IFB DPW 18-106 - Final.docx

Town of Amherst Department of Public Works Invitation For Bid [IFB]

Bid documents submitted by all bidders shall be enclosed in outer and inner envelopes, both of which shall be sealed and clearly labeled with the words:

Wildflower Drive Pumping Station

Bids shall be submitted no later than 2:00 p.m. on Tuesday, December 19, 2017 and can be mailed or delivered to:

Town Accountant’s Office Town Hall 4 Boltwood Ave Amherst, Ma 01002

Attn: Anthony P. Delaney delaneya@amherstma.gov Phone: (413) 259 3026 Fax: (413) 259-2401

TOWN OF AMHERST

DEPARTMENT OF PUBLIC WORKS

Wildflower Drive Pumping Station

BID DOCUMENT: IFB #DPW18-106

TABLE OF CONTENTS

Contents

1 LEGAL NOTICE

INSERTION ORDER

TYPE OF AD: Legal

PUBLICATION(S) & PUBLICATION DATES:

DAILY HAMPSHIRE GAZETTE – Friday, December 1, 2017

PLEASE BILL:

Accounting Town Hall 4 Boltwood Ave Amherst, MA 01002

The Town of Amherst invites sealed bids for a pre-fabricated, fully enclosed, suction lift, wastewater pump station with standby generator. Invitations for Bids may be obtained by contacting the Town Accountant's Office, Town Hall, 4 Boltwood Ave., Amherst, MA 01002, (413) 259-3025 or delaneya@amherstma.gov.

Bids shall be submitted no later than 2:00 p.m. on Tuesday, December 19, 2017, to the Town Accountant’s Office at the above address, where the bids will be publicly opened and recorded at that time.

The Town of Amherst reserves the right to reject or accept any or all bids, in whole or in part, when at its sole discretion, said action is deemed to be in the best interest of the Town. In accordance with the Town of Amherst's M/WBE Program, minority and women-owned business are encouraged to submit bids.

2 GENERAL SPECIFICATIONS

2.1 SUMMARY OF WORK:

Equipment provided by the Contract is shown and described in Drawings and Specifications entitled:

TOWN OF AMHERST

DEPARTMENT OF PUBLIC WORKS

Wildflower Drive Pumping Station

BID DOCUMENT: IFB #DPW18-106

Plan Set (Sheet 1) Wildflower Drive Pumping Station

3 PURCHASE DESCRIPTION

4 BID SUBMISSION TERMS AND REQUIREMENTS

4.1 Bids will be publicly opened and recorded at date and time ("the bidding deadline") and at the place, as follows:

DATE: Tuesday, December 19, 2017

TIME: 2:00PM

4.2 Security deposits will be required in the form of a Bid Bond, certified check, or cashier's check, from a responsible bank, trust company, or insurance institution, in the amount of five percent (5%) of the total bid price, payable to the Town of Amherst. Should any bidder to whom an award is made fail to enter into a contract with the Town within ten (10) business days after the award is mailed to the bidder, or fail within such time to furnish a performance bond as required, the amount of the bid deposit so received from such bidder shall become the property of the Town as liquidated damages for such failure. Thereafter the Town may proceed to award the contract to the next responsible and responsive bidder.

4.3 The successful bidder will be required to furnish a Payment/Performance bond in the amount of Fifty percent (50%) of the contract award, not later than ten (10) working days after the award notification. Bonds will be for one (1) year and shall be renewed annually at the Contractor's expense.

4.4 Wherever applicable, the conditions of Employment and Prevailing State Wage Rate, as set forth by the Massachusetts Department of Labor and Industries, as contained in specifications, shall prevail in the execution of work under this contract.

4.5 The Town of Amherst reserves the right to reject any and all bids in whole or in part and to waive informalities, when at its sole discretion is deemed to be in the best interests of the Town and to the extent permitted by law.

4.6 Bids shall be evaluated based on responsiveness to the criteria, terms and conditions contained in this IFB and its attachments. Failures to follow the instructions, meet the criteria, or agree to the terms and conditions contained in this IFB may be cause for rejection of the bid as nonresponsive.

4.7 All bids shall be submitted to the Town, as and where set forth above, on or before the bidding deadline. Bids and unsolicited amendments to bids received by the Town after the bidding deadline will not be considered, and requests for extensions of time will not be granted. Bidders who mail bids should allow sufficient time for receipt by the Town by the bidding deadline. Bid received after the bidding deadline will be returned to the bidder unopened.

4.8 All bids shall be signed in ink by the bidder. If the bidder is a corporation, the authority of the individual signing shall be endorsed upon, or attached to, the bid and certified by the clerk of the corporation.

4.9 All bids submitted shall be binding upon the bidder for a minimum period of thirty (30) calendar days following the opening of bids.

4.10 The contract will be awarded within 30 days after the bid opening unless the time for award is extended by mutual consent of the parties.

4.11 Bids submitted to the Town shall be securely kept and shall remain unopened until bidding deadline and the public opening of bids.

4.12 Bids once submitted may, upon request of the bidder prior to the bidding deadline, be withdrawn or amended. If amended, resubmission of the bid shall comply with all requirements of this IFB.

