SOW - 608-23-116 SPS steam and sterilization r1.docx

SPS steam and sterilization 718 Smyth Road, Manchester NH 03103 608-23-116

1.0 INTRODUCTION

There are several issues with the current state of operations in the Sterile Processing Service (SPS) department. The sterilizers are experiencing wet packing on the instruments. The air used for drying instruments is from the house pneumatic system and frequently has oil in the lines. The sterilizer room is consistently hot, out of compliance and does not exhaust outdoors. This project will aim to resolve these issues and more to make the department function in better compliance with Veterans Affairs (VA) National SPS standards.

The work includes but is not limited to: provide all equipment, layout, material, testing, tools, labor, rigging, mechanical, electrical and plumbing work as well as all safety requirements to perform work for fill the contractual obligations.

2.0 SCOPE

Below are the eleven (11) tasks that are required to meet the requirements of this contract and to get the SPS suite closer to compliance in their current space. This is a stop gap project, meant to keep the SPS department running and correct deficiencies in place while a new suite will be built.

a. Task 1 – Replace compressed air piping distribution in SPS suite. Provide and install an instrument grade compressor LES30-145-RP (or VA pre-approved equivalent) in 7th floor penthouse. Run type K, copper, 1 ½” diameter line from 7th floor to Basement floor, each floor to have valved takeoffs, unconnected lines to have caps installed after floor isolation valves, from the main to serve equipment on each floor, following existing medical air/vacuum path and chase. Each noted equipment take off must, as seen from ceiling, an isolation valve, pressure regulator and female quick disconnect coupling. System will need to be cleaned (to NFPA 99 instrument air standards) and certified (to NFPA 99 instrument air standards) by a 3rd party prior to being put into service. Install 4 drops of instrument air in Room N478 and 1 drop of instrument air in room N261. Remove existing non complaint airlines in SPS suite (existing instrument air lines), filtration, accumulator tank system (located in room N260) and feed to 7th floor penthouse and cap.

b. Task 2 – Measure steam dryness at each sterilizer, as well as at the building 7 boiler house exit and provide copy of report and results to Contracting Officers Representative (COR). Install digital measurement system that will interface with existing Johnson Controls (JCI) Metasys system (Local JCI tech recommends Armstrong QM-1). Johnson controls to set up graphics and data logging/reports on these 3 points.

c. Task 3 – Install exhaust fan through window opening in room N260 (basis of design CUE-090E), sized to ensure room stays in negative pressure. Exhaust fan will be capable of variable, settable speeds via remote or integral rheostat. On/Off Controls for exhaust fan will be via thermostat, shutting off/turning on the exhaust fan at below/above 45 degrees. Blank over return grill in room to allow for greater return flow on other spaces served by AHU. Remove supply tap closest to window and seal. Provide and install hard piped lineal diffuser on supply tap farthest away from exterior wall.

d. Task 4 – Install digital audio/visual indicators to alert of improper pressure relationships at the entrances of the following rooms: E13, E216, N266, N239, D203, D242, N258, N261, N265 and N488. These room pressure relations must be set up per the current function and as outlined in the VA HVAC design manual.

e. Task 5 – Extend Reverse Osmosis (RO) water supply and return to Medivators and connect Medivators to RO water system. Provide and install two point of use electric stainless steel water heaters (one for each medivator) set at 95 deg F (+/- 4 deg F) with a minimum of 1.4 GPM flow, between 40 and 87 psi to supply the medivators. Install in accordance with the Installation manual for heater and medivators.

f. Task 6 – Provide and install new pass-through window between clean and sterile rooms. Make/model as follows: UV FLASH Standard Unit by Hospital Safety Solutions / Healthguard UCV or VA preapproved equivalent. Sailient Characteristics of the mentioned unit attached at end of SOW.

g. Task 7 – Remove filter banks and piping in N262 and connect pipes to each other in room N260. These lines currently feed the medivators. Patch and paint where brackets are removed to match existing finishes.

