – 3150A, continuous. 1000m Medium Voltage Motor Controllers shall have the following ratings with HRC fuses: Rated voltage (kV) Power frequency withstand voltage 50 Hz - 1 min (rms kV) Lightning impulse withstand voltage 1.2/50 µs (kV peak) Rated current (A) Short time withstand current (kA/3 s) (kA/2 s) Disconnector (kA/0.25 s) Equipment (after fuses) (kA/1 s) (kA/30 s) Earthing Switch Fault Close (kA Symmetrical) (kA Peak) Internal arc withstand (Optional) (kA/ 1s) (kA/ 0.5 s) (kA/ 0.25 s) Last update :2017-05-08 7.2 20 60 200 - 400 40 50 50 4.2 – 7.8 1.7 – 3.0 5 14 25 40 50 - 42 - Contactor Rating: Rated current Electrical Endurance Mechanical Endurance (A) (cycles) (cycles) Standard Latched Short Circuit Interrupting (kA rms Sym.) Short Circuit Withstand at Rated Voltage (fused) (kA Symmetrical) (kA Peak) Short time withstand current (kA/1 s) (kA/30 s) Chopping Current (Avg. A rms) Switching Frequency (Ops per hour) Maximum Closing Time (milliseconds) Maximum Opening Time (milliseconds) Efficiency: 200 - 400 250,000 2,500,000 250,000 6.3 50 130 4.0 – 6.0 2.4 0.5 1200/300 latched 100 or less 30 or less 350 or more (delayed) 99.7% through SCRs, 99.97% in bypass mode. 8.6 Components The disconnector shall be a two position, externally and manually operated three-pole device, such that in the open position, it earths and isolates the line side from the load compartment. The switch-operating handle shall be removable. The operating mechanism shall be rugged, simple and shall have provisions for three padlocks in the on or off position. As an option, a changeover contact shall be provided for remote position indication of the disconnector. Mechanical interlocks shall be provided to prevent the opening of the high voltage access door with the noload disconnector closed. To access the medium voltage compartment, the no-load disconnector shall be opened to the earth position. The interlock shall be directly attached to the operating mechanism and shall not rely on long cables and linkages. All interlocks shall not require adjustments over the life of the equipment. This shall be demonstrated by a test of 10 times the industry standard’s maximum. A viewing port shall be installed in the disconnector enclosure to enable visible verification of the blade position. As an option, a LED light with pushbutton operation shall be provided for ease of viewing. As an option, a cable earthing switch shall be provided. The earthing switch shall be used to earth the load cables. It shall be mechanically interlocked with the disconnector and be operated using the same handle. The earthing switch shall have a spring operated, quick make device, capable of making 14kA peak. The cable earthing switch shall be mounted in the load box at the motor lead terminals. The earthing switch shall be a maintenance free device. Fuses shall be of the current limiting type. The blown fuse indicator shall be an "Extended Travel” type with a minimum of 25 mm of travel. Fuses shall have a 50kA interrupting. The fuses shall incorporate special time/current characteristics for motor service allowing proper coordination with the contactor and overload relay for maximum protection. This coordination shall be such that under a low fault condition the interrupting rating and dropout time of the contactor shall be properly coordinated with all possible fuse Last update :2017-05-08 - 43 - sizes to eliminate contactor racing. The power fuses shall be vertically mounted permitting easy inspection and replacement without the need for removing the contactor. As an option, a FuseLogic shunt trip, single phase protection system using DIN style fuses (or equal) shall be provided to automatically open the vacuum contactor when a fuse blows or a fuse is not installed. This is intended for backup protection only to the motor overload relay. The system shall further prevent potential single phasing conditions by blocking the closing of the contactor when a fuse is blown or a fuse has not been installed. (Provide optional changeover contact for trip indication}. The vacuum contactor shall be withdrawable and magnetically held or mechanically latched, rated at 200 or 400 A, with single-break high-pressure type main contacts. The vacuum contactor contact wear shall be easily checked with the use of a “go/no-go” gauge, included with each controller. As an option, a built-in test circuit shall be included within each controller to permit checking the control and pilot circuits, with the medium-voltage de-energized and isolated, and the contactor in its normal position. A viewing window shall be provided to view the contactor status. The contactor shall withdraw on a rail system. When the contactor is lowered it shall disconnect the contactor and when raised, it shall connect the contactor and lock it in position. Accessories: - The controller mounted control power transformer (CPT) shall be 300, 500, 750 or 2000VA, and be 60kV BIL rated. Fuse holder with two primary current limiting fuses. - The controller mounted open delta voltage transformer shall be provided for metering and protection. 8.7 Power and earth busbar (Motor Control Centre Construction Only) When controllers are grouped together in a line-up, the horizontal main busbar shall be located in its own compartment. To allow for ease of maintenance or extension of line-ups, the main busbar shall be front, rear, top, and side accessible. Main power busbars shall be tin-plated copper and braced for 50 kA 2-seconds (40 kA 3 seconds). All busbar shall be braced to withstand maximum let-through current permitted by the current limiting fuses, without damage or deformation. Copper earth busbar shall be continuous and extend from one end of the motor control centre to the other through each vertical section. Minimum size to be 6.35 mm by 50mm. 8.8 Wiring / Terminations Standard control wire shall be 1.5mm2. Current transformer circuits shall use 2.5 mm2 wires. Controllers shall be complete and control wires including terminations for external connections. Phase sequencing shall have proper identification and all wires shall have suitable markings at all terminations. 8.9 Motor protection A microprocessor-based multi-function, motor protective relay shall be provided, which monitors threephase ac current and makes separate trip and alarm decisions based on pre-programmed motor current and temperature conditions. Last update :2017-05-08 - 44 - 8.10 Metering Microprocessor-Based Metering Package A UL Listed solid-state microprocessor-based metering package shall be provided with digital display and optional waveform capture. Wiring for communication to other devices shall be included. Auxiliary Devices Fixed mounted potential transformer, fused type, 3 phase open delta, shall be proposed as an option, for use with the Motor Protection Relay and metering package. 8.11 Controllers The controllers shall be provided by a single manufacturer with a complete product offering of controllers to accommodate induction motors. Composition Each Soft Start, Non Reversing, Induction Motor Controller shall include: - Medium Voltage Compartment: One three-pole non-load break isolating disconnector, Three Current limiting power fuses, One Draw-out three-pole vacuum contactor assembly, One optional Control circuit transformer: 300, 500, 750, or 2000VA, Two optional Control circuit primary current limiting fuses. One set of Electrical and Mechanical interlocks, Three Load terminals. An anti-rotational terminal pad shall have provision for two hole cable lugs, One three phase donut Type Low Power Current Transformer One Zero Sequence CT (2000:1 or 50:5) Two optional sets of thermal sensing optical probes for instant temperature detection placed in which have been determined to have the most significant temperature rise. The probes shall be designed to withstand constraints related to the medium voltage environments. The optical technology shall provide reliable measurements and give the system a long service life. The probes shall be factory-built assemblies comprised of 6 sensors attached to the power circuit, optical connections and a module connector. The connector shall incorporate an optoelectrical conversion unit eliminating any optical connections. - Low-Voltage Compartment Door: One Motor protection relay (MPR), One Microprocessor metering package, Mounting space for any additional low voltage control, protection, or metering device, Components to be directly mounted on door (size of door cut-outs to match size of mounted component). - Low-Voltage Compartment: Two Control relays. One Control circuit secondary fuse. One set of control circuit terminal blocks. Customer terminal blocks with screw compression type connections. Mounting space for any additional low voltage control, protection, or metering device. Last update :2017-05-08 - 45 - - Operator panel: Disconnector operator mechanism, Mechanical open-close indication, Disconnector Viewing Window, Two 22 mm pushbuttons, Two 22 mm indicating lights, One optional elapsed time meter, Optional Key Interlocks: shall be provided for the disconnector operating mechanism. - Soft Starter Module Solid state reduced voltage motor starters shall be complete with the following standard features and adjustments. Motor and Load Protection shall be integral to the starter assembly. Motor protection shall be based upon modelling of the thermal characteristics of the motor as programmed by the user and measured by the starter. All current referenced protection features shall be calculated from the motor nameplate FLA, and automatically adjusted for the Service Factor, NEMA Design, Insulation Class, Line Voltage and Line Frequency as entered by the user. All time based protection features shall be based on a Real Time Clock, remaining active through any power loss. Functions Starter shall provide the following functions: - Thermal Overload shall be provided by the on-board microprocessor control. Basic protection shall be inverse time-current trip curves as defined by NEMA trip curve Classes. The trip curve classes shall be programmable from between Class 5 and Class 30 and the starter shall be UL listed to provide each individual class. As the most important protection feature of a starter, the overload protection shall be based on a Dynamic Thermal Register retained in memory and provide the following features: o Retentive Thermal Memory shall be used to ensure that the Dynamic Thermal Register does not loose track of motor temperature after the power is lost or shut down. Upon reapplication of power, the microprocessor shall be automatically updated as to the motor temperature and adjusted for real time cooling while the power is off. o Dynamic Reset Capacity shall retain a snapshot of the thermal capacity necessary to restart the motor. The starter shall determine these requirements by recording and averaging the previous 3 successful start-ups. After an overload trip has occurred the protection shall prevent resetting until enough cooling time has passed and sufficient motor thermal capacity is available. o True Thermal Modelling shall be a feature of the overload and reset calculations. Once established at setup, the Dynamic Thermal Register shall be biased according to the following input information when available: Cold Stall Time, Hot Stall Time, Stopped Cool Down Time, Running Cool Down Time, and all of the real time information from the Resistance Temperature Detector (RTD) Option if ordered. o Separate Trip