4.13 Negligence on the part of the bidder in preparing the bid confers no right of withdrawal after the bidding deadline. The Town does not assume any responsibility for errors, omissions, or misinterpretations which may have resulted in whole or in part from the use of incomplete bid documents. Any bidder finding an ambiguity, inconsistency, or error shall promptly notify the Town.

4.14 If it becomes necessary to revise any part of this IFB or if additional data are necessary to enable an exact interpretation of provisions, such addenda will be provided to all bidders who have requested this IFB. No addenda will be issued within the immediate three (3) business day period prior to the bidding deadline.

4.15 Questions and inquiries will be accepted from any and all bidders and must be in writing. Questions will be answered in writing and both questions and answers will be distributed to all bidders who receive the IFB provided, however, that all questions are received at least ten (10) days in advance of the bidding deadline.

4.16 By submitting a bid in response to this IFB, the bidder shall be deemed to have certified that no officer, agent, or employee of the Town has a direct or substantial financial interest in the procurement, that the bid is submitted in good faith and exclusively on bidder's own behalf, without fraud, collusion or connection of any kind with any other bidder for the same work or with any undisclosed party.

4.17 All terms and provisions contained in the "LEGAL NOTICE" of this procurement (a copy of which is attached hereto) are incorporated by reference into this IFB.

4.18 The bid price(s) shall be written both in words and figures, and in the case of a discrepancy between the two the amount in words shall govern.

4.19 It is understood, agreed upon and made a part hereof, and shall be a part of the contract, that the contract entered into between the Town and the successful bidder shall not be assigned or assignable by way of sub-contract or otherwise, unless or until the Town shall have first assented thereto in writing.

4.20 All bids must be submitted on the forms provided or on attachments approved in advance by the Town.

4.21 All bids must include a signed copy of the following: non-collusion form, tax compliance certificate, certificate of authority and bid pricing sheet.

5 SPECIFICATIONS

PART 1 - TIP-UP TWIN-PAC

1.1 GENERAL

A. The contractor shall furnish and deliver, as shown on the plans, one (1) pre-fabricated, skid mounted, weatherproof, wastewater pump station. The standby power system within the pump station shall monitor incoming electrical utility and shall provide its own standby power to the pump station in the event of power loss, phase loss, etc. The pump station and appurtenances shall be maintained in an enclosed fiberglass structure designed to provide resistance to rusting, operational reliability through environmental control, and provide ease of access to housed components. It is the supplier’s responsibility to include all necessary appurtenances to provide for a complete, automatic, and smooth operating pump station.

B. The principal items of equipment shall include, but not be limited to, the following:

1. Wastewater pump and motors

2. Wastewater piping and valves

3. Pump control system

4. Engine generator set

5. Engine control

6. Generator control

7. Automatic transfer switch

8. One-piece seamless fiberglass enclosure

9. Fabricated steel base structure

10. Intake and exhaust louvers and ductwork

11. Environmental accessories

1.2 BASIS OF CONTRACTORS BID

A. The system shall be manufactured by Precision Systems, Calumet City, IL utilizing integral Smith & Loveless duplex vacuum-primed pumps and Kohler standby power equipment. The equipment specified has been deemed most suitable for the application. The contractor is required to base their submitted bid on the specified equipment.

PART 2 - PUMPING EQUIPMENT

2.1 OPERATING CONDITIONS

A. Furnish and install two (2) vacuum primed pumps which shall be capable of continuous operation while pumping unscreened wastewater in accordance with the operating condition defined in Table 1.

2.2 PUMP CONSTRUCTION

A. The pumps shall be vertical, non-clog type of heavy cast iron construction, especially designed for the use with mechanical seals and vacuum priming. In order to minimize seal wear caused by lineal movement of the shaft, the shaft bearing nearest the pump impeller shall be locked in place so that end play is limited to the clearance within the bearing. To minimize seal wear resulting from shaft deflection caused by the radial thrust of the pump, the shaft from the top of the impeller to the lower bearing supporting the impeller shall have a minimum diameter as noted in Table 1. Shaft overhang, defined as the distance from the centerline of the lower bearing to the top of the impeller, shall not exceed 6 in.

B. The bearing nearest the impeller shall be designed for the combined thrust and radial load. The upper bearing shall be free to move linearly with the thermal expansion of the shaft and carry only radial loads.

C. The shaft shall be solid stainless steel through the mechanical seal to eliminate corrosion and abrasive rust particles. Removable shaft sleeves will not be acceptable if the shaft under the sleeve does not meet the specified minimum diameter.

D. CLOG-RESISTANT IMPELLER- The pump impeller shall be specifically designed to allow for free and unrestricted flow of high volumes of consumer flushables such as wipes, rags, stringy materials, etc. The clog-resistant impeller shall prevent accumulation of material in the pump to where proper operation and pumping would cause pump failure. The clog-resistant impeller shall be a standard product of the pump manufacturer and be of field-proven, demonstrable design and manufacture for a minimum of ten (10) years. The clog-resistant impeller shall be Smith and Loveless model X-peller, with flushable-passing technology.

The clog-resistant impeller shall be designed for 4”, 6”, and 8” size vertical centrifugal close-couple pumps and flow rates from 75 to 1700 GPM, as specified herein and shown on the contract drawings. The clog-resistant impeller shall allow for the use of variable frequency drives (VFD) on low flows and shall be in conformance to Hydraulic Institute vibration standards. The clog-resistant impeller shall be designed for speeds of 900, 1200, and 1800 RPM.