h. Task 8 – Provide pricing to install properly sized centrifugal steam separator, piping and traps on the lines leading into the sterilizers (proposed location in room N260, building 1) as well as a centrifugal steam separator at boiler plant steam header exit, building 7; each separator as an add alternate pricing. Verification, measurement and reporting to the VA of the dryness of the steam after installation is also required as part of this add alternate.

i. Task 9 – Replace SPS Pressure reduction valve (PRV) in N72, bypass and isolation valves and traps in line with SPS medium pressure steam valves and items. Install new piping to SPS sterilizer room, main feed to be 2” diameter. Schedule 80 steel threaded piping from outlet of PRV to take off of sterilizers. Replace condensate return line, following the existing path with threaded schedule 80 piping.

j. Task 10 – Replace Feedwater booster pumps in SW2 and N74. Pumps sets will be of same manufacturer, as well as the VFD drives. Sequence of operation for pumps will be lead/lag. New piping and isolation valves to completely isolate each pump will be included. Tie in feed for domestic hot water heaters, located in N72 to N74’s set of pumps. Existing pumps, VFDs and motor cut sheets provided at end of SOW. Replace with equivalent equipment. Expansion tanks to be charged minimum 70 psi.

k. Task 11 – Replace current VPRO power outlet (existing - 120V 20A; replace with a 3ph 208 20A disconnect). Existing power outlet can stay in place. Meter panel AC-2 for 30 days to ensure capacity for sub panel to be installed. Provide and install new 42 breaker, 208V 200A sub panel in Room N260, fed from AC-2.

3.0 PROJECT DELIVERABLES

All work (including warranty) will be performed with pre-approved interruption to the SPS department. All work shall be coordinated with the COR at least two weeks in advance of starting.

Contractor shall conduct site visit prior to submitting pricing.

Contractor shall submit a safety plan outlining procedures/guidelines per OSHA requirements.

All material and equipment shall be submitted for approval prior to the start of work.

All new piping to be in accordance with specifications. Hot work permits are required each day prior to brazing, cutting, grinding or welding operations Attached to this package are a general overview of specifications and sketches for the project, not be considered all inclusive.

4.0 PERFORMANCE REQUIREMENTS

Contractor will follow ICRA, PCRA and ILSM for each area being worked. The majority of the work is in the SPS and OR suite which will necessitate Level IV precautions – see attached ICRA docuement at the end of this scope of work for general expectations and classifications of work requirements.

All work will be performed between the hours of 7:00am to 4:00 pm Monday thru Friday, excluding federal holidays and weekends. Off hours and weekend work may be required to allow for utility/service outages. An estimated 6 week (42 calendar day) outage is expected in the suite to complete tasks that are invasive and require extensive work in the space. This outage can be adjusted if the contractor can show the need to extend or contract the outage. The first task to be accomplished in the SPS suite must be task 2, as this will drive other possible work in the suite.

Any work to run instrument airline in OR suite and drops in Room 478 and pressure monitor in room N488 will need to be accomplished either after hours (3:30p- 5a M-F) or during weekends (3:30p Friday to 5a Monday).

All work shall be in accordance with each of the manufacturer’s specifications and requirements. Contractor must follow manufacturer recommendations on installation.

Vendor shall comply with all OSHA Safety Guidelines.

Contractor shall supply VA with as-builts of how the systems are installed for each discipline. Sizes, any elbows or offsets etc. will be shown.

All O&M manuals shall be turned over at the completion of work, and contractor shall conduct a brief training (1hr) for the VA maintenance staff on the operation and maintenance of the equipment. The contractor will video record this training and submit the video with the closeout package.

Contractor shall begin work with 7 days of the notice to proceed being issued, unless lead time on material and equipment prevents start of the work.

The period of performance (PoP) of this contract once mobilized is 180 calendar days.

