Crown Boiler WWD224W-2 Specifications

WaterMax
SUPER SPORTS TURF PUMP STATION
Variable Frequency Drive Control System
GENERAL SPECIFICATIONS
Project Name: ?
Project Location: ?
Pumping System Model #: WaterMax SSTV-HP-Voltage-Phase-Flow-Boost
Total Design Criteria: Quantity of Pumps: ?
Station Design Capacity: ? GPM @ ? PSI Discharge
08/22/06
SCOPE OF WORK
It is the intention of this specification to describe an automatic, prefabricated, self-enclosed, pump station for
irrigation purposes. Design, fabrication, testing and service shall be the sole responsibility of the pump station
manufacturer. The pump station shall provide water to the irrigation system while simultaneously maintaining
a constant discharge pressure by using a prefabricated pump station with variable frequency drive (VFD)
pumps for pressure regulation, under varying flow conditions up to the maximum specified capacity.
Construction shall include a fabricated steel plate and skid assembly to support all components during
shipping and to serve as the installed mounting base.
SECTION 1: GENERAL
1.1
The prefabricated pumping station shall have a minimum capacity and discharge pressure at skid
edge as stated in the technical specifications.
1.2
The station shall be completely wired, piped, hydraulically and electrically tested prior shipment.
1.3
The discharge manifold from the pump station shall terminate at or near the pump station skid edge
and be provided by the pump station manufacturer.
The pumping station shall be model number WaterMax SST as manufactured by WATERTRONICS, INC. 525
Industrial Drive, P.O. Box 530, Hartland, Wisconsin 53029-0530, www.watertronics.com.
SECTION 2: MANUFACTURER REQUIREMENTS
2.1
MANUFACTURER
The pump station shall be manufactured by Watertronics Inc., Hartland, Wisconsin. The following information
must be furnished by the contractor or manufacturers representative:
a.
A complete specification and submittal of all major components for the proposed pump
station with individual pump performance verification.
b.
A detailed pump station proposal drawing complete with component location, sizes and
dimensions specific to the installation.
c.
A complete electrical schematic for all high and low voltage circuits showing breaker/fuse
sizing, wire numbering and color.
d.
Pump station manufacturers U.L. file number for the entire pump station.
e.
A copy of the manufacturers certificate of insurance.
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SECTION 3: PUMPS AND MOTORS
3.1
PUMPS
Pumps shall be electric motor driven, horizontal centrifugal with mechanical shaft seal, volute case and
impeller.
The shaft seal shall be a self-adjusting mechanical type to prevent leakage and eliminate the need for drain
piping. The volute case shall be precision machined from gray cast iron and engineered to modern hydraulic
standards. It shall be possible to rotate the discharge connection to any of four positions. A heavy cast iron
bracket shall maintain alignment between the motor and volute cast.
The impeller shall be an enclosed type and balanced to provide smooth operation. The impeller is to be keyed
to the shaft and locked with a special cap screw and washer. The motor shaft is to be manufactured from high
grade steel and of reduced length to increase shaft rigidity, extend bearing life, and reduce the overall length
of the pump and motor assembly. The motor shaft shall be protected with a replaceable stainless steel sleeve.
3.2
MOTORS
Each pump motor shall be a squirrel cage induction horizontal solid shaft type. The pump impeller shall be
direct mounted and keyed to the motor shaft with a stainless steel protective sleeve. The temperature rise of
the motor shall be to NEMA Standard MG-1- Class F insulation.
Radial and thrust bearings of ample capacity to accommodate the hydraulic thrust of the pump shall be
incorporated into the motor. The motor shall be of proper size to drive the pump at any point on it's operation
curve without exceeding the service factor nameplate rating.
SECTION 4: SKID, PIPING, VALVES, GAUGES, MECHANICAL EQUIPMENT
4.1
SKID CONSTRUCTION
Pump station skid shall be formed from a single sheet of steel. Continuous welded and smooth ground at all
corners resulting in a seamless, one piece structure with rounded edges and corners. If required, the skid shall
be strategically reinforced underneath with structural channel iron to support pumps, manifold control
enclosure and periphery. Flat steel, diamond or checker plate welded over structural steel shall not be
permitted. The skid shall be drilled and tapped for mounting of pumps, manifolds, relief valves and other
equipment. All tolerances shall permit direct bolting of pump station components to skid. The exterior of the
skid will have drilled holes for anchor bolts. There will be two holes at each corner for lifting. The skid shall be
primed and painted per enclosed specifications on both top and bottom.
4.2
FABRICATED PIPING
All fabricated piping shall conform to ASTM specifications A53 for Grade B welded or seamless pipe.
