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H2O Drive® Engineering Specifications
Download H2O Drive® Engineering Specs Document (rtf format)
I. General
1.1 Scope Of Work
The contractor shall furnish, and install a pump control system designed to operate one pump in a constant pressure application using Variable Frequency Drives (VFDs) as described herein. The control system shall be designed utilizing proven technology in control design for constant pressure water booster stations. The control system shall be operator and maintenance friendly to ensure ease of system set up and to limit down time.
The pump control system shall be capable of operating one pump as manufactured by _______________Model______ at ___HP, ___ Voltage, ___ full load amps ( FLA ), ___ 3 phase, 60Hz. The incoming power on site shall be ____Vac, ___phase, 60Hz.
The control system shall use a pressure transmitter connected to the discharge piping of the pump. The factory assembled system shall include:
- Variable Frequency Drive
- Line and load reactor as required
- Lightning arrestors
- Pressure transmitter
- Enclosure
- Main disconnect
- Circuit breaker
- Alarm and Communication interface
These specifications describe model H2O-Drive® control panel as manufactured by SJE-Rhombus®, Detroit Lakes, Minnesota, USA or approved equal.
II. Products
2.1 General
2.1.1 Codes
Electrical equipment, materials and workmanship shall comply with all applicable codes, safety and fire law regulations at the location of the work and shall conform to applicable codes and standards of the organizations listed below.
1. National Electric Code (NEC)
2. National Electrical Manufacturers Association (NEMA)
3. American National Standards Institute (ANSI)
4. Underwriters Laboratories (UL 508)
5. International Electrotechnical Commission (IEC)
2.1.2 Component Standards
All equipment and materials shall be new and shall bear the manufacturers name and trade name. In cases where the standard has been established for the particular material, the material shall be so labeled. The equipment to be furnished shall essentially be the standard product of a manufacturer regularly engaged in the production of the required type of equipment for this type of work and shall be the manufacturers latest approved design.
2.2 Construction
2.2.1 Enclosure
For indoor applications:
The described equipment shall be housed in a single NEMA 12 painted steel enclosure. The enclosure shall be sized approximately to allow easy access to component and adequate ventilation for VFDs. The enclosure shall also include louvers, filter fans and air conditioning as required from VFD heat loss calculation and average ambient temperature.
For outdoor enclosures:
The described equipment shall be housed in a single NEMA 3R free standing painted steel enclosure. The enclosure shall be sized approximately to allow easy access to component and adequate ventilation for VFDs. The enclosure shall also include louvers, filter fans, air/air heat exchanger, water/air heat exchanger and air conditioning as required from VFD heat loss calculation and average ambient temperature. Additional measure such as mounting the heat sink of the VFD on the outside of the enclosure, painting the enclosure white, installing a sun shield, adding heaters and adding insulation to the inside of the enclosure shall also be considered as to prevent the temperature inside the enclosure from exceeding the acceptable VFD temperature limits.
2.3 Control Circuit Wiring
Control circuit wiring inside the panel shall be 18 gauge (AWG) minimum, type MTW or THW, rated for 600 volts. All power wiring shall be 12 gauge (AWG) minimum rated for 600 volts. Conductors shall be color coded using the same colors throughout the entire panel.
III. Components
3.1 Variable Frequency Drive
A variable torque Variable Frequency Drive (VFD), of the pulse width modulated type shall be mounted inside the enclosure. The VFD shall monitor the discharge pressure signal (4-20mA loop powered signal) and control the pump speed using an integrated PI control loop controller, in order to maintain a constant pressure in variable flow demand conditions.
The VFD shall be sized to the pump motor supplied by the CONTRACTOR and be compatible with all equipment utilized at the pump station. The VFD's shall meet the following requirements:
Analog Input
The VFD shall come standard with a 4-20mA input channel. The input signal shall be scalable from 0.0 to 999.9 and the displayed unit shall be selectable from: PSI, Bar, Pa, WC, and %. The controller shall detect invalid sensor readings and open loop circuit and display a fault message. The analog input channel shall have a 0.1% resolution and incorporate noise filtering.
Sizing/Efficiency
The VFD shall be sized to the motor Service Factor Amps (SFA) and not the Full Load Amps (FLA) for deep submersible well pumps. The efficiency rating shall be of 95% or better across the full operating speed range. Overload current capacity of 120% for 1 minute.
Pump/System Protection:
The VFD shall have the following pump and system protection: Low Pressure, High Pressure, Low Water Input (low suction pressure/low level), Broken Pipe, Loss of Prime, Dry Well, Feedback Loss Alarm & Pump over-Cycling.
Motor/Drive Protection:
The VFD shall protect the motor and the drive against the following conditions: Output Phase Loss, Ground Fault, Motor Overload, Motor over-Temperature & Broken Shaft. Over Voltage, Input Phase Imbalance, Under Voltage, Phase Imbalance and Short Circuit protection.
These faults shall provide an orderly shutdown of the VFD with clear indication of the fault. The history of previous faults shall be stored in memory for future review.
Phase Conversion:
For installations where 3 phase power is not available, single phase power shall be supplied to the VFD and it shall convert it to 3 phase. Extreme care shall be taken to properly size the VFD in phase conversion applications; it shall only be done in accordance to the manufacturer. In all cases a 3 phase motor shall be used.
