Multitrode_MultiSmart_Control_Panel_Specification_8-15-08.pdf

Instrumentation and Control System Specification

1.1. Pump Control Equipment

A. Surge Suppression Include line-voltage surge protection in all control equipment. Comply with UL 1449 and ANSI C62.41 Standards.

B. Description:

Microprocessor based, intelligent pump controller with pre-configured pump control logic and fault handling. The Pump Control Equipment shall be MultiTrode MultiSmart Series Pump Controller or approved equal.

C. Standard functions:

The pump controller shall be supplied with the following pre-configured (default) parameters which can be changed or modified via the user interface keypad:

1. Set point adjustment for pump activation/deactivation and level alarms

2. Level device inputs: 4-20mA signal or (conductive) level probe

a. Redundant level device inputs

3. Selectable between charge (fill) & discharge (empty)

4. Pump control of up to 6 pumps

a. Including pump grouping and alternation

5. Station optimization including:

a. Maximum off time for any pump

b. Maximum pumps to run simultaneously

c. Maximum pump starts per hour

d. Inter-pump start and stop delays

e. Maximum run time for any pump

f. Blocked pump detection (when enabled by configuration key)

g. Well washer control functions

h. Well clean out (periodic pump down to off point)

6. Alternate profiles of level set points (Conditional pump management)

7. Data logger functions

8. 3-phase supply monitoring and supply protection including:

a. Under-voltage

b. Over-voltage

c. Phase fail

d. Phase rotation

9. Monitoring of dc supply, battery voltage, and internal temperature

D. Optional Functions: (Based on Controller Model) (Some Functions Require Firmware Key)

1. Motor protection & power module including:

a. Three phase current monitoring with over current and under current detection

b. Ground/earth fault

c. Motor winding insulation resistance test (IRT) up to 1000vdc

d. KVA, kW and power factor measurement

2. Calculated flow function

3. VFD control algorithm

E. Input/Output Description:

Available I/O types shall include:

• Digital inputs (voltage free, discrete input)

• Digital outputs (240V, 5A resistive)

• Analog inputs (10bit) (4-20ma)

• Analog outputs (10bit) (4-20ma)

1. Standard (Configurable) Digital Inputs:

a. Pump Seal/Leakage sensor

b. Pump PTC Thermistor or other over temp device

c. Pump PT100 Sensor

d. ITT Flygt FLS Sensor

e. Conductive probe (for liquid level sensing)

F. User Interface:

The field hardware shall include a user interface for operations and configuration. The display shall provide status of the pump station, control of pumps, resetting of faults and configuration of parameters as follows:

1. Status:

The following parameters shall be displayed on the main screen:

a. Level

b. Set points for alarms and pump start/stop

c. Pump Running/Stopped

d. Pump Available

e. 3-phase current for each motor (if optional motor protection is installed)

f. Pump faults

g. 3-phase supply voltage

h. Access to Faults, History, Information and Settings.

2. Information screens:

The following parameters shall be available via the keypad:

a. Elapsed Time accumulators for each pump & the pump station.

b. Number of Starts accumulator for each pump & the pump station.

c. Flow values, either derived from calculations (when enabled by configuration key), or via a flowmeter, including inflow, pump flow rate, total volume.

d. Overflow information, including start time, duration, and estimated volume. (when enabled by configuration key)

e. Insulation resistance value for each motor.

f. Status of Inputs & Outputs.

3. Control:

The following functions shall be controlled through the user-interface:

a. Pump mode for each pump, (Hand/Off/Auto)

b. Pump fault reset

c. Level alarm reset

G. Communications:

1. Physical:

The pump controller shall include the following types of connection ports:

a. Ethernet port up to 10Mbit/s

b. (3) RS232 ports up to 115kBit/s

2. Media:

The controller shall support a variety of communication network types including:

a. Private radio

b. PSTN

c. Wireless LAN

d. Cellular voice and data

3. Communication Protocols: (Optional Functions) (When Enabled By Firmware Key) The communication protocols supported shall be as follows:

a. MODBUS RTU, DNP3 (when enabled by configuration key)

H. VFD Functions: (Optional Functions) (When Enabled By Firmware Key)

1. VFD Equalization: The pump control unit shall be capable of regulating the speed of individual pumps and fine tune the transition stage of hydraulic flow when more than one pump is running. A single 4-20ma analog output from the pump controller shall be used to control multiple VFD drives. As multiple pumps are activated, the analog output signal shall be recalculated so that the net flow through the discharge piping is averaged over the activated pumps and the controlling signal shall be adjusted such that all of the pumps are running at the same speed to produce the required flow.