The clog-resistant impeller shall be of the enclosed mono-port type made of closed-grained cast iron and shall be in dynamic balance when pumping wastewater. Conventional two-port impellers shall not be accepted. The dynamic balance shall be obtained without the use of balance weights or liquid filled chambers. The clog-resistance impeller shall be designed to allow for the trimming of the impeller to meet design condition changes without altering the balance. The eye and port of the clog-resistant impeller shall be of proper size to permit the passage of a sphere 3” in diameter in accordance with nationally recognized codes. To further prevent clogging the clog-resistant impeller port shall have a minimum area of 10.6 square inches. The clog-resistant impeller shall be keyed with a stainless steel key and secured to the motor shaft by a stainless steel cap screw equipped with a Nylock or other suitable locking device. The clog-resistant impeller shall not be screwed or pinned to the motor shaft and be readily removable without the use of special tools. To prevent the build-up of stringy materials, grit, and other foreign particles around the pump shaft, all impellers less than full diameter shall be trimmed inside without impeller shrouds. The shrouds shall remain full diameter so that close minimum clearance from shrouds to volute is maintained. Both end of the shaft and the bore of the impeller shall be tapered to permit easy removal of the clog-resistant impeller from the shaft.

E. The pump shall have an adaptor providing a large water reservoir above the impeller to provide for positive exclusion of air from the impeller. The seal shall be inside this area to assure lubrication. Pumps which do not use hollow priming adapters for positive lubrication of the seal will not be acceptable.

F. The pump shall be so constructed so as to permit priming from the low pressure area behind the impeller. Priming from the high pressure connections will not be acceptable. The priming bowl shall be transparent to enable the operator to monitor the priming level.

G. The pump shall be arranged so that the rotating element can easily be removed from the volute without disconnecting the electrical wiring or disassembling the motor, impeller, backhead or seal, so that any foreign object may be removed from the pump or suction line.

H. The pump shaft shall be sealed against leakage by a single mechanical seal constructed so as to be automatically drained and primed each time the pump is drained and primed. Water which lubricates the mechanical seal shall be automatically drained from around the seal if the pump loses prime, in order to allow both the pump and the seal to be drained.

I. The seal shall be of carbon and ceramic materials with the mating surfaces lapped to a flatness tolerance of one light band. The rotating ceramic shall be held in mating position with the stationary carbon by a stainless steel spring.

J. The pump volute shall be furnished with mounting lugs and be bolted to the station floor plate, forming a gas-tight seal.

2.3 MOTOR CONSTRUCTION

A. The pump motors shall be vertical, solid shaft, NEMA Pbase, squirrel cage induction type. They shall have class F insulation, suitable for temperatures up to 105 degrees C. Insulation temperature shall, however, be maintained below 80 degrees C. The motors shall have normal starting torque and low starting current, as specified by NEMA Design B characteristics. They shall be open dripproof design with forced air circulation by integral fan. Openings for ventilation shall be uniformly spaced around the motor frame. Leads shall be terminated in a cast connection box and shall be clearly identified.

B. The motors shall have 1.15 service factor. The service factor shall be reserved for the Town's protection. The motors shall not be overloaded beyond their nameplate rating, at the design condition, nor at any head across the entire pumping curve for the impeller selected.

C. The motorpump shaft shall be centered, in relation to the motor base, within 0.005". The shaft runout shall not exceed 0.003". The motor-pump shaft shall equal or exceed the diameter specified in Table 1, at all points from immediately below the top bearing to the top of the impeller hub.

D. A bearing cap shall be provided to hold the bottom motor bearing in a fixed position. Bearing housings shall be provided with fittings for lubrication as well as purging old lubricant.

E. The motor shall be fitted with heavy lifting eyes, each capable of supporting the entire weight of the pump and motor.

F. The wastewater pumps shall be the brand and model specified in Table 1 or engineer pre-approved equal.

2.4 VACUUM PRIMING SYSTEM

A. A separate and independent priming system shall be provided for each wastewater pump, providing complete standby operation. Each priming system shall include a separate vacuum pump. Vacuum pumps shall have corrosion resistant internal components. They shall each be capable of priming the wastewater pump and suction piping in less than 60 seconds, under rated suction lift conditions of 20' at mean sea level.

B. Each priming system shall be complete with vacuum pump, vacuum control solenoid valve, prime level sensing system, and a float operated check valve installed in the system ahead of the vacuum pump to prevent liquid from entering the vacuum pump. The float operated check valve shall have a transparent body for visual inspection of the liquid level and shall be automatically drained when the vacuum pump shuts off.

C. The priming system shall automatically provide positive lubrication of the mechanical seal each time the wastewater pump is primed. To prevent excessive stoppage due to grease accumulation, no passageway in the priming system through which wastewater must pass shall be smaller than the equivalent of a 2½" opening.