Discharge piping 6" and smaller shall be Schedule 40. All welding flanges shall be forged steel slip-on or
welding neck type. All welding fittings shall be seamless, conforming to ASTM Specification A234, with
pressure rating not less than 150 PSI.
4.3
DRAIN VALVES
Drains are to be provided from any possible low point in the system and are to consist of 1/4" brass petcocks.
They include, but are not limited to, the following:
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Drain for each pump discharge check valve
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Drain in discharge manifold
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4.4
A wash-down 3/4" brass hose bib shall be provided downstream of the control valves,
upstream of the main station isolation valve
PUMP CHECK VALVES
Pump check valve shall be of the silent operating type that begin to close as forward velocity diminishes and
be fully closed at zero velocity preventing flow reversal. Valve bodies shall be cast from ASTM-126C cast-iron
or better and shall be free from blow holes, sand holes, and other impurities. The valve design shall
incorporate a center guided, spring loaded poppet, guided at opposite ends and having a short linear stroke
that generates a flow area equal to the pipe diameter. Internals shall be machined bronze disc, seat, and stem
guide. Valves shall be sized to permit full pump capacity to discharge through them without exceeding a
pressure drop of 2.5 PSI. Valves 4” and smaller to be pressure rated for 250 PSI, and 6” to be pressure rated
to 150 PSI.
4.5
ISOLATION VALVES
Isolation valves shall be butterfly type with ten position lever for sizes 4" and smaller and gear operators for
sizes above 4". All shall be rated at 200 PSI WOG working pressure. Trim shall include stainless steel stem,
bronze or nickel coated iron streamlined disc, and full faced resilient seat designed to eliminate need for flange
gaskets.
4.6
PRESSURE GAUGES
A pressure gauge shall be located on the discharge manifold for the purpose of measuring regulated,
downstream pressure. Pressure gauge shall be 304 stainless steel case and bezel construction. Gauge shall
be 2-1/2" diameter, liquid filled. Pressure sensing connection shall be 1/4" NPT lower gauge connection.
SECTION 5: U.L. LISTED CONTROL PANEL, LOGIC AND SENSORS
5.1 GENERAL
The pumping station electrical controls shall be mounted in a self-containing NEMA 3R enclosure fabricated
from not less than 12 gauge steel. Door gasket seals shall be neoprene sponge, sufficient to protect interior
components from weather and dust. The electrical panel door(s) shall be constructed from 12 gauge steel with
integral latches.
All external operating devices shall be dust and weather proof. All internal components of the enclosure shall
be mounted on a removable back panel. Mounting screws for components shall not be tapped into the
enclosure wall.
All internal wiring within, and interconnecting between, the panels shall be complete and no field wiring within
the panels shall be required. Wiring troughs and cable raceways shall be self-contained within the enclosure
and no external cable trays or wiring roughs are permitted.
No pressure gauges, pressure switches, water activated devices, or water lines of any sort shall be installed in
any electrical control panel.
The control panel shall be designed, built, tested and U.L. listed by the pump station manufacture.
The pump station discharge pressure shall be regulated to provide surge-free constant pressure as
programmed via the control panel operator interface. The control system will have the following features:
a.
Gradual entry of water from the pump into the discharge manifold to allow for
complete purging of air to eliminate pressure surging.
b.
c.
Maintain programmed downstream pressure regardless of discharge flow.
Up to six, user adjustable PID control settings to ensure accurate pressure regulation
at all flows, programmed pressure, or connected pump combination.
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d.
Adjustable pressure ramp-up and ramp-down to assure surge free pressure
regulation.
e.
After a drop in pressure, gradually increase system pressure over a user adjustable
period of time to eliminate surging.
f.
Rate of change of pressure control to anticipate and eliminate rapid pressure
changes caused by changing system demand.
Discharge pressure regulation shall be by a Variable Frequency Drive. Adjustment of regulated downstream
pressure shall be accomplished though the control panel operator interface. Hydraulic type, pilot controlled
pressure reducing valves shall not be accepted.
5.2
VARIABLE FREQUENCY DRIVE (VFD)
The variable frequency drive shall be IGBT based with selectable carrier frequency up to 15 KHZ. The VFD
shall include terminals for incoming power, motor output power and control terminals.
The VFD shall generate a sine-coded, variable voltage/ frequency, three phase output for optimum speed
control. The VFD shall incorporate power loss ride-through for a minimum of 2 seconds. VFD protective
features shall include current limit, auto restart, short circuit protection, electronic motor overload protection
and ground fault protection. The VFD shall have a push button programming display for easy access to
operation parameters. The VFD shall be protected on the primary side by fuses of the appropriate amperage.