2. VFD Equalization Programming: The VFD pump control unit shall be programmed with the following pump settings:

A. Start and Stop level %

B. Start Speed % C. Maximum speed level %

3. VFD Advanced Modes: The VFD pump control unit shall be programmed with the following advanced modes of operation:

A. Multi-Pump Mode – Allows control of up to nine VFD drives when the pump control is networked with two other VFD controllers.

B. Mimic Mode – The analog output shall be the same across any networked controllers. C.

Multi-Well Mode – Up to three wells shall be able to be controlled as follows:

(a) The VFD algorithm will run on each controller in the network (3 maximum).

(b) The networked arrangement shall allow VFD’s in each well to be properly cycled across the wells.

(c) Each VFD pump controller will generate its own output signal to the VFD drives associated with it’s own well according to the level in that particular well.

1.2. Backup Control System (Level Control Relays):

A. Description: The backup control system shall consist of one or more level sensing relays. The number of relays required shall be determined by the number of pumps specified for backup control. The Backup Level Control Relays shall be MultiTrode Model MTR-3, MTRA-3 or equal.

B. Specifications: The level sensing relays shall be supplied with the following specifications:

1. The relay shall accept 2 or 3 level inputs from a conductive level probe or ball floats

2. All settings shall be dip switch programmable from the front panel and shall be as follows:

a. Conductive probe sensitivity adjustment.

b. Activation Delays.

c. Charge/Discharge selection. (MTR-3 model only)

d. Alarm Delay. (MTRA-3 model only)

e. Alarm Output Flashing/Steady. (MTRA-3 model only)

3. Output Contact Rating: 250VAC, 5 Amps Resistive, 2 Amps Inductive

C. Mounting and Installation: DIN Rail or 2 x #6 screws Base Mount

1.3. Level Sensing Equipment (Probe):

A. Description: A Multi-Stage Level Sensing Device designed to detect liquid level at specified intervals in tanks or sumps and interface with an electronic controller for pump control and liquid level display. The Level Sensing Equipment shall be MultiTrode (Level Sensing Probe) or equal.

B. Construction: Where the level sensing technique utilizes a sensing device inserted into the liquid, all cavities within each sensor unit assembly shall be PVC injected to seal the unit and prevent any moisture from entering the sensor assembly. Where a sensor unit consists of a multi-sensored probe, each sensor on the probe shall be rotated 90 degrees horizontally from the previous sensor along the probe length to eliminate tracking between sensors. Level sensing probes shall be pressure injected with an epoxy resin at final assembly to encapsulate all internal components and connections, thereby creating a rigid, sealed, homogeneous unit.

C. Cable: The flexible cable used for the Level Sensing Probe shall be comprised of PVC/PVC multi-conductor construction with a common oversheath that is water and oil resistant. The multi-conductor cable shall be identified with numbering and text along the entire length of the outer sheath at required intervals. Individual conductors of the multi-conductor cable shall be numbered and colored for easy identification, as well as connection to the pump controls.

Cables shall be secured to the top of probe bodies by synthetic rubber compression fittings for strain relief. Flexible cables shall be rated to physically support the combined weight of the level sensing probe and any suspended cable connected to the probe.

D. Mounting and Installation: Mounting connections shall be stainless steel. The mounting assembly for probes shall include a device available to maintenance personnel to clean the level sensing probe at desired maintenance intervals.

1.4. Hazardous Location Protective Device (Intrinsically Safe Barrier):

A. Equipment Description: The Hazardous Area Protective Device is intended to protect equipment and personnel in areas where hazardous conditions may be present. The Hazardous Area Protective Device shall be Multitrode Model MTISB, or approved equal. The intrinsically safe device shall be supplied according to the following specifications:

1. The intrinsically safe barrier shall be 5 or 10 channels (project specific). The device shall be panel mounted and designed to protect a multi-sensored conductive probe. The barrier shall be certified intrinsically safe for use with Multitrode equipment in installations up to and including Class 1 Zone O.