Liquidated damages of $6,317.04 per work day (Monday – Friday, excluding federal holidays) will be sought for unexcused delays causing the staff in the SPS suite to be displaced in excess of agreed to duration to the contact in accordance with FAR 52.211-12. (Above figure is based on 9 staff displaced to the referral lab at White River Junction for the construction period.)

If contractor feels additional time is needed, they shall propose a corrected outage estimate and/or a different PoP to the Contracting Officer.

All installed work and equipment to be in accordance with VA standards, manuals and design guides - https://www.cfm.va.gov/til/index.asp.

If conflict exists between manufacturers recommendations and VA TIL specifications, the more stringent standards will take precedence.

All equipment and materials proposed for construction must be approved by the VA before installation. If the contractor installs any materials/equipment without VA approvals, they do so at their own risk

5.0 CONTRACT REQUIREMENTS

Contract shall be a firm and fixed price.

Provide one-year warranty on work.

Instrument air work will be performed in accordance with the latest published edition of NFPA 99 and any other related NFPA codes or VA design guides that apply Electrical work will be performed in accordance with the latest published edition of NFPA 70, 70E and any other related NFPA codes or VA design guides that apply. All wire will be stranded XHHW copper HVAC Ductwork altered or installed by this project will be sealed to ASHRAE/SMACNA class A and any applicable VA TIL design guides.

Any changes in the contract shall be brought to the attention of the Contracting Officer. The Contracting Officers Representative (COR) does not have authorization to modify the contract.

6.0 CONTRACT DELIVERABLES

Installation of a complete 100% functioning system with all components, testing, balancing, commissioning and training included The expected outcome of the project is to provide a more compliant SPS department with better quality instrument air, HVAC temperature control in the sterilizer room and steam quality at the sterilizers as well as eliminate many non-compliance items from national surveys.

Vendor will notify COR at least two weeks in advance of the installation, utility outages if needed, and start-up tasks

7.0 REFERENCES

ASHRAE - American Society of Heating, Refrigerating and Air-Conditioning Engineers SMACNA - Sheet Metal and Air Conditioning Contractors' National Association NFPA- Nation Fire Protection Association VA TIL – Veteran’s Affairs Technical Information Library

-END OF SCOPE OF WORK-

REFERENCED ATTACHMENTS

VFD SW addition Aquavar AV2V2S050D.pdf

Variable Speed Pump Control

Installation Programming & Operation

Models covered:

All AV2 Model

AQUAVAR II Controllers software revision 120

AQUAVAR® AV II

IM131R01

UL®

AQUAVAR II Controller Model _________________ Transducer Model_______________________ AQUAVAR II Serial Number _________________ Transducer Rating_______________________ Date purchased _________________ Purchased from _________________

Pump Model _________________ Software Version _______________________

Pump Code Number _________________

Program Record Please use the following to record the final values programmed into the AQUAVAR controller after installa-tion.

Required Value____________________ (select) Level 2____________________________ (%) Autostart ________________________ (on/off) Intensity 1 _________________________ (%) Password ________________________ (value) Intensity 2 _________________________ (%) Window ___________________________ (%) Pressure Increase ___________________ (PSI) Ramp Hysteresis _____________________ (%) Pressure Decrease___________________ (PSI) Ramp 1 _______________________ (seconds) Enable Sequence Control______________ (Hz) Ramp 2 _______________________ (seconds) Switch Interval ___________________ (hours) Ramp 3 _______________________ (seconds) Optional Value _________________________ Ramp 4 _______________________ (seconds) Synchron Limit _____________________ (Hz) Max. Frequency _____________________ (Hz) Sychron Window ____________________ (Hz) Min. Frequency ______________________ (Hz) Pump Address _________________ (# or off) Config. F Min. __________ (F –>0/F –>F min.) ADC Reference ___________________ (select) Stop - Delay F Min._______________ (seconds) Freq. Lifting________________________ (Hz) Sensor Adjust _______________ (out of range) Lift Intensity________________________ (%) Sensor Curve _____________ (linear/quadratic) Analog out ______________________ (select) Sensor Range - 20mA=362.6 __________ (PSI) Pressure Unit ____________________ (select) Mode___________________________ (select) Test Run After__________________ (in hours)