Overload capacity: 120% rated output current for one minute. Voltage Fluctuation: +10%, -15%. Sine wave
PWM with full range, automatic torque boost. Frequency Control Range: 0.1 to 400Hz. Frequency Accuracy:
Digital, 0.01Hz, Analog. .1%. Motor overload protection, Instantaneous Over current of 180% of rated output
current. Over voltage at 820VDC if 460V input. Under voltage: user adjustable. Momentary Power Loss: up to
2 second ride through. Electronic Ground Fault. LED capacitor charge indicator. Input Phase loss alarm.
Ambient temperature range of + 14 to 104 degrees F. Humidity of 95% non-condensing.
5.3
MAIN SERVICE DISCONNECT
A three-pole, main service rated disconnect shall be contained within the NEMA 4 control enclosure. An
externally mounted service disconnect shall not be acceptable. Disconnect shall isolate all power to the control
enclosure. The disconnect shall have an operating handle mounted in the enclosure door, mechanically
interlocked to prevent entry while disconnect is in the ON position.
5.4
MOTOR FUSES, STARTERS AND OVERLOADS
Each started shall be protected on each leg by a time delay fuse of the appropriate amperage. Motor starter
coils shall be 120 volt operated. Overload relays shall be electronic type, ambient compensating and
differential tripping type. Bi-metallic or melting alloy type overloads shall not be permitted. The overload shall
protect each power leg and shall be set to the motor's full-load current rating. Further protection shall include
sensitivity to current imbalance and single phase conditions.
5.5
CONTROL TRANSFORMER
A control transformer shall provide 120 volt power to the pump station controls. The control transformer shall
be protected on the primary and secondary sides with appropriately sized fuses. No load other than the pump
station controls shall be supplied by the control transformer.
5.6
CONTROL LOGIC
The pump sequence controller shall be an industrial grade PLC with diagnostic LED's for monitoring of
discrete inputs and outputs. Not less than two additional analog inputs and outputs shall be standard for
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monitoring and control purposes. The PLC shall contain two communication ports for monitoring and
programming purposes. The PLC shall contain an EEPROM, battery backed RAM and non-volatile memory for
storage of critical configuration data.
5.7
ALARMS
Controls shall shut down the pump station in the event of the following alarm conditions. The controls shall
attempt to restart the system after alarm shutdown or loss of power to minimize loss of irrigation. After a user
adjustable number of attempts to re-pressurize the system, the controls will go into hard shut down and remain
there until manually reset.
5.8
1.
Low discharge pressure cutout. Pressure remains 20 PSI below regulated set point for a set
time delay.
2.
High discharge pressure cutout. Pressure remains 11 PSI above regulated set point for set
time delay.
3.
Phase / voltage cutout; High or low voltage; loss of phase or phase reversal.
4.
High pump volute temperature cutout. Pump temperature stays above 120 degrees F. for
a set time delay.
5.
Starter fail cutout. Output to starter is not met with corresponding running input for set time
delay. Indicates overload, phase imbalance or control fuse.
Operator Interface
Operator interface shall be a full color TFT active matrix LCD display unit mounted in the enclosure door.
Operator interface shall be used for logical display of all pump station functions. The operator interface
shall be NEMA 4 rated. The operator interface shall be touch sensitive with intuitive on-screen user
instruction for ease of operator use. The use of buttons or keys or off-screen user instructions shall not be
permitted. The operator interface shall be LCD color display type with no less than 240 x 320 pixel
resolution, with viewing area measuring not less than 5.7" diagonal. User memory for storing critical pump
operation data shall not be less than required for up to 1 year of data.
The operator interface shall allow the user to view and modify all pertinent operation parameters. The
operator interface shall incorporate password protection for modification of critical pump station
parameters. The operator interface capabilities shall include but are not limited to the
following:
a
Overview screen showing pump system configuration. Screen shall show if
each individual pump is enable or disabled, the number of hours on each
pump, station full flow and pressure design criteria
b.
System screen with information on current regulation pressure, setpoint, regulation
pressure, System status, restarts remaining, VFD reference speed, pressure regulation
method (VFD or EBV modes) and adjust settings button. Adjust settings button will allow
changing parameters etc after entering password.
c.
Settings menu to allow changes to pressure regulation settings, pipe
saver mode, VFD manual mode, analog calibration, flow calibration,
program or register settings.
d.
Flow screen will display pressure in PSI, flow in GPM and total gallons
pumped in thousands of gallons. Separate display for total gallons pumped
since last reset.
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5.9
e.
Alarm status with time stamping, display of pump station conditions at shutdown and
restart. Alarms will be displayed in red when activated and a separate listing will be
displayed in green when the alarm is reset. Alarms will be logged to a compact flash disk
allowing the service technician to upload data to a spreadsheet type program.
f.
