PROSPECT PUMP STATION REHABILIATION...2019/07/18 · PROSPECT PUMP STATION REHABILIATION...

CUPERTINO SANITARY DISTRICT

PROSPECT PUMP STATION REHABILIATION

ATTACHMENTS TO SPECIFICATION

(DISTRICT FURNISHED MATERIALS AT NO COST TO THE CONTRACTOR)

1) TESCO CONTROLS, INC. DATED 6/27/2019, AS

AMENDED

2) SHAPE INC. - FLYGT PUMPS NZ3153 AND SERVICE CART

3) SHAPE INC. – FLYGT MULTISMART PUMP STATION MANAGER

4) SHAPE INC. – ABB INC. VARIABLE FREQUENCY DRIVES

1) TESCO CONTROLS, INC. DATED 6/27/2019, AS AMENDED

Corporate Office

8440 Florin Road, Sacramento, CA 95828

P.O. Box 299007, Sacramento, CA 95829

PH: 916.395.8800 FX: 916.429.2817

File Ref. 19D233Q02 Page | 1 of 3

To: Bidding Contractors Quote Date: 6/27/2019

Attn: Estimators Quote No.: 19D233Q02

Re: Cupertino Sanitary District Prospect Pump Station Improvements

Bid Date: 4/23/2019

Dear Customer: Thank you for your continued interest in TESCO products, services, and solutions. We are pleased to quote the following scope of work pertaining to the above-referenced project. Only the materials/services listed in the below scope are quoted in general conformance with the requirements of the applicable portions of sections: Electrical Drawings Only – Updated Finalized Drawings Received 6/26/2019

Scope of Work

Item Qty Description

1 1 Electrical Service / Control Panel to include: ▪ Custom Low-Profile Freestanding NEMA 3RX – 304 Stainless Steel

Enclosures to be Powder Coated Brown (5-Sections) ▪ Provisions for 400 Amp Utility Metering ▪ 400 Amp Main Disconnect Circuit Breaker ▪ Distribution Breakers as Required ▪ Surge Protection Device ‘SPD’ ▪ Power Failure Relay ▪ 400 Amp Automatic Transfer Switch ‘ATS’ with Controls ▪ 15 Amp Motor Circuit Protection ‘MCP’ Breaker ▪ Three-(3) 60 Amp Motor Circuit Protection ‘MCP’ Breakers ▪ Size 1 ‘FVNR’ Starter – Full Voltage Non-Reversing (Exhaust Fan

Starter) ▪ Three-(3) 20 HP Variable Frequency Drives ‘VFDs’ with

Programmable Keypads ▪ Three-(3) 3% Line Reactors ▪ Three-(3) Pump Controls & One-(1) Exhaust Fan Controls:

▪ Push-Buttons ▪ Indicating Lights ▪ HOA Switches ▪ Elapsed Time Meters

▪ Four-(4) Control Power Transformers ▪ 7.5 KVA Transformer ▪ Power Supplies ▪ Surge Protector ▪ Flygt Multi-Smart Pump Controller ▪ Battery Back-Up System ▪ Duplex Convenience Receptacle ▪ Panel Fan Kits ▪ Panel Lights and Switches ▪ Panel Heaters and Thermostats ▪ Nameplates, Terminal Blocks and Relays as Required

Drawings E-3 to E-5

Quotation TESCO CONTROLS, INC.


Item Qty Description

2 1 10” Magnetic Flow Meter

3 1 Level Transmitter

4 3 Float Switches with 65 Feet of Cable

5 Lot Professional Services: ▪ Engineering (Submittals and O&M Manuals) ▪ Project Management ▪ Manufacturing Services – Fabrication, Manufacturing, Assembly,

Equipment Wiring and Factory Testing ▪ Product Startup Services – Product Quality Review, Verification of

Product Installation, Product Parameter Adjustments, Product Programming, Software Upload/Download as Required, Instrument/ Device Signal Spanning, Product/Equipment Reconfiguration as Required, Product Function Checks and Product Startup

▪ Start-Up of Multi-Smart Controller & Level Instrumentation by Flygt

TOTAL EXPEDITED OPTION (including applicable sales tax): $177,065.00

PROJECT COMPLETION DATE OF 12/31/2019

Project Bid Clarifications

▪ Unless otherwise indicated by the Scope of Work above, quote is to furnish only and does not include any trade labor, trade work, construction work, site improvement, contractor services, or any trade installation services. Any trade labor and/or related trade work shall be performed by others/contractor.

▪ Unless otherwise indicated by the Scope of Work above, the following is not included within this quotation: ▪ 10” Flow Meter Quoted per Owner’s Direction on Line Sizing Required ▪ Pumps Show Existing on Plans (New Pumps Being Provided by Shape/Flygt) ▪ Conduit, field wire, tubing, or basic trade installation materials (brackets, j-box, stanchions, pull-box, etc.) ▪ Instrumentation mounting components, brackets, stanchions, sunshields, etc. ▪ Local control stations and/or field mounted disconnects. ▪ Instrumentation, devices, components, or equipment not specifically identified in the above quotation. ▪ Fiber optic patch panels, cable, splicing or terminations. ▪ Networking infrastructure or architecture modifications to existing facilities. ▪ Any 3rd party testing, harmonic testing/analysis, protective device coordination study, short-circuit

analysis, or Arc-Flash Risk Assessment (AFRA) services. ▪ Electrical interconnection diagrams for equipment not furnished by TESCO. ▪ ISA process control loop diagrams. ▪ Signal loop diagrams for equipment not furnished by TESCO.

Quotation TESCO CONTROLS, INC.


Terms and Conditions

▪ Quote is firm for 30 days unless otherwise stated. ▪ Standard Submittals: to be provided approximately 10-12 weeks after receipt of purchase order or written

notice of intent. o EXPEDITED SUBMITTALS REQUIRED: Approximately 4 Weeks After Receipt of Order

▪ Standard Delivery: to be scheduled approximately 12-16 weeks minimum after submittal approval. o EXPEDITED DELIVERY REQUIRED: Approximately 10-12 Weeks After Approval of Submittals

▪ Addendums Acknowledged: 0 ▪ Unless otherwise stated above, price does not include any sales tax, use tax, or applicable fees; please apply

any taxes and/or fees as appropriate. Please note that all invoices will include sales tax where applicable. ▪ TESCO price is FOB factory, full freight allowed. ▪ TESCO warranties against defect in design workmanship and materials for a period of one year from date of

installation and does not exceed 18 months from the date of shipment from the factory. ▪ TESCO carries liability insurance, with full workman's compensation coverage. ▪ Terms are net 30 days on approved credit accounts. ▪ Interest will be applied to all past due invoices. ▪ All merchandise sold is subject to lien laws. ▪ Final retention to be paid within 10 days after the project notice of completion. Please feel free to contact us at (916) 395-8800 to discuss any questions or comments you may have regarding this quotation. Sincerely, TESCO CONTROLS, INC.

Tim Fassio Water/Wastewater Sales Estimator [email protected]

2) SHAPE INC. - FLYGT PUMPS

NZ3153 AND SERVICE CART

SHAPE INC. SUBMITTALSubmitted To: Mark Thomas Cupertino SD Date: 8-Jul-19

Submittal No.: 1.0Engineer: AECSalesman #: 134

Project Name: Prospect Pump Station Improvements Shape Job#: 8202FLEquip.Specification:Number and Name: Waste Water Pumps 1, 2 & 3 QTY DESCRIPTION

3 Pump:NZ3153 HT 463 Hard Iron

Manufacturer:Flygt

Installation:Dry Pit Horizontal

Design Conditions:

Shut Off:124ft

#1) GPM: #1) TDH:599 70.9ft

Suction:Flooded

Discharge:4”

Options: #1)Explosion Proof Motor #2)65ft of shielded power cable #3)FLS Moisture Detection/Thermal Switch

3 Motor:Submersible

Frame:3153

H.P.:20

Insulation:H

NEMA:B

Volts:460

Phase:3

Hertz:60

R.P.M.:1,755

S.F.:1.15

FLA:26A

Description: #1)Explosion Proof #2)Power Cable OD: ” (2 .0mm)

QTY ACCESSORIES3 Flygt NZ3153.095 – HT463 Hard Iron Impeller, 4” Discharge, 20HP, 460V/3/60, FM (Explosion Proof),