(actuator/controller/multicontroller/synch.) Test Frequency______________________ (Hz) Regulation Mode _________________ (normal) Conveyor Limit _____________________ (PSI) Start Value _________________________ (PSI) Delay Time ____________________ (seconds) Config. Second Value _________________ (off) Error Reset ______________________ (on/off) Relay Config.__________________ (run motor) Display Contrast_____________________ (%) Offset Input ____________________________ Lock Function ____________________ (on/off) Level 1 ____________________________ (%)

AQUAVAR II Controller Owner’s Information Record

Index System Design

Important Safety Instructions

Installation Procedures Materials Checklist

1. Mounting the AQUAVAR II Controller

2. Electrical Connections

3. Pump Priming

4. Run Test

Programming

1. The Main Menu - Setting One Pump Constant Pressure

2. Single Pump - Pump Protection

• To Set Run-Out Protection

• To Set Low/No Flow Protection

3. Single Pump - System Curve Compensation

• Entering Compensation Values

• Circulator Applications

4. Single Pump Constant Flow

5. Single Pump - Level Control Applications

6. Single Pump - Submersible

7. Setting a Second Required Value

8. Variable Second Required Value

9. Multiple Pump Constant Pressure and System Curve Compensation

• Synchronous Control

10. Multiple Pump - Pump Protection

• To Set Low/No Flow Protection

Operator Custom Features and Displays

• Jog Mode

• Window

• Ramp Hysteresis

• Ramp Settings

• Ramp 1-4

• Maximum Frequency

• Minimum Frequency

• Config. F Min

• Stop-Delay F Min

• Sensor Adjustment

• Sensor Curve

• Mode

• Start Value

• Config. Required Value 2

• Relay Config

• Submenu Offset

• Regulation Mode

• Submenu Sequence Control

• Actual Value Increase

Index (continued) Operator Custom Features and Displays (continued)

• Actual Value Decrease

• Enable Sequence Control

• Switch Interval

• Source Required Value

• Submenu Synchronous Control

• Synchronous Limit

• Synchronous Window

• Pump Sequence

• Bus

• Pump - Address

• ADC Reference

• Frequency Lifting

• Lift Intensity

• Reference

• Analog Out

• Pressure Units

• Test Run

• Submenu Test Run Manual

• Submenu Errors

• Clear Errors

• Operating Hours

• Total Run Time

• Display Contrast

• Set Password

• Lock Functions

• Heating On

• Default Values

• Save ??

Repair of Faults and Errors

• Lack of Water

• Conveyor Control

• Error 1-8

• Pressure Sensor Error

• Inverter Error

• External Device Error

• Active Fault / Warning and Fault History Mode

• Aquavar II Electrical Fault Codes

Programming Flow Chart

Help Windows

Appendix A - Pressure Transducer Data

• Technical Characteristics

Appendix B - AQUAVAR Controller Technical Data and Terminals Appendix C - Interference Suppression Measures

System Design - Typical Constant Pressure Systems

The following diagrams show typical single pump and multi-pump systems using the AQUAVAR con-troller. Connection can be made directly to a water supply or water can be drawn from a supply tank or well. In the case of supply tanks and wells, level switches, (item 10) can be used to shut down the pumps when water is low. In the direct connection, a pressure switch on the suction side (item 8) can be used.

A diaphragm pressure tank is used on the discharge side of the pump or pumps to maintain pres-sure in the line when there is no demand. This will keep the pumps from continuing to run. With the AQUAVAR controller, it is not necessary to have a large tank for supply purposes. In selecting a tank, make sure it can withstand maximum system pressure. The tank should have a capacity of at least 10% of the maximum system flow rate in gpm. Pre-charge the tank to the following:

System Design

1 Pump with AQUAVAR controller 2 Diaphragm tank 3 Distribution panel 4 Gate valves 5 Check valves 6 Foot valves 8 Incoming pressure switch 9 Pressure gauges 10 Level switches 11 Supply tank 14 Pressure transmitter

(Included with AQUAVAR) *

Closed loop circulator systems may not require a pressure tank.