Full control of and capability of monitoring, adjusting and viewing any
options present such as water level, inlet strainer, wye strainer,
filtration, chemical injection, or liquid tank levels. Adjustment of automatic/manual
pressure regulation set points.
g.
Graphing capability for up to 1 full year detailing flow rate and pressure. Graphing function
shall give option to graph and plot a point every minute. The graph function will be
selectable by day, month and year as well as the time of desired graph. All data will be
logged to a compact flash disk allowing the service technician to upload data to a
spreadsheet type program.
WATERVISION REMOTE MONITORING SOFTWARE (OPTION: Must be called for in the
Technical Specification Section)
Pump station monitoring software (Watervision), will be fully compatible with Windows 95, 98, Me, 2000, and
NT 4.0 for workstations. Software will include full graphical representation of the pump station and its features.
The software will be capable of communicating at rates up to 19200 baud to the pump station over direct wire,
dial-up telephone modem, cellular modem, radio modem, short haul modem, or over fiber cable. The software
shall also be capable of communicating over the Internet and Intranets including dial-up networking to the
computer connected to the pump station. One software package and installation procedure shall cover all
above connection types. All connections and setting shall be field configurable. The remote monitoring
software independent of connection type shall be capable of changing all operating parameters of the pump
station. A single copy or multiple copies of the software can be loaded on a single computer to communicate
to up to 256 different pump locations. A single site license will be supplied for each pump station location.
A.
The pump station manufacturer will supply all required communication hardware except; computer
and computer accessories including phone modem, all necessary direct burial cable.
The remote monitoring software shall require a PC based computer with minimum requirements: Pentium7
233MHz, 32MB RAM, 30MB of free hard drive space, VGA graphics card, one free serial port without IRQ
sharing, mouse or trackball, 9600 baud phone modem if communications to the pump station require.(Above
equipment by end user).
B. The remote monitoring software shall feature full data sharing interaction between leading irrigation
manufactures software using PumpLink.
C. The software supplied by the pump station manufacturer will include all of the following features as
standard, further customization to fit customer’s needs shall be available.
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Graphical overview of system operations including Pump Status, Flow, Pressures and Regulate Set Points
Operational status of pumps; Enabled/Disabled, Running/Not Running, Position of Hand/Off/Auto switch
Total number of hours of each pump’s operation since first activation
Individual time of day lockout for each pump
Display of maximum GPM designed for each pump
Individual pump/motor alarm status such as overload relay trip due to excessive amperage draw and in
HC stations, pump case temperature alarm
View system Pressure and Flow in both digital and vertical bar graph form
View of Final Regulate pressure set point and Current Regulate system pressure status in digital numbers
View location for any current alarms with help screens for each. Alarms are: low pressure, high pressure,
phase loss, low/high voltage, low water level, (if desired), individual motor overload with I.D., PLC low
battery, VFD alarm, (if equipped), Pressurization Alarm, Final shutdown alarm
Alarm reset button, with digital read out of re-starts remaining before final shutdown
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System status: System O.K. or System Pressurizing
Seven, (7) different pressure regulation points based on seven different user definable GPM flow brackets
Set single pressure set point value. (Desired system pressure set point regardless of flow)
Toggle between either Single Set Point or Flow Based Pressure Set Points
Pump station’s historic total gallons pumped. Not user re-settable.
Pump station’s total gallons pumped since last time user pushed reset button on either the Touchscreen
operator interface or the monitoring software’s on screen mouse click button
View and make individual adjustments for wet well inlet self-flushing filter, or discharge filter: 1. Duration of
flush. 2. Frequency of flush. 3. Flush enabled or disabled. 4. Differential PSI. 5. Manual Flush 6.
Flushing On/Off indicator
Pressure set point for flush activation, (if so equipped).
View and adjust the activation level in inches for the remote fill pump or valve. Value is based on input
from a submerged, stainless steel 4-20ma pressure transducer
Password protected entry window to alter PLC registers for Watertronics personnel or advanced users
Window to log the pump stations Highest Pressure, Lowest Pressure, Highest Flow, Lowest Flow, with
Month, Day, Year, Time of event since last reset of Running Log.
Total number of starts for each pump
Time and Date log for last station or individual motor alarm
Pump station’s lifetime historic event log tagged for date and exact time for Pressure Changes, Flow
Changes, Pumps On/Off, Alarms, and Customizable events like inlet and discharge filter flush count.
Logs 300,000 events or approximately one season’s data
Data can be searched for by date. Data can be downloaded to a disc.