FLS (Leakage Sensor), Motor Thermal Protection, 65ft of Shielded Power cable 3 Flygt “Z” Stand Kits (Includes suction unit w/ telescopic opening, and hardware)3 Flygt “Z” Service Kart, 316SS3 Flygt Service Kart Rails, 316SS1 Flygt Service Lifting Device1 Lot: Factory Testing (1 Test Per Pump)1 Lot: Standard Factory Coating on Pumps1 Lot: Startup Assistance, Documents & Freight (Expedited)

Notes: #1) All Pumps Motors Inverter Rated

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Issued: Supersedes:

N-3153.185,095Materials of Construction

8/13

Major Castings:

Pump Lifting Handle:

Motor Cable:

Cable Entry Grommets:

Shaft:

Impeller:

Insert Ring

O-Rings:

Lubricant Plug

Screws, studs and nuts

Inner Mechanical Shaft Seal:

Outer Mechanical Shaft Seal:

Components Cast Iron Pump

Cast iron, A48, Class 35B

Stainless steel

Chloroprene rubber jacketed

Nitrile rubber

Stainless steelASTM A479 S43100-T

Hard IronTM (25 ASTM A-532 (Alloy III A) 25% chrome cast iron)

Hard IronTM (25 ASTM A-532 (Alloy III A) 25% chrome cast iron)

Nitrile rubber

316 Stainless steel

316 Stainless steel

*Tungsten carbide/*Tungsten carbide

*Tungsten carbide/*Tungsten carbide

1/13

*All corrosion and abrasion resistant

Conductors(in one cable)

Cable Size/Nominal O.D.

Standard - Unshielded Cable

Conductors(in one cable)

Cable Size/Nominal O.D.

Optional - Shielded Cable

PartNumber

PartNumberAWG**

PartNumber

Power Cable - cross reference

rgarcia

Rectangle

rgarcia

Rectangle

Issued: Supersedes:

Model

3085

3102

3127

3153

3171

3202

3301

3315

Description

Z - Stand Kit

Z - Stand KitZ - Stand KitZ - Stand Kit


Z - Stand KitZ - Stand KitZ - Stand KitZ - Stand KitZ - Stand Kit


Z - Stand KitZ - Stand KitZ - Stand KitZ - Stand KitZ - Stand Kit

Z - Stand KitZ - Stand KitZ - Stand KitZ - Stand Kit

Z - Stand KitZ - Stand KitZ - Stand KitZ - Stand Kit

Steel

Part number

768 23 00

768 23 11768 23 10768 23 10

768 23 11768 23 11768 23 10

768 25 03768 25 04768 25 00768 25 01768 25 02

768 25 12768 25 11768 25 10

768 25 23768 25 21768 25 22768 25 21768 25 20

768 25 33768 25 34768 25 32768 25 31

768 25 37768 25 38768 25 36768 25 35

Z Stand Kits

Version

MT/SH

LTMTSH

LTMT

HT/SH

LT 4 poleLT 6 pole

MTHTSH

LTMT

HT/SH

LTMT 4 poleMT 6 pole

HTSH

LT 6 poleLT 8 pole

MTHT

LT 6 poleLT 8 pole

MTHT

Telescoping Inlet

SS 316

Part number

--

------

------

785 90 03785 90 04785 90 00785 90 01785 90 02

785 90 12785 90 11785 90 10

785 90 23785 90 21785 90 22785 90 21785 90 20

785 90 33785 90 34785 90 32785 90 31

785 90 37785 90 38785 90 36785 90 35

6/14 5/13

TelescopingInlet

1/4" pressure gauge

connection

Issued: Supersedes: 6/14

NZ Accessories

3153

3171

3202

3301

3315

Service Cart

Service Cart

Service Cart

Service Cart

Service Cart

767 40 00767 40 10

767 44 00/01767 44 10/11

767 48 00/01767 48 10/11

767 52 00/01767 52 10/11

767 52 01767 52 11

Service Carts

Rail

Service Cart Rails

3153

3171

3202

3301

3315

Rail

Rail

Rail

Rail

Rail

767 43 00767 43 10

767 47 00/01767 47 10/11

767 51 00/01767 51 10/11

767 55 00/01767 55 10/11

767 55 02767 55 12

SteelSS 316

SteelSS 316

SteelSS 316

SteelSS 316

SteelSS 316

Model Description Material Part number

Part numbers ending in 00 & 10 are for pumps with standard motors.Part numbers ending in 01 & 11 are for pumps with extended premium efficiency motors.

Model Description Material Part number

SteelSS 316

SteelSS 316

SteelSS 316

SteelSS 316

SteelSS 316

Part numbers ending in 00 & 10 are for pumps with standard motors.Part numbers ending in 01 & 11 are for pumps with extended premium efficiency motors.

Service Cart

5/13

Issued: Supersedes: 6/14

Z Accessories

Model

3085

31023127

Description Part number

768 21 00

768 56 00

Pump Lifting Devices

All components below are included in kit.

Service Lift

Service Lifting Bracket

Model

315331713202

33013315

Description Part number

768 48 00

768 48 01

Service Lifting Device

Service Lifting Device

3085

3102 & 3127

Lifting drive unit onlyLifting complete pump

Service Lift Lifting Bracket

Flygt Dry Horizontal InstallationsSTRAIGHTFORWARD MAINTENANCE AND SERVICING IN A SAFE WORKING ENVIRONMENT

A safe and smart installation for wastewater pumps

Benefits of a dry horizontal installation

Faster maintenance and servicing with the Flygt patented telescopic inlet.

Sometimes you will require access to the impeller without having to dismantle the entire pump. For horizontal installed systems, our patented telescopic inlet provides access to the pump suction end.

1 Safe handling with lifting equipment and service cart/sled. Horizontal installed

Flygt pumps can be equipped with a service cart/sled that ensures safe pump handling.

2

For years we have been there, onsite, day in, day out, helping customers around the world. This has given us a unique understanding when it comes to managing wastewater and sludge. With over 60 years of experience, we can ensure a high degree of predictability when handling challenging media – experience that is easily available and proven through new innovation and groundbreaking technology. This experience led us to develop and launch a cutting-edge dry installation assortment ensuring the best suction performance and operational efficiency, whilst also allowing ease of service without dismantling the entire pump. Flygt’s innovation is consistently evolving to try and solve customer challenges. For example, the new patented telescopic inlet means getting into the pump impeller to check clearance or to service, is now a straight-forward and trouble free operation.

Unique solution for large capacity pumpsPumps with an inlet size above 350 mm (14”) use the patented pivoting service inlet providing the same benefits with faster maintenance and servicing as the telescopic inlet. The larger pumps also use a service sled instead of the wheeled cart and a double acting hydraulic actuator providing safe handling and an improved working environment.

Improved working environment and better drainage. Flygt submersible pumps

installed in dry installations offer flood-proof motors. If the pump station is flooded, the pump keeps on working. We have also added a drainage port to ensure the pump housing is empty before any work begins on the pump – a simple innovation that makes a big difference to your working day.

4

Plus all the benefits of Flygt’s self-cleaning N-technology pumpsN-technology pumps are designed to handle the world’s toughest wastewater and sludge applications. Every N-pump is designed, engineered and manufactured with care to optimize operations, delivering efficient and continuous pumping, thereby cutting the total cost of ownership.

Horizontal Installation – Z 3085-3127 Concertor® 3153-3356 3351-3800

Patented telescopic inlet • • •

Pivoting service inlet O

Pressure gauge connection • • •

Lifting equipment O O O O

Service cart O O O

Service sled O

Drainage hole • • •

( O = Optional )

Enhanced performance and efficiency. Horizontally installed pumps benefit from

higher available NPSH (Net Positive Suction Head) and no need for shaft alignment compared to vertically installed systems. Additionally, we have added a connection valve for a pressure gauge.

3

1) The tissue in plants that brings water upward from the roots2) A leading global water technology company

We’re a global team unified in a common purpose: creating advanced technology solutions to the world’s water challenges. Developing new technologies that will improve the way water is used, conserved, and re-used in the future is central to our work. Our products and services move, treat, analyze, monitor and return water to the environment, in public utility, industrial, residential and commercial building services settings. Xylem also provides a leading portfolio of smart metering, network technologies and advanced analytics solutions for water, electric and gas utilities. In more than 150 countries, we have strong, long-standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise with a strong focus on developing comprehensive, sustainable solutions.

