ROTARY FREQUENCY CONVERTER:

Series RFC Guideform Specification

1.0 GENERAL:

1.1 Summary:
The following specification is intended for use by consultant engineering firms to provide bidding specifications for products with the quality and performance characteristics required for a rotary frequency converter system. This specification describes a three phase rotary frequency converter system and all its necessary operations. In order for a response to this request to be considered it shall require submittal of a proposal of adequate depth to fully define and identify the rotary frequency converter being offered. The rotary frequency converter, hereafter, shall be referred to as the "RFC".

1.2 Furnished with Equipment:

Factory Test Report
Protective Packaging
Installa
Warranty Statement

1.3 Documents & Standards:

National Electrical Code, NFPA 70-2005.
American National Standards Institute (ANSI).
NEMA Publications Number PB-1 and MG-1.
IEEE Standards 45.
Occupational Safety & Health Act (OSHA).
Local Codes & Authorities having jurisdiction for this installation.

1.4 System Description:

1.4.1:
The RFC shall be a rotary type with regenerated true sinusoidal waveform, with a regulated phase/voltage relationship output. The RFC and associated controls shall provide a means of electro-mechanically converting the Alternating Current (AC) power source to the desired output frequency. Electro-mechanical conversion inherently provides power conditioning, as well as, true electrical isolation through the mechanical couple.

1.4.2:
[Induction - Synchronous] or [Synchronous - Synchronous] Motor-Generator (M-G): This portion of the RFC system that shall generate new, clean AC true sinusoidal, phase/voltage relationship, regulated power to be supplied to the critical loads. The winding of the motor and generator shall be at least 23 cm (9") apart allowing for total electrical isolation from the input to output.

1.4.3:
The RFC shall be a single system rated to supply the full load as specified herein. A (N+X) paralleled RFC system shall be utilized for accomplishing redundancy, or for building power as required for the application. A redundant RFC system shall have each module rated to supply full load as specified. A paralleled RFC intended for building power shall be rated as specified by the requirement.

1.5 System Operation:

1.5.1 Normal:
Alternating current (AC) line power shall be supplied continuously to the RFC. The generator output shall be connected to the critical load within the specified voltage and frequency range.

1.5.2 Input Power Disturbance:
The RFC may drop off line when a disturbance to the normal AC power supply is encountered. Once the input power has been restored the RFC will automatically restart and resume operation. The automatic restart is a functional option when specified accordingly.

1.5.3 Output Power Disturbance:
If a disturbance to the downstream equipment being powered by the RFC is encountered, the RFC system will continue to supply conditioned AC power to the load. If the downstream disturbance could possibly short circuit the output of the RFC then the RFC will automatically shut down in order to protect its critical components. The RFC will not continue operation until manual restart is engaged.

1.6 Quality Assurance:

1.6.1:
The manufacturer shall have a Quality Assurance (QA) program in place with inspection of incoming parts, modular assemblies, and final products. The manufacturer shall have a designated QA manager who is responsible for overseeing the overall QA process, as well as, Quality Control (QC) representatives responsible for actively overseeing the manufacturing process.

1.6.2:
A final test procedure for the product shall include a check of all performance specifications and a minimum "burn in" period. An on-site test procedure shall include a check of controls and indicators after installation of the equipment.

1.6.3:
Storage, Handling, & Delivery: The equipment shall be shipped on a wooden pallet suitable for forklift handling. The equipment shall be covered with clear plastic sheeting to prevent dust and dirt from entering the unit during shipment. For international shipment, a wooden pallet will be constructed of treated wood and shall meet all other specifications required for international freight.

1.7 Submittals:

1.7.1 Proposal:
Catalog cut sheets and/or data sheets describing the proposed equipment shall be submitted with the proposal. A users listing shall be available upon request giving company names, locations, and systems installed. All deviations from this specification shall be listed and included with the proposal.

1.7.2 Receipt of Order:
A minimum of two sets of installation drawings showing outline dimensions, weights, connections, and a one-line diagram of the RFC shall be sent to the purchaser to be used in planning the installation of the system.

1.7.3 Formal Approval:
If a formal submitted approval is required for the project then the following should be requested, submitted, and approved before design/construction of the RFC commences:

Equipment Installation Outline
External Cabling Connection Diagram
Equipment One-Line Power Diagram
Equipment Elevation Drawing
"Other" Site Evaluation Diagrams

1.7.4 Delivery of Equipment:
As a minimum, the following shall be provided with the equipment upon its arrival to the final destination:

Operation & Maintenance Manual
System Installation Procedures
System Operation Procedures
System Troubleshooting Instructions
System Maintenance Milestones
Recommended Spare Parts List
Final Test Report Copy

1.8 Warranty:

1.8.1:
The manufacturer shall state the warranty of the equipment, and in no case shall it be less than 12 months after start-up or 18 months after shipment, whichever occurs first. A warranty statement will be provided with the equipment and included as part of the overall O&M manual.