A data chart in spread sheet form showing all collected data with controls for the user to navigate to data
by date
A full graphical trending chart scalable for any time span from minutes to years to view pressure, flow, and
pumps running as standard. The graph is customizable by the user to graph and record any of the 3755
PLC data registers
Full print abilities for all charts
All data will by collected by event to capture critical data point without filling memory limitations
An Alarm Paging window to configure up to three, (3), different pagers to be called for sending of a digital,
coded alarm message
Input window for initialization string to configure the phone modem and computer before connection to
pager. Includes serial port identifier locator
Each pager phone number has a window for entering pager commands. Test button to test set up and
send a test call to the pager selected
Modes of communication for connecting to the pump system include: Direct Wire, Short Haul Modem,
Radio Modem- Spread Spectrum, UHF, and VHF, Fiber Optic Cable, Dial-up Phone Modem, and Cell
Phone Modem.
Each installed software package can be setup to be a network server or client. The package
connected to the pump system will be a sever allowing up to 5 remote clients to attach to it. Thus
allowing any form of PC running Watervision to connect to the server using TCP/IP via an Intranet or
over the Internet. Because the same software is loaded, the user interface will be identical at home
as in the office, only the means of connection will vary.
When using a dial-up type connection an Auto Dial feature is available. User configured, allowing the user
to be connected on particular days and times
Area to set the initialization string guaranteeing compatibility with nearly every modem
Area to set the phone number of the remote site
Settable node address allowing connections to 245 different pump sites
Settable serial port connection
Settable data rate up to 19200 baud
Settable connection setting including: Data Bits, Parity, and Stop Bits
Performance setting allowing adjustments if necessary for different computer speeds and connection
types
Connection diagnostics for troubleshooting any communications problems
PumpLink Sharing allowing the user to setup up to 16 different data viewers out of all 2056 pump station
analog and 1699 digital data points.
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The data and the user given description is then also available in the PumpLink. OCX utility for use by any
irrigation equipment company’s software.
A print button allowing the user to print setup configurations
Allows the user in one click to cascade or tile all open windows
All screen items will have a help window available to the user
A full pump station owners manual in digital form including graphic images of all touch screens
A database software utility (Maintenance Manager) will be supplied allowing the user to manage and
record all service aspects of his pump station. The utility automatically gets information such as pump
hours and total gallons from Watervision. The database is fully customizable allowing the user to also log
and schedule any other service work completed on ground maintenance equipment or facilities.
Time of use lockout (ability to set up to three unique lockout periods per day of irrigation pumps, water
feature pump, lake fill, and fertigation injection pumps)
Email report notification: Email report can be sent to a specified time each day and or at time of alarm
Audible alarm indication: Upon an active pump station alarm a banner to be displayed on the computer
screen along with an audible alarm noise
Ability to setup fertigation chemical tank diameter and display tank level in gallons
Ability to modify the chemical to station flow ratio without having to manually adjust injection pump
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D.
Installation of the pump station software shall be seamless to the user. An easy to use
configuration program shall be started by simply inserting the media into the users computer drive
and following the easy to understand instructions.
Watervision, PumpLink, and Maintenance Manager are registered trademarks of Watertronics Inc.
Microsoft, Windows, and Windows NT are registered trademarks of the Microsoft Corporation. Other
brands and product names are trademarks of their respective holder/s.
5.10
PRESSURE TRANSDUCER:
A solid state pressure transducer shall provide a noise free, linear output proportional to discharge
pressure. Transducer shall be solid-state, strain gauge type with integral voltage regulating and output
accuracy not less than 0.25%. Transducer shall be constructed of stainless steel and rated for the
maximum pump station discharge pressure.
5.11
FLOW SENSOR:
The pump station discharge manifold shall incorporate an insertion type, pulse frequency output flow
sensor for continuous output to the pump station controls. The flow sensor output pulse shall be
conditioned and fed directly to the PLC interrupt input for conversion and display in Gallons Per Minute.
For accuracy and security considerations, conversion to an analog signal prior to PLC input shall not be
accepted. Flow sensor accuracy shall be no less than 2% for flow velocities ranging from 1-30 feet per
second.
5.12
LIGHTNING ARRESTER
The main power supply feeding the pumping station shall be equipped with a 3 phase secondary surge
arrester having a breakdown current rating of not less than 80,000 amps. Duty cycle testing: 2500, 10KA
(8x20jus) impulses with less than 10% drift. Sine wave tracking, EMI/RFI noise rejection and <5ns
response time. U.L. category C. approvals 1449 2nd addition. Arrester will meet IEEE standard 587.
5.13
SECONDARY CONTROL CIRCUIT FUSES
Single-pole secondary distribution fuses with appropriate ratings shall supply power to each pump starter
coil circuit, the control system and to other circuits as specified.