Curves shall be provided for Start and Run, allowing a higher level curve to avoid nuisance tripping during acceleration, but dropping to another level for accurate motor protection while at full speed. To maximize flexibility, each trip curve shall be programmable as follows: Basic, using the NEMA Class ranges described above. Locked Rotor programmable between 400 – 800% of FLA, and a trip time from 1 – 30 seconds. Measured Start Capacity (I²t curve area) taken from the previous successful start (only applicable to the Start Curve). Last update :2017-05-08 - 46 - o Overload Alarm shall be provided to warn users of an impending overload trip. The Alarm level shall be programmable between 40 – 95% of the Dynamic Thermal Register value. It shall provide an adjustable delay of 1 – 20 seconds. o Manual or Automatic Reset shall be selectable in programming to provide for automatic reset in unattended remote applications. o Phase Monitoring shall be standard and based on motor current. In order to protect against disconnected motor leads, this feature shall function even if the line voltage remains normal. o Phase Loss shall shut down the starter if current through any leg drops to 20% of unit FLA or less. This protection shall be implemented via hardware and shall be non-adjustable. It shall provide an adjustable trip delay of 1 – 20 seconds. o Phase Imbalance Protection shall be provided with programmable sensitivity to provide both Alarm and Trip points. The sensitivity shall be adjustable for phase-to-phase imbalances of between 5% and 30%. Each point shall provide an adjustable delay of 1 – 20 seconds. o Phase Rotation protection shall be self-learning and field programmable. If phase rotation varies from the initial set pattern, the starter shall trip immediately. If phase rotation is correct, the starter can be re-taught to recognize the new rotation. - Short Circuit Detection with dual mode protection for starting and running operation shall be provided as standard. This protection shall be implemented via hardware and shall be non-adjustable. - In the starting mode the starter shall employ a ¼ second pre-check routine to determine if the load circuit has a fault condition and disable the ramping prior to reaching the Initial Voltage setting. - In the running mode, this feature shall shut down the starter if current through any leg exceeds 10 times unit FLA for 12.5 milliseconds. - Over Current Protection shall be provided separate from the above to be used as a Shear Pin trip. It shall be adjustable at lower levels for protecting mechanical components from undue shock when rapid unexpected load changes occur. - Adjustment level shall be from 100% to 300% of the programmed motor FLA. - A time delay of up to 20 seconds shall avoid nuisance tripping from short duration transients. - Under Current Protection shall alarm the starter on an adjustable condition. This Load Loss sensor shall be programmable from 10% to 90% of the programmed motor FLA, and, with a time delay of up to 20 seconds shall avoid nuisance tripping from short duration transients. - As an option, Ground Fault protection shall be provided using the Residual Current method. An Alarm and 2 trip levels, each adjustable from 5 – 90% shall be available with separate trip times as follows: o ALARM level preset at 5% with a 0.5 – 20 second delay. o LOSET Trip level preset at 7% with a 1 – 20 second delay. o HISET Trip level preset at 10% with an 8 – 250 millisecond delay. - Line Frequency Window shall be programmable from a 1 – 6Hz variance from the nominal line frequency as entered by the user. It shall provide an adjustable trip delay of 1 – 20 seconds. - Coast Down Lockout shall be provided. The coast down lockout time shall be programmable between 0 and 60 minutes following a Stop command. - Starts-per-Hour Lockout shall be provided. The maximum starts-per-hour shall be programmable between 1 and 10 starts. Last update :2017-05-08 - 47 - - Time Between Starts Lockout shall also be programmable to work with the above. A minimum time of between 0 and 60 minutes between start attempts shall prevent restarting too rapidly for the motor and load conditions as determined by the user. Acceleration Control shall be fully adjustable in programming to match any application. As a minimum, starter shall come complete with the following settings: - Ramp Type: the starter shall provide all of the following methods of closed loop acceleration ramp control: Voltage Ramp, Voltage Ramp with Current Limit, Current Limit Only (Current Step), Current Ramp (Torque Ramp) or up to 3 Custom Ramp profiles that can be programmed by the user. Starting Torque: Initial torque output shall be programmable as either Current or Voltage output, and adjustable between 0-100% of maximum Locked Rotor Torque (600% current) available from the motor. Maximum Current Limit: Current Limit shall be adjustable between 200 and 600% of the unit rating. Lighter duty starters with lower current limit settings shall not be acceptable. Ramp Time: The time between Initial Torque and Full Output shall be adjustable between 1 and 120 seconds. Dual Ramps: the starter shall provide 2 separately adjustable ramp profiles, selectable via a dry contact closure. Each ramp shall provide all of the above features. Custom Ramp Curves shall be available that can be configured by the user to match any load or starting condition. Each of the 3 available custom curves can be profiled by entering 8 torque and time points. The starter shall create a smooth acceleration curve from these plotted axis points. Kick Start: the starter shall include a Kick Start feature that shall apply a high output for a short time on initial start command. The Kick-Start voltage level shall be adjustable from 10 – 100% voltage, for 0.1-2 seconds max. Jog: the starter shall provide a programmable Jog feature, adjustable from 5 – 75% of line voltage. Deceleration Control (Ramp Down) shall be completely independent of any Acceleration Ramp settings and provide a fully adjustable Deceleration profile. Pre-programmed Deceleration “algorithm” systems that do not allow contouring to match load conditions are not acceptable. - Step Down Voltage: adjustable from 100 to 0% of line voltage. - Deceleration Ramp Time: adjustable from 0 – 60 seconds. - Stop Voltage Level: adjustable from 100 – 0% of line voltage to automatically turn off the starter when the output torque has reached a desired level. Programming shall not allow the Stop level to be set higher than the Step Down Level. External timers shall not be needed to turn off the starter. - Selectable Operation During Overload shall be available to allow the user to decide if the motor shall turn off or continue to Decelerate when an overload condition is detected. Starter Protection shall be provided to maintain reliability of both the equipment and the circuit components, with the following features: - Shorted SCR Detection shall be standard. This function shall automatically prevent a “start” sequence when at least one SCR is shorted. A means of having qualified service personnel defeat the lockout of this circuit SHALL be provided to allow for “Shall Run” situations. - Shunt Trip Circuit shall be standard. This feature shall instantly energize a dry relay contact that can be wired to a “Shunt Trip” coil of the circuit breaker in order to protect the motor from damage. This protection shall only operate if there is current flowing through any phase of the starter when in the “Off” condition, such as when there are multiple shorted SCRs or a bypass contactor stuck on. This feature shall be independent of the above Shorted SCR protection so that it cannot be defeated. - Starter Over-temperature Trip shall be built-in and protect the SCRs from excessive heat build-up in the enclosure or heat sinks. Thermal sensors on the heat sinks shall be pre-wired to one of the programmable inputs that has been factory preset as the Over Temp input. Last update :2017-05-08 - 48 - Inputs shall be provided for the control and option selection of the starter as follows: - Digital Inputs: All input and control devices shall be rated for 120VAC control or shall require dry contact closures without the need for external power supplies or interposing relays. - On-Off Control shall be 120VAC to avoid potential problems with voltage drop in long control wire runs. The starter shall provide for 2-wire or 3-wire control schemes. Seal-In relay contact for the 3wire control scheme shall be internal, dedicated to that use and not counted as an output contact. Terminals shall be provided for use in interlocking with programmable output relays or external devices. - User Inputs: 4 programmable digital inputs shall be provided. Each input shall accept dry contact closures from external user supplied devices, and can be named for display on the DCU when energized. 2 of these inputs shall be preset as Temperature and Dual Ramp Select, but can be changed by the user. Inputs can be programmed as N.O. or N.C., and programmed with a de-bounce timer of 0 – 60 seconds. Each input can be assigned to operate any of the Programmable Outputs. - Analogue Input shall be provided for optional Tach Feedback Starting. This input shall accept 420ma with adjustable offset and gain. Outputs shall be provided for the following functions in addition to the seal-in relay used in 3-wire control schemes as mentioned above. - - Digital Outputs shall be eight (8) Form “C” contact relay outputs, rated for 240VAC, 5A, 1200VA max., with each relay being programmable for any one of the following functions; Indicator Relay programmable to change state on any of the following conditions: Run / Stop, Start / End of Decel, Timed Output, At Speed / Stop, At Speed / End of Decel, Dual Ramp Selected, Self Test Fail. Fault Trip Relay programmable for each of the following fault conditions: Overload, Phase Imbalance / Loss / Reversal, Lock Out Inhibits, External Inputs, Short Circuit, Over Current / Shear Pin, Ground Fault HISET / LOSET, Over / Under Frequency, I²t Start Curve, Shorted SCR, Shunt Trip, Over Temp, Under Current / Load Loss. Alarm Relay including the following conditions: Overload Warning, Overcurrent Warning, Ground Fault Warning, Under Current Warning, Imbalance Warning, Thermal Register Warning. RTD Relay (when RTD Input option is ordered) including Stator or Non-Stator Trip and/or Warning, and RTD Failure. Analogue Outputs (2) shall be included for providing information to external controls and be programmable as RMS Current or Percentage of Motor FLA. If the Tachometer Feedback Starting option is used, the Analogue outputs can be programmed as RPM. If the RTD input option is used, the Analogue outputs can be programmed as Hottest RTD Temperature for Stator or Non-Stator RTDs. Operator Interface Panel that provides simple to use adjustment and status indication on a dead-front shroud of the starter shall be provided. - Adjustments shall be made by keypad with tactile feedback keys for high noise environments. To prevent confusion, no binary coded dip switches shall be used for programming. Pass code protection shall be available to prevent unauthorized changes to the programming. - Alpha-Numeric Display shall be Backlit LCD with 2 lines by 20 characters. - Indicators using long life LED devices shall provide additional quick annunciation of Power, Run Alarm and Trip operation, as well as the status of the eight output relays. - Password Protection shall be