For more information on how Xylem can help you, go to xyleminc.com

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Xylem, Inc.4828 Parkway Plaza BlvdCharlotte, NC 28217Tel 704.409.9700Fax 704.295.9080855-XYL-H2O1 (855-995-4261) www.xyleminc.com

WARRANTYXylem Water Solutions USA, Inc.

Ver.14 -0

For the period defined, Xylem Water Solutions USA, Inc. offers a commercial warranty to the original End Purchaser against defects in workmanship and material on Flygt Products. Warranty covers Flygt parts and labor as outlined in ADDENDUM – A.

COVERAGE: Xylem Water Solutions USA, Inc. will pay the cost of parts and labor during the warranty period, provided that the Flygt product, with cable attached, is returned prepaid to a Xylem Water Solutions USA, Inc. Authorized Service Facility for Flygt Product repairs. Coverage for Flygt parts and labor will be provided for the period shown in ADDENDUM - A. The warranty period will begin from date of shipment or date of a valid Start-up (For permanently installed pumps only). In cases where the Start-up date is used as the beginning of the warranty on a permanently installed Flygt pump, a Start-up Report completed by an approved service technician from a Xylem Water Solutions USA, Inc. Authorized Service Facility for Flygt products must be received by the Xylem Water Solutions USA, Inc. Area Service Manager for Flygt Products within thirty (30) days of the initial onset of the unit placed into service. If not received, the beginning of the warranty coverage will default to the Flygt product ship date. A Start-up for a permanently installed Flygt pump must occur within one (1) year from the date of shipment from a Xylem Water Solutions USA, Inc. authorized facility for Flygt Products or warranty will automatically default to ship date as start of warranty. (See STORAGE section) When using the start-up date as the beginning of the warranty, a copy of the Start-up Report will be required to support any Warranty Claims. Warranty on Flygt Dewatering pumps will begin with ship date only. No other date on Flygt Dewatering pumps will be considered.

Xylem Water Solutions USA, Inc.’s sole obligation under this Warranty for Flygt Products shall be to replace, repair or grant credit for Flygt Products upon Xylem Water Solutions USA, Inc.’s exclusive determination that the Flygt Product does not conform to the above warranty. In the event that the Flygt product is replaced, warranty on the replacement product will be equal to the balance remaining on the original product or ninety (90) days, whichever is greater.

MISUSE: This Warranty shall not apply to any Flygt product or part of Flygt product which (i) has been subjected to misuse, misapplication, accident, alteration, neglect, or physical damage (ii) has been installed, operated, used and/or maintained in a manner which is in an application that is contrary to Xylem Water Solutions USA, Inc.’s printed instructions as it pertains to installation, operation and maintenance of Flygt Products, including but without limitation to (iii) operation of equipment without being connected to monitoring devices supplied with specific products for protection; or (iv) damaged due to a defective power supply, improper electrical protection, faulty installation or repair, ordinary wear and tear, corrosion or chemical attack, an act of God, an act of war or by an act of terrorism; or (v) has been damaged resulting from the use of accessory equipment not sold by Xylem Water Solutions USA, Inc. or not approved by Xylem Water Solutions USA, Inc. in connection with Flygt products.

WEAR PARTS: This warranty does not cover costs for standard and/or scheduled maintenance performed, nor does it cover Flygt parts that, by virtue of their operation, require replacement through normal wear (aka: Wear Parts), unless a defect in material or workmanship can be determined by Xylem Water Solutions USA, Inc.. Wear Parts are defined as Cutters, Cutting Plates, Impellers, Agitators, Diffusers, Wear Rings (Stationary or Rotating), Volutes (when used in an abrasive environment), oil, grease, cooling fluids and/or any items deemed necessary to perform and meet the requirements of normal maintenance on all Flygt equipment.


Ver.14 -

DISCLAIMERS: (i) Xylem Water Solutions USA, Inc.’s warranties are null and void when Flygt Products are exported outside of the United States of America without the knowledge and written consent of Xylem Water Solutions USA, Inc.; (ii) Xylem Water Solutions USA, Inc. makes no independent warranty or representation with respect to parts or products manufactured by others and provided by Xylem Water Solutions USA, Inc. (however, Xylem Water Solutions USA, Inc. will extend to the Purchaser any warranty received from Xylem Water Solutions USA, Inc.’s supplier for such parts or products).

LIMITATIONS: XYLEM WATER SOLUTIONS USA, INC. NEITHER ASSUMES, NOR AUTHORIZES ANY PERSON OR COMPANY TO ASSUME FOR XYLEM WATER SOLUTIONS USA, INC., ANY OTHER OBLIGATION IN CONNECTION WITH THE SALE OF ITS FLYGT EQUIPMENT. ANY ENLARGEMENT OR MODIFICATION OF THIS WARRANTY BY A FLYGT PRODUCT DISTRIBUTOR, OR OTHER SELLING AGENT SHALL BECOME THE EXCLUSIVE RESPONSIBILITY OF SUCH ENTITY.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY AND ALL OTHER EXPRESS OR IMPLIED WARRANTIES, GUARANTEES, CONDITIONS OR TERMS OF WHATEVER NATURE RELATING TO FLYGT PRODUCT(S), INCLUDING AND WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH ARE HEREBY EXPRESSLY DISCLAIMED AND EXCLUDED. PURCHASER’S EXCLUSIVE REMEDY AND XYLEM WATER SOLUTIONS USA, INC.’S AGGREGATE LIABILITY FOR BREACH OF ANY OF THE FOREGOING WARRANTIES IS LIMITED TO REPAIRING OR REPLACING FLYGT PRODUCTS AND SHALL IN ALL CASES BE LIMITED TO THE AMOUNT PAID BY THE PURCHASER HEREUNDER. IN NO EVENT IS XYLEM WATER SOLUTIONS USA, INC. LIABLE FOR ANY OTHER FORM OF DAMAGES, WHETHER DIRECT, INDIRECT, LIQUIDATED, INCIDENTAL, CONSEQUENTIAL, PUNITIVE, EXEMPLARY OR SPECIAL DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF USE, LOSS OF PROFIT, LOSS OF ANTICIPATED SAVINGS OR REVENUE, LOSS OF INCOME, LOSS OF BUSINESS, LOSS OF PRODUCTION, LOSS OF OPPORTUNITY OR LOSS OF REPUTATION.

XYLEM WATER SOLUTIONS USA, INC. WILL NOT BE HELD RESPONSIBLE FOR TRAVEL EXPENSES, RENTED EQUIPMENT, OUTSIDE CONTRACTOR'S FEES, OR ANY EXPENSES ASSOCIATED WITH A FLYGT PRODUCT REPAIR SHOP NOT AUTHORIZED BY XYLEM WATER SOLUTIONS USA, INC. U.S.A., INC. REIMBURSEMENT COSTS FOR CRANES AND/OR ANY SPECIAL EQUIPMENT USED IN CONJUNCTION FOR THE REMOVAL AND/OR REINSTALLATION OF ANY FLYGT EQUIPMENT IS NOT COVERED UNDER THIS WARRANTY.

ANY UNAUTHORIZED ALTERATIONS TO SUPPLIED FLYGT EQUIPMENT USED WITHOUT XYLEM WATER SOLUTIONS USA, INC. SUPPLIED FLYGT BRAND CABLE OR CONTROLS WILL NOT BE COVERED UNDER THIS WARRANTY, UNLESS IT CAN BE PROVEN SUCH ANCILLARY EQUIPMENT IS SUITABLE FOR THE PURPOSE AND EQUAL TO XYLEM WATER SOLUTIONS USA, INC. SUPPLIED FLYGT BRAND CABLES OR CONTROLS THAT WOULD ORIGINALLY HAVE BEEN SUPPLIED WITH THE TYPE OF EQUIPMENT IN USE.

REQUIREMENTS: A copy of Electrical System Schematics of the Control used (including a Control’s Bill of Material) could be required to support a Warranty Claim when a non Flygt Brand Control is used. In addition, a written record, hereby known as “the log”, will be associated with each unit serial number and must be maintained by the organization having product maintenance responsibility. The log must record each preventative maintenance activity and any repair activity during the life of the warranty or verification that a Xylem Water Solutions USA, Inc. authorized Service Contract for Flygt Products is in force and must be available for review and/or auditing. Failure to meet these conditions could render this warrant null and void. Such logs could be required to determine warranty coverage.