D. The following spare parts will be provided by the manufacturer for pumping system:

1. (2) Domes

2. (2) Mechanical Seals

3. (1) Sonic Start Sensor

4. (1) Vacuum Pump

5. (2) Volute Gaskets

6. (2) Seal Chamber Gaskets

7. (2) Rapid Jack Top Gaskets

PART 3 - STATION PIPING

A. The pump suction shall be drilled and tapped for a 125-pound American Standard flange for ready connection of the suction riser. The discharge line from each pump shall be fitted with a Rapid-Jack check valve and terminate into a common three way eccentric plug valve. Size, location, and quantity of valves shall be as shown on the drawings. The cast iron check valve body shall be designed so that the upper portion may be easily removed, without disturbing the end flange seals to adjacent piping, to service the shaft, arm and clapper or to remove any material which may be causing clogging. Provide one spare body gasket for each valve.

B. Protrusions through the station floor shall be sealed where necessary to effect sealing between the equipment chamber and the wet well. The suction and discharge connections, where they pass through the floor, shall be sealed by gaskets in order to prevent corrosive, noxious fumes from entering the station. Welded joints that do not allow adjustment or replacement will not be considered for this application. The pump station manufacturer shall extend the suction and discharge connections below the floor at the factory so that field connections can be made without disturbing the gas-tight seals. Once the station is installed, however, it shall be possible to remove the entire 4” or 6” (100 or 150 mm) suction pipes through the station floor without having to enter the wet well to unbolt them.

C. The manufacturer shall provide a plain end pipe for connection to the common discharge pipe. The manufacturer shall provide a dresser coupling and a quick connect bypass coupling for force main connection.

PART 4 - PUMP CONTROL SYSTEM

4.1 GENERAL

A. The control equipment shall be a Precision Systems duplex control system with a NEMA Type 12 metallic enclosure. The pump controller, control switches, pilot lights and elapsed time meters shall be mounted on the enclosure observable and operable without accessing the high voltage interior of the enclosure.

B. Thermal magnetic circuit breakers shall be provided for branch disconnect service and short circuit protection of all motor control and auxiliary circuits for the environmental systems within the station. Circuit breakers shall be operable without accessing the high voltage interior of the enclosure. A minimum of one (1) spare circuit breaker shall be provided.

C. IEC rated magnetic across-the-line starters with under-voltage release and overload coils for each phase shall be provided for each pump motor to give positive protection. Each single phase auxiliary motor shall be equipped with and over-current protection device in addition to the branch circuit breaker or shall be impedance protected. All switches shall be labeled and a coded wiring diagram shall be provided.

D. Non-resettable six digit elapsed time meters shall be provided for each pump to monitor the cumulative operating time of the pump.

E. Pilot lights shall be provided to indicate:

1. High/Low wet well level "Red" (integral to controller)

2. Two (2) Pump running "Green" F. Pump starting shall be done via time delay to prevent overload due to simultaneous pump starting. The delay shall be adjustable and shall be set to prevent the pumps from starting less than five seconds apart.

G. The control system shall be supplied with a lightning and surge arrestor wired into each of the three legs of the three phase service.

H. A red alarm strobe shall be mounted on the exterior of the enclosure as well as dry contacts for indication of the following alarm conditions:

1. High/low wet well

2. Station flood

3. Utility power fail

4. Pump fail

5. Generator fail I. Ten (10) spare terminal blocks shall be provided in the pump control panel for connection of external alarm criteria into pump panel to provide a central interface point.

J. All switches shall be labeled and a coded wiring diagram shall be provided.

4.2 CONTROLLER

A. The ultrasonic level controller shall be a Siemens Hydroranger 200 HMI (NEMA 4X, single point, 6-relay, 120V, general purpose, programmer unit, panel mount kit) to match Town's existing infrastructure. The Hydroranger shall be mounted on the Duplex Pump Control Panel but shall be viewable without opening the Control Panel.

4.3 TRANSDUCER

A. The liquid level transducer shall be a Siemens Echomax XPS-15 transducer (Class 1, Division 2, 1” NPT mounting thread, mounting hardware, manufacturer cable of sufficient length to reach transmitter) to match Town's existing infrastructure.

4.4 REDUNDANT CONTROL SYSTEM

A. An independent high level alarm and redundant control capability with features hereinafter listed shall be provided in addition to the specified primary control system. If shall be powered by a 120 VAC circuit breaker (other than the one powering the primary system) and use one or more direct-acting float switches as described.

B. The independent alarm/control panel equipment shall be designed to UL 508 Industrial Control Panel standards and shall incorporate a 120 VAC input transformer with transient protection and a DC power supply with limited 12 VDC to supply the level sensing float circuit(s). The control shall be used here with up to four float switches. The float switch shall be mounted in the wet pit in accordance with manufacturer’s instructions or as shown on the plans.

C. The front face of the controller shall include n LED for independent Float Status, Pump 1 Status, Pump 2 Status and Backup Control Status.

D. The front face of the controller shall have switches to select the operating sequence based upon float quantity and the pump alternation sequence.

E. The front face of the control shall have a 0-60 second timer for pump operating time when a single float switch is utilized. shall be provided . A selector switch shall allow for pump alternation sequence.