2. The intrinsically safe barrier shall have screw terminals for wire connections.

3. The intrinsically safe barrier shall be protected and current limited according to the requirements of UL Class I (Groups A, B, C & D), Class II (Groups E, F, & G) and Class III certification.

4. The intrinsically safe barrier shall allow for a maximum short circuit current of 10 ma.

B. Mounting and Installation: The intrinsically safe barrier shall be surface mounted using the attached mounting flanges on either side of the unit assembly. The unit shall be fastened with approved screws or bolts in accordance with NEC requirements.

1.5. Control Panel Construction & Assembly

A. General Requirements:

1. Control Panels shall be manufactured in accordance with ISO 9000-2001 specifications and shall be so constructed for the application of a UL Listing Label by an approved UL Control Panel Assembly Facility.

2. Control Panel wiring shall be installed and arranged in an organized, efficient manner. All control panel wiring shall be inspected for safety and verified by performing a point to point test.

3. All electrical connections shall be properly inspected and torqued in compliance with ISO specifications. External connections to the control panel shall be by way of numbered terminal blocks.

4. Control Panels shall be properly checked and load tested with power applied. A control panel test log shall be supplied with the control panel.

5. Control Panels shall be supplied from a UL approved control panel assembly facility with all of the required labels properly attached.

B. Control Panel Enclosure Environmental Rating:

1. Control Panel Enclosure rating shall be specified according to the particular project requirements or drawings as either NEMA 3R, 12, 4, or 4X. (Painted or Stainless Steel)

C. Control Panel Enclosure Specific Construction Requirements:

1. Enclosure shall be sized according to physical and functional device requirements.

2. Enclosure seams shall be continuously welded and ground smooth.

3. Enclosure door opening flange trough shall exclude liquids and contaminants.

4. Enclosure shall include an integral body grounding stud and sub-panel mounting studs.

5. Enclosure shall be wall mounted, unless otherwise specified.

6. Enclosure door shall have hidden hinges for a clean, aesthetic appearance.

7. Enclosure door opening angle shall be standard, full access, 135 degree opening radius.

8. Enclosure door shall be interchangeable and removable by pulling a captive hinge pin.

9. Enclosure door shall have a high-impact thermoplastic data pocket mounted on the inner side of the enclosure door.

10. Enclosure door shall have a seamless, foam-in-place, one-piece gasket to provide an oil-tight, dust-tight seal against contaminants.

11. Enclosure shall have a three-point latching system with a zinc die-cast handle that is painted with black textured polyester powder paint.

12. Enclosure handles shall be capable of being padlocked.

13. Steel sub-panel shall be white.

14. When enclosure cut-outs for instruments and other devices are required, holes shall be cut, punched, or drilled and finished with rounded edges.

15. A door stiffener shall be used where applicable to prevent door deflection under instrument loading or operation.

E. Instrument Location Requirements:

1. Instruments or control devices designated for sub-panel (back) mounting shall be located in a manner that will allow for maintenance and adjustment.

2. Instrument mounting height shall not exceed 6’-6” to the top of the instrument and shall not be lower than 3’-0” to the bottom of the instrument (unless otherwise specified).

F. Wiring Requirements:

1. Wiring for AC and DC control circuits shall be Type THHN or Type MTW stranded copper and shall be sized for the applied voltage and current. Unless otherwise noted, control circuit wiring shall not be smaller than No. 16 AWG.

2. Cable wiring for analog signal circuits shall be twisted, shielded pairs of stranded copper conductors that shall not be smaller than No. 20 AWG.

3. Wiring for special signalling equipment such as communications, digital data, and multiplexed signals shall be provided by the equipment supplier.

4. Wiring shall be numbered and marked at each termination point.

5. Terminal blocks for internal or external wiring shall be DIN rail mount, individual screw compression type terminals with machine printed labels.

G. Nameplate Requirements:

1. Nameplates are defined as inscribed, plastic plates mounted above or near a panel face mounted component. Unless otherwise noted, nameplates shall be engraved, rigid, laminated plastic with an adhesive back. Nameplate color shall be white with black letters.