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5.14
PHASE MONITOR
The incoming power and each motor shall be protected by a phase loss/low voltage system dropout relay
to de-energize the pump station control circuit or motor contactor if either a phase failure, phase reversal
or low voltage condition occurs. If, after attempted automatic re-starts the phase failure/low voltage alarm
condition remains, the alarm must be manually reset. Individual motor overloads will also act as phase
monitors for each motor.
5.15
CORROSION INHIBITING MODULES
Corrosion inhibiting modules shall be installed in all electrical enclosures in accordance with the
manufacture's recommendations.
SECTION 6:
SKID WIRING
Skid wiring shall conform to National Electrical Code Standards. All wiring from control panels to motors
shall be in metal reinforced, water tight, flexible conduit with copper conductors rated not less than 600
volts and of proper size to carry the full load amperage of the motors without exceeding 70% capacity of
the conductors. A grounding cable sized to National Electrical Code requirements shall be included in the
flexible conduit. There shall be no splices between the motor starters and the motor connection boxes.
Wiring to flow sensors and pressure transducer shall be multi-conductor, shielded cable suitable for Class
II low voltage controls. Wiring to motor operated valves shall be in flexible conduit with TFFN #18 gauge
copper conductors rated not less than 600 volt.
SECTION 7:
CONSTRUCTION
Construction shall be of modular form utilizing a steel base structurally adequate to support pumps, piping,
tanks, and electrical equipment as a single integral assembly, a lockable, vented enclosure and cover. All
nuts, bolts washers, and fasteners shall be zinc or cadmium plated for corrosion resistance.
SECTION: 8
8.1
ENCLOSURE & FAN
ENCLOSURE
Construction shall include a weather resistant, 14 gauge, all metal enclosure with welded lockable lid
guides on top and bottom. The front side of the enclosure shall have oversized cooling vents and be easily
removable for servicing. The enclosure is to be supplied with twin internally mounted, heavy duty gas filled
lift struts to keep the access door open. All components are to be accessible from top and front sides with
the lid completely open. Enclosure is to be suitable for mounting to the pump station base and shall
include openings for suction and discharge piping.
Stainless steel or marine grade aluminum enclosure is available but must be called for in the technical
specifications.
8.2
EXHAUST FAN
For the purpose of cooling the pump motor, switchgear and control logic, an exhaust fan shall be located
inside the pump enclosure, mounted to the enclosure. The exhaust fan shall be activated upon pump start
and shall run until the pump stops. The fan shall be black die-cast aluminum construction with UL94V-0
rated polycarbonate propeller and rated for not less than 240 CFM. Fan motor shall be permanent split
capacitor type with stainless steel ball bearings, class B insulation and automatic thermal protection.
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SECTION 9:
PAINTING (steel enclosure)
Painting of the entire unit shall consist of a multi-step coating system which includes metal preparation,
and a two part polyurethane finish having a total dry film thickness of not less than 5 mils. Paint shall be
ultraviolet insensitive. Pump station components shall be painted Watertronics green.
SECTION 10:
TESTING:
The pump station manufacture shall conduct a complete factory dynamic test of the pump station prior to
shipment. Pump station shall be tested throughout the entire operating range at the net discharge
pressure called for in the technical specifications. Individual pump pressure, flow, RPMs, volts, amps, KW
and power factor shall be documented for verification by the consulting engineer or owners' representative
prior to delivery upon request.
SECTION 11:
ON-SITE START UP
Shipping, off-loading and setting of pump station to be by purchaser. Technical start up shall be furnished
by the pump station manufacturer or a qualified service agency. Location and mounting details shall be
furnished by the pump station manufacturer. Electrical connection by purchaser, shall consist of a single
conduit from owners disconnect to the pump station main disconnect. Further electrical service by
purchaser shall include bumping manual motor starter controls to prove correct rotation and securing local
inspection / approval.
Technical start up procedures by the pump station manufacturer shall include the following:
a.
Station start up and pressurization
b.
Pressure, flow and programming adjustments
c.
Monitoring of complete golf course irrigation cycle when possible
d.
Customer training and presentation of owner manual
SECTION 12:
12.1
ADDITIONAL EQUIPMENT (options to be described in the Technical Specification)
Lake Level Controls (Optional; must be called for in the Technical Specification)
The irrigation reservoir shall be continuously monitored by an electronic pressure transducer which will
send a continuous 4-20ma signal to the PLC. The reservoir level will be read on the Touchscreen
operator interface in inches. The user shall be able to control the remote signal activation level by making
the desired adjustments on the screen. When low, (set point), level has been maintained for the pre-set
period of time, a 120 v AC signal shall be sent to a dry contact relay in the pump station panel to activate
the start signal for a fill pump or valve. Upon a rise in the reservoir level the signal will stop and the relay
will drop out to stop the filling operation.
12.2
Motor Space Heater (Optional; must be called for in the Technical Specification)
The pump station will be supplied with 120 volt space heaters in the motor windings of each VHS motor to
prevent condensation during non-use times. The heaters will be inoperative while the motors are running.
12.3
Remote Monitoring Software (Optional; must be called for in the Technical Specification)
The Watervision software features and capabilities are described in Section 5.9 of this specification. The
remote monitoring software option must be called for in the Technical Specification.
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12.4
Discharge Drop Pipe (Optional; must be called for in the Technical Specification)
The pump station manufacturer shall supply the discharge drop pipe for connection to the irrigation main
line. The pipe will be of Schedule 40 steel, painted to match the pump station and sized for depth and
termination based on the irrigation contractors requirements or as shown on the bid documents.
12.5
Earth Grounding (Optional; must be called for in the Technical Specification)
The contractor will be responsible to provide earth grounding of the pump station to meg ohm reading of
not more than 10 ohms. The pump station manufacturer will provide the Paige Electric equipment part #
182007 for the ground rod, part # 182199L for the grounding plate assemble part # 1820039 for the Aone
shot@ welding kit and part # 1820058 for the PowerSet earth contact material This equipment shall be
install by the contractor per the Paige Electric instructions.
12.6
Filtration (Optional; must be called for in the Technical Specification)
Pump station discharge filtration will be described in the Technical Specification. The style, brand, model,
size, and mesh/micron size and mode of flush activation will be identified the Technical Specification.
12.7
Fertigation Injection System (Optional; must be called for in the Technical Specification)
Scope: Pump system manufacturer shall provide the following as part of the pumping system. These
items shall be shipped loose and installed on site. If there are any discrepancies between this section and
the main specifications, this section takes precedence
Fertigation Feed Injection System:
General Description: Pump station manufacturer shall provide a fertigation feed nutrient injection system
capable of independently injecting as specified in the technical data sheet up to four separate liquid
product(s).
Each injection pump shall to be controlled by a separate AC Variable Speed Drive. The pump(s) shall be
mounted on separate fiberglass base(s). The electrical controls to be mounted inside the pump station
control panel, and shall not be separate. The injection system software controls will be integrated as part
of the program logic controller operating the irrigation pump station. The pump(s) shall not be mounted on
the irrigation pump station skid unless otherwise specified. It shall be the responsibility of the irrigation
pump station manufacturer for installing wire and conduit from the control panel to the motors, installation
from injection pump discharge into the injection quill and start-up.
The pump station manufacturer shall provide a run relay, which shall provide a start/stop signal for a
fertigation pump(s). The run relay shall allow the fertigation pump to run only when a main pump is
operating and flow is in excess of 100 GPM. The GPM to activate or de-activate the fertigation pump shall
be field adjustable through the operator interface. Run relay will be mounted in a J-box on the control
panel exterior. Customer is responsible for installing the chemical supply tanks and the suction line to
each injection pump unless otherwise noted in the specification. The fertigation nutrient injection system
to be manufactured by Watertronics Hartland, Wisconsin Model EZ Feed.
The fertigation nutrient injection pump(s) shall have Teflon diaphragm with Alloy 20 contour plates and
Alloy 20 wetted parts. Each pump capable of delivering product from 3 GPH up to 80 GPH at the station
rated pressure. Pump(s) to be independently driven via AC Variable Speed Drive to accurately control
injection rate. As part of the injection system the suction and discharge isolation valves shall be
constructed of PVC, with PVC suction and discharge tubing.
The nutrient injection system shall automatically vary its flow output in proportion to irrigation flow. The
irrigation pump station flow sensor will provide the input signal to provide accurate application. All
calibration, setup, and operation functions shall be accomplished through pump station PLC controls and
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Touch Screen Operator Interface and include a run light, HOA switch and speed pot. In manual mode, the
user can manually adjust pump speed.
A Clear PVC calibration tube shall be included on the injection pump suction to accurately calibrate the
metering pump over a minimum 30-second test.
Chemical Storage Tank Level Transducer: If called out for in the specifications, a fluid separated level
transducer shall be provided to monitor chemical storage tank level of each tank. The transducers will be
wired to and scaled by the same PLC, which controls that irrigation pump station. The level will be
displayed in inches of tank level on the pump station operator interface devise. If supplied as part of the
specification the level will also be displayed through the pump manufacturer’s remote monitoring and
control software on customers PC. Tank information can be monitored in inches or if configured, volume
in gallons. From either location, at the pump station or remotely, an alarm setpoint can be configured for a
low chemical level shutdown of the injection pump. This alarm will be logged at the pump station and at
the remote PC. The alarm will notify the user by email notification or using a dial up pager.