Note

Systems MUST be designed by qualified technicians only.

PSI Set Pressure 15 30 45 60 75 90 105 120 135 150 PSI Tank Pre-charge 12 21 37 52 64 77 95 110 125 138

Diagram 2 Single Pump Layout

Diagram 1 Multiple Pump Layout

Indirect connection via tank

Suction out or a well Direct connection

5 4

*Check with tank pressure limitations before precharge.

Important: Read all safety information prior to installation of the AQUAVAR controller.

1. This manual is intended to assist in the installation, operation, and repair of the AQUAVAR controller and must be kept with the AQUAVAR controller.

2. To avoid serious or fatal personnel injury or major property damage, read and follow all safety instructions in this manual.

This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the manual, look for one of the following signal words and be alert to the potential for personal injury or property damage.

Warns of hazards that WILL cause serious personal injury, death, or major property damage.

Warns of hazards that CAN cause serious personal injury, death, or major property damage.

Warns of hazards that CAN cause personal injury or property damage.

Indicates special instructions which are very important and must be followed.

Safety Instructions

DANGER

WARNING

CAUTION

NOTICE

All operating instructions must be read, understood, and followed by the operating personnel. Goulds Pumps accepts no liability for damages or operating disorders which are the result of non-compliance with the operating instructions. When in doubt, call for assistance.

3. Installation and maintenance MUST be performed by properly trained and qualified personnel.

4. Review all instructions and warnings prior to performing any work on the AQUAVAR controller.

5. Any safety decals MUST be left on the AQUAVAR controller unit and pump.

6. In addition to instructions contained in this manual, you must meet any local safety, electrical, or plumbing codes and requirements. Installation, maintenance, or repair work must only be carried out by trained, skilled, and qualified personnel, using proper protective gear and tools.

7. The AQUAVAR controller drive head must be disconnected from the main power supply before attempting any operation in the electrical or mechanical part of the system.

When in operation, the motor can be stopped, but power remains at the drive head. The motor and pump could start unexpectedly and produce serious injury. When the AQUAVAR controller drive head is connected to the main power supply, the inverter power supply and master control unit are also connected to the power supply.

Inspect AQUAVAR controller for any damage after unpacking from shipping crates.

Report any damage immediately to the carrier or distributor/dealer immediately.

FAILURE TO DISCONNECT ELECTRICAL POWER BEFORE ATTEMPTING ANY

MAINTENANCE CAN CAUSE SHOCK, BURNS, OR DEATH.

WARNING!

Hazardous voltage can shock, burn or cause death.

8. The AQUAVAR controller has electronic safety devices which will stop the motor in the event of electrical or thermal faults. This does not remove power to the AQUAVAR controller.

9. The system must be properly grounded before being put into operation. Use a common ground for the entire system.

10. High voltage tests of the AQUAVAR controller may damage the electronic components.

Before carrying out such a test, bridge the incoming and outgoing terminals L1 - L2 - L3 - U - V - W. Isolate the motor from the AQUAVAR controller drive to avoid incorrect capacitor metering inside the AQUAVAR controller.

FAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL POWER AND WAIT

FIVE MINUTES FOR CAPACITOR DISCHARGE BEFORE SERVICING AQUAVAR

CONTROLLER CAN CAUSE SHOCK, BURNS, OR DEATH.

TOUCHING THESE COMPONENTS SERIOUSLY ENDANGERS LIFE! Voltages of up to 800 volts are possible (higher if there is a fault).

Before removing the AQUAVAR controller drive top cover, the system must be discon-nected from the main power supply. After switching off the power supply, you must wait at least 5 minutes before starting work on or inside the AQUAVAR controller drive head. This allows the capacitors in the circuit to be discharged by the discharge resistors.