Ver.14 -

STORAGE: Should a delay occur between ship date and the date of start-up, maintenance as outlined in Xylem Water Solutions USA, Inc.’s Care & Maintenance Manual for Flygt Products must be performed by the “CONTRACTOR” and/or “OWNER” during any such period of storage. Documentation providing proof and outlining what maintenance was performed must be provided to Xylem Water Solutions USA, Inc. or its Flygt Products representative within thirty (30) days of said maintenance, or the Xylem Water Solutions USA, Inc. warranty for Flygt Products could be considered void.

CONTROLS: Warranty coverage for permanently installed controls will start for the end purchaser on the date of shipment. This warranty does not apply to controls that have been damaged due to a defective and/or improper input power supply, improper electrical protection, accidental damage, improper or unauthorized installation and/or repair, unauthorized alteration, negligence, environmental corrosion or chemical attack, improper maintenance or storage of control, any act of God, an act of war, an act of terrorism or damage resulting from the use of accessory equipment not approved by Xylem Water Solutions USA, Inc.. Further, this warranty does not apply in the event an adjustment is found to correct the alleged defect.

Solid state devices will be covered for a period of one (1) year. Electrical control panels containing controllers, PLC’s, drives, soft starts, and other computerized equipment will require Transient Voltage Surge Suppression (TVSS) protection in order to satisfy the requirements of this warranty. The protection equipment associated with the control must be kept in working condition during the life of the warranty. Auxiliary equipment supplied with the control (air-conditioners etc.) is limited by the respective original equipment manufacturer’s warranty offered. Consumable items such as: light bulbs, fuses, and relays are covered under normal operating conditions. Electrical surges experienced during startups and/or during normal operating use of the control panel will cause the consumable items not to be covered under this warranty policy. Components not supplied by Xylem Water Solutions USA, Inc. will not covered by this warranty.

TOP (The Optimum Pump Station) Xylem Water Solutions USA, Inc. will warrant the Flygt TOP pre-engineered fiberglass pump station components against defects in material and workmanship for a period of one (1) year from date of start-up or eighteen (18) months from date of shipment and is valid only to the original owner of the station. Warranty shall cover the cost of labor and materials required to correct any warrantable defect, excluding any removal and reinstallation costs, FOB Xylem Water Solutions USA, Inc.’s authorized warranty service location for Flygt’s TOP.

Flygt Products contained within a TOP pre-engineered fiberglass pump station will carry the standard Xylem Water Solutions USA, Inc. warranty for Flygt products and/or accessories installed in the TOP pre-engineered fiberglass pump station.

All Flygt Product restrictions and/or limitations as outlined and described within the context of this warranty are germane to all sections of this Xylem Water Solutions USA, Inc. Warranty document.

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3) SHAPE INC. – FLYGT

MULTISMART PUMP STATION MANAGER

Document MultiSmart Pump Station Manager Specification

Date January 6, 2016

Revision 7.0

MultiSmart version 3.3.4

Specification MultiSmart Pump Station Manager Specification

MultiSmart Pump Station Manager Specification

Page 2 of 12 MultiSmart Specification R7

1 Functionality The Pump Station Manager shall provide “Out of the box” control of a typical pump station, with an intuitive user-interface. The product shall come with pre-built configuration parameters which are selectable via the user interface, including:

• Functionality for advanced pump control of up to 6 pumps

• Pump mode, for each pump, between Auto/ Manual / Off

o In manual control (semi-automatic manual) pump switches off at deactivation setpoint and reverts to Auto mode to prevent accidental pump run on

o To pump beyond off set point in manual button must be held down (full manual)

• Setpoint adjustment for pump activation/deactivation and level alarms

• Level device from 4-20mA, conductive probe or remote level

o Redundant level device handling

• Selectable between fill / empty

• Functionality for advanced pump control of up to 6 pumps including grouping and alternation

• VFD control algorithm

o Pump Cleaning Function

When reading current from the VFD or from current transformers the MultiSmart iPSM may detect pump clogging and implement a self-cleaning function.

Hard Clogging: When motor currents exceed a pre-set limit, the VFD is stopped then sent the reversing and forward run commands timed to clear the debris from the impeller. This can be performed one or more times until the debris is cleared. Once the cleaning function is complete the MultiSmart iPSM returns to normal operation.

o Sump Cleaning Function

To insure solids and grease do not build up in the sump, the controller shall have the option for a sump cleaning function.

The sump cleaning function may be configured to operate on one of the following.

1. Set number of pump cycles.

2. One of four timers

The sump cleaning function shall operate the pumps at full speed until one of the following options is met.

1. Pre-determined level setpoint

2. Low power factor as read from the VFD or calculated from CT’s

3. Low motor current as read from the VFD or CT’s

4. Low flow rate as read from flow meter

5. Pre-determined amount of time

o Pipe Cleaning Function

Adjustable startup sequence allows running motor at full speed to clear debris in the pipe and prevent the motor from clogging.

This feature allows for the VFD to be sent a speed and time reference to run the motor at during the beginning of each cycle to allow for the clearing of debris in the pipe and to prevent pump clogging.



The initial speed reference is 100% for 10 seconds but is configurable to meet system requirements.

o Energy Efficient Speed Reference

The VFD algorithm will find the speed at which the outflow rate matches the inflow rate which may run the pump at a more efficient rate than full speed.

This will also minimize pump starts and stops and reduce wear and tear on bearings, seals and valves.

o Ability to run at a set speed when in manual mode

o Automatic speed adjustment when multiple pumps are running so not to increase flow rapidly and reduce water hammer.

o Runs all pumps at the same speed reference

o Speed reference is controlled by 4 parameters

Start speed as a percentage of total speed

Full speed level setpoint

Off level/minimum speed

Speed compensation

o Example VFD speed operation

• Station optimization including

o Max off time (odour reduction)

A timer that shall start a pump after the configured time has expired and will run one or more pumps to the pre-set off point

o Maximum pumps to run (overload protection)

Pump controller shall have a configurable maximum number of pumps allowed to run at a single time and whether to stop a running pump and start a lag pump or to prevent a lag pump to start.

o Maximum starts per hour (pump protection)



o Inter-pump start and stop delays

Pump controller shall provide delays for the following

• Start-start delay to prevent multiple pumps from starting at the same time and overloading electrical and hydraulic equipment

• Stop-stop delay to prevent or reduce the effects of water hammer

• Stop-start delay to prevent a pump from starting while a pump is ramping down and possibly damaging valves

• Start-stop delay to prevent a pump from stopping shortly after a pump has started and possibly damaging valves

o Maximum run time (turn off inefficient or partially blocked pumps)

Pump controller shall shut a pump off and optionally set an alarm if a motor has been running longer than normal

o Blocked pump detection

Pump controller shall have configurable option to detect pump blockages and take action when a pump blockage occurs using one or more of the following options

• Low power factor detection

• Lag pump start counter

• Low metered flow rate

Optional features may be required

o Well washer controls

o Well clean out (periodic pump down to snore point)

Pump controller shall have the ability to pump to the snore point using the following methods

• Configurable amount of time to pump below the off point

• Pump down to a configurable level point

• Detect low motor power factor

• Detect low motor current consumption

o Pump groups with different configurations (e.g. alternation schemes) for each group

• “Locked level” alarm to indicate level device problem

o User-defined % change within a time period

o Different values for low use, high use times (user defined)

• Flow measurement/calculation

o Calculated flow via draw down test

o Not available when using VFD to control motor speed

• Alternation schemes including:

o Fixed lead/duty

o Alternation

o Alternation N:1 (e.g., 3:1)

o Run most efficient pump, N:1 ratio, e.g. more efficient pump runs 20 times for each operation of the less efficient pump(s)

o Alternation by hours run or starts

• Pump decommission/commission



o Decommissioned pump automatically removed from control algorithm, alarms, displays, etc

o SCADA tag flags decommissioned status

• Six profiles of setpoints for spill management, off peak pumping, tariffing, etc

o Automatic profile change on date/time

o Selectable from SCADA, digital input, logic tag or faceplate

o Profile includes some pump control parameters – max no of pumps, max run time, max off time