2.0 PRODUCT:

2.1 System Size:

2.1.1:
The RFC system will be sized to handle any application up to 2,000kVA (LV) and 15,000kVA (MV).

2.2 RFC Input:

2.2.1 Input Voltage/Frequency:
208, 440, 460, 480, or 600 Volts (LV) and 4160, 7200, or 13800 Volts (MV) at 60Hz and 208, 380, 400, 415, or 600 Volts (LV) and 3300, 6600, 11000 Volts (MV) at 50Hz. These three phase input voltages are available in 3-wire (DELTA) or 4-wire (WYE) configurations.

2.2.2 Voltage Range:
+15% to -20% of Nominal.

2.2.3 Voltage Transient Impulse:
Up to 1500V for no more than 1 millisecond.

2.2.4 Starting Inrush:
Starting the RFC "Across the line" will be (6x) the nominal input amperage. Starting the RFC using a "Reduced voltage starter" (WYE-DELTA or Series Parallel) will be (3x) the nominal input amperage.

2.2.5 Power Factor:
0.8 Leading to 0.8 lagging.

2.3 RFC Output:

2.3.1 Output Voltage/Frequency:
208, 440, 460, 480, or 600 Volts (LV) and 4160, 7200, or 13800 Volts (MV) at 60Hz and 208, 380, 400, 415, or 600 Volts (LV) and 3300, 6600, 11000 Volts (MV) at 50Hz, and 200/115 and 208/120 Volts (LV) at 400Hz. These three phase output voltages are available in 3-wire (DELTA) and 4-wire (WYE) configurations.

2.3.2 Voltage Regulation:
1% Steady-state.

2.3.3 Recovery Time:
0.5 Seconds.

2.3.4 Voltage Adjustment:
+/- 10% of Nominal.

2.3.5 Frequency:
[25Hz, 50Hz, 60Hz, 100Hz, 200Hz, and 400Hz]

2.3.6 Transient Voltage Regulation:
+/- 8% with 50 step load.

2.3.7 Power Factor:
0.8 Lagging.

2.3.8 Harmonics:
5% RMS (Total) and 3% RMS (Single).

2.3.9 Phase Separation:
120° +/-1° (Balanced Load). 120° +/- 3° (Unbalanced Load).

2.3.10 Overload Capacity:
110% (Continuous), 125% (10 Minutes), 150% (1 Minute).

2.4 Environmental:

2.4.1:
The equipment shall be suitable for installation indoors (altitude 0 to 12,000 meters or 0 to 4,000 feet) with ambient temperatures ranging from 0° to +40°C (32° to +104°F) with 1% de-rating for each 1°C above 40°C up to 50°C, and relative humidity from 0% - 95% non-condensing.

2.4.2 Site Conditions:

Ambient: 0° to 40°C (32° to 104°F) with 50° and 55° (Optional).
Humidity: 0% to 95% Non-condensing.
Audible Noise: 90dB Open Frame. Lower noise levels (Optional).
Construction: Suitable for indoor application. Outdoor enclosures (Optional).
Bearings: Grease lubricated, Anti-friction type.
Service Factor: Continuous duty, 24-hour service.

2.5 Physical Characteristics:

2.5.1 Physical Description:

Brushless, two bearing [Induction] or [Synchronous] motor
Brushless, two bearing synchronous generator
Reduced current motor starter
Motor controls
Generator controls
Motor input circuit breaker
Brushless direct connected AC exciter with rotating filters
Belts and sheaves (4 Bearing Models)
Generator output circuit breaker
Common mounting steel base
[Spring] or [Rubber] Vibration isolators