provided, allowing 3 levels of access to program information, 2 of these levels requiring separate Passwords. Metering functions shall be provided through the Alpha-Numeric Display for indicating the following: - Output Current for each individual phase or avg. of all 3. Indicating range to be 0.0 – 9999.9 amps. - Ground Fault Current Last update :2017-05-08 - 49 - - - Motor Load % of FLA Line Frequency Phase Order Remaining Thermal Capacity to indicate heating effect and cooling rate of the motor. Range shall be 0 – 100% of the remaining capacity and count up towards 100% while cooling. Thermal Capacity to Start indicating the required value that shall be added to the thermal register as learned and averaged from the previous 3 successful starts. Average Start Time learned from previous 3 successful starts Average Start Current learned from previous 3 successful starts I²t to Start measured from the previous start. Last Start Time measured from Start Command to At-Speed. RTD Metering (when RTD Option is ordered) for up to 12 Stator and Non Stator RTDs, displayed in degrees C and degrees F. Metering includes Hottest RTD, each RTD Temp, each RTD Max Temp Since Clear, Measured Run Cool Time in minutes, and Measured Stop Cool Time in minutes. Starter Status including Ready, Starting, Running, Last Trip Cause Remaining time for O/L Trip, Thermal Inhibit, Coast Down Lock Out, Time Between Starts and Starts per Hour. Event Recorder (last 60 events) with Phase and GF currents record at each event. Last Trip including Cause, Phase and GF currents, Unbalance %, Hz, Hottest Stator and Non Stator RTD recorded. Statistics including Elapsed Run Time, Total Trips, Trips on Short Circuit, Start O/L, Run O/L, Frequency, Overcurrent, Stator RTD, Non-Stator RTD, G/F LOSET and HISET, Acceleration Time, Start Under Curve, Start Over Curve, I²t Start, Fail Shunt Trip, Phase Loss, Tach Accel, and 4 External Inputs Learned Start Curve. When enabled, the starter shall record a start curve with 100 data points of current and time between Start and At-Speed. This data can be exported via the Comm. Port to be plotted on a graph or spreadsheet for baseline measurement and maintenance analysis. Learned Start Curve. When enabled, the starter shall record a start curve with 100 data points of current and time between Start and At-Speed. This data can be exported via the Comm. Port to be plotted on a graph or spreadsheet for baseline measurement and maintenance analysis. Available control or protection options shall include the following: - An input card to allow linear speed acceleration based on closed loop feedback from a tachometer, - Biasing and adjustment of the Dynamic Thermal Register based on real-world temperature readings from up to 12 RTDs, with the following features: o Programmable RTD Type, shall accept 100 ohm platinum, 100 ohm nickel, 120 ohm nickel and/or 10 ohm copper RTDs o Configurable RTDs allowing for up to 6 RTDs to be used for the Stator. All RTDs can have names assigned in programming for clear indication on the display. o RTD Voting providing for the requirement of at least 2 RTDs to be exceeding the set points for Trip or Alarm. This feature shall be programmable as Enabled or Disabled.. Serial Communications shall be built-in as a standard feature without the need for separate modules. - Communications protocol shall be RS-232 to a Windows® based program for data entry, and/or Modbus RTU protocol via RS485 signals. - Units shall be capable of being connected to an intelligent communication device in a network of up to 247 devices with unique addresses. Design Specifications SCR Modules: - Control Method: firing circuits shall use individual phase transformer coupling method for maximum isolation and rapid rise of firing pulse, Last update :2017-05-08 - 50 - - Noise Immunity: The gate firing circuitry shall be protected from electrical noise and transients to ensure reliable starting and firing of the SCRs under all power conditions, regardless of the available fault current or motor lead length, The starter shall not require line reactors in the Medium Voltage power section, For additional reliability and to protect against EMI/RFI interface generated by the internal components, connections to the Digital Control Unit shall be fibre optic The gate drive shall be maintained for 240 electrical degrees from the zero cross point to avoid motor switching transients. Ambient Conditions: - Temperature: As a standard of unit design quality, starter shall be documented to show the design has been tested for 0 – 50° C (-32 to 122° F) operation, and Overload Capacity shall be rated at this temperature. Altitude: 3300 ft (1000 m) maximum without de-rating. Humidity: 0 – 95% RH, non-condensing. Thermal: Heat sink temperature switches designed to trip at 85° C. Electronics: - - 8.12 Non-Volatile Memory shall be used throughout the control and protection systems. Battery back-up memory systems shall not be allowed. The starter shall store all factory defaults in a preset replaceable EPROM memory chip. User Programming and statistical data shall be stored in EEPROM memory for ready alteration. Loss of power shall not affect memory status. For fast updates and operation, running programs shall use DRAM memory. The starter shall store the DRAM memory contents to the EEPROM upon power failure, and restore it upon return to normal. Data Sampling: o Critical operating data such as instantaneous current for Short Circuit, Ground Fault and Immediate Overload calculations shall be sampled every 2 milliseconds to prevent lagging operation. o Non-Critical data shall be obtained from a true RMS calculation circuit, and sampled in a 350 millisecond moving window of individual phase currents. Real Time Clock with automatic leap-year updating shall be provided. This clock alone shall use a battery back-up with a Lithium-Ion battery rated for at least 10 years of continuous operation without power applied. The clock shall be capable of being reset in the field after changing the battery, without affecting any other stored information. Mechanically latched contactor Mechanically-latched contactors shall be provided for transformer disconnect circuits, and other uses when it is required to have contactor remain closed, regardless of voltage condition. Mechanically-latched contactor shall be closed electrically from a local or remote ”close“ push-button, and an electrically operated solenoid shall be supplied to open the contactor from a remote location. A mechanical opening device shall be provided to mechanically open the contactor. 8.13 Incoming Line sections to MCC Each incoming line section shall be 500mm wide (for bottom entry only) or 750mm wide (for top or bottom entry) and shall be connected to an adjacent controller. Last update :2017-05-08 - 51 - Incoming Line section shall have a rating of 630, 1250, 2500, or 3150A. An optional Voltage Presence Indication System shall be provided, connected by a capacitive circuit to the main bus. The system lights shall indicate voltage when the equipment is energized. As an option, the section shall contain a top mounted pull box (432 mm high) to ease in cable pulling and for additional shielded cable bending space. 8.14 Manufacturing Construction: Each cubicle shall be a separately constructed cubicle assembled to form a rigid freestanding unit. Adjacent cubicles shall be securely bolted together to form an integrated rigid structure. Each individual unit shall be braced to prevent distortion. All busbar joints shall use Belleville washers. Torqued bolts that are used for busbar joints or for insulators and direct support of any current carrying parts shall be marked with a bead of highly visible bright orange "torque seal", that shall readily show when a bolt has loosened. Height: 2300mm, maximum including auxiliary support members on top and bottom. Main busbar shall be copper, non-insulated or insulated, rated at 630, 1250, 2500 or 3150A, and shall be supported directly by the disconnector. For single cubicles, include an earth pad with lug. For multiple cubicle line-ups, include continuous earth busbar through the motor controller assembly, securely connected to the steel frame of each cubicle. Main busbar and earth busbar connections shall be designed for easy future extensions. Cut-out areas with removable bolted on covers shall allow for future extension of the main busbar. A knockout shall be removable for the extension of the earth busbar. 8.15 Factory finishing All non-painted steel parts shall be zinc plated. All painted steel parts shall be cleaned and a zinc-phosphate pre-treatment applied prior to paint application. All Paint Colour shall be RAL9002 White Frosted TGIC polyester powder, applied electrostatically through air. Following paint application, parts shall be baked to produce a hard durable finish. The average thickness of the paint film shall be 2.0 mils. Paint film shall be uniform in colour and free from blisters, sags, flaking and peeling. All adequacy of paint finish to inhibit the build-up of rust on ferrous metal materials shall be tested and evaluated per paragraphs 5.2.8.1-7 of ANSI C37.20.3-1987. Salt spray withstand tests in accordance with paragraph 5.2.8.4 shall be performed on a periodic basis to provide conformance to this corrosion resistance standard of at least 600 hours minimum. Last update :2017-05-08 - 52 - 9. Power monitoring equipment 9.1 General requirements This specification applies to an Intranet-based electrical power monitoring system. The system shall include, but without being limited to, remote monitoring devices, power equipment protection devices, full Intranetenabled power equipment, communication interfaces, connection cables and associated services. Each PC workstation connected to the Intranet / Internet network shall have equivalent access to the data supplied by the power monitoring devices so as to centralize data displays, data recording and other power monitoring operations. Each workstation shall be independent of the other workstations in order to allow the user to recover data based on user requirements. The system shall be compatible with Medium and Low Voltage electrical installations, without any specific modifications, whether for electrical distribution or motor control. It shall also be compatible with an existing equipment base (installed equipment base) upgrade or additional new equipment. It includes an e-services capability to enable third parties to carry out remote operations on the system in order to analyze electrical data. This analysis could include monitoring of the site’s power consumption, quality and availability or optimization of equipment potential. The manufacturer shall prove that the system is not a prototype and that analogous devices have been installed and successfully operated for at least five years in applications. The vendor shall take full responsibility for ensuring that the system works as specified. The TCP/IP Ethernet standard shall be used as the main high-speed network capable of direct connection of an unlimited number of PC workstations at any point on the network. Mainly dedicated to only electrical network monitoring, the system shall also allow direct access to power monitoring devices to activate remote manual or automatic controls on electrical actuators via the Modbus TCP/IP communication protocol according to IETF specifications. This function is only activated if a Digital Monitoring and Control System – DCS or SCADA - is added. No software other than Microsoft Internet Explorer shall be necessary to set parameters and operate the system. Systems requiring the purchase of additional software licences are not permitted. No competencies in IT, software programming or Ethernet network architectures are required to add components to the monitoring system. 