• Datalogger for user-defined faults and events (process values)

o 50,000 events to internal flash memory

o 10,000,000 events by writing direct to Compact Flash card

o Download event and fault log as csv to Compact Flash for Excel analysis

o ftp transfer of event and fault log as csv for Excel analysis

• 3-phase supply monitoring and supply protection

o Under-voltage

o Over-voltage

o Phase fail

o Phase rotation

• Monitoring of dc supply, battery voltage, and internal temperature

• Energy, power and pump efficiency monitoring:

o kW, kVA, power factor, kWHr, KVAH calculation for each pump

o pump efficiency calculation (litres or gals per KWHr) for each pump

• Motor protection including:

o 3-phase current monitoring for each pump

o Over- and under-current trip

o Ground/earth fault

o Current phase imbalance fault

o I2T fault

o Insulation resistance testing for motor windings

Values and user-definable fault threshold

Perform test at 250,500 or 1000 VDC

• Fault module with flexibility for any fault to

o hold out pump(s) or be display only

o auto-restart after user-defined time subsequent to fault condition clearing

o auto-restart user-defined number of times (subsequent to fault condition clearing) before locking out

o Manual/ SCADA reset required

• Built in Web Server

• Remote control via SCADA for

o changing mode of pumps (auto/off/manual)



o reset of pump and station faults

o changing pump and alarm setpoints

o changing setpoint profiles

• Security

o Admin user sets PINs for access to configuration of the unit

o Automatic datalogging of who has entered the configuration menu

o Automatic logging of all unsuccessful login attempts with date/time

o Digital input option, e.g. key switch, for access to configuration menu

• SD and USB port allows

o Firmware upgrades

o Save/load configuration (allows backup to be restored, or configuration copied from another station)

o Download datalogger in CSV

o Export/import Modbus and DNP3 points list in csv format

2 Programmability The product shall have the option of IEC61131-3 and IEC61499 compliant PLC programming language to enhance/interact with all the modules in the pump station manager.

The product shall have the option of a simple logic engine to enhance/interact with all the modules in the pump station manager.

3 I/O The I/O shall be expandable to many hundreds of I/O points per unit.

Available I/O types shall include:

• Digital inputs (voltage free input), also configurable as counters

• Digital outputs (240V, 5A resistive)

• Analog inputs (10bit)

• Analog outputs (10bit)

3.1 Digital Inputs configurable for seal, thermistor, and other pump station requirements Additionally, the Digital Inputs shall be selectable as pump station specific I/O to reduce components in the panel and therefore save cost, e.g. remove pump relays such as mini-CAS relays, MAS relays.

• Seal sensor (conductive)

• PTC Thermistor

• Flygt FLS & CLS

• Conductive probe (for liquid level sensing)

3.2 Specific I/O for motor protection and current/voltage monitoring The product shall have I/O cards to minimise additional components which include:

• Insulation resistance test (IRT) to 1000v



• 3-phase current monitoring, derived from CT’s, 0.5% resolution

• 3-phase supply monitoring, 0.5% resolution. Up to 630V phase to phase.

3.3 Support for Duo Probe The product shall have an internal atmospheric pressure sensor to allow for atmospheric pressure sensing and correction.

4 User interface The field hardware shall include a user interface for operations and configuration. The display shall provide status of most aspects of the pump station, control of pumps, resetting of faults, and configuration of parameters.

4.1 Status The following parameters shall be displayed on the main screen:

• Level in user definable units eg %, metres or custom units

• Setpoints for alarms and pump start/stop

• Pump running/stopped

• Pump available/unavailable

• 3-phase current for each motor

• Faults

• 3-phase supply

• Date/time

• User-configurable option to display pump efficiency, flow rates, total starts, total hours run and other parameters

The screen will also have buttons to allow the user to access Faults, History, Information and Settings.

4.2 Information screens The following parameters shall be available via a user key press from the main screen:

• Hours Run accumulators for each pump & the station with the following comparisons

o last minutes run

o this hour, last hour

o today, yesterday

o this week, last week

o total hours run

• Starts accumulators for each pump & the station with the following comparisons

o this hour, last hour

o today, yesterday

o this week, last week

o total starts

• Flow values, either derived from calculations or via a flowmeter

o Inflow

o pump flow rate



o total volume

o overflow data, including start time, duration, estimated volume



• Power & efficiency

o pump efficiency in litres or gals per kWHr - or KVAH

o power in kW, KVA

o power factor

o energy accumulators per pump in KWHr and KVAH

• Insulation resistance value for each motor from 1000v test

• Status of all I/O

o Digital I/O open/closed and accumulator

o Analog I/O mA and scaled

o 3-phase voltage, current, frequency, phase angle, power factor

• Database viewer to view all datapoints/tags in real time

• Communications stats

4.3 Control The following aspects of the system, as a minimum, shall be controlled intuitively through the user-interface:

• Pump mode, for each pump, between Auto/ Manual (Hand)/ Off

• Pump fault reset

• Level alarm reset

4.4 Fault screen The main screen shall include a Fault button which takes the user to a Fault screen and allows them to check all current and unacknowledged alarms.

The fault screen will detail the fault (e.g. contactor fail, seal fault, motor overtemp, over-current, etc) along with date/time each fault occurred and cleared.

A reset option for a fault will be presented to the user when faults can be acknowledged/reset.

4.5 History screen The main screen shall include a History button which takes the user to a History screen

• View all date/time stamped faults and events

• Filter by pump or other station parameters, by time period

• Export via CSV for analysis in Excel

4.6 Configuration The user interface should allow intuitive configuration of the system, including as a minimum:

• Setup Wizard to allow a complete configuration (display, IO and configuration of functional blocks) by the user answering simple questions

• Set-points, including alarm and pump setpoints

• Enable/disable level alarms (so that for example, the low level alarm can be easily activated or deactivated)

• Start, stop and alarm delays



• Alternation/ fixed sequence and grouping of pumps where necessary

• Configure I/O

o Assign primary/backup level to any input, e.g. 4-20mA or conductive probe

o Assign pre-defined (or user-defined) faults, e.g. thermal overload, contactor fail, to any digital input

o Zero and span analog inputs

o Set Digital outputs to change state with any digital tag in the system

o Set Analog outputs to follow any analog value, including primary level

• Fault configuration for each fault to either

o display only

o manual/SCADA reset before pump becomes available

o auto-restart (after fault condition clears) with configurable restart time

o auto-restart user-selectable number of times within time window before locking out

o customized text for fault and event name

• Pump station optimization parameters such as:

o Max off time (odour reduction)

o Maximum pumps to run (overload protection)

o Maximum starts per hour (pump protection)

o Inter-pump start and stop delays

o Maximum run time (turn off inefficient or partially blocked pumps)

o Well washer controls

o Well clean out (periodic pump down to snore point)

o Random duty start (random time after activation point reached before pump starts) to reduce fat build up

o Optimization parameters applied differently to different groups of pumps if required

• Supply protection

o Under- and over-voltage alarm points

o Volts phase imbalance and volts phase rotation

o DC-supply alarm point

• Motor protection

o Under-current

o Over-current

o Ground/earth fault

o Phase fail

o I2T protection

• Communications ports, speeds and addresses

The configuration of the unit will also allow the user to save a known good configuration on the unit itself that they can revert back to at any time.



4.7 Configuration backup and restore & Firmware upgrades The Configuration interface will allow the user to save and restore configurations onto a SD card or USB storage device, to allow easy configuration from saved versions (or copying settings from one site to another).

The unit will allow the user to backup system log files, alarm and event log files, and custom scripts via the SD or USB ports.

The unit shall allow for the import of DNP3 and Modbus point lists and custom logic scripts via the SD or USB ports.

Firmware upgrades will be possible by copying the upgrade image onto a SD card, or USB storage device, then inserting into a field unit and cycling power.

4.8 Maintainability The supplier shall also demonstrate that their system is maintainable in the future, especially that future applications do not incur any user-interface development cost on the customer, i.e., the user-interface shall be an integral part of the system.

5 Communications Integral RTU/outstation

5.1 Physical The product shall include:

• Two Ethernet ports to 10Mbit/s

• Two RS232 ports to 115kBit/s

• Two RS485 ports to 115kBit/s

5.2 Media The system shall support a variety of media and communications networks including:

• TCP/IP

• UDP

• RS232

• RS485

• Private radio over RS232

• PSTN

• Wireless LAN

• Cellular data (via integral pppm module)

• Cellular voice

5.3 Protocols DNP3 master & slave, level 2 compliant, including:

• Change of state reporting

• Native date/time and quality stamps for each data point



• Event buffering for different classes of data

• Support for multiple masters and slaves to be configured on the unit

• DNP Security (for securing communications between master station and RTU)

Modbus master & slave including:

• Modbus TCP

• Modbus RTU

• Modbus ASCII

• Support for multiple masters and slaves to be configured on the unit.