F. A 10 second lag pump start delay shall be integral into the control circuitry of the controller. Upon the occurrence of a high level condition sensed by the high alarm float, the Backup LED shall light, a form A, normally-open Backup output contact circuit shall transfer to operate the specified alarm devices and two (2) form A, normally-open, redundant-control (10 amps/240VAC) circuits shall close to provide redundant pump operation. These control circuits shall be wired in parallel with the primary control system two-wire control circuits to provide a redundant capability. Once active the pumps will operate through the action of the Start and Stop float switches. As the level recedes from the high level float, the alarm contact shall return to its normal setting of the off-delay timer. After that time interval (which is to commence following the lowering of the high level float) the control relay contacts are to re-open.

G. The redundant control/alarm capability shall be completely integrated in the specified control panel and system as described and in accordance with all applicable codes and job requirements.

PART 5 - ENGINE GENERATOR SET

5.1 OPERATING CONDITIONS

A. Engine generator set shall be capable of continuous standby rating at 0.8PF at the conditions and minimum capabilities listed in Table 2. The unit shall be capable of the KW and KVA for motor starting at a maximum sustained voltage dip of 10% listed in Table 2.

B. Generator shall meet or exceed the performance and design characteristics outlined in Table 2.

C. The standby generator model and manufacturer shall be as specified in Table 3.

5.2 ENGINE

A. The minimum 3.0 liter displacement engine shall deliver a minimum of 50.8 HP at a governed engine speed of 1800 rpm, and shall be equipped with the following:

1. Electronic isochronous governor capable of 0.5% steady-state frequency regulation

2. 12-volt positive-engagement solenoid shift-starting motor

3. 70-ampere automatic battery charging alternator with a solid-state voltage regulation

4. Positive displacement, full-pressure lubrication oil pump, cartridge oil filters, dipstick, and oil drain

5. Dry-type replaceable air cleaner elements for normal applications

6. The engine shall be naturally aspirated and fueled by Natural Gas.

7. The engine shall have a minimum of 4 cylinders and be liquid-cooled

8. The engine shall be EPA certified from the factory

9. The generator must accept rated load in one-step.

10. Natural Gas fuel supply pressure, measured at the generator set fuel inlet downstream of any fuel system equipment accessories shall be within the operating range of 1.74-2.74 kPa (7.0-11.0 in. H²O).

B. The engine shall be liquid-cooled by a closed loop, unit mounted radiator rated to operate the generator set at full load at an ambient temperature of 50 degrees C (122 degrees F). The radiator fan and other rotating engine parts shall be guarded against accidental contact.

C. The air cleaner shall provide engine air filtration which meets the engine manufacturer's specifications under typical operating conditions.

D. Each genset requires a maintenance free BCI group 24 battery which must meet the engine manufactures' specifications for the ambient conditions specified in Part 1 Project Conditions and shall comply with the NFPA requirements for engine cranking cycles. This battery shall be rated according to SAE Standards J-537 with a minimum cold cranking amp of 650 amps and a minimum reserve capacity of 120 Minutes at 80F. The battery plates shall be constructed of a Calcium-Lead alloy to provide long waterless operation and extended battery life. The battery must contain a handle to aid in lifting and the case must be constructed of polypropylene to resist breakage and extend service life.

E. Battery rack and battery cables capable of holding the manufacturer's recommended batteries shall be supplied.

5.3 GENERATOR SET MICROPROCESSOR CONTROL

A. Decision-Maker® 3000 Generator Set Controller

1. The generator set controller shall be a microprocessor based control system that will provide automatic starting, system monitoring, and protection. The controller system shall also provide local monitoring and remote monitoring. The control system shall be capable of PC based updating of all necessary parameters, firmware, and software.

2. The controller shall be mounted on the generator set and shall have integral vibration isolation. The controller shall be prototype and reliability tested to ensure operation in the conditions encountered.

B. Codes and Standards

1. The generator set controller shall meet NFPA 110 Level 1 requirements and shall include an integral alarm horn as required by NFPA.

2. The controller shall meet NFPA 99 and NEC requirements.

3. The controller shall be UL 508 listed.

C. Applicability

1. The controller shall be a standard offering in the manufacturer's controller product line.

2. The controller shall support 12-volt and 24volt starting systems.

3. The controller's environmental specification shall be: -40°C to 70°C operating temperature range and 5-95% humidity, non-condensing.

4. The controller shall mount on the generator or remotely within 40 feet with viewable access.

D. Controller Buttons, Display and Components

1. The generator set controller shall include the following features and functions:

a. Push button Master Control buttons. The buttons shall be tactile-feel membrane with an indicator light to initiate the following functions:

b. Run Mode: When in the run mode the generator set shall start as directed by the operator.

c. Off/Reset Mode: When in the Off/Reset mode the generator set shall stop, the reset shall reset all faults, allowing for the restarting of the generator set after a shutdown.

d. Auto Mode: When in Auto the mode the generator set shall be ready to accept a signal from a remote device.

e. Emergency Stop Switch. The remote stop switch shall be red in color with a "mushroom" type head. Depressing the stop button will immediately stop the generator set and lockout the generator set for any automatic remote starting.

f. Push Button/Rotary Selector dial. This dial shall be used for selection of all Menus and sub-menus. Rotating the dial moves you through the menus, pushing the dial selects the menu and function/features in that menu. Pushing the button selects the feature/function and sub-menus.