9.2 Applicable standards Standard IEC 60068-2-52 IEC 60255-5 IEC 60255-21 IEC 60255-21-1 IEC 60255-21-2 IEC 60255-21-3 IEC 60255-22-1 Last update :2017-05-08 Title Environmental testing - Part 2: Tests - Test Kb: Salt mist, cyclic (sodium chloride solution) Electrical relays - Part 5: Insulation coordination for measuring relays and protection equipment; Requirements and tests Electrical relays; part 21: vibration, shock, bump and seismic tests on measuring relays and protection equipment; section 1: vibration tests (sinusoidal) section 2: shock and bump tests section 3: seismic tests Electrical relays. Part 22: Electrical disturbance tests for measuring relays and protection equipment. 1 MHz burst disturbance tests - 53 - IEC 60255-22-4 IEC 61000-2 IEC 61000-4-3 IEC 61000-5 FCC part 15 Electrical relays - Part 22-4: Electrical disturbance tests for measuring relays and protection equipment - Electrical fast transient/burst immunity test Electromagnetic compatibility (EMC); part 2: environment Electromagnetic compatibility (EMC) . Part 4-3: Testing and measurement techniques . Radiated, radio-frequency, electromagnetic field immunity test Electromagnetic compatibility (EMC) - Part 5: Installation and mitigation guidelines Federal Communications Commission: Regulations for Low Power, NonLicensed Transmitters Product characteristics in terms of service temperature, vibration, pollution withstand, installation category, dielectric withstand and EMC shall be compatible with service in an industrial environment. All of the products shall be certified UL 508, CSA approved, and carry the CE marking. The product shall be certified NOM 001, 003, 024. 9.3 Technical characteristics Impulse wave withstand according to IEC 60255-5: 5 kV Vibration, shock, bump and seismic tests according to IEC 60255-21: Class II 1 MHz burst disturbance according to IEC 60255-22-1: Withstand Class III Electrical fast transient/burst immunity test according to IEC 60255-22-4: Withstand Class IV Radiated, radio-frequency, electromagnetic field immunity test according to IEC 61000-4-3: Withstand Class III Degrees of protection according to IEC 60529: IP52 for the front face Regulations for Low Power, Non-Licensed Transmitters FCC part 15: Class A 9.4 Commissioning the system and training On-site commissioning and training shall be included in the project offer. Commissioning shall include a full demonstration of how the system works with simulation of possible operating conditions which could occur. The training shall include all practical exercises and the necessary documentation to allow electrician staff to take full operational responsibility after the training period. The project tender shall indicate the number of days for assistance on commissioning and for training, including trips. The vendor shall provide regularly scheduled factory training for customers concerning all aspect of power monitoring and control, including: - Installation, configuration and full operation of equipment and software - Advanced functions and data reports - Advanced functions for power consumption monitoring, power quality and disturbance monitoring. The system manufacturer shall provide a telephone call centre for customers. 9.5 Medium or Low Voltage Metering Units The system shall be suitable for implementation in an existing electrical network or for network extensions based on metering and protection products fitted with a Modbus communication link. These products can be integrated with MV or LV power equipment. The products shall have an accuracy of 0.5% for voltage readings and current selection and an accuracy of 1% for power and energy readings. These accuracies shall be maintained for both partial and full loads. No Last update :2017-05-08 - 54 - annual recalibration shall be necessary by users for these levels of accuracy to be maintained. The voltage and current for all phases shall be simultaneously sampled in order to ensure high accuracy. The product shall have an operating temperature range of 0°C to 60°C. The measurement inputs shall use current transformers. The rated current shall be 5A and 10A full scale, with over-current withstand of 15A continuous and 500A for 1 second. The products shall not require voltage transformers when used below 600V AC. The power supply voltage shall be in the range of 110-400VAC, 50 or 60 Hz or 24-350VDC. In each product, a RS-485 communication device shall be incorporated in order to allow multipoint communication with IT workstations, PLCs and other devices, with a data transmission speed of up to 19,200 bauds and maximum length equal to 3000 m. Data communication shall be optically isolated in order to ensure reliable operation. Each product shall be equipped with a multi-line backlit display. The display shall automatically scale readings without the need to use factors. Setting shall be possible using the display. No micro-switch or other equipment shall be necessary for remote setting. The product shall supply diagnostics in order to remedy faulty cabling. All data shall be available on the display or via the RS-485 communication device. The data supplied by the meter shall include the following: - Current, for each phase Voltage, phase - phase & phase - neutral Actual power (kW), per phase & total of the three phases Reactive power (kvar), per phase & total of the three phases Apparent power (kVA), per phase & total of the three phases Power factor (real), per phase & total of the three phases Frequency Actual energy (kWh), total of the three phases Reactive energy (kvarh), total of the three phases Apparent energy (kVAh), total of the three phases 9.6 High performance metering unit High-performance metering unit shall be able to detect and capture voltage peaks and dips, transients under 1 microsecond, measure flicker, store large volume of past data, acquire rms values, compare measurements with EN50160 power quality standard, notify alarms by e-mail. This product shall be connected to Ethernet either directly or via a Modbus RS485 communication link connected to an Ethernet server. The product shall have a copper 1/100 Mbits/s link or a fiber optic 100 Mbits/s link. The product can also be used as a gateway for Modbus slave products via a RS485 link. Due to the large quantity of data to be analyzed by the user, the user-machine interface shall be specific for this type of product when accessed via the site’s Ethernet network, in the form of HTML pages. The metering unit shall be capable of working at nominal frequencies of 50, 60 or 400 Hz without any modification. Last update :2017-05-08 - 55 - The power supply voltage range shall be 100-264 Vac, or 100-300 Vdc, or 18-60 Vdc. A capacitor-based device shall be available to provide a back-up power supply for at least 8 seconds. The operating temperature range shall be - 25°C to + 70°C. The metering unit shall save maximum and minimum values in a permanent memory for each of the indicated instant values, with time stamping. Metering units shall accept standard industry metering transformer inputs (secondary 120 Vac for voltage transformers and secondary 5A for current transformers). Connecting to circuit voltages of up to 277/480Vac shall be possible without using voltage transformers. Current inputs shall withstand over-currents of 500 A for 1 second. The product shall provide accuracy of 0.15% on reading, 0.05% over the total scale for voltage and current measurements and an accuracy of 0.3% for all power and energy functions. - These accuracies shall be maintained for both partial and full loads. - No annual re-calibration by users shall be required for these accuracies to be maintained. - Voltage and current for all phases shall be sampled simultaneously in order to ensure a high level of accuracy under conditions with a low power factor or with major waveform distortion. - Current and voltage signals shall be digitally sampled at a sufficiently high rate to supply real accuracy beyond the 30th harmonic (50 or 60 Hz). A fourth current transformer input shall be available in order to measure the neutral or earthing current. If the fourth current transformer input is not used, a residual current shall then be calculated by arithmetic addition of the phase currents. In four-pole connections, the product shall use the neutral as a shared reference for the circuit rather than earth in order to ensure the accuracy of measurements. The metering unit shall be surface-mounted or fitted in an enclosure with a finishing collar. The metering units shall be equipped with an continuous, long duration integral display in order to provide local access to the measured values, as well as the maximum and minimum value of each instant value since the last min/max reset operation. The metering unit shall have a communication port as standard equipment. The port shall be totally accessible during the normal operations and shall not require the operator to expose himself in usage, to any hazardous voltages. The operator shall be capable of quickly connecting a Personal Computer to this port without having to use tools or connectors. It shall be possible to update the internal software in the field in order to improve functions. No dismantling or changing of integrated circuit board chips shall be necessary. It shall not be necessary to de-energize the circuit or the equipment in order to make improvements to the internal software. The following measured values, as well as instant minimum and maximum readings since the reset operation shall to be communicated: - Frequency, - Temperature, - rms current for phase and neutral (if applicable), - Average three-phase rms current, - Phase - phase and phase - neutral voltage, - Voltage imbalance, - Power factor for each phase, - Three-phase total power factor, - Actual power per phase and total three-phase power, - Reactive power per phase and total three-phase power, - Apparent power per phase and total three-phase power, Last update :2017-05-08 - 56 - - Total harmonic distortion (THD), voltage and current, per phase, K factor per phase. All the average calculations shall be carried out according to one of the following calculation methods, as selected by the user: - Thermal average using a sliding window updated every 15 seconds (default average calculation method). The length of the window shall be graduated by the user from 5 to 60 minutes in fiveminute increments. - Fixed interval with optional sub-intervals. The length of the window shall be graduated by the user from 5 to 60 minutes by 5-minute intervals. The user shall be capable of setting the sub-interval length from 5 to 30 minutes by interval of 5 minutes. - External synchronization of impulses using an impulse synchronization device supplied from the outside. An optional status input shall be to detect the impulse. - Sliding interval with continuous sliding sub-intervals of 15 seconds. The following average readings shall be indicated by the product: - Average current per phase. - Average peak current per phase. - Average real power, reactive power and apparent power. - Average forecast real power, reactive power and apparent power. - Average