Keypad/Operation:
The VFD shall be equipped with an interface keypad with HAND/OFF/AUTO buttons and a 4 line display for the visualization of process and alarm status. The keypad shall be mounted on the door of the enclosure for indoor applications. The main screen shall display the set-pressure, the actual pressure (in PSI) and the motor speed in (Hz) simultaneously, without the need to scroll to another screen. The keypad shall allow the user to navigate through the configuration menus and adjust set point values via the front keypad. The VFD setup shall be simple and shall not require the use of a laptop computer . The VFD shall be factory configured and tested as to minimize field programming and start up time.
The VFD shall be provided with a 12 month warranty against defects in workmanship and materials under normal use operation and service from the date of startup.
3.2 Pressure Transmitter
The pressure transmitter shall be industrial grade and have a static accuracy of 1% of full scale or better. The pressure transmitter shall be two-wire loop powered and produce a 4-20mA signal proportional to the discharge pressure and be fully temperature compensated. No calibration of the transducer shall be required in the field. The transmitter shall be connected to the pump discharge and shall have an isolation and bleed valve. The connection shall be ¼ inch NPT male and shall be mounted vertically and in such a manner as to minimize the possibility of air accumulation between the transmitter and the discharge pipe.
3.3 Communication
The control panel shall be capable of communicating to a building Management System (BMS) via RS 232 or RS 485 port using MODBUS protocol.
3.4 Circuit Breakers
All electrical circuits shall be protected by molded case circuit breakers. Each pole of the breaker shall provide inverse time delay overload protection and instantaneous short circuit protection by means of a thermal magnetic element.
The breaker shall be operated by a toggle-type or rotary handle and shall have a quick make, quick break switching mechanism that is mechanically trip free from the handle. Tripping due to overload or short circuit shall be clearly indicated by the handle automatically assuming a position midway between the manual “on” and “off” position. Breakers shall be completely enclosed in a molded case and shall bear the UL label. The short circuit interrupt capability shall exceed the fault level (Isc) of the incoming power. The circuit breakers for the VFDs shall be mounted on the sub-panel of the enclosure with the operating handles mounted through the door. The handles will interlock with the door mechanism, only allowing the door to open when the breakers are in the OFF position.
3.5 Relays
Relay contacts shall be rated for 10 amps at 300VAC. Relay sockets shall have screw terminals with self-lifting clamps and terminal identification numbers located at each connection on the relay socket. A “Motor Running” relay and a “VFD Ready” relay shall be available for user interface.
3.6 Lightning Arrestor/Surge Arrestor
A lightning/surge arrestor shall be provided at the incoming power terminals to the control panel. The unit shall be of the solid state type and be able to clamp in five (5) nanoseconds and absorb up to 25KA peak surge current during an occurrence. The unit shall have a surge life expectancy of 10,000 occurrences at 200 amps.
3.7 Line and Load Reactors:
A 5% impedance line reactor shall be installed ahead of each VFD as to reduce the effects of current and voltage harmonics.
The VFD shall require a load reactor if the pump leads from the VFD exceed the following lengths:
800 ft for 208-240V applications
200 ft for 460V applications
50ft for 575V applications
The VFD shall require a dV/dt filter if the pump leads from the VFD exceed the following lengths:
1,500 ft for 208-240V applications
500 ft for 460V applications
200 ft for 575V applications
IV. Quality Assurance
4.1 Manufacturer Experience
4.1.1. UL Certification
The manufacturer of the control system shall be certified by Underwriters Laboratories (UL) as being a UL 508 listed manufacturing facility and certified to install a serialized label for quality control and insurance liability considerations.
4.1.2 Experience
The manufacturer of the control system must be able to document seven years of experience in successfully designing and manufacturing similar control system using variable Frequency Drives in pumping applications.
4.2 Manufacturer Quality Control
The control system shall be functionally tested at the manufacturing facility and certified as a complete system to assure proper operation per specification.
4.3 Manufacturer Approval
Manufacturers listed in this specification do not constitute approval. All controls must have the capabilities and functions as outlined in the specifications.
V. Submittal Requirements
5.1 Base Bid
The base bid control system shall be the H2O-Drive® control system as manufactured by SJE-Rhombus®, Detroit Lakes, Minnesota. Contract shall be awarded on the base bid control system. Alternative deductive systems will be considered only after contract award and must be specified with any applicable deducts at bid time in order to receive consideration. Bidders submitting alternate quotations shall submit appropriate cut sheets, circuit drawings and a detailed bill of materials with their alternate bid packages. Approval of an alternative system shall be at the sole discretion of the engineer. All equipment and materials shall be new and shall be specifically designed for the function herein.
5.2 Substitutions
The Engineer will consider proposals for substitution of materials, equipment, methods and services only when proposals are accompanied by full and technical data and all other information required by the Engineer for the proposed substitution. Substitution of materials, equipment, methods and/or services is not allowed unless such substitution has been specifically approved by the Engineer.
5.3 Shop Drawing Submittals
5.3.1 Drawing Requirements
All drawings are to be of the computer generated class.
5.3.2 Engineering Approval
The Engineer reserves the right to approve or disapprove any and all equipment based upon his evaluation. Approval for fabrication and installation will be made only after submittal and review of all shop contract documents. The information required for approval shall include the following items and be provided in (8) sets as a minimum:
1. Appropriate cut sheets
2. Complete electrical schematics detailing the system
3. A complete bill of material
4. Detailed drawings of the enclosure
5. Exploded detail of every control face plate, light, switch or meter mounted on the exterior of the enclosure.
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