Communications redundancy supported

5.4 Full Remote Control of Pump Station Pump control and configuration tags allow integrated remote control via SCADA including:

• Start / stop pumps (change mode to auto/ off/ manual)

• Reset pump and station faults

• Change pump & alarm setpoints

• Change setpoint profile

6 Environmental The unit shall meet the following environmental ratings

• Working temperature -10°C to +60°C

• Storage temperature -40°C to +90°C

• Humidity 5% to 95% (non-condensing)

• IP Rating Controller: IP20, Nema 1

Display: IP65, Nema 4

7 Warranty The unit shall come with a 5-year manufacturer’s warranty.

MultiTrode Pty Ltd—UK Operations Ivybridge, Devon

Tel: +44 1752 547355 Fax: +44 1752 894615

E-mail:[email protected]

MultiTrode Pty Ltd—Head Office Brisbane Technology Park

18 Brandl Street PO Box 4633

Eight Mile Plains Qld 4113 Ph: +61 7 3340 7000 Fx: +61 7 3340 7077

E-mail: [email protected]

MultiTrode Inc—USA Unit 3, 990 South Rogers Circle

Boca Raton Florida 33487 Tel: +1 561 994 8090 Fax: +1 561 994 6282

E-mail: [email protected]

Visit www.multitrode.com for the latest information

http://www.multitrode.com/

4) SHAPE INC. – ABB INC. VARIABLE

FREQUENCY DRIVES

July 18, 2019 [Project Name] Variable Frequency Drives ACQ580-PNPT01U-EN REVC Effective: 12/07/18 Page 1

__________________________________________________________________________________

Master Specification Note - Delete this page before use

__________________________________________________________________________________

ABB Inc. Effective September 1, 2018

ACQ580-PNPT01U-EN Sample Specification for

Variable Frequency Drives For Water & Wastewater Applications

Example styles in this document per CSI Master/Section/Page specifications. Sub paragraphs levels 5 and 6 are added to compensate for all 9 multi-list level styles in Microsoft Word

PART 1.01 PART | ARTICLE

A. Part | Article | Paragraph 1. Part | Article | Paragraph | Sub 1

a. Part | Article | Paragraph | Sub 2 1) Part | Article | Paragraph | Sub 3

a) Part | Article | Paragraph | Sub 4 (1) Part | Article | Paragraph | Sub 5

(a) Part | Article | Paragraph | Sub 6 __________________________________________________________________________________

Master Specification Note: This guide specification is written according to the Construction Specifications Institute (CSI) Format. The section must be carefully reviewed and edited by the Architect or Engineer to meet the requirements of the project. Coordinate this section with VFD schedule, other specification sections and the drawings.

__________________________________________________________________________________


WATER AND WASTEWATER VARIABLE FREQUENCY DRIVES

GENERAL 2.01 DESCRIPTION

A. This specification is to cover a complete Variable Frequency Drive (VFD aka: VFD, AFD, ASD, Inverter, AC Drive, et al) consisting of a pulse width modulated (PWM) inverter designed for use with a standard AC induction motor, synchronous reluctance (SynRM) and permanent magnet (PM) motors in water and wastewater applications. The VFD must provide a V/Hz or sensor-less vector mode of operation. The drive manufacturer shall supply the drive and all necessary options as specified. VFDs that are manufactured by a third party and “brand labeled” shall not be acceptable. All VFDs installed on this project shall be from the same manufacturer.

2.02 QUALITY ASSURANCE

A. Referenced Standards and Guidelines: 1. Institute of Electrical and Electronic Engineers (IEEE)

a. IEEE 519, Guide for Harmonic Content and Control. 2. Underwriters Laboratories (as appropriate)

a. UL508C b. UL61800-5-1

3. National Electrical Manufacturer’s Association (NEMA) a. ICS 7.0, AC Adjustable Speed Drives

4. International Electro-technical Commission (IEC) a. EN/IEC 61800-3 b. 2014/35/EU Low Voltage Directive c. 2014/30/EU Electromagnetic compatibility (EMC) d. 2006/42/EC Machinery Directive

5. National Electric Code (NEC) a. NEC 430.120, Adjustable-Speed Drive Systems

6. International Building Code (IBC) a. IBC 2012 Seismic – referencing ASC 7-05 and ICC AC-156

B. Qualifications: 1. VFDs and options shall be UL508C listed. The ACQ580 standard VFD shall be UL labeled 100

kA SCCR, RMS Symmetrical, 600V max. 2. UL-APPROVAL the VFDs shall be available as UL compliant version which complies the

technical regulations of UL according to UL61800-5-1. A UL listing document shall be available to confirm VFDs compliance with the requirements. Manufacturer’s statements of UL compliance or pending approval are not accepted. The VFD shall comply the technical regulations of UL according to UL508C. UL listing document shall be available to confirm VFDs compliance with the requirements.

3. Environmental Manufacturing: The VFD shall comply with Restriction of Hazardous Substances in Electrical and Electronic Equipment directive 2011/65/EU requirements, so called RoHS II requirements. The VFD shall be easy to recycle. The manufacturer shall make recycling instructions publicly available. The recycling instructions shall provide recycling information in accordance to Waste Electrical and Electronic Equipment directive 2012/19/EU (WEEE)

4. FUNCTIONAL SAFETY a. The VFDs shall support ‘Safe Torque Off’ (STO) function capable for safety related

applications up to SIL 3, SILCL 3 and PL e.


b. The VFD shall comply with the following standards 1) IEC 61508:2010; SIL 2) ISO 13849-1:2006; PL e 3) IEC 62061:2005; SILCL 3 4) IEC 61800-5-2:2007; SIL 3

2.03 SUBMITTALS

A. The Submittals shall include the following information: 1. Product Overview 2. Dimensional Drawings 3. Control Circuit Drawings 4. Engineering Data including rating tables and weight 5. General Notes

VARIABLE FREQUENCY DRIVES (VFD) 3.01 VARIABLE FREQUENCY DRIVES (VFD)

A. The VFD shall be solid state, with a Pulse Width Modulated (PWM) output. The VFD shall be a Sensor-less Vector AC to AC converter utilizing the latest Insulated Gate Bipolar Transistor (IGBT) technology. The VFD shall employ a Sensor-less Vector inner loop torque control strategy that mathematically determines motor torque and flux. The VFD must also provide an optional operational mode for V/Hz Operation.

B. Acceptable manufacture: ABB ACQ580 product family C. Ratings

1. The VFD shall be rated to operate from 3-phase power at 480 +10%/-15%, 48Hz to 63Hz. The VFD shall employ a full wave rectifier to prevent input line notching and operate at a fundamental (displacement) input power factor of 0.98 at all speeds and nominal load. The ACQ580 standard VFD efficiency shall be 98% or better at full speed and load.

2. VFDs 1-350 HP shall have internal chokes (reactors) to reduce input current harmonic content, provide protection from power line transients such as utility power factor correction capacitor switching transients and reduce RFI emissions. An internally mounted AC line reactor shall be provided, on 400-700 hp, ACQ580 VFDs to reduce input current harmonic content, provide protection from power line transients such as utility power factor correction capacitor switching transients and reduce RFI emissions.

3. The overvoltage trip level shall be a minimum of 30% over nominal, and the under-voltage trip level shall be a minimum 35% under the nominal voltage.

4. Normal Duty / Variable Torque output voltage and current ratings shall match the adjustable frequency operating requirements of standard, (380-480) VAC, 3ph, 60Hz, standard AC induction motor, synchronous reluctance (SynRM) and permanent magnet (PM) motors in water and wastewater applications. The short term normal duty overload current capacity shall be 110% of rated current for one (1) minute out of ten (10) minutes.

5. Heavy Duty / Constant Torque output voltage and current ratings shall match the adjustable frequency operating requirements of standard (380-480) VAC, 3ph, 60Hz, standard AC induction motor, synchronous reluctance (SynRM) and permanent magnet (PM) motors in water and wastewater applications. The short term heavy duty overload current capacity shall be 150% of rated current for one (1) minute out of ten (10) minutes and peak overload capacity shall be 180% for two (2) seconds out of each minute with an instantaneous overcurrent trip at 350% or higher.