2.5.2 Relay Logic Controls (Standard):

Motor Control: START switch of the RFC that activates the motor starter.
Motor Starter: Reduced voltage start system.
Instruments: Metering (2% Accuracy) shall monitor the following points: AC Input Voltmeter (Each line voltage with selector switch), AC Input Current (Each phase with selector switch), AC Output Voltage (Each line-to-line voltage with selector switch), AC Output Current (Each phase with selector switch).
Voltage Adjustment Range: Control shall provide +/- 10% adjustment from nominal.
Fault Detectors: The RFC shall be equipped with protective devices which shall shut the unit down and activate internal latched indicators. These indicators shall retain the fault indication after the rotational energy has stopped to simplify troubleshooting. The following faults will be detected: Output Over Voltage, Output Under Voltage, Starter Overload, Output Under Frequency, Motor Overload, Motor Over Temperature, and Generator Bearing Over Temperature.
Status Lights: Indicator lights shall indicate (Motor On), (Load On), and (System Fault). EPO Button: This feature provides for the interface of the customer supplied "Emergency Power Off" via a set of switchable normally close/normally open dry contacts.
Controls: The RFC control shall be mounted in a floor standing cabinet, or on the base with the motor generator set, depending on the rating and configuration chosen.
Power Outage Protector: The RFC shall be equipped with protector circuits, and in the event of a sustained power outage, the output will be disconnected when the output frequency decays to a preset level. Furthermore, the motor shall be protected from return of utility power before the RFC has coasted to a complete stop.

2.6 Construction:

2.6.1 Quality:

2.6.2 Design:

2.6.3 Experience:

2.6.4 Maintainability:

2.6.5 System Layout:

2.6.6 Installation:

2.7 Optional Features:

2.7.1 Two Beating, Common Shaft Design:

2.7.2 PLC Based Color Touch Screen Controls:

Motor Control: The START pushbutton on the RFC touch screen interface will activate the reduced current motor starter.
Motor Starter: Reduced current motor starting shall be accomplished by one of the following methods: Series Parallel, WYE-DELTA, Pony Motor, and Current Limiting Reactor. Depends on system specification and rating; consult factory for details.
Metering (1% Accuracy) shall monitor the following points: AC Input Voltage (Each Phase), AC Input Current (Each Phase), AC Output Voltage (Each Phase), AC Output Current (Each Phase), and System Output Power (kVA).
Voltage Adjustment Range: Output voltage control shall provide up to a 10% adjustment range from nominal using the color touch screen HMI.
Fault Detectors: The RFC shall be equipped with protective devices, which signal the PLC to shut the unit down and alarm. Each fault will be displayed on the touch screen for clarity. Each fault message shall have a date and time stamp to allow easy recognition of the latest fault. The fault messages shall be retained after the motor generator has stopped and after cycling power to simplify troubleshooting. The following faults will be displayed: Output Under Voltage, Output Over Voltage, Starter Overload, Output Under Frequency, Motor Overload, Motor Over Temperature, and Generator Bearing Over Temperature.
Event History: The PLC shall store the last 50 events and faults. The memory space shall be FIFO after it is full. Each event shall have a date and time stamp.
Emergency Power Off (EPO) Button: This feature provides for the interface of the customer supplied "Emergency Power Off" via a set of switchable normally closed/normally open dry contacts.
Controls: The RFC controls shall be mounted in a floor standing cabinet, or on the base of the motor generator set, depending on the rating and configuration chosen.
Power Outage Protector: The RFC shall be equipped with protector circuits and, in the event of a sustained power outage, the output will be disconnected when the output frequency decays to a preset level. Furthermore, the motor shall be protected from return of utility power before the RFC has coasted to a complete stop.

2.7.3 Remote Monitoring System:

Modbus: Modbus over serial line with RTU protocol. A modbus serial port is provided to remotely access the RFC modbus registers and status bits. All the RFC analog metering information, operational status information, and messaging will be provided via Modbus protocol. Modbus over TCP is also available. An Ethernet port is provided to remotely access the RFC Modbis registers and status bits the same as RTU but with a TCP interface that runs n Ethernet. Please contact factory for additional information.
Web Based: The web based remote monitoring/control feature puts the user at the control screen of the RFC, anywhere in the world, via the world wide web (www). The web interface can be programmed to give limited access based on responsibility or full access of the whole user interface. Please contact the factory for additional information.
Remote Color Touch Screen: All RFC analog metering and operational status are displayed on a remote screen that can be installed in secure or remote locations. All real-time data is displayed with a dedicated communications link. Link via Profibus DP or Profinet Industrial Ethernet. Please contact the factory for additional information.

2.7.4 Exhaust Silencer:

2.7.5 Sound Attenuated Enclosure:

2.7.6 Outdoor Rated Enclosure:

3.0 EXECUTION:

3.1 Manufacturing:

3.1.1:

3.1.2:

3.2.1.1:

3.2.1.2:

3.2.2:

3.2.3:

3.3:

3.3.1:

3.3.2: