PART C –

BOILER SPECIFICATIONS WORKS

1.0 ELECTRIC WATER HEATER

1. Hot water heaters shall be horizontal / vertical type. Heaters shall be fitted
with immersion heaters to give the maximum output KW. Vessel shall be
constructed for 125 PSi working pressure. Vessel shall be GLASS-LINED with
magnesium anode protection. Entire Vessel and electrical controls shall be
encased in a rectangular or cylindrical sheet metal enclosure with baked enamel
finish. Tank shall be insulated with fibre glass or polyurethane injected
insulation. Enclosure shall have hinged locking doors over electric controls.
Heating elements shall be complete with prewired terminal leads, control with
circuits, master pilot switch, etc. A thermostatic control of contacts shall be
provided to balance the water heating input to the actual demand. (Five years
full warranty for the body and element shall be provided).

1.1 GAS FIRED HOT WATER BOILER SYSTEM

Hot water boiler

Boiler characteristics (Hot water)

2. The Hot Water Boiler capacity shall be as shown on drawing. The maximum
water temperature will be 90°C and the maximum system temperature drop
will be 20°C.

General Boiler Design

3. A. The boiler shall be three pass horizontal fire tube updraft boiler with five (5)
square feet of heating surface per rated boiler horsepower. It shall be mounted
on a heavy steel frame with integral forced draft burner and burner controls.
The complete package boiler shall be approved as a unit by underwriters
laboratories and shall bear the UL / ULC label or equal approved European
laboratory.
4.
5. The boiler shall be completely preassembled and fire tested at the factory.
The unit shall be ready for immediate mounting on floor or simple foundation
and ready for attachment of water, steal, fuel, electrical, vent and blow down
connections.

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B. Boiler Shell (Hot water)

1. The boiler shell shall be constructed in accordance with ASME Boiler Code and
must receive authorized boiler inspection prior to shipment. A copy of the
inspection report shall be furnished to the purchaser.
6.
7. The hot water return and outlet connections shall be located on the top center
line of the boiler. The boiler shall be designated to rapidly mix the return water
with the boiler water. Forced internal circulation shall be used.
8. A dip tube shall be included as an integral part of the water outlet.
9. Two lifting eyes shall be located on top of the boiler.
10. Front and rear doors on the boiler shall be hinged or davited. Doors are to be
sealed with fiberglass tadpole gaskets and fastened tightly using heavy cap
screws that thread into replaceable brass nuts.
11. Rear refractory and insulation shall be contained in the formed door, which
must swing open for inspection of brick work.
12. The boiler tubes shall not include tabulators, swirlers or other add-on
appurtenances.
13. Front and rear tube sheets and all flues must be fully accessible for inspection
and cleaning when the doors are swung open. The shell must be furnished with
adequate hand holes to facilitate boiler inspection and cleaning.
14. For boilers 125 horsepower and over, a manhole shall be provided.
15. The exhaust gas vent shall be located near the front of the boiler on the top
center line and shall be capable of supporting.
16. 15 – 100hp. 1000 lbs and shall contain a stack thermometer.
17. Observation ports for the inspection of flame conditions shall be provided at
each end of the boiler.
18. The boiler insulation shall consist of 2 inch blanket under a sectional preformed
sheet metal lagging. This insulation must be readily removable and capable of
being reinstalled, if required.
19. The entire boiler based frame and other components shall be factory painted
before shipment using a hard finish enamel coating.

1.3 Hot Water Boiler Trim

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A. Low Water Cutoff

A low water cutoff control (manual reset) shall be mounted on the top centerline
of the boiler wired into the burner control circuit to prevent burner operation if
boiler water falls below a safe level.

B. Pressure and Temperature Gauges

Pressure and temperature gauges shall be mounted on the boiler with

temperature sensing element located adjacent to the hot water outlet.

C. Relief Valves

Water relief valves of a type and size to comply with ASME code requirements shall
be shipped loose.

D. Temperature controls

Temperature controls to regulate burner operation shall be mounted on the unit with
temperature sensing elements located adjacent to the hot water outlet. Controls shall be
high limit (manual rest), operating limit (auto reset), and firing rate control (30 – 800
hp).

18.1.4 Burner and Controls

A. Mode of Operation

- 30 and 40hp boilers. Burner operation shall be high-low-off principle. The

burner shall always return to low fire position for ignition.

- 50 – 800 hp boilers. Burner operation shall be full modulation principle. The

burner shall always return to low fire position for ignition.

18.1.5 Blower

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A. A Air for combustion shall be supplied by a forced draft blower mounted in the
front boiler door, above the burner, to eliminate vibration and reduce noise level.

B. Maximum sound level of the boiler / burner package shall not exceed 70 dbA
(when measured in accordance with ABMA Sound Test Standards).

C. The impeller shall be cast aluminium, radial blade, carefully balanced, and
directly connected to the blower motor shaft.

18.1.6 Combustion Air Control

A. 30 and 40 hp combustion air damper shall be linked to damper motor. Auxiliary

switch on the damper motor shall control high or low firing rate.

B. 50 – 800 hp combustion air damper and cam operated fuel metering valves shall
be operated by single damper control motor that regulates the fire according to
load demand. Potentiometer type position controls shall be provided to regulate
operation of the damper control motor (remove this sentence when a CB-HAWK
flame safeguard is used).

18.1.7 Fuel specification and piping

1. Fuel Series 700 – Gas Fired

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1. Burner Type – The burner shall be integral with the front head of the boiler and
of high radiant multi-port type for gas. The burner shall be approved for
operation on natural gas fuel.

2. Gas Pilot – The gas pilot shall be a premix type with automatic electric ignition.
An electronic detector shall monitor the pilot so that the primary gas valve cannot
open until pilot flame has been established. The pilot train shall include two
manual shut-off valves, solenoid valve, pressure regulator and pressure gauge.

3. Gas Burner Piping – Gas burner piping on all units shall include primary gas
shutoff valve, motor operated with proof of closure switch and plugged leakage
test connection. The main gas valve(s) shall be wired to close automatically in
the event of power failure, flame failure, low water or any safety shutdown
condition. A lubricating plug cock or butterfly shutoff valve shall be provided as
a means for a tightness check of the primary shut off valve. An additional plug
cock on butterfly valve shall be

4. furnished at entrance to gas train. Select one of the following:

- 60 – 100 hp high and low gas pressure switches shall be

provided.

- 125 – 250 hp high and low gas pressure switches shall be

provided. A second motorized safety shutoff valve, plus an
additional plugged leakage test connection shall be provided.

181.8 Boiler Flame Safeguard Controller and Control Panel

The controller and control panel shall comprise of the following:

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1. Flame safeguard

2. Boilers with control – Each boiler shall be factory equipped with flame
safeguard controller providing technology and functions.

Controller shall be computerized solid state having sequence and flame-on lights
and digital “first out” fault code indications of flame safeguard trip
functions. It shall include dynamic self-check logic. The controller shall
have a fixed operating sequence incapable of being manually altered. The
sequence shall include start, pre-purge, pilot and main fuel ignition run
and post-purge cycles.

The controller shall have a run / test switch. It shall allow interruptions to
sequence just after prepurge, during pilot ignition trial and run cycles for
adjustments to firing rate motor, damper linkages and pilot flame for
minimum turndown tests.

3. Control panel: The control panel shall be mounted on the front door of the
boiler in a location convenient to the operator. The hinged metal cabinet will
have NEMA 1A rating that includes a neoprene dust seal and a Yale cabinet
key type lock.

The panel shall contain the boiler flame safeguard controller, blower motor starter,
indicating lights and selector switches.

The panel shall have a removable sub-base for mounting the flame safeguard controller,
blower motor starter, and terminal blocks. For combination gas-oil and
heavy oil fired boilers the panel will contain the fuel selector and / or oil
heater selector switch.

4. Lights

- White – load demanded.

- White – fuel valve open

- Red-low water

- Red – flame failure.

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5. Control switches

- Burner ON-OFF.

- Manual-Automatic.

- Manual Firing Rate Control.

6. Oil, heat and moisture resistant wire shall be used and identified with
circuit numbers corresponding to the electrical wiring diagram.

7. All electrical equipment and wiring shall be in conformance with

Underwriters Laboratories requirements.

8. Boiler to be supplied with a control circuit transformer and fuse protection

for the control circuit.

9. Flame Safeguard

Each boiler shall be factory equipped with a Boiler Management Control

System providing technology and functions.

The system shall consist of a computer based boiler controller and solid
state sensors totally integrated to provide automatic burner sequencing,
flame supervision, and indications of system status, faults, and self-
diagnostics.

The boiler controller shall consist of chassis, program module, keyboard

display, and flame signal amplifier. It shall be the non-recycle type and
have a fixed operating sequence incapable of being manually altered. The
sequence shall include standby, pre-purge, pilot, main fuel ignition, and
run, and post-purge periods.

The system shall incorporate full modulating control of fuel and

combustion air as well as firing rate control based on system demand.
The boiler controller shall have a non-volatile memory that retains history
files and sequence status after interruptions.

An 80 character, 2 line liquid crystal (LCD) display and keyboard shall be

provided to adjust control settings and display 73 fault messages, 12
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diagnostic messages, 38 historical messages as well as system status

messages and operating pressures and temperatures. Boiler firing rate shall
also be displayed in addition to the last 6 lockouts and boiler operating
information when the lockout occurred. Provisions for a security access
code shall be provided.

Separate status indicators will show:

• Ready: Operational.

• Demand: call for heat.

• Main Valve: fuel valve open.

• Low Water: low water condition.

• Alarm: safety shutdowns.

The boiler controller shall incorporate a five function run/test switch.

The system shall be characterized for each individual model boiler. The
system shall also incorporate a tailored pre-purge cycle that minimizes
pre-purge energy losses, while maintaining the maximum required air
changes. It shall permit the user to select a specific rate control program
for precise load tracking that reduces on-off cycling due to load swings.
The system shall also provide an integrated thermal stress protection
program to prolong boiler life. An assured low fire cutoff feature shall also
be provided.

The system shall monitor inputs from solid state sensor for gas pressure,
oil pressure, and temperature. A single solid state sensor shall be used for
both on-off and proportioning control of the burner. The high/low limits
and operating set points of all sensors will be programmable from the
keyboard display. The system shall be capable of detecting a jumpered or
defective sensor. A dynamic check of the gas pressure sensor shall be
made prior to the main flame establishing period to ensure it is fully
operational.
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An optional 2 way communications module with built-in modem to allow

for remote control of non-safety settings and monitoring of up to 6 boilers
shall also be available. Up to 3 preprogrammed telephone numbers shall
be called in the event of a fault condition. Options such as Lead/Lag,
Boiler Efficiency, and Heating Boiler packages can be interfaced to this
module without any change to the existing system structure. The
communications module shall be able to interface with an IBMTM PC or
compatible system.

10. Control Panel: The control panel shall be mounted on the front door of the
boiler in a location convenient to the operator. The hinged metal cabinet
will have NEMA 1A rating that includes a neoprene dust seal and a Yale
cabinet key type lock.

The panel shall contain the boiler flame safeguard controller, indicating
lights and selector switches.

Panel shall have a removable sub-base for mounting the flame safeguard
controller, and terminal blocks. For combination gas-oil and heavy oil
fired boilers the panel will contain the fuel selector and/or oil heater
selector switch.

11. Oil, heat, and moisture resistant wire shall be used and identified with
circuit numbers corresponding to the electrical wiring diagram.

12. All electrical equipment and wiring shall be in conformance with

Underwriters Laboratories requirements.

13. Boiler to be supplied with a control circuit transformer and fuse protection
for the control circuit.

17.1.9 Efficiency Guarantee

The boiler manufacturer shall guarantee that, at the time of startup, the boiler will
achieve 90% fuel-to-steam efficiency at 100% firing rate when burning natural
gas.
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The specified boiler efficiency is based on the following conditions.

1. Natural Gas

Carbon, % (wt) = 69.98

Hydrogen, % (wt) = 22.31

Sulfur, % (wt) = 0.0

Heating value, Btu/lb = 21,830

2. Efficiencies are based on ambient air temperature of 80 °F, relative

humidity of 30%, and 15% excess air in the exhaust flue gas.

3. Efficiencies are based on manufacturer’s published radiation and

convection losses.

4. Any efficiency verification testing will be based on the stack loss method.

17.1.10 Warranty

1. All equipment is to be guaranteed against defects in materials and/or

workmanship for a period of 12 months from date of start-up or 18
months from date of shipment, whichever comes first.

17.1.11 Shop Tests

1. The packaged boiler must receive factory tests to check the construction,
controls, and operation of the unit. All tests shall be witnessed by the
Client and Consultant Engineers.

2. Start-up Service

1. After boiler installation is completed, the manufacturer shall provide

the services of a field representative for starting the unit and
training the operator at no additional costs.

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a. A factory approved and authorized start-up report shall be

submitted to the customer/user at the time of start-up.

17.2 LADDER AND PLATFORM

To facilitate operation and routine maintenance at boiler top level a mild steel
platform shall be provided to give access to manhole, main steam crown valve,
and safety valve.

A vertical ladder shall be provided leading direct from firing floor level to boiler
top level. When necessary safety hoops are fitted to the upper portion of the
ladder.

Handrailing shall be fitted to three sides of the platform.

18.3 PAINTING

On completion the boiler is thoroughly cleaned and painted one undercoat and
one top coat in the following colours:-

BOILER SHELL ..... WHITE (Self colour hot

dip Zintec sheeting)

SCREEN PLATES ..... BLUE

BASE, OUTLET BOX & ACCESS DOORS ..... BLUE

17.4 DRAWINGS

Two copies of the Boiler General Arrangement Drawings and Electrical Wiring
Diagrams shall be provided.

17.5 OPERATING INSTRUCTIONS

One set of our Standard Comprehensive Operating and Maintenance Instructions

shall be provided.

17.6 BOILER STACK AND BREECHING COMPONENTS

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Boiler stack and breeching components, supports and terminations shall be

factory prefabricated.

All stack and breeching components shall be tested and listed by Underwriters
Laboratories (UL and ULC), and / or equivalent European standards for use with
building heating equipment burning gas, liquid, or solid fuels, as described in
NFPA 211, Chapter
2.

All stacks and breechings will have inner walls of 20-gauge Type 304 stainless
steel for gas and No. 2 oil, or 20-gauge Type 316 stainless steel for coal, solid
fuels, and No. 4 thru No. 6 oil.
Outer walls shall be 24-gauge aluminum-coated steel or stainless steel for sizes
up to 24" ID and 20-gauge for sizes of 26" to 48" ID.

The stack and breeching shall be engineered, approved, and manufactured for the
boiler equipment manufacturer.

The stack and breeching manufacturer must supply complete CAD system design
drawings which include a complete component bill of materials.

Stack and breeching systems must be designed to adjust to thermal expansion

caused by the heating and cooling of normal boiler operation.

All stack and breeching components must be warranted for a minimum of 15

years when installed according to the manufacturer's installation instructions.

The stack and breeching shall comply with national safety standards and all
building codes where applicable.

The stack section joints shall be field sealed by use of containment bands with
captive fasteners and high temperature joint sealant.

All stack and breeching components shall be shipped on pallets and shrink-
wrapped to simplify on-site handling and protect materials until installation.

The system is to maintain air-tight integrity at pressures up to 72" WC at room

temperature.

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The system shall have a minimum clearance to combustibles with flue gas
temperatures greater than 1000 F and not exceeding 1400 F continuous, and a
minimum clearance to combustibles with flue gases not exceeding 1000 F
continuous.

17.7 CHEMICAL FEED SYSTEMS AND METERING PUMPS

17.7.1 GENERAL

Provide two completely preassembled, packaged chemical feed

system(s)/chemical metering pump(s)for the boiler packages. Package shall be
hydraulically and electrically tested at the factory and shall be assembled to the
fullest extent possible. Package shall be furnished with all required lubricants,
special tools, and installation instructions.

17.7.2 PUMP

Pump capacity shall be adjustable through 100% of the range by manual

micrometer dial while the pump is running or stopped. Pump stroking speed shall
not exceed 60 spm.

The pump shall be sized to deliver the required capacity at 85% of maximum
stroke length. Stroke adjustment shall be a variable micrometer type mechanism,
with the plunger powered through its entire travel. Lost motion designs are not
acceptable.

The pump shall include an automatic vent and refill mechanism on the hydraulic
side, which operates once each stroke. The pump shall have an external hydraulic
relief valve which is adjustable.

Double ball check valves shall be provided on the discharge to ensure accurate
repeatable metering. The pump valves shall be removable for cleaning or
replacement without the need to disturb suction or discharge piping.

The pump shall be field convertible to automatic stroke adjustment without the
use of special tools, and without the need to replace any major frame parts.

The pump shall be furnished with a factory-mounted driver suitably sized for
continuous operation at the maximum relief setting. The motor shall be integrally

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mounted direct coupled. No belts or pulleys should be used in the drive train or
for capacity adjustment.

17.7.3 FEED SYSTEM

Complete chemical feed system(s) shall be furnished suitable for handling the
required size of plant. Each system will consist of two pump(s), tank, piping, and
accessories as defined below. Manufacturer will select all materials in contact
with the chemical and guarantee their suitability for the particular service.

17.7.4 TANK

The tank shall be constructed of stainless steel and furnished with a removable
cover. Tank shall include connections for pump suction, drain, level gauge,
chemical fill, dilution water, and relief valve return piping. Drain connection
shall be separate from pump suction connection. Drain shall be located in the
bottom of the tank for complete emptying of contents.

Tank shall be furnished with a drain valve and a level switch (level gauge).

17.7.5 MIXER

An angle plate mount mixer with 304SS shaft and propeller shall be furnished.
The mixer propeller shall operate at 1450 rpm. The purpose of the mixer shall be
to mix liquids after pouring it in the tank.

18.0 HOT WATER STORAGE CALORIFIER

Carbon Steel Glass / Copper Lined Hot Water Vertical Storage Calorifiers
manufactured to the following specification:

18.1 Capacity : as shown on drawings.

18.2 Shell : Carbon Steel lined internally with Glass / Copper sheets

18.3 Supports : 3- Carbon Steel legs 150mm high made from 150x 76 RSC

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18.4 Battery : Low –Fin Copper Integron u tubes expanded into a RNB tube
plate with fabricated steel header chest

18.5 Inspection Opening : Each calorifier will be fitted with a 450mm dia carbon steel /
glass copper lined inspection manhole.

18.6 Gaskets : Non asbestos Fibre/ Nitrile Rubber.

18.7 Connections : Carbon steel copper lined flanges to PN16, Gun Metal Screwed.

18.8 Duty : Battery to raise specified capacity in 1 hour with a deg C temperature rise,
when supplied with primary hot water @ 4.5 Bar (g) as
show on drawings.

18.9 Insulation : Each calorifier will be supplied with factory fitted insulation
consisting of mineral wool laced to the shell and encased
in stucco aluminium sheets.

18.10 Accessories : Each calorifier will be supplied with 100mm dial thermometer,
100mm dial water pressure gauge, 100mm dial steam
pressure gauge, safety valve , drain cock , anti vacuum
valve

18.11 Code : Designed and manufactured to BS853 1996 Part 1 Grade A.

18.12 Testing : In accordance with BS853 1996. Suitable for a secondary working
pressure of 7.0 Bar and hydraulically tested 11.55 Bar.
Primary tested 7.0 Bar, Test certificates are to be supplied.

18.13 Drawings : Full manufacturing drawings shall be submitted for approval.

19.0 HOT WATER CIRCULATING PUMPS

Pumps shall be all bronze construction with cast bronze body rated for 150 psi working
pressure, bronze impeller, stainless steel shaft and mechanical seals. Motor shall
be TEFC, Class “F” insulation, 1450 rpm. Pump shall be controlled and
monitored at BMS as indicated on data point schedules.

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20.0 PACKAGED PRESSURE SETS

20.1 The booster pumpset shall be a factory manufactured works tested.

20.2 The pump set shall incorporate two centrifugal pumps with one as duty pump and
the other as as standby. Each pump shall have a duty as scheduled. Pump shall
be complete with cast iron casing, bronze/stainless steel impeller, stainless steel
shaft and mechanical seal.

20.3 The control panel shall be complete with star-delta starters, door interlocked
isolator, indicator lights, fuses, main isolator, duty select switch, test pushbutton,
adjustable 0-6 minute timer for each duty pump, anti-condensation heater an
cable numbering, all in steel enclosure IP 65.

20.4 The diaphragm pressure vessel shall be constructed of a steel shell with
polypropylene lining on internal wetted areas and a butyl rubber diaphragm.

20.5 All interconnecting pipework shall be copper to BS 2871 Table X with a gate valve
on the suction and discharge of each pump and a silent check valve on the
discharge branches of each pump.

20.6 A pressure switch for each of the pumps and a system pressure gauge should be
mounted on a common Aluminium Pressure Manifold to eliminate using small
bore fittings, to ensure easy replacement of pressure switch or gauge, and to
ensure that the pumpset arrangement is compact and has only one common
pressure signal source.

20.7 Demand shall be met in the first instance from the pressure vessel. When the vessel
pressure has fallen to a pre-set minimum (the "cut-in" pressure) the first duty
pump shall start. In the event of the failure of the duty pump the standby pump
shall automatically take its place.

As demand reduces again and the pressure builds up to a pre-determined cut-out

pressure, the pump will stop. An adjustable timer for each pump shall be fitted in
the control panel to ensure frequent switching cannot occur.

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20.8 After final assembly of the complete packaged unit, the automatic controls shall be
fully tested in the workshop to simulate site operating conditions and piping
tested to 150% of maximum operating conditions. The unit shall be cleaned
down, and painted one undercoat and one coat hammerite paint.

21.0 WATER TRANSFER PUMPSET

The unit shall be a packaged factory assembled and tested unit complete with
duty/stand-by pump, interconnecting pipework in copper, bronze valves, safety
devices and pre wired control panel.

Pumpset shall in general comply with the requirements of clause 17.0 except that
pumps shall be vertical multistage type.

Control of pumps shall be as follows:

- Pumps switching shall be controlled by float switches installed in the roof

storage tank.

- A low level float switch installed in the underground storage tank shall
prevent dry running of pumps.

22.1 PACKAGED WATER PUMPSET – VARIABLE SPEED

22.2 General

22.1.1 The pumping unit shall be a variable speed system. The pumping system shall
include, as a minimum, the programmable pump logic controller, adjustable
frequency drive, remote sensor / transmitters, motors and pumps.

The pump manufacturer shall be responsible for the successful operation of the system
supplied by him.

22.1.2 The manufacturer of the packaged pumping system shall provide a minimum of
one day’s training at the job site for the owner’s personnel the operation and
maintenance of the packaged pumping system.
22.1.3 The variable speed pumping system shall be as manufactured by the pump
manufacturer. A pump manufacturer is defined as a company who is regularly
engaged in the design and manufacturer of the pumps specified, herein. The
pump manufacturer shall have been in the business of manufacturing complete
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pumping systems for a minimum of ten (10) years and shall catalog variable
speed pumping systems.

An assembler of pumping systems, not engaged in the design and manufacturing of the
specified pumps or a representative of a pump manufacturer assembling
systems., shall not qualify as a manufacturer of pumping systems.

22.1.4 The system consists of variable speed pump (s) sized to meet system duty
condition as indicated on the pump schedule, adjustable frequency drive(s),
bypasses, a pump logic controller, and sensors / transmitters all as described
herein.

22.1.5 At the time of submittal for approval, the pump manufacturer shall provide a
complete system profile analysis which shall include as a minimum : the pumps
performance (variable speed pump curves) and the operating characteristics in
the system (system curve).

22.1.6 This system profile analysis shall include pump motor and adjustable frequency
drive efficiencies, staging points, horsepower, and kilowatt / hour draw.

241.7 A spring loaded non slam triple duty check valve with soft seat shall be installed
on the discharge of each pump. Valve shall be iron body with a pressure rating
equal to ANSI 125 lb. Valve trim shall be bronse with stainless steel spring. It
shall be equipped with brass readout valves for more accurate system balance.

22.1.8 Pump shall be bronze fitted centrifugal, single stage, end suction type or vertical
multistage type. Pump shall be rated for a minimum of 175 PSIG working
pressure. Casings shall have gauge ports, vent and drain ports at top and bottom
of casing.

22.1.9 Headers shall be copper – type L.

22.1.10 Motors shall be TEFC, Class ‘F’ insulation, 2900 RPM suitable for
415V/3PH/50HZ supply.

22.2 Pump Logic Controller

22.2.1 The pump logic controller shall be provided and the operator interface flush
mounted in the door of the packaged pumping system control cubicle. The
pump logic controller assembly shall be listed by and bear the label of
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Underwriters’s Laboratory, Inc. (U.L). All components within the pump logic
controller panel shall be U.L. listed or recognised components. The pump logic
controller shall meet FCC Part 15, for Class A computing devices.

The pump manufacturer shall supply and be responsible for the operation of a
programmable solid stage Variable speed pump logic controller. The controller
shall function to a proven program that safeguards against damaging hydraulic
conditions including :

a) Motor overload

b) NPSHR above NPSHA

c) Hunting

22.2.2 The adjustable frequency drives shall be controlled by a direct digital pump logic
controller with discrete input signal selection. Use of a multiplexer for multiple
sensor inputs is not acceptable. All individual sensor / transmitters shall be
individually wired to the pump logic controller for continuous scan and
comparison function. The pump logic controller shall be microcomputer based
and hold its software in EPROM. On line field modified data entries, such as set
point, shall be stored in RAM memory.

EPROM memory storage shall prevent accidental loss of data due to voltage surge or spike.
RAM memory shall be backed up by EPROM. In the event of a complete power
outage, all factory preset values remain stored and shall be able to be recalled by
the operator.

22.2.3 The pump logic controller shall be capable of receiving upto two process
variable analog input signals. It will then select the analog signal that has
deviated the greatest amount from its set point. This selected signal will be used
as the command feedback input for a closed loop hydraulic stabilization function
to minimise hunting. Each input signal may be programmed for a different set
point and set points shall be able to be changed in the field by keypad entry
through password security.

22.2.4 The pump logic controller shall be capable of displaying an additional analog
input corresponding to flow. The analog input signal shall be the feedback and
the set point shall be the command. The closed loop hydraulic stabilization

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function shall have the capability of performing the traditional proportional,

integral and derivative modes. The proportional function shall have range and
be infinitely programmable with that range.

Rates shall be in percent gain. The integral function shall also be infinitely
programmable and compatible with the adjustable frequency drive (s) AFD(s) and
the hydraulic system. It shall be entered as repeats / minute. Derivative shall be
entered in units of seconds and be fully programmable within the range allowing
infinite entries with that range.

22.2.5 The scan and compare rate that selects the command set point and process
variable signal shall be continuous and automatically set for optimum operation.
Each sensor shall be scanned every 20 milliseconds.

22.2.6 The pump controller shall have off line and on line diagnostic software. Off line
diagnostics shall consist of CPU, EPROM, EEPROM and RAM memory test. It
shall have self calibration of all analog inputs with diagnostics, display test,
program test, and all I/O tested and status of above displayed. The controller
shall include a watchdog circuit to provide system protection / operation in the
event of a controller failure. In the event of a controller failure, the system shall
be able to be operated manually across the line operation.

On line diagnostics include off line diagnostics and operational diagnostics including
but not limited to individual pump fault (s), AFD fault (s), overloads and sensor /
transmitter fault(s).

22.2.7 Further fault information may be accessed by interrogating the pump logic
controller through the front mounted keypad. In case of failure, the controller
shall fail in a predetermined safe operating mode. Reset after failure shall not
result in a no flow condition unless all equipment fails.

22.2.8 The pump logic controller and sensor / transmitters shall be self powered. The
pump logic controller shall be powered by 220 / 1Ph / 50 Hz. The incoming
power and I/O circuitry shall reject electromagnetic (EMI) and radio frequency
(RFI) interference. All digital outputs shall be electrically isolated.

22.2.9 All external transmitters furnished by the pumpset manufacturer shall be

powered by the pump logic controller through a quality integral 24 volt power
supply. Overvoltage and short circuit protection shall be on board.

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22.2.10 The pump logic controller shall operate the pump (s) in a predetermined manner
as indicated in the sequence of operation section.

Failure of any pump, motor or drive in the system shall cause the controller to not only
display the fault conditions, but alternate or transfer the operation to another
operating unit as indicated in the sequence of operation section. The pump logic
controller shall be capable of utilizing individual differential pressure switches to
determine pump failure.

22.2.11 Pump, AFD and overload trip faults shall not clear automatically. They must be
manually reset after correction of the fault. All above faults shall be displayed
before starting. First faults shall always be displayed. Faults shall not trigger
erroneous fault messages.

22.2.12 The pump logic controller shall be self prompting. It shall display all messages
in plain English. The messages shall include, but not be limited to, how to
obtain default values, when to turn it on, and if it is in the active remote control
mode.

22.2.13 The operator interface shall have the following:

(a) Multi fault memory and recall.

(b) On screen help functions.

(c) LEDs (pilot lights) and switches.

(d) Light and switch shall also be displayed in plain English messages scrolled
continuously.

22.2.14 The operator interface shall be capable of remotely being started / stopped.

22.2.15 The operator interface and process controller units shall be modular. They shall
be able to be interchanged with locally available parts without further
programming required.