6. Output frequency shall be adjustable between 0Hz and 500Hz forward or reversing. Operation above motor nameplate shall require programming changes to prevent inadvertent high-speed operation.


7. The VFD shall be furnished in an Open Chassis (IP00) , UL Type 1 (NEMA 1) or UL Type 12 (NEMA 12) listed enclosure rated as specified for operation at ambient temperatures between -15oC and 40oC at an altitude not exceeding 3300 feet, with relative humidity less than 95% and no condensation allowed.

8. The printed circuit boards (PCB) shall be conformal coated to protect from atmospheric contamination by Chemical gasses and Solid particles per IEC 60721-3-3; Chemical gasses Class 3C2 and Solid particles Class 3S2.

3.02 MOTOR CONTROL

A. The VFD shall be capable of controlling an induction motor, permanent magnet motor and synchronous reluctance motors as standard. Have a maximum allowed motor cable length 1000 feet (300 meters). The VFD shall commission an induction motor, permanent magnet motor and synchronous reluctance motor with the motor nameplate values only, without the need to get the motor values from other sources.

B. Scalar and vector control modes shall be supported and there shall be independent control chains and parameters for both of the motor control modes.

C. The overload rating of the VFD shall be 110 % of its rated normal duty current for 1 minute every 10 minutes and with a minimum of 130 % for 2 seconds every 1 minute. Overload ability shall be available at all times - not only at start.

D. The VFD shall be capable of sensing the loss of load (broken belt / broken coupling / dry pump) and signal the loss of load condition. The drive shall be possible to be programmed to signal this condition via a control panel warning, relay output and/or over the serial communications.

E. Relay outputs shall include programmable for on/off time delays that will allow for drive acceleration or deceleration to and from zero speed, without signaling a false underload condition.

F. It shall be possible to disconnect a motor running full speed by opening an optional contactor between motor and VFD without causing any damage to the VFD.

G. The VFD shall include a standard embedded functional safety feature Safe Torque Off, (STO), to make the motor mechanically safe.

H. The VFD shall include an energy optimization circuit (flux optimization) that will automatically reduce applied motor voltage to the motor to reduce energy consumption by up to 10% and lower audible motor noise.

I. The VFD shall be capable of starting into a spinning load (forward or reverse) up to full speed and accelerate or decelerate to a set-point (flying start) without tripping or component damage.

J. The VFD shall restart after a power loss without the need to resend the start command. This feature shall be there regardless of the control source, control panel, I/O or fieldbus.

K. Flux braking shall be available, where the VFD controls the motor to dissipate the extra rotary energy as heat whenever braking is required. It shall be possible to use this flux braking feature to decelerate the motor from one speed to another – not only for stopping the motor.

L. Power-Loss-Ride-Through shall be programmable. If the incoming supply voltage is cut off, the VFD continues to operate using the kinetic energy of the rotating motor. The drive continues to be operational as long as the motor rotates and generates energy.

M. The VFD shall include a switching frequency control function. This adjusts the switching or carrier frequency, based on actual VFD temperature and allows the highest carrier frequency without de-rating the VFD or operating at high carrier frequency only at low speeds (temperature fold-back). It shall be possible to set a minimum and a reference switching frequency.

N. The VFD shall include a noise smoothing function, which distributes the acoustic motor noise over a range of frequencies instead of a single tonal frequency resulting in lower peak noise intensity.

O. The VFD shall have three (3) programmable critical frequency or critical speed lockout ranges to prevent the VFD from operating the load continuously on an undesirable speed range (skip frequencies)

3.03 STANDARD CONTROL HARDWARE FEATURES - ADJUSTABLE BY THE USER


A. General I/O 1. All I/O terminals shall be color coded to simplify wiring and troubleshooting, and shall have a

special mode for testing I/O and the drive configuration without being connected to equipment. 2. All I/O shall be accessible (monitor and control) for fieldbus protocols (pass-through I/O). 3. It shall be possible to monitor status of the I/O from VFDs control panel

B. ANALOG I/O 1. The VFD shall have at least two (2) programmable analog inputs. Both inputs shall accept

current (0 to 20 mA or 4 to 20mA) or voltage (0 to 10 VDC) signals. The signal type selection, voltage or current, shall be made via VFD user interface. DIP-switches or jumpers are not allowed for input type programming. Analog Input shall have an inaccuracy of ≤1 % of full scale in both current and voltage modes

2. The analog inputs shall be programmable to be used as: speed reference, frequency reference, pressure monitor, PID loop controller’s set-point reference or signal feedback, or other defined inputs.

3. If the analog input reference (4 to 20 mA or 2 to10 VDC) is lost, the VFD shall give the user the option of: (1) stopping and displaying a fault; (2) running at a programmable preset speed and displaying an alarm; (3) hold the VFD speed based on the last good reference received and displaying an alarm. The drive shall be programmable to signal this condition via a control panel warning, relay output and/or over the serial communication bus.

4. The VFD shall have at least two (2) programmable analog outputs (0 to 20 mA or 4 to 20 mA) out of which one shall be software configurable to be either voltage (0 to 10 VDC) or current output. Analog Output shall have an inaccuracy of ≤1 % of full scale in both current and voltage modes

5. The analog outputs shall be programmable to give an output signal proportional to frequency, motor speed, output voltage, output current, motor torque, motor power, DC bus voltage, active reference or other defined data.

C. DIGITAL I/O 1. The VFD shall have at least six (6) programmable digital inputs (24 VAC and 12 to 24 VDC,

PNP or 5 pcs NPN) to connect to external devices, as follows: a. All inputs can be configurable for PTC sensors. b. There shall be a programmable run permissive circuit. c. Up to four (4) programmable free text interlock inputs shall be available. d. The VFD shall have at least one digital input which can be configured to receive a pulse

signal up to 16 kHz. D. Relay I/O

1. The VFD shall have at least three (3) programmable digital Form-C relay (changeover) outputs. The relays shall include programmable on and off delay times and adjustable hysteresis.

E. I/O Optional Extension Modules 1. The following I/O option modules shall be available:

a. Relay Extension module with two relay outputs and one digital output, with an external input 24 volt to maintain power and control of module.

b. PTC input module for up to 6 PTC sensors with an external input 24 volt to maintain power and control of module, and is capable of triggering the STO circuitry of the VFD.

c. Digital input option module to provide additional 6 digital inputs which can be operated with 115 VAC or 230 VAC voltage.

3.04 SOFTWARE FEATURES A. Pump SPECIFIC features:

1. The VFD shall have 2 quick ramps that allow for quick acceleration and/or deceleration of the pump motor.

2. The VFD shall offer a pump cleaning feature to reduce build-up of debris on the pump impeller. This feature can be activated by: Every start or Stop, when drive is in a underload / overload


condition, timed interval or digital input. The cleaning cycle status shall be visible in the panel screen when cleaning is active. The VFD shall operate normally after the cleaning cycle is completed.

3. The VFD shall offer torque boost for applications where increased torque is needed for initial starting of the pump motor.

4. The VFD shall have intelligent pump control (IPC) with multi-pump functionality and an intelligent master/follower configuration for controlling up to 8 parallel pumps equipped with VFD’s without additional modules. VFD shall have a parameter synchronization feature to program the PID, IPC and AI parameters in all parallel VFD’s. The Functionality to start and stop the pumps based on capacity, operating time or efficiency of the pump to ensure each pump is operated regularly. a. The IPC shall control:

1) Level Control 2) Flow Control 3) Pressure Control 4) Pump Alternation

5. The VFD shall have the ability to calculate the flow either based on the measured pressure difference or sensor-less flow calculations based on the power curve of the pump

6. The VFD shall have soft pipe filling functionality, can be used to fill an empty pipe, by having programmable pipe fill time.

7. The VFD shall have a programmable Sleep functionality for PID control in pumping systems to stop the pump during low demand. “Sleep Boost” shall be available to reduce short cycling of the pump. The boost function will boost the pressure or water level before the pump shuts down to sleep.

B. PID CONTROL 1. PID controller shall be standard in the drive, allowing an analog input signals to be connected

to the VFD for the closed loop control. The VFD shall have 250 mA of 24 VDC power to power an external transmitter supplied by others. The loop controller set-point shall be adjustable from the VFD control panel, analog inputs, or over field bus. The set-point shall be set and displayed in engineering units.

2. There shall be two parameter sets for the first PID loop controller. Switching between the sets shall be possible via digital inputs, timed function, and serial communications or from the control panel.