real peak power, reactive power and apparent power. Each product shall be capable of receiving a circulation message on the communication network which can be used to synchronize calculation of averages in several products. This message does not need to be addressed to a particular product. The following energy readings shall be given: - Accumulated energy. - Accumulated reactive energy. - Accumulated apparent energy. For the indicated values of real energy and reactive energy, separate totals of energy flows in each direction shall be established, with an arithmetic sum. Each product shall be capable of operating a KYZ transistorized output relay in order to supply output impulses corresponding to an energy increment defined by the user. The minimum service life of the relay shall exceed one billion operations. All products shall include a current and voltage waveform capture function. The user shall be capable of selecting the corresponding waveform capture at 4, 12, 24, 36, 48 or 60 data cycles. - One or other of the waveform capture types shall be installed from a workstation using the appropriate software or by the product by a user-defined alarm status. Furthermore, an external release can initiate a waveform of 12, 24, 36, 48 or 60 cycles. The waveform capture sequence shall be initialized within one millisecond after tripping has been detected. A user-defined period of 2 to 10 cycles shall determine the number of cycles before the event included in the waveform capture. - The product shall capture and save to a permanent internal memory, 128 digitally sample data points for each phase voltage and current cycle up to a maximum of 30 cycles per capture. When sampling at 64 times per cycle, the product shall save up to 60 cycles of data per capture. The number of waveform captures saved on board the product shall depend on the quantity of available memory. - For the purposes of display, archiving and analysis, the product shall transfer waveform samples to the workstation via the network. - Each voltage and each current in all of the phases shall be sampled simultaneously so that the appropriate phase reports are maintained, for the harmonics flow analysis to be carried out and for the effect of a disturbance to be observed on all phase current and all phase voltages. Last update :2017-05-08 - 57 - - Harmonic analysis carried out on captured waveforms shall calculate the harmonics up to the 63rd harmonic. The data used to display the waveform captured at four cycles shall also be used to determine measured values in order to supply significant additional data. All of the waveforms shall reflect the actual performance of the circuit. Synthesized or postcomposed waveforms shall not be acceptable. Chronological data recording can be carried out either inside the product or on the workstation or on both. Each product shall be capable of chronologically recording data, alarms and events as well as multiple waveforms. The devices shall provide 1.1 Mb. of permanent on-board memory. This data shall be communicated to the workstation as an option. Chronologically recorded data to be saved in the product include: - The user shall be able to configure up to 14 chronological recordings separate from data. Each chronological recording shall be time and date stamped. The type of recorded data shall be selected from a list of 175 values being monitored. The user shall be capable of configuring each chronological recording input which shall involve from one to more than 75 values of instant data according to the data type. It shall be possible to set each chronological recording to include data according to a specific, user-defined programmed interval. In addition, the user shall be able to define an event or a new min. / max. status which shall trigger chronological recording file input. - Chronological data recordings can be configured by users for Input & Blocked memory or Circular (First In / First Out - FIFO). - A min. / max. chronological recording file shall include the time, date and minimum and maximum of each of the instant measured values. - Chronological recording of events and alarms shall include the time, date, event data and corollary information for each alarm or event defined by the user. This chronological recording shall have a capacity of 1,000 events at most selected from more than 100 alarms or events. - Chronological recording of waveforms shall memorize the captured waveforms at 4, 12, 24, 36, 48 and 60 cycles, as defined by the user. Chronological recording inputs shall be programmed at a userdefined interval, triggered from the outside or forced in response to a user-defined event. Chronological waveform recordings shall be either Input and Blocked memory or Circular (First in / First out - FIFO), as defined by the user. - A simple user-interface shall be available in order to allow users to allocate product memory to different chronological recording functions. Alarm events shall be user-definable. The following event categories shall be available as alarm events: - Overcurrent / undercurrent, - Overvoltage / undervoltage, - Current imbalance, - Phase current loss, Phase voltage loss, - Voltage imbalance, - Excess kVA, Excess kW or kvar in / off load, - Over-frequency / under-frequency, - Power factor and cos. - Excess THD, - Excess K factor, - Excess average values, current or power, - Inverse power, - Phase inversion, - Input status change, - End of differential energy interval, - End of average interval, - Over / under analogue inputs / Reduction / increase in current, Last update :2017-05-08 - 58 - - Reduction / increase in voltage. For each measured value alarm as an over / under value, the user shall be able to define the sensor, disabling and time delay. There shall be four severity levels for alarms so that the user can easily prioritize his reactions relative to the most important events. An indication of alarm status shall be given on the front face. All products shown on the project drawings shall include a disturbance detection function. The following aspects characterize this function: - The product shall permanently monitor incoming current and voltage disturbances. There shall be a zero dead time; each cycle shall be monitored individually. - Disturbance events less than one cycle in length shall be detected. - The user shall be able to set a threshold and time delay which shall be used by the product to determine whether an event has taken place. The threshold shall be defined by the user either as a fixed set point or as a relative set point. When using a relative set point, the product shall set a rated voltage or a rated current equal to the current average values. The product shall automatically adjust the rated current and voltage values in order to avoid nuisance alarms caused by gradual daily variations in currents and voltages. - When it detects a disturbance, the product shall be capable of: chronologically record the waveform of the event at 12, 24, 36, 48 or 60 cycles length for all phase currents and voltages. be able to operate any type of output relay on an optional Input / Output module. record the disturbance in a chronological event log with time stamping to the nearest millisecond. cause an alarm for the operator on the workstation. - All chronological recording of data and waveforms shall be subject to communication on the local network or via the communication port on the front face so that the user can visualize and analyze the data using software and the workstation. Examples of customized programs shall include: measuring the level of specialized electrical supply, including real time tariff and reducible levels. reducing data using advanced chronological data recording monthly chronological recording / automatic restoring of peak kWh and average analysis of the statistical profile of measured values verification calculations according to IEEE-519 measuring combined utilities: gas, water, steam, electricity non-critical control programs, such as load control or power factor correction based on multiple statuses, i.e. time of day and input condition Advanced data on harmonics shall be available via the product. This data shall include calculation of harmonic magnitudes and angles for each phase voltage and current up to the 63rd harmonic. - This data shall be available for all three phases, current and voltage, plus neutral current. To ensure maximum analytical accuracy, data concerning current and voltage for all phases shall be simultaneously obtained from the same cycle. - The product shall have a minimum of 100 kb memory in order to chronologically record harmonic magnitudes and angles. - Harmonic magnitudes shall be indicated as a percentage of the fundamental or a percentage of the real values (rms), according to the user’s selection. The product shall be comparable with the Merlin Gerin Circuit Monitor product. Last update :2017-05-08 - 59 - 9.7 Medium Voltage protection relays Protection devices: Each Protection and Control unit shall contain all of the necessary protection devices, their number and type shall depend on the application considered: sub-station protection, generator protection, motor protection, transformer protection. Each protection device shall have wide setting ranges, in particular for current protection which shall allow the choice of definite time curves (DT), reciprocal time (SIT, VIT, LTI, EIT, UIT, RI, IEC SIT / A, IEC VIT or LTI / B, IEC EIT / C, IEEE moderately inverse time, IEEE highly inverse time, IEEE extremely inverse time, IAC inverse time, IAC highly inverse time, IAC extremely inverse time) and time delay values for Instant response (50 ms) to 300 s minimum adjustable either using the time delay or via the TMS factor. The phase and earth current protection systems shall have an adjustable memory time to allow detection of recurrent faults. The earthing protections shall have harmonic 2 withstands that can be activated or not. Groups of predetermined setting implementing over-current protections, shall be possible to select via an internal logic device to quickly adapt to a change in protection plan. The device shall enable the use of a logical discrimination principle both upstream and downstream enabling coordination between cascading protection devices. Settings shall be carried out by directly inputting the value of the primary currents. Tripping per protection shall be indicated on the front face via an light indicator and a message indicating the cause of the fault. Measurements: Each Protection and Control unit shall have measurements necessary to operate and commission the device, this being at least: - rms value of the three phase currents, - the residual current, measurement of average and maximum consumed currents, - measurement of broken fault currents on each phase, - additional measurements such as the imbalance value, temperature rise percentage, etc. One of the measurements shall be available on an analogue output. Communication: Each Protection and Control unit shall be connected with a RS 485 type interface module, Modbus protocol with a maximum rate of 38,400 bauds. The response time for a control order shall be less than 15 ms (time between the sending of the order to the unit and the acknowledgement of receipt). The protection and control unit shall allow access to measured data, the reading of settings, disturbance recording data and remote protection device setting via the communication system. Remote control