Care must be taken when connecting external control wires and jumpers to avoid short circuit to neighboring components.

Repair of electrical faults can lead to the automatic restart of the motor and pump.

You must remove all main line power to the AQUAVAR controller before attempting to correct a fault.

Step 1- Identify Materials The following materials are provided with the AQUAVAR II controller. Please familiarize yourself with each prior to installation.

Part Quantity

1. AQUAVAR Controller 1

2. Pressure Transducer Assembly 1

a. Pressure transducer - 25 bar 1/4” NPT

b. Transducer adapter - (available as 1/4” NPT female threads & 3/8 B male thread per separate part only) See price book. UNI ISO/228/1 (British Standard pipe threads)

c. 30 ft. transducer cord (standard) for AV II.

THE AQUAVAR CONTROLLER AND PUMP MUST BE TOTALLY DISCONNECTED FROM ALL

POWER SUPPLY SOURCES BEFORE BEGINNING INSTALLATION OR REPAIR.

FAILURE TO DISCONNECT ELECTRICAL POWER BEFORE ATTEMPTING ANY MAINTE-

NANCE CAN CAUSE SHOCK, BURNS, OR DEATH.

3 . 4 5

1 . 0 7

3⁄4” HEX

1⁄4” NPT

2c 2a 2b (If needed.)

Installation Procedures

YOU MUST USE THE CABLE THAT IS PROVIDED WITH THE TRANSDUCER. DO NOT USE

DIFFERENT CABLES OR OLDER STYLE CABLES.

Step 2 - Mounting the AQUAVAR II controller:

AQUAVAR Controller The AQUAVAR controller may be installed as a wall or panel mounted unit. The AQUAVAR controller may be mounted up to 60 feet away from the pump motor*. In addition, alternative motor enclosures may be selected such as ODP, explosion proof or wash down motors in addition to the TEFC enclo-sure required for on the pump mounting.

Typical applications for the AQUAVAR Wall Mount controller include:

1. Hazardous environment applications including high heat, humidity or combustibility.

2. Installation to an existing pumping system with non-standard motors.

3. Installations where the operator desires all controls to be grouped together.

Mounting of the AQUAVAR II Controller

1. An alternative mounting style is used in the AQUAVAR II controller configuration.

In this style, the AQUAVAR II controller is supplied with a fan and mounting bracket already installed and can be mounted to a wall or panel.

2. The mounting bolts for all units should be 1⁄4". The length of bolt and the strength of the mounting surface must be adequate to support the weight of the AQUAVAR II controller.

3. The AQUAVAR II controller may be positioned up to 60 feet from the pump motor. The pump motor must be three phase. Unlike the standard AQUAVAR controller, the motor may be ODP, TEFC or explosion proof.*

4. Mount the AQUAVAR controller to the panel, wall or frame using bolts at the points indicated on the following drawings. Be sure the unit is level and secured to the mounting surface before continuing.

5. Ensure plenty of airflow for the AQUAVAR controller, when mounting.

*NOTE: If the AQUAVAR II controller is more than 60 feet wire length to motor, then the use of a load reactor (impedance coil) is required.

Step 2 - Mounting the AQUAVAR controller: (continued)

Power Rating Weight HP Pounds Kilograms 1 24.0 10.9 2 24.0 10.9 3 24.0 10.9 5 24.0 10.9

71⁄2 24.0 10.9 10 24.0 10.9 15 28.0 12.7 20 28.0 12.7

HP Rating A B C D E F G in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)

1 – 10 (230 – 3)

3.20 7.88 16.50 9.32 17.44 12.08 0.28

1 – 5 (230 – 1) (81.28) (200.15) (419.10) (236.70) (442.98) (306.71) (7.11)

1 – 20 (575) 15 – 20 (230 – 3) 71⁄2 – 10 (230 – 1) 3.20 7.88 19.25 11.44 20.19 13.51 0.28 25 – 40 (460) (81.28) (200.15) (488.95) (290.53) (512.83) (343.20) (7.11) 25 – 40 (575) 25 – 75 (460) 3.20 7.88 28.00 12.68 31.37 14.00 0.42 25 – 75 (575) (81.28) (200.15) (711.20) (322.07) (796.80) (355.60) (10.67)

Note that the E-dimension in the 50-75 HP is maximum overall height to the conduit box rather than the bottom of the foot.