3. The VFD shall have the ability to calculate water or air flow from pressure difference, from a differential pressure transducer or two separate pressure transducers.

C. FUNCTION BLOCK PROGRAMMING 1. The VFD shall provide a PLC kind programming capability as standard. 2. It shall be possible to use different kinds of arithmetic, logical, selection, comparison and

operation function blocks to monitor and control the VFD, functions, inputs, outputs and variables.

3. There shall be a possibility to run different kinds of function block programs in different states and to set the criteria, when to change the state.

D. TIMED FUNCTIONS 1. Real-time clock and calendar shall be available as standard for giving true time and date

information to fault event history. The real-time clock should have a minimum of 10 years power-off back-up without optional components. Back-up battery shall be replaceable without opening the VFD enclosure

2. Real time clock shall be possible to use with timed functions, which shall allow controlling the VFD and its functions based on time of the day, day of the week, seasons of the year, holiday periods and holiday dates and special working periods and working days

3. Timed functions should be possible to use for starting and stopping the drive, for selecting the speed reference, for selecting the PID loop controller’s set-point, for controlling the relay


outputs, for selection the control location, for giving the run permissive or interlock signal to the VFD, etc.

4. There shall be also a boost function, which allows starting the VFD and/or its functions regardless, time of the day, day of the week, seasons or holidays.

E. Fault Logger: A fault logger shall accommodate seven diagnostic values together with a date and time stamp.

F. Built in Energy Calculators: There shall be built-in counters for calculating energy savings achieved with the VFD.

1. Used and saved energy 2. CO2 reduction 3. Saved money 4. Programmable kW Rate

G. Pre-Set Speeds: There shall be seven (7) programmable pre-set speeds.

H. Operating Values: All applicable operating values shall be capable of being displayed in engineering (user) units. A minimum of three operating values from the list below shall be capable of being displayed at all times. Engineering units shall be freely configurable for the user to display.

1. Output frequency 2. Motor speed (RPM, %, or engineering units) 3. Motor current 4. Calculated motor torque 5. Calculated motor power (kW) 6. DC bus voltage 7. Output voltage 8. Energy Consumption

I. Underload and overload curves shall be user-definable. J. Independently adjustable acceleration and deceleration ramps with 1 to 1800 seconds adjustable

time ramps. There shall be a possibility to use start delay before acceleration to ensure that all start conditions have been fulfilled.

K. Changed parameters list shall be available in order to assist commissioning and troubleshooting. L. The VFD shall include pass code protection against unauthorized parameter changes. The pass code

and the protection level shall possible to be defined by the user. M. The VFD shall have ability to use any internal parameter value as input for any other parameter N. The VFD shall have the capability to fault or to show warning when triggered from external sources.

3.05 PROTECTIONS

A. The following protection functions shall be available: 1. Dry pump Protection: (Prevent the pump from running dry. Protects the pumps bearings and

shaft seal from damage when there is no water in the pump) 2. Overvoltage and under-voltage controller 3. Ground Fault (Earth-leakage) supervision 4. Motor short-circuit protection 5. Output and input switch supervision 6. Overcurrent protection 7. Phase-loss detection (both motor & line) 8. Underload and overload supervision 9. Freely configurable supervisions for any parameter or signal to trigger an action. 10. Communication loss functionality to ensure uninterrupted operation. The drive shall change

control location from PLC to other external location identified by user, e.g. drive’s embedded PID/loop controller and change back when communication is recovered.


11. The VFD shall have pump protection functions for flow and pressure to avoid damages of the pump and for leakage detection. a. Inlet protection for avoid dry run, cavitation and blocked pipe b. Outlet protection for avoid high pressure and leakages c. Stall protection for avoid running locked pump

3.06 USER INTERFACES

A. DETACHABLE CONTROL PANEL 1. The control panel shall include Hand-Off-Auto selections and manual speed control. The drive

shall incorporate “bump-less transfer” of speed reference when switching between “Auto” and “Hand” modes. There shall be a possibility to reset the VFD from the control panel.

2. The control panel shall include a backlit LCD. The display shall be in complete words, in a language selectable by the user, for programming and fault diagnostics (alphanumeric fault codes are not acceptable)

3. The control panel shall have a real-time clock with battery backup for adding time stamps to events and also timer functions utilizing real-time clock.

4. There shall be an editable home-view in the control panel to allow different customer specific configurations

5. A dedicated “Help” button shall be available on the control panel. The Help button shall provide context sensitive assistance for programming and troubleshooting.

6. The control panel shall provide interactive assistants (wizards) to help to commission and use the drive.

7. The control panel shall provide a clear, interactive, context sensitive menu based user interface to make it easy to adjust the settings of the drive.

8. The control panel shall provide an easy to use I/O menu, where the user can see the status and function of all the analog and digital inputs and outputs.

9. The control panel shall have a menu, which contains diagnostic data about the drive operation collected in one single location. The data shall include data about active faults, warnings and events. In addition the data shall contain a summary of VFD active control sources.

10. The user shall be able to take a screen capture snapshot of the display with the control panel and be able to download the screen capture for user’s computer for further purposes.

11. The user shall be able to connect a PC tool with a USB cable to the control panel to be able to set up and control the VFD. It shall be possible to connect the USB cable without using any tools.

12. The VFD shall provide a possibility for wireless communication to allow working outside the arc flash boundary area and to allow connection to the VFD remotely when there is no easy or safe access to the VFD. Wi-Fi connection is not acceptable because of its cyber security limitations.

13. The VFD supplied with wireless communications shall have a local control panel with control buttons regardless of the wireless connection possibility.

14. The control panel shall contain a back-up information of the VFD settings. Back-up information shall be possible to be saved on the control panel both manually and automatically.

15. The control panel shall be detachable in all types of enclosures, without tools to allow easy commissioning and programming of multiple VFDs.

16. The control panel shall have the capability to copy VFD settings from a VFD to next VFD, regardless of the VFD power, voltage or enclosure rating.

17. The control panel shall have an editable contact info that shows up in case of a fault. B. SERIAL COMMUNICATIONS

1. The VFD shall have an EIA-485 (RS-485) port for serial communications as standard. 2. The VFD shall be equipped with built-in fieldbus communication of type Modbus RTU 3. There shall be following optional protocols available as plug-in and inbuilt options:

a. EtherNet/IP, Modbus/TCP, DeviceNet, PROFIBUS-DP, PROFINET.


b. The use of third party gateways or multiplexers is not acceptable and all communication modules shall fit inside the enclosure of the VFD.

c. Serial communication capabilities shall include, but not be limited to: run-stop control, speed set adjustment, proportional/integral/derivative (PID) control adjustments, loop controllers’ set-point adjustment, current limit, acceleration/deceleration time adjustments and lock and unlock the keypad.

EXECUTION 4.01 INSTALLATION

A. Installation shall be the responsibility of the installation contractor. The contractor shall install the drive in accordance with the recommendations of the VFD manufacturer as outlined in the VFD installation manual.

B. Power wiring shall be completed by the electrical contractor, to NEC code 430.122 and adhering to local electrical codes, wiring requirements based on the VFD input current. The contractor shall complete all wiring in accordance with the recommendations of the VFD manufacturer as outlined in the installation manual.

4.02 START-UP

A. Factory start-up shall be provided for each VFD by a factory authorized service professional. A start-up form shall be filled out for each drive with a copy provided to the owner, and a copy kept on file at the manufacturer.

4.03 PRODUCT SUPPORT

A. Factory trained application engineering and service personnel that are trained on the VFD products offered shall be locally available at both the specifying and installation locations.

B. A toll free 24/365 technical support line connected to factory support personnel located in the US shall be available. Technical support offered only through the local sales office is not acceptable.

C. Training shall include installation, programming and operation of the VFD, and serial communication. Factory authorized start up and owner training to be provided locally upon request.

4.04 WARRANTY

A. The VFD Product Warranty shall be 24 months from the date of manufacture. A 36 month warranty shall be available with authorized factory start up and drive registration. The warranty shall include all parts, labor, travel time and expenses. A toll free 24/365 technical support line shall be available.

B. Extended Warranty shall be available for purchase not to exceed 72 months from date of manufacture.

END OF SECTION

PROSPECT PUMP STATION REHABILIATION...2019/07/18 · PROSPECT PUMP STATION REHABILIATION...

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