g. Digital Display. The digital display shall be alphanumeric, with 2 lines of data and approximately 24 charters. The display shall have back lighting for ease of operator use in high and low light conditions. The display shall display status of all faults and warnings. The display shall also display any engine faults. While the generator set is running, the display shall scroll all-important information across the screen for ease of operator use. The scroll can be stopped by pushing the rotary dial. The display shall fall asleep when the generator set is not running and will wake-up when the generator set starts or the rotary dial is depressed.

h. Fault Light. The controller shall have an annunciator fault light that glows red for faults and yellow for warnings. These faults and warnings shall be displayed in the digital display. The fault light will also glow yellow when not in AUTO.

i. Alarm Horn. The controller shall provide an alarm horn that sounds when any faults or warnings are present. The horn shall also sound when the controller is not in the AUTO mode.

j. Alarm Silence/Lamp Test Button. When this button is depressed, it shall test all controller lamps. This button will also silence the alarm horn when the unit is not AUTO.

k. USB Connection. The controller shall have a USB connection on the face of the controller. This connection shall allow for updating of all software and firmware. This port shall also allow for all servicing of generator set parameters, fault diagnostics and viewing of all controller information via use a laptop computer.

l. Dedicated user inputs. The controller shall have dedicated inputs for remote emergency stop switch, remote 2-wire star for transfer switch and auxiliary shutdown.

m. The controller shall have auto resettable circuit protection integral on the circuit board.

E. System Controller Monitoring and Status Features and Functions

1. The generator controller shall display and monitor the following engine and alternator functions and allow adjustments of certain parameters at the controller:

a. Overview menu

1. Active shutdowns and warnings shall be displayed if present and without the need of operator interface

2. Engine runtime with total hours

3. Average line to line voltage

4. Coolant temperature

5. Fuel level or pressure

6. Oil pressure

7. Battery voltage

8. Software version

9. Frequency

10. Average current

b. Engine metering menu.

1. Engine speed

2. Oil pressure

3. Coolant temperature

4. Battery voltage

c. Generator metering menu.

1. Total power in VA

2. Total power in W

3. Rated power % used

4. Voltage L-L and L-N for all phases

5. Current L1, L2, L3

6. Frequency

d. Generator set information.

1. Generator set model number

2. Generator set serial number

3. Controller set number

e. Generator set run time.

1. Engine run time total hours

2. Engine loaded total hours

3. Number of engine starts

4. Total energy in kW

f. Generator set system

1. System voltage

2. System frequency 50/60Hz

3. System phase, single/three phase

4. Power rating kW

5. Amperage rating

6. Power type standby/prime

7. Measurement units, metric/English units adjustable

8. Alarm silence, always or auto only

g. Generator set calibration, the following are adjustable at the controller.

1. Voltage L-L and L-N all phases

2. Current L1, L2, L3

3. Reset all calibrations

h. Voltage regulation, +/-0.5% regulation, the following is adjustable at the controller.

1. Voltage Adjustable +/- 10%

i. Digital and Analog Inputs and outputs

1. Displays settings and status

2. Event Log

3. Stores event history, up to 1000 events F. Controller Engine control features and functions

1. Automatic restart - the controller has automatic restart feature that initiates the start routine and re-crank after a failed start attempt.

2. Cyclic cranking - the controller shall have programmable cyclic cranking

3. Engine starting aid - the controller shall have the capability of providing control for an optional engine starting aid.

4. The control system shall include time delays for engine start and cool down.

5. The control system shall interface with the engine ECM and display engine fault codes and warnings. The ECM shall also include sender failure monitoring to help distinguish between failed senders and actual failure conditions.

6. The controller shall monitor and display engine governor functions with include steady state and transient frequency monitoring G. Controller Alternator control features and functions

1. Integrated hybrid voltage regulator. The system shall have integral microprocessor based voltage regulator system that provides +/- 5% voltage regulation, no-load to full load with three phase sensing. The system is prototype tested and control variation of voltage to frequency. The voltage regulator shall be adjustable at the controller with maximum +/- 10% adjustable of nominal voltage.

2. AC output voltage regulator adjustment. The system shall allow for adjustment of the integral voltage regulator with maximum of +/- 10% adjustment of the system voltage.

3. Alternator thermal overload protection. The system shall have integral alternator overload and short circuit protection matched to each alternator for the particular voltage and phase configuration.

4. Power metering. The controller digitally displays power metering of kW and kVA.

H. Other control features and functions

1. Event logging. The controller keeps a record of up to 1000 events, for warning and shutdown faults. This fault information becomes a stored record of systems events and can be reset.

2. Historical data logging. The controller total number of generator set successful start shall be recorded and displayed.

3. Programmable access. The control system shall include a USB port that gives service technicians the ability to provide software and firmware upgrades. The system shall also be capable of allowing setting of all critical parameters using the service software and a laptop computer. All parameters and setting should be capable to being stored on a laptop for future upgrades of printing for analysis.