Diagram 3

WEIGHTS OF MODELS - Table 1: NEMA 12

Electrical Connections

Installation and maintenance must only be performed by properly trained and qualified personnel equipped with the proper tools.

INSTALL AN ALL LEG DISCONNECT SWITCH NEAR THE MOTOR.

INSTALL, GROUND, AND WIRE ACCORDING TO LOCAL AND

NATIONAL ELECTRICAL CODE REQUIREMENTS.

DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE

INSTALLING OR SERVICING.

MOTORS WITH AUTOMATIC THERMAL PROTECTION MAY OPEN THEIR

ELECTRICAL CIRCUIT WHEN A THERMAL OVERLOAD EXISTS. THIS CAN

CAUSE THE MOTOR TO START UNEXPECTEDLY AND WITHOUT WARNING.

ELECTRICAL SUPPLY MUST MATCH PUMP’S AND AQUAVAR CONTROLLER NAME

PLATE SPECIFICATIONS. INCORRECT VOLTAGE OR WIRING CAN CAUSE FIRE

DAMAGE, AND VOIDS WARRANTY.

Power Rating Weight HP Pounds Kilograms 25 52.0 23.6 30 52.0 23.6 40 60.0 27.2 50 107.0 48.6 60 107.0 48.6 75 107.0 48.6

Electrical Connections continued

Step 3 - Preliminary Inspection Before storing or installing the AQUAVAR controller, thoroughly inspect the device for possible shipping damage. Upon receipt:

1. Remove the controller from its package and inspect exterior for shipping damage. If damage is apparent, notify the shipping agent and your sales representative.

2. Remove the cover and inspect the controller for any apparent damage or foreign objects.

Ensure that all mounting hardware and terminal connection hardware is properly seated, securely fastened and undamaged.

3. Read the technical data label affixed to the controller and ensure that the correct horsepower and input voltage for the application had been purchased.

4. If you will store the controller after receipt, place it in its original packaging and store in a clean, dry place free from direct sunlight or corrosive fumes, where the ambient temperature is not less than -20ºC (-4ºF) or greater than +65ºC (+149ºF).

Step 4 - Installation Precautions Improper installation of the AQUAVAR controller will greatly reduce its life. Be sure to observe the following precautions when selection a mounting location. Failure to observe these precautions will void the warranty!

1. Do not install the controller in a place subjected to high temperature, high humidity, excessive vibration, corrosive gases or liquids or airborne dust or metallic particles. See Technical Data Appendix B for temperature, humidity and maximum vibration limits or contact factory.

2. Do not mount the controller near heat-radiating elements or in direct sunlight.

3. Mount the controller vertically and do not restrict the air flow to the heat sink fins.

4. The controller generates heat. Allow sufficient space around the unit for heat dissipation.

CAUTION!

EQUIPMENT DAMAGE HAZARD - DO NOT OPERATE OR INSTALL ANY CON-

TROLLER THAT APPEARS DAMAGED. FAILURE TO OBSERVE THIS INSTRUC-

TION CAN RESULT IN INJURY OR EQUIPMENT DAMAGE.

Step 5 - Considerations for Mounting AQUAVAR Controllers in Host Enclosures

The AQUAVAR controller is available from stock in a variety of enclosures that meet the requirements of almost any application. Yet, special applications (such as use in washdown environments or in integrated systems) may make it desirable to mount AQUAVAR controllers in a host enclosure.