Controller Hardware Specifications:
Full battery backed memory for program storage, product configuration information and control
parameters.
RS232 port available for MODBUS™ communication over modem, wireless or wired connections.
Real Time Clock/Calendar.
Hardware for monitoring of water flow meter rate.
Analog inputs available upon request for chemical tank level monitoring
Controller Functional Capabilities:
System shall be capable of injecting each product proportional to the irrigation pump station flow rate.
All injection programs and applicable parameters must be accessible through the pump station Operator
Interface Device and through pump manufacturers remote monitoring and control software.
At the pump station the user shall have the ability through the color Touch Screen Operator Interface
device and remotely through monitoring software controls the ability to set QTY (3) unique separate
lockout periods per day. Also, the remote monitoring software shall have the functionality to automatically
email a report notification, audible alarm indication and having the ability to change each metering pumps
injection rate proportional to station flow without having to do so manually at each pump.
The fertigation software controls shall have the ability to monitor and display the chemical tank levels and
to shut down the injection pumps on a low tank level. The injection system shall provide the ability to
setup the chemical storage tank diameter and display the tank level in gallons when a level transducer is
supplied by the pump manufacturer.
Hoses and fittings per pump:
15 feet of ½” diameter discharge hose rated to 250 pounds working pressure
15 feet electrical conduit
15 feet motor cable
PVC check valve
PVC isolation valve
PVC injection quill
PVC suction and discharge plumbing at each head
Fiberglass mounting base
Installation /Start-up:
It is the responsibility of the customer to provide any necessary pad or containment for tanks prior to
installer arrival. It is the responsibility of the customer to provide the chemical supply tanks and connect
from tanks to suction connection of each injection pump. Installation to include complete assembly and
water testing of system & operator training
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9.4
Chemical Storage Tanks (Optional; must be called for in the Technical Specification)
Scope: Pump system manufacturer shall provide the following as part of the pumping system. These
items shall be shipped loose and installed on site. If there are any discrepancies between this section and
the main specifications, this section takes precedence.
Installation /Start-up: It is the responsibility of the customer to provide any necessary pad or
containment for tanks prior to installer arrival. It is the responsibility of the pump station manufacturer to
provide the chemical storage supply tanks and connect from tanks to suction connection of each injection
pump. Installation to include complete assembly and water testing of system & operator training.
The quantity and size of the chemical storage tanks to be provided by the pump station manufacturer will
be called out either on the drawing or in the technical specifications.
500 gallon HDPE cone bottom tank with leg stand, 2" outlet with 2" suction isolation valve, 2" return
line fitting, and 30' of 2" suction hose.
1050 gallon HDPE cone bottom tank with leg stand, 2" outlet with 2" suction isolation valve, 2" return
line fitting, and 30' of 2" suction hose.
1600 gallon HDPE cone bottom tank with leg stand, 2" outlet with 2" suction isolation valve, 2" return
line fitting, and 30' of 2" suction hose.
12.8
Stainless steel wet well inlet screen (Optional; must be called for in the Technical
Specification)
An all stainless steel box screen will be provided if called for in The Technical Specification. The screen
will be box style with stainless steel mesh on three sides. The top, bottom and outlet sides will be solid
stainless sheet. For support of the screen, stainless steel legs will be attached to the bottom. The
Technical Specification will describe the overall minimum dimension of the screen and will specifically
identify the inlet pipe style, and exact outside diameter. The box screen will have a clamp on style fitting
with stainless steel bolts and nuts to slide over the inlet pipe.
SECTION 13:
WARRANTY
The manufacturer shall warrant the pumping station to be free of defects and product malfunctions for a
period of one year from date of start up or fifteen months after shipment, whichever occurs first. Failures
caused by, lighting strikes, power surges, vandalism, flooding, operator abuse, or acts of God are
excluded from warranty coverage. All warranties implied or otherwise shall not exceed those warranties
extended by major or sub-component suppliers.
SECTION 14:
SITE PREPARATION DRAWINGS
Drawings shall be furnished by the manufacturer within two weeks after receipt of order. Drawings shall
indicate pump station alignment, discharge piping size, and electrical services required from local
contractor. The owner shall return one set of drawings marked approved or corrected within one week of
receipt.
SECTION 15:
OPERATION AND MAINTENANCE MANUALS
An operation and maintenance manual shall be furnished at time of start up.
END OF SPECIFICATION: SSTV Written Spec-08-22-06
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