I. Generator Set Warning, Shutdown Alarm and Status

1. The generator set shall have alarms and status indication lamps that show non-automatic status and warning and shutdown conditions. The controller shall indicate with a warning lamp and or alarm and on the digital display screen any shutdown, warning or engine fault condition that exists in the generator set system. The following alarms and shutdowns shall exist as a minimum:

a. Engine functions

1. Critical high fuel level (alarm)

2. ECM communication loss (shutdown)

3. ECM diagnostics (alarm & shutdown)

4. Engine overspeed (shutdown)

5. Engine start aid active

6. Engine under speed (shutdown)

7. Fuel tank leak (alarm & shutdown)

8. High DC battery voltage (alarm)

9. High coolant temperature (alarm & shutdown)

10. High fuel level (alarm)

11. Low DC battery voltage (alarm)

12. Low coolant level (shutdown)

13. Low coolant temperature (alarm)

14. Low cranking voltage (alarm)

15. Low engine oil level (alarm & shutdown)

16. Low fuel level (alarm & shutdown)

17. Low fuel pressure (alarm)

18. Low oil pressure (alarm & shutdown)

19. No coolant temperature signal (shutdown)

20. No oil pressure signal (shutdown)

21. Overcrank (shutdown)

22. Speed sensor fault (alarm)

b. Generator functions

1. AC sensing loss over & under current (alarm & shutdown)

2. Alternator protection (shutdown)

3. Ground fault input (alarm)

4. kW overload (shutdown)

5. Locked rotor (shutdown)

6. Over-frequency (shutdown)

7. Over AC voltage (shutdown)

8. Under-frequency (shutdown)

9. Under AC voltage (shutdown)

10. Emergency stop (shutdown)

c. Other General functions

1. Battery charger fault (alarm)

2. Common fault (shutdown)

3. Common warning (alarm)

4. Master switch not in auto (alarm)

5. Generator running

6. Input/Output fault (alarm)

d. The generator set controller shall also be capable of meeting all necessary NFPA 110 level 1 requirements that include several of the above along with; EPS supplying load, Master switch “not in auto”, and contacts for local and remote common alarm.

J. Communications

1. If the generator set engine is equipped with an ECM (engine control module), the controller shall communicate with the ECM for control, monitoring, diagnosis, and meet SAE J1939 standards

2. Kohler proprietary RBUS communication shall be available.

3. A RBUS shall be able to monitor and alter parameters, and start or stop a generator.

4. The controller shall have the capability to communicate to a personal computer (IBM or compatible) and appropriate application software

5. A variety of connections shall be available based on requirements:

6. A single control connection to a PC via USB

7. Internet connection via Ethernet

8. Generator and transfer switch controls shall be equipped with communications modules capable of connecting to the same communication network.

5.4 OVERCURRENT PROTECTION

A. The generator shall be provided with a factory installed, 80% rated line circuit breaker rated at 100.00 amperes that is UL489 listed. Line circuit breakers shall be sized for the rated ampacity of the loads served by the breaker per the NEC.

B. The circuit breaker(s) shall incorporate a thermo-magnetic trip unit.

C. Load side lugs shall be provided from the factory. The line circuit breaker shall include auxiliary contacts, shunt trip, undervoltage trip, alarm switch, and overcurrent switch functionality. Load side breaker connections made at the factory shall be separated from field connections.

D. The shunt trip device shall be connected to trip the generator breaker when the generator-set is shut down by other protective devices.

E. When GFI is required per the NEC, additional neutrals shall be factory installed, and the alarm indication shall be integrated with the other generator-set alarms.

F. Barriers to provide segregation of wiring from an emergency source to emergency loads from all other wiring and equipment, if required by the NEC, shall be provided.

5.5 ALTERNATOR

A. The alternator shall be salient-pole, brushless, 2/3-pitch, with 4 bus bar provision for external connections, self-ventilated, with drip-proof construction and amortisseur rotor windings, and skewed for smooth voltage waveform. The ratings shall meet the NEMA standard (MG1-32.40) temperature rise limits. The insulation shall be class H per UL1446 and the varnish shall be a vacuum pressure impregnated, fungus resistant epoxy. Temperature rise of the rotor and stator shall be limited to 130°C Standby. The PMG based excitation system shall be of brushless construction controlled by a digital, three phase sensing, solid- state, voltage regulator. The AVR shall be capable of proper operation under severe nonlinear loads and provide individual adjustments for voltage range, stability and volts-per-hertz operations. The AVR shall be protected from the environment by conformal coating. The waveform harmonic distortion shall not exceed 5% total RMS measured line-to-line at full rated load. The TIF factor shall not exceed 50.

B. The alternator shall have a maintenance-free bearing, designed for 40000 hour B10 life. The alternator shall be directly connected to the flywheel housing with a semi-flexible coupling between the rotor and the flywheel.

C. The generator shall be inherently capable of sustaining at least 300% of rated current for at least 10 seconds under a 3-phase symmetrical short circuit without the addition of separate current-support devices.

D. Motor starting performance and voltage dip determinations shall be based on the complete generator set. The generator set shall be capable of supplying 140.00 LRKVA for starting motor loads with a maximum instantaneous voltage dip of 35%, as measured by a digital RMS transient recorder in accordance with IEEE Standard 115. Motor starting performance and voltage dip determination that does not account for all components affecting total voltage dip, i.e., engine, alternator, voltage regulator, and governor will not be acceptable. As such, the generator set shall be prototype tested to optimize and determine performance as a generator set system.

5.6 ACCESSORIES

A. The generator set shall be supplied with a common failure relay to provide means of signaling fault and/or shutdown conditions.

1. The common failure relay shall remotely signal auxiliary faults, emergency stop, high engine temperature, low oil pressure, overcrank, and over speed via one single-pole, double-throw relay with 10 amps at 120 VAC contacts.