can be carried out in 2 modes: direct mode, "SBO" (select before operate) mode An RS 232 port shall be available on the front face of the relay to allow communication with a PC using an appropriate software. Dependability: The Protection and Control unit shall have: - a self-monitoring device for its internal functions activating at least one (2 desirable) fail-safe, - watchdog, - changeover contacts, - a failsafe position automatic control with inhibiting of output controls when an internal failure is detected and front face indication via an indicator light and via a message of the self-test status. Last update :2017-05-08 - 60 - Installation: The Protection and Control unit shall be compact and easy to install: reduced depth (<100 mm), optional remote modules with factory built cables. User-machine interface (front face): Each Protection and Control unit shall have a screen indicating: the measured values, messages, for operation (choice of English language or local language), maintenance messages. The screen shall have a minimum of 2 lines to allow the clear display of messages. Eight indicator lights shall be available to give alarms and statuses such as circuit breaker position (open/closed), relay selftesting, phase and earth fault data. It shall be possible to customize the meaning of the various indicator lights. The protection and control unit shall comprise a keypad allowing the following operations to be carried out: display of measurements and operating data, alarm messages, alarm clearance, unit resetting, access to protection settings, access to unit parameter setting. These access procedures shall be protected by 2 different passwords comprising at least 4 characters: one password to protect the access to settings, the other protecting the access to parameters. It will be possible to have a display separate from the unit in order to facilitate its installation in a more visible position to facilitate operating and maintenance procedures. Control and monitoring: The protection and control unit shall comprise logical inputs and outputs required to control the circuit breaker (or the contactor) and to interface with the process monitoring and control device. The unit shall have at least 4 output relays with the possibility of extending this up to 8 output relays and 10 logical inputs. This extension of the number of input and outputs shall be possible in order to allow: opening and closing control, whatever mechanism type (over or undervoltage coil), ANSI 69 / latched closing, remote opening. As an option, trip circuit monitoring shall be available (covering power supply, wiring and coil status) allowing preventive maintenance: operating and reset time of the circuit breaker, cumulative broken amperes for 5 current ranges, number of switching operations, pressure (for SF6 circuit breakers). As an option, temperature monitoring shall be available (for motors and transformers), as well as data backup (even if the auxiliary power source is down). As an option, 8 temperature probe inputs shall be available (motor and transformer applications). Disturbance recording: Recording shall be triggered on the occurrence of an event, either automatically or manually. Each recording shall allow data to be saved for at least 80 periods, 12 samples per period with an adjustable number of periods before the event. The recording shall comprise at least the date, the channel characteristics, 4 current channels (I1, I2, I3, I0) and the logical inputs. At least 2 recordings shall be saved. The recording file format shall be of COMTRADE 97 format. The unit shall record dated events with an accuracy of 1 ms. Software: The appropriate software (using Microsoft/Windows®) allows measurement and operating data to be collected, together with alarm messages, circuit breaker diagnosis data (cumulative broken amperes, number of switching operations, etc). Disturbance analysis shall include: display of one or several graphs, 2 pointers for differential measurements, zoom, printing. Last update :2017-05-08 - 61 - Environment: Since it is integrated close to the switchgear, this protection unit shall satisfy the most severe requirements in terms of environmental withstand, and in particular: - operating temperature: -25°C to + 70° C, - auxiliary power supply voltage: 24, 48, 127 & 220 Vdc and 110 & 230 Vac, - The protection and control unit shall be UL compliant, - The unit shall be disconnectable or withdrawable in order to facilitate its replacement - Current circuit connectors shall be withdrawable without preliminary short-circuiting, - output relays withstand current: 8 A. 9.8 Low Voltage protection unit The communication function shall be available for all Low Voltage circuit breakers in the range of 630 to 1600A, with Modbus RS485 protocol. The function enables all control units to analyze network parameters for operating and maintenance requirements, status indication, identification of fault causes, device identification. Status indication by communication is independent of the device’s indication contacts, which remain available for traditional usage. The maximum characteristics of the Modbus link shall be: - up to 31 fixed devices or 15 withdrawable devices on the same RS485 network - max. bus length: 1200m - maximum speed: 19200 bauds. The cabling system shall facilitate the bus connection of devices via junction blocks, connectors and preequipped cables for quick and error-free cabling. Daisy chain cabling of devices via their terminal shall be avoided. Bus connection with branching shall be the preferred solution . 9.9 Ethernet server Specified characteristics of connection and networking of power monitoring products for MV, LV and MCC equipment: - All the memorized data in the power monitoring products shall be accessible via RS-485 series communications. - It shall be possible to connect one communication port to another (preferring bus connection to branching) so that it is possible to connect up to 32 power monitoring devices in order to form a continuous communication link over a distance of up to 10,000 feet (3,300 meters). - The communications links shall be compatible with RS-485 multipoint communication standards. - Transmission speeds on links shall be adjustable up to 19.2 kbps in order to provide an acceptable data flow for power monitoring products. Specified characteristics of Ethernet data network: - Products shall be connected using the Ethernet as a main high-speed network. - The high-speed network shall include Ethernet gateways or Ethernet communication modules which allow computers, PLCs or other sub-networks or networks on a higher level to have access to the electrical data collected by the measurement units and protection relays, etc. - It shall be possible to simultaneously connect up to 8 workstations to the high-speed network to access the same server. The adding of a new workstation shall not require modification of any other existing workstation. The adding of a workstation shall not require anything other than simple connection to the networks. Recabling or cabling of each monitoring device group shall not be necessary. Last update :2017-05-08 - 62 - Specified characteristics of Ethernet router/server: - All power monitoring devices shall be connected to the Ethernet via one or several router/servers as indicated on the site drawings. - The router/server shall be connected to Ethernet via a standardized RJ-45 port with a view to connecting a shielded twisted pair cable or an optic fiber link via a transceiver. - Indicator LED lights shall be provided for Ethernet connections in order to provide assistance in the case of problems. Indicators are required for transmission, reception, collision, link and connection polarity. - Each RS-485 port can be configured for 2 (prefered) or 4 wire communication. - The router/server shall allow protocol conversion between standardized Ethernet network protocols and Modbus devices on the same daisy chain. - The router/server shall totally comply with TCP/IP, therefore allowing access of power monitoring software to the power monitoring data from any point on the local network (LAN) or via an extended network (WAN). - The router/server shall have a server function in IT terms, in other words a supplier of data to clients making requests – in this case the user PC’s with Internet Explorer-type browsers. The server shall have at least the following web services on board: modbus TCP/IP, SNMP, FTP, SNTP, SMTP, HTML. NTP allows time synchronization of the measurement gateway with the time available on the site NTP server. The SMTP service is used to send e-mails from the measurement table at a settable time interval. - The protocol used on Ethernet by the router/server shall correspond to the manufacturer’s messaging specification in international standard IEC 9506 which is a well-defined open-ended protocol. - Installation of the router/server shall be carried out by an RS-232 interface integrated on board the router/server or via its Ethernet connection via a standard Ethernet crossed cable. All of the settings parameters shall be protected by passwords in order to protect against intentional and-or involuntary access. It shall also be possible to update internal software in the router/server so as to integrate new system characteristics. - The Ethernet server parameters can be set via a local operator interface on a laptop PC, i.e. via the Ethernet socket accessible on the front face of the equipment without opening the doors or dismantling the front panel. The parameters are limited to Ethernet database data specified by the IT manager on the final site, in particular the fixed IP address. - All of the Ethernet cabling shall be installed by a competent data transmission cable installer or by a qualified electrical engineer for data transmission equipment. All of the communications cabling shall be category 5 for a rated power of 10/100Mbps. - The system shall work dependably via an encryption algorithm so that non-authorized personnel cannot intentionally or unintentionally modify communication or settings parameters. - A dedicated Ethernet router/server shall be used which does not require any adjustment or modification of other equipment. Standard personal computers (PC) or plc's are not acceptable as gateways towards power monitoring and control devices. - The Ethernet router/server shall be equipped with an integral power supply adapted to connection to a 24VDC power input. Protection devices shall equip the power supply input which shall be able to be easily maintained in the field. - The router/server shall have compact dimensions, be independent and adapted to fitting to electrical enclosures, telephone rooms or network rooms. It shall also be adapted to fitting in the instrument compartments of electrical equipment. Its dimensions shall not exceed 5" high and 8" wide and 10" deep (12.5 high, 20 cm wide and 25 cm deep). It shall be possible to mount the gateway on the side or at the top using optional fixing brackets. - The Ethernet router/server shall be UL certified, CSA approved, NOM labelled, in conformity with IEC standards and have the CE marking. - The Ethernet server can be downloaded with the latest version supplied by the manufacturer via the Ethernet network. - The Ethernet server is accessible via an RJ45 socket on the front face for temporary access via a laptop PC during commissioning or normal operations. Last update :2017-05-08 - 63 - 9.10 Electrical