2. Component Labels are defined as printed, vinyl labels mounted above, below or near a sub-panel (back) mounted component for identification. Printed vinyl labels shall be white in color with black letters and an adhesive back.

H. Grounding:

1. Control Panel enclosure shall be properly grounded in accordance with the National Electrical Code and local code requirements.

2. Each analog signal loop shall only have its shield wire connected to ground at a single point for the loop. Shields shall be grounded at control panels where signals are input to the receiving device and not at the source of the transmitting device.

I. Electrical Transient (Surge) Protection:

1. All electrical and electronic components of the Control Panel shall be protected against damage due to electrical transients induced in interconnecting lines from lightning discharges and surges in nearby electrical systems.

2. The transient surge protector shall be rated for 40kA per phase or larger.

J. Circuit Breakers:

1. Power Circuit Breakers shall be thermal magnetic type designed for AC current with a minimum interrupting capacity of 15,000 amperes.

2. Control Circuit Breakers shall be in accordance with section UL 489 with a minimum interrupting capacity of 10,000 amperes.

K. Control Power Transformers:

1. Control Power Transformers required to provide control system and accessory power shall be machine tool type control transformers with epoxy encapsulated coils or resin impregnated coils, high quality silicon steel laminations, copper magnet wire, moulded-in terminals and 55° C rise (Class 10 insulation system).

L. Voltage/Phase Monitor:

1. The voltage-phase monitor shall continually measure the voltage of each of the three phases of the incoming power to the equipment and provide protection for three phase motors, as well as sensitive electronics, etc. The phase monitor shall sense the following conditions:

under- and over-voltage, voltage unbalance, phase loss and phase reversal.

M. Control Relays:

1. Control relays shall be square base type, 120VAC or 12VDC (based on design schematic).

2. Control relays shall be 4PDT (4 Pole, Double Throw) with normally closed/normally open contacts rated at 120VAC, 5 amps minimum.

3. Control relays shall include an integrated test button and relay energized flag indicator.

N. Full Voltage Magnetic Motor Controller:

1. The motor controller shall be a NEMA rated, full voltage, non-reversing, across the line contactor and overload relay combination.

2. The motor overload relay shall be an ambient compensated type with inverse-time-current characteristic and shall be provided with heaters or sensors in each phase matched to nameplate full load current of the specific motor to which it connects .

O. Power Supply:

1. The 12 Volt DC Power Supply shall be rated for 120VAC Input and 12VDC Regulated Output according to the following specifications:

a. 85-265 VAC Input Range

b. High Efficiency (70%) or Better

c. Short Circuit Protection

d. Over Voltage Protection

e. EMI Input Filter

f. DIN Rail Mountable

2. The Power Supply shall be Astrodyne Model AD55-A/DRL, or approved equal

P. Backup Battery:

1. The 12 Volt DC Backup Battery shall be sealed lead acid type.

2. The battery shall be rated for a minimum of 12 Amp Hours.

Q. GFCI Convenience Receptacle:

1. There shall be a 120VAC, 15 Amp GFCI rated convenience receptacle mounted on the dead front swing door of the control panel. Receptacle circuit shall be protected by a thermal magnetic circuit breaker.

R. Enclosure Heater:

1. There shall be a 120VAC, 50 watt enclosure heater inside the control panel.

2. The heater shall be a silicone rubber, insulated strip type enclosure heater.

3. The heater shall be Chromalox Model #SL-B-2-5-55P, or approved equal.

S. Current Transformers: (Optional with Motor Monitoring in Pump Controller)

1. Current Transformers shall be used for monitoring of motor current load.

2. The current transformers shall be three phase type, moulded as a single device with mounting feet for base mounting.

T. Local Alarm (Flashing Light):

1. There shall be a Flashing Alarm Light mounted on top of the control panel enclosure for local alarm indication. The flashing alarm light shall be supplied according to the following specifications:

a. UL Recognized for use with UL NEMA Type 3R, 4, 4X, 12 & 13 Enclosures.

b. Shatter Resistant Lexan globe, U.V. Stabilized and Flame Retardant.

2. The Flashing Alarm Light shall be by Ingram Products, or approved equal.