2. The relay contacts shall be gold flashed to allow use of low current draw devices (100ma @ 28VDC min.).

3. Once energized the relay shall remain latched until the system is reset by the main controller switch.

B. Battery rack and battery cables capable of holding the manufacturer's recommended batteries shall be supplied.

C. The generator set shall be supplied with a 6-ampere automatic float/equalize battery charger capable of charging both lead-acid and gel-cell type batteries, with the following features:

1. Automatic 3-stage float to equalization charge

2. 1% steady-state voltage regulation from no load to full load over 10% AC input line voltage variation

3. Indicator LED lamps for charge state indication (bulk charge/absorption/float)

4. Ambient temperature operating range: -40°C to 70°C

5. Potting for durability and waterproofing

6. Short-circuit and reverse polarity protection

7. UL 1236 listed

8. UL 2200 compliant

9. CSA certified

10. Ring terminals for battery connection.

D. The generator set shall be provided with a run relay which shall provide a three-pole, double-throw relay with 10-amp/250 VAC contacts to indicate that the generator is running. The run relay dry contacts can be used for energizing or de-energizing customer devices while the generator is running (e.g. louvers, indicator lamps, etc.)

E. A radiator duct flange to provide a convenient connection to duct work for the radiator discharge air shall be included.

F. The exhaust piping shall be gas proof, seamless, stainless steel, flexible exhaust bellows and includes the flex exhaust tube and the mounting hardware.

G. Block Heater - The block heater shall be thermostatically controlled, 1,500 watt, 110-120 VAC - single phase, to maintain manufacturers recommended engine coolant temperature to meet the start-up requirements of NFPA 99 and NFPA 110, Level 1.

H. Vibration isolators shall be provided between the engine-alternator and heavy-duty steel base.

PART 6 - AUTOMATIC TRANSFER SWITCH

6.1 GENERAL

A. Furnish and install an automatic transfer switches system(s) with 3-Pole / 4-Wire, Solid Neutral, 100 Amps, 480V/60Hz. Each automatic transfer shall consist of an inherently double throw power transfer switch mechanism and a microprocessor controller to provide automatic operation.

B. The transfer switch shall be model KSS-AMTA-0100S as manufactured by Kohler Power Systems.

6.2 CONSTRUCTION

A. Operation

1. The transfer switch shall be electrically operated and mechanically held with double throw construction, and operated by a momentarily energized solenoid-driven mechanism.

2. All transfer switch sizes shall use only one type of main operator for ease of maintenance and commonality of parts.

3. The switch shall be positively locked and unaffected by momentarily outages, so that contact pressure is maintained at a constant value and contact temperature rise is minimized for maximum reliability and operating life.

4. All main contacts shall be silver composition. Switches rated 600 amperes and above shall have segmented, blow-on construction for high withstand and close-on capability and be protected by separate arcing contacts.

5. Inspection of all contacts shall be possible from the front of the switch without disassembly of operating linkages and without disconnection of power conductors. Switches rated 800 amperes and higher shall have front removable and replaceable contacts. All stationary and moveable contacts shall be replaceable without removing power conductors and/or bus bars.

6. Designs utilizing components of molded-case circuit breakers, contactors, or parts thereof, which are not intended for continuous duty, repetitive switching or transfer between two active power sources, are not acceptable.

7. For two and three pole switches, where neutral conductors are to be solidly connected as shown on the plans, a neutral conductor plate with fully rated AL-CU pressure connectors shall be provided.

8. For four pole switches with a switching neutral, where neutral conductors must be switched as shown on the plans, the contactor shall be provided with fully rated switched neutral transfer contacts. Overlapping neutral contacts may be used as an alternative.

B. Enclosure

1. The ATS shall be furnished in a NEMA 1 enclosure.

2. All standard door mounted switches and indicating LEDs shall be integrated into a flush-mounted, interface membrane or equivalent in the enclosure door for easy viewing & replacement. The panel shall be capable of having a manual locking feature to allow the user to lockout all membrane mounted control switches to prevent unauthorized tampering. This cover shall be mounted with hinges and have a latch that may be padlocked. The membrane panel shall be suitable for mounting by others when furnished on open type units.

6.3 CONTROLS

A. Display

1. A four line, 20 character LCD display and dynamic 4 button keypad shall be an integral part of the controller for viewing all available data and setting desired operational parameters. Operational parameters shall also be available for viewing and control through the communications interface port or USB. The following parameters shall only be adjustable via a password protected programming on the controller:

a. Nominal line voltage and frequency

b. Single or three phase sensing

c. Operating parameter protection

d. Transfer operating mode configuration (Standard transition, Programmed transition, or Closed transition) B. Voltage and Frequency

1. Voltage (all phases) and frequency on both the normal and emergency sources shall be continuously monitored. Voltage on both normal and emergency sources and frequency on the emergency sources shall be adjustable with the following pickup, dropout, and trip setting capabilities (values shown as % of nominal unless otherwise specified):

a. Parameter Dropout/Trip Pickup/Reset

b. Under voltage 75 to 98% 85 to 100%

c. Over voltage 06 to 135% 95 to 100% of trip

d. Under frequency 95 to 99% 80 to 95%