data for the user A menu enabling easy selection of the web pages shall be available. Five (5) summary pages shall be prepared in factory, supplying shared data for the units. General page: - name of power devices in the equipment, rms or complex voltage, average current A, Active power kW, power factor, circuit breaker position as appropriate. For motor feeders (variable speed drives or direct on line) the thermal status of the motor, the open/closed position, the output frequency as appropriate, and rms currents shall be given. Instant load current page: - power device name in the equipment, rms current per phase in amperes. Average load current page: - power device names in the equipment, average current per phase in amperes. Power page: - power device names in the equipment, current values in kW, maximum recorded values in kW with date and time of appearance. Energy page: - name of power devices in the equipment, active energy in kWh, reactive kvarh and date of last reset. Per unit: - detailed page with real time data refreshing adapted to each device, Long term recordings (at least 150 days) of energies as appropriate in the form of value curves and tables. The tables shall be exportable via the FTP web service on Ethernet in csv format. Download of customized web pages via the Web FTP service for operator requirements shall be possible. List of units recognized as a minimum by the Ethernet server: - Measurement unit: Power Meter range, Merlin Gerin Circuit Monitor range - Medium Voltage Protection Unit: Merlin Gerin Sepam range - Low Voltage Protection Unit: Merlin Gerin Micrologic range - Variable Speed Drives and Soft Starters: Telemecanique ATV and ATS range - Motor controller: Telemecanique TeSys U range Last update :2017-05-08 - 64 - The Ethernet server shall be of Merlin Gerin EGX400MG type. 9.11 MV, LV, and MCC equipment General: This section describes the characteristics of MV, LV, and MCC (Motor Control Center) electrical distribution equipment to be integrated in the electrical network monitoring system. An industrial Ethernet server product shall be included with predefined web pages in HTML format, allowing display of measurements and connected power device status via RS485 ports. No additional software shall be required for implementation and consultation of measurements. The user interface shall be the same, whatever the power equipment considered (MV, LV or MCC), in order to optimize user ergonomics by authorized people. The power equipment shall include Web services, directly connected to the Local Ethernet at the site, compatible with the end user’s Intranet. Ethernet Connectivity: The interconnection of metering units, circuit breaker protection units, Variable Speed Drives and motor control units integrated in the equipment, shall be possible using a multipoint RS485 Modbus series communication network. The network shall be connected to the Ethernet gateway with web server functions. All of the equipment necessary for a 10BaseT Twisted Pair, 100BaseT Twisted Pair, 100BaseFX Fiber-Optic connection shall be included in the equipment. All the communication links shall be factory checked with the Ethernet gateway. The equipment shall integrate a hub enabling: - the connection to the site’s Ethernet network, - two Ethernet connections, one to the Ethernet server and the other for the RJ45 Ethernet socket on the front face of the equipment. The equipment shall also be fitted with two Ethernet cables, one directly connected to the Ethernet server and the other connected to the front face of the equipment for data consultation in normal operation. The Ethernet server parameters shall be set via a local operator interface on a laptop PC, via the Ethernet socket accessible on the front face of the equipment without opening the doors or dismantling the panels. The parameters are those necessary for Ethernet and TCP/IP, including a fixed IP address as defined by the IT manager of the Intranet. A very simple “Quick start” document shall be supplied with the equipment allowing the parameters to be set on the equipment without any previous knowledge of IT or of communication networks via stage with an Internet browser from any PC. The Ethernet server shall supply diagnostic data of series and Ethernet links together with data on the internal status via web pages that are accessible from an Internet browser. Drawings to be submitted Drawings of the power equipment shall clearly show the metering and protection products integrated in the equipment and the internal or external connections. They shall also show the communication components for local networks, series links or Ethernet together with the type of cable and connection terminals. Last update :2017-05-08 - 65 - Factory drawings shall be on the equipment Ethernet server in electronic form, and shall be consultable with normal office software (e.g.: Acrobat Reader / Adobe). Updating of the dossier shall be carried out by Intranet. Product catalogues shall be separately supplied and show data for dimensions, connections and electrical characteristics. 9.12 e-Services The system shall allow remote analysis via Internet by electrical networks experts. This support can be oneoff or permanent. On the basis of the equipment described in the present document section "MV, LV and MCC Equipment", the simple addition of a modem to the site’s Ethernet network shall enable transmission of electrical data. The modem shall be supplied by the service supplier. It shall be connected to: - the site Intranet network, - the telephone network or the site messaging server to be able to regularly send data to the service provider. It shall be designed so it is not possible to activate the modem from outside the site for security reasons. Objectives The analyses shall be sent to the site user by a password controlled access on the service supplier’s web site who shall offer a permanently updated management chart of the situation concerning: - Compliance with the electricity supply contract: it shall be possible to know the consumption profile to optimize the contract as well as analytical breakdowns to reduce consumption, - Installation operating conditions: the necessary data shall be provided for implementation of conditional preventive maintenance, management of replacement parts, and even schedule of refurbishment, - The quality and availability of electrical power supplying loads: the sources of disturbances shall be analyzed and solutions offered to ensure the quality and availability of power according to the activity’s requirements. Scope This e-Service shall be a global service provided via Internet including: - Remote parameter setting of metering and protection products, to capture data according to the objectives, - The creation of the confidential database, - Interpretation of data by specialists, using expert software, - Recommendations on detailed periodic reports, - Ongoing overview via a management chart. The service shall be customized according to requirements: from assistance to the end user in carrying out his own analysis right through, to detailed analysis by experts and direct access to specialists. Extension The following shall be included in a more extensive Services Contract: - Installation audit, - Diagnosis of equipment whose status is considered critical, - Preventive equipment maintenance, - Study of network architecture, - Support Services such as management of replacement parts, definition of maintenance plans, telephone assistance (Hot Line). Last update :2017-05-08 - 66 - 10.MV Power Factor Correction 10.1 General requirements Power Factor Correction (PFC) shall be managed by implementation of capacitor banks at MV, with detuned reactors for protection against harmonic distortion. The PFC equipment shall be designed to be used in electrical networks up to 12kV. It shall be made of unpainted aluminium or galvanised steel frame and panels, equipped with MV capacitor units, SF6 contactor, HRC fuses and detuning reactors. The bank shall be arranged in delta connection with HRC fuses insuring the protection against capacitor internal fault. A complete automatic PFC system with several capacitor stages shall be controlled by a power factor relay. 10.2 Applicable standards The MV capacitor bank shall be designed, manufactured, and tested according to the relevant IEC standards: Standard IEC 60076-6 IEC 60255 IEC 60282-1 IEC 60470 IEC 60787 IEC 60871-1 IEC 60871-2 10.3 Title Power transformers –Part 6: Reactors Electrical relays High-voltage fuses –Part 1: Current-limiting fuses High-voltage alternating current contactors and contactor-based motor-starters Application guide for the selection of high-voltage current-limiting fuse-links for transformer circuits Shunt capacitors for a.c. power systems having a rated voltage above 1000 V; Part 1: General - Performance, testing and rating – Safety requirements - Guide for installation and operation Part 2: Endurance testing Technical characteristics The PFC equipment shall be made of unpainted aluminium or galvanised steel frames and panels. It shall be designed for the following installation conditions: - Indoor installation, - Altitude less than 1000m, - Average daily ambient temperature of between -25°C and +35°C, and a maximum of 40°C. The protection degree of the enclosure shall be IP 23. Available options for the enclosure: - Door with lock for indoor type enclosure, - Outdoor type enclosure, - Door with lock for outdoor type enclosure, (to be used with outdoor type cubicle option). 10.4 Electrical characteristics The PFC equipment shall be designed for voltages up to 12kV, 50 or 60Hz. According to the network rated voltage, the insulation level of equipment shall be as follows: Last update :2017-05-08 - 67 - Rated voltage (V) Insulation level (kV) 4600 7100 12000 7,2 7,2 12 Power freq. voltage withstand (kV rms) 20 20 28 Impulse voltage withstand (kV peak) 60 60 75 The tolerance on the rated power of the capacitor bank shall be : 0/+10%, The capacitance variation according to temperature shall be limited to : -3,5.10-4/°C. Acceptable over-current and over-voltage: The PFC equipment shall be designed for: - 1,10 x Un over-voltage - 12 hours per day, - 1,15 x Un power frequency over-voltage - 30 minutes per day, - Permanent over-current : 1,3 x In. Design voltage, design power and marking: According to IEC 60871, capacitor unit or capacitor bank nameplates shall indicate the maximum power and voltage for which it is designed (Qdim & Vdim). Operating values can be equal or lower than these values (Qn and Vn). The documents supplied with equipment (price lists, order forms, catalogues, …) shall provide reactive power values for the most common network voltages. Composition: Each capacitor bank shall include the following components: Basic components : - Unpainted aluminium or galvanised steel cubicle, IP23 for indoor installation, - Capacitor units, (1, 2 or 3 units per stage, depending on the rated power of the bank), - One contactor, - One three-phase detuning reactor, - Three HRC fuses. The following items shall be proposed as options: - Set of two quick discharge coils, - Control and protection box. The stages shall be designed to include up to 3 capacitor units in delta connection. Capacitor units: The capacitor units used in PFC banks shall have the following characteristics: - All film technology, - Filled with biodegradable dielectric fluid, - Three-phase, delta connected, - Fitted with three epoxy resin