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22.2.16 The readout shall be bright LCD super twist backlit capable of displaying any set
point value, I input or output signal (s), and alarm function in engineering units.
There shall be forty 6mm characters in a two line display.

22.2.17 The pump logic controller shall be capable of operating in automatic, manual or
off line diagnostic modes.

22.2.18 Three levels of password and software security shall be provided for protection
of field programs and use accessible features.

22.2.19 The pump logic controller shall provide hardware communications to the
building management system.

22.3 Adjustable Frequency Drive

22.3.1 Drive shall be of a microprocessor based PWM design, employing a diode bridge
rectifier to convert 3 phase AC to a fixed DC voltage. No input transformer
may be used for either power supply or DC bus power within the drive. A
constant displacement power factor of .95 shall be at all speeds and rated loads.

22.3.2 The DC bus shall consist of a choke and a capacitor bank to eliminate line
disturbances. A. switching power supply operating off the DC bus will provide
excellent undervoltage and ride through capability.

Control and invertor logic shall be isolated from the power section.

22.3.4 Bipolar power transistors shall be used in the invertor section converting a fixed
DC voltage to a 3 phase adjustable frequency output with a minimum 97%
efficiency at rated load.

22.3.5 For maintenance purpose, the drive shall be capable of starting, stopping and
running with stable operation with the motor completely disconnected (no load).

22.3.6 Drive must protect itself against all phase to phase and phase to ground faults,
removal of load, single phasing, power outages, and prevent starting with wrong
phase rotation.

22.3.7 Protection is defined as normal shut down with no component damage.

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22.3.8 The drive shall employ adjustable torque limit control which will override the
speed command and decrease the frequency while maintaining the correct
volt/hertz ratio whenever the load level surpasses the drive design level.

Torque limit shall be setable from 50 to 115% of full drive rating. When torque limit
engages, the output frequency is steadily reduced until the load reduces to the
design capacity. At that point the speed will stabilise. If the load reduces further
the drive will reaccelerate to the preset speed.

Lectronic motor overload provides electronic equivalent to thermal motor overload and
shall be adjustable from 60 to 100% of the drive rating.

The drive shall be capable of being started by a 2 wire control circuit, a 240 Volt AC
signal or application of input power.

Adjustments shall include :

Current Limit Min / Max Speed Motor Boost

Accel Time Decel Time V/Hz Ratio

Speed Reference signals shall be :

Potentiometer input 10,000 ohms

Voltage input 0 to 10 VDC

Current input 0 to 20 or 4 to 20 mAmp.

Analog output shall be a non isolated 0 to 5 VDC, selectable for frequency or

amperage.

The drive shall provide as standard 3 relays to indicate drive run, drive fault, and
current limit condition.

Full RS 232 communications shall be provided as optional equipment.

The variable frequency drive including all factory installed option shall have
ETL or UL agency approvals.

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VFD specifications

For detailed VFD specifications, refer electrical specification volume.

Input voltage : 220V / 1PH/50Hz

415V/3PH/50HZ

Input Range : +/- 10%

Speed Range : 20:1 Maximum or as specified.

Ambient Temperature : 0 – 40 C

Humidity : 0 – 95 % Non Condensing

Altitude : to 3300 feet above sea level

Efficiency : 96% or greater at rated load

Power Factor : 0.95 regardless of speed or load.

Adjustments : Min. / Max. speed, accel / decel independently adjustable to

min. 120 sec., current limit, 12 T.

Drive Protection : Over temperature, under / over voltage, phase to phase

short circuit, phase to ground short circuit, overcurrent, current limit, decel
limit.
Status Indication : Drive enabled, power fault indication for under /
over voltage, over current, motor trip, accel /
decel limit.

Sequence of Operation

With the pumpset in the “Automatic” mode and the duty pump selector on “pump No. 1,
the duty pump 1 shall operate through the AFD which is being controlled by a
signal generated by the pump logic controller. Pump 2 will start if duty is not met
and pressure can not be maintained. Pump 2 shall generally remain as standby.

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In the event of a system differential pressure failure, due to duty pump or overload fault,
the pump logic controller will automatically initiate a timed sequence of
operation to start the backup pump in the variable speed mode. A solid red
indicator light shall signal this condition and a message shall be displayed on the
operator interface of the pump logic

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