bushings, - Fitted with internal discharge resistors (residual voltage is less than 75V within 10 minutes after disconnection). Last update :2017-05-08 - 68 - Contactor: The PFC banks shall include a contactor with magnetic holding. The high breaking capacity of the contactor (10kA) shall provide perfect co-ordination when used in conjunction with HV fuses (with ratings of up to 250A). Reactors: The reactors used shall be three-phase, dry type, with iron core and natural air cooling. The rated current shall be equal or higher than 1,43 times the capacitor bank nominal current. The inductance value shall be calculated so that the L-C tuning frequency is 4,3 times the fundamental frequency value (215Hz for 50Hz network, or 258Hz for 60Hz network). Connections: The connections shall be bare copper bars, with connection supports made of porcelain or epoxy resin.. Low voltage wiring: Low voltage wiring shall be insulated with black PVC, 1000 V grade, with the following cross-sections: - 2,5 mm² for currents circuits, - 1,5 mm² for voltage circuits. Each extremity of wire shall be marked using the independent marking system. Quick discharge coils: Quick discharge coils shall be proposed as an option for a very fast discharge time (less than 10 s). Control and protection box: A control and protection box shall be proposed, including the following devices : - One power factor controller, - Signalling lamps : Voltage "on", For each stage : Stage "On", Stage "Off", Melted fuse. - Optional : a local manual control switch with three positions : "Auto" : stages controlled by the power factor relay, "Manu" : stages manually controlled by a 2 position switch, (1 per stage), > "0" : stages remaining off all the time (no automatic nor manual operation permitted). Auxiliary voltages: Here are the voltages which shall be accepted by the PFC equipment: - Control and signalling circuits (contactor coils, lamps, auxiliary relays): ac : 110 – 230V dc : 48 – 110 – 125 – 220V - Power factor controller reference voltage : ac : 110 – 230 – 400V. Last update :2017-05-08 - 69 - 10.5 Operating conditions Internal fault protection: The capacitor units shall be protected by HRC fuses only. Additional protections: To provide a suitable protection level for the equipment, the capacitor bank feeder shall include the following additional protection devices : - Short-circuit protection : recommended setting values : 3 x In / 0,1s, - Overload protection : recommended setting values : 1,4 x In / 10s, Important note: The feeder circuit-breaker shall be suitable for capacitor current switching. 10.6 Factory tests Each PFC equipment shall pass routine testing before delivery, performed according to IEC relevant recommendations and including the following: For capacitor units: - capacitance measurement, loss angle measurement (tg ), sealing test, internal discharge resistor value checking, voltage test between terminals, voltage test between terminals and container. For PFC equipment: 10.7 phase to phase capacitance measurement, insulation measurement, conformity checking, functional test (off-load operation), Documents The following documents shall be supplied to the final customer : - three sets of routine test certificates (french / english) - three sets of drawings and diagrams (french / english or french / spanish), - one instruction manual (french / english / spanish) Last update :2017-05-08 - 70 - 11.Soft starters 11.1 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). 11.2 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. 11.3 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. Last update :2017-05-08 - 71 - 11.4 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. 11.5 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. Last update :2017-05-08 - 72 - 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. 11.6 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. 11.7 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. 11.8 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. Last update :2017-05-08 - 73 - 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. 11.9 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 :2017-05-08 - 74 - 12.Variable speed drives 12.1 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. 12.2 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 Last update :2017-05-08 - 75 - 12.3 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 shall be available in maximum 5 days on site. 12.4 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 :2017-05-08 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 - 76 - 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. 12.5 AC Drive performance Control modes: - Motor control type: o Quadratic kN² o Energy saving Last update :2017-05-08 - 77 - - 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 shall 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 - 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) The “Power Removal” safety function shall have a redundant electronic architecture (1) that shall be monitored continuously by a diagnostics function. Last update :2017-05-08 - 78 - 12.6 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. 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: - 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 12.7 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. 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 At least, the following standard Inputs and Outputs shall be provided, to be used in interface with the control system: Last update :2017-05-08 - 79 - 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 Last update :2017-05-08 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 - 80 - 12.8 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 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 : Last update :2017-05-08 - 81 - - 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 12.9 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. Last update :2017-05-08 - 82 - 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 12.10 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 Last update :2017-05-08 - 83 - 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. 12.11 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. 12.12 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 Last update :2017-05-08 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. - 84 - 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 Last update :2017-05-08 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. - 85 - 12.13 Documents Documents to be provided to customer: Manuals Drawings Quality assurance As an option: Environmental aspect These shall 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. Last update :2017-05-08 - 86 - 13.Automatic transfer switches 13.1 General requirements By construction, the remotely operated transfer switch equipment shall offer in the optimum security conditions, the following possibilities: either the control by an automatism created by the customer, or the control by an automatism created by the manufacturer. 13.2 Applicable standards Standard IEC 60947-1 IEC 60947-2 IEC 60947-3 IEC 60947-4-1 IEC 60947-6-1 13.3 Title Low-voltage switchgear and controlgear - Part 1: General rules Part 2: Circuit-breakers Part 3: Switches, disconnectors, switch-disconnectors and fuse-combination Part 4: contactors and motor-starters; section one: electromechanical contactors and motor-starters Part 6: multiple function equipment; section one; automatic transfer switching equipment Electrical characteristics The transfer switch equipment shall have the following characteristics: Rated impulse withstand voltage (Uimp) of 8kV Rated insulation voltage (Ui) of 750V AC Rated operation voltage (Ue) of 550V AC or 690V AC Power frequency: 50 or 60 Hz Control voltage: 48 to 415V AC (50/60 Hz), or 440V AC (60Hz only ), or 24 to 250V DC Over voltage Category IV up to a rated impulse voltage of 690V according to IEC 60664-1 Class II insulation, according to IEC 60664-1, between the front face and the internal power circuits Utilization category AC32B according to IEC 60947-6-1 13.4 Construction, operation and environment Operating temperature range: –25°C to +70°C. The transfer switch equipment shall have 3 pole or 4 pole variants, the number of poles for the normal and the replacement circuit breakers being compulsorily the same. By construction, the transfer switch equipment shall provide 3 stable positions : normal circuit breaker OPEN, CLOSED, replacement circuit breaker OPEN The OFF position will be an isolation position. It shall also be possible to lock each circuit breaker in the OPEN position. It shall be also possible to operate manually the transfer switch equipment in case of lack of control voltage. The remotely operated transfer switch equipment based on circuit breakers shall be of a mechanical locking type and/or an electrical locking type, in order to avoid any coupling possibility of the normal and replacement source. The transfer switch equipment shall contain obligatorily an electrical interlocking system. Last update :2017-05-08 - 87 - A combination of circuit breakers having different breaking capacities and switches shall be possible. In the case of utilization of a switch, the upstream protection shall have to be specified by the manufacturer. The transfer switch equipment shall contain 2 circuit-breakers (fixed or withdrawable), installed on a base plate. The 2 circuit breakers can be mechanically interconnected. The mechanical locking of the 2 fixed or withdrawable circuit-breakers shall be possible The transfer switch equipment based on circuit-breakers shall ensure the protection against overloads and short-circuits. The transfer switch equipment shall also contain an earth-leakage protection, by the means of an incorporated or separately mounted residual current device. In order to ensure the isolation suitability according to IEC 60947-1 and IEC 60947-2, §7.2.7, the mechanism shall be designed such that: the toggles or handles can only be in OFF position (O) if the power contacts are all actually separated, in OFF position, the toggles or handles shall indicate the isolation position. Isolation shall be provided by a double break on the main circuit. The minimum operating transfer time for the contacts of the transfer switch equipment will be less than 1 second. 13.5 Endurance The mechanical durability on the Normal Open – Replacement Close – Replacement Open – Normal Close (NO-RC-RO-NC) shall be: 10000 cycles, for the ratings ≤ 250A 8000 cycles, for higher ratings. The electrical durability on the NO-RC-RO-NC cycles for the operating voltages ≤ 440V shall be: 10000 cycles, for the ratings ≤ 250A 3000 cycles, for the ratings 400 – 630A The electrical durability on the NO-RC-RO-NC cycles for higher operating voltages shall be of 1500 cycles. 13.6 Auxiliaries It shall be possible to equip the transfer switch equipment with a downstream coupling device, simplifying the connection between the bars and the cables with lugs. It shall allow the association of circuit breakers of identical dimensions and shall be used on fixed versions only. Every circuit-breaker of the transfer switch equipment shall be equipped with auxiliary contacts et alarm contacts (TRIPPED state signaling) The transfer switch equipment shall be equipped with voltage presence indicators and it shall be possible to equip it with permanent insulation monitoring devices. Last update :2017-05-08 - 88 -