When the AQUAVAR controllers are mounted in a host enclosure, the watts dissipated by the drives must be dissipated by the host enclosure. If this is not accomplished, the control circuitry of the AQUAVAR controller will be damaged.

Two techniques are available for mounting AQUAVAR controllers in a host enclosure:

• The controllers may be entirely enclosed in the host enclosure or

• The controllers may be mounted with their cooling fins outside of the host enclosure.

The following sections discuss these two mounting techniques in greater detail.

Models Entirely Enclosed in the Host Enclosure When an AQUAVAR controller is entirely enclosed in a host enclosure, the host enclosure must be properly sized to dissipate the heat generated by the controller and any other power-dissipated by the various models of the AQUAVAR controller at various switching frequencies. Use this information to adequately size the host enclosure.

Models with Fins External to the Host Enclosure By mounting an AQUAVAR controller so that its heatsink fins are outside of the host enclosure, you may select a smaller host enclosure than that required when the controller is mounted entirely inside the host enclosure. For most applications with this type of mounting, typically you will not need such additional cooling devices as fans, heat exchangers or air conditioners.

The amount by which the load on the host enclosure is reduced is the amount of watts dissipated by the heatsinks of the controllers. Table 3 shows the watts dissipated by each AQUAVAR model after deducting the amount of watts dissipated by the heatsinks of the model. Use the values shown in the table to adequately size the host enclosure.

AQUAVAR Switching Frequency Max. Switching Model Watts Dissipated Watts Dissipated Watts Dissipated Frequency for AV2V- at 4 kHz at 7 kHz at 10 kHz Rated Current (kHz)

2S010D 37 44 51 10 2S020D 59 71 81 10 2S030D 77 92 106 10 2S050D 162 212 220 10 2S075D 195 251 271 10 2S100D 267 312 354 10 20010D 37 44 51 10 20020D 59 71 81 10 20030D 77 92 106 10 20050D 112 135 156 10 20075D 162 212 220 10 20100D 195 251 (1) — 6 20150D (2) (2) (2) (2) 20200D (2) (2) (2) (2) 40010D 33 43 53 10 40020D 52 69 84 10 40030D 68 90 110 10 40050D 99 131 161 10 40075D 112 144 174 10 40100D 139 180 217 10 40150D 170 210 255 (1) 9 40200D 200 245 — 7 40250D 280 383 — 7 40300D 335 371 (1) — 5 40400D 398 (1) — — 2.5 40500D 600 670 (1) — 5 40600D 710 (1) — — 4 40750D 720 (1) — — 2 50010D 40 52 64 10 50020D 62 83 101 10 50030D 82 108 132 10 50050D 85 115 155 10 50075D 91 131 172 10 50100D 112 160 — 8 50150D 164 — 282 (1) 9 50200D 218 277 (1) — 6 50250D 286 364 (1) — 6 50300D 343 388 (1) — 5 50400D 417 — — 4 50500D 700 — — 4 50600D 720 (1) — — 3 50750D 745 (1) — — 2

(1) Dissipation at rated current and maximum switching frequency.

Table 2: Required Dissipation for Models Entirely Inside an Enclosure

AQUAVAR Model Watts Dissipated

AV2V2S010D 19

AV2V2S020D 20

AV2V2S030D 27

AV2V20010D 19

AV2V20020D 20

AV2V20030D 27

AV2V20050D 29

AV2V20070D 36

AV2V20100D 34

AV2V20150D 68

AV2V20200D 73

AV2V40010D 20

AV2V40020D 21

AV2V40030D 27

AV2V40050D 30

AV2V40070D 36

AV2V40100D 40

AV2V40150D 46

AV2V40200D 50

AV2V40250D 75

AV2V40300D 76

AV2V40400D 80

AV2V40500D 134

AV2V40600D 145

AV2V40750D 150

AV2V50010D 20

AV2V50020D 21

AV2V50030D 27

AV2V50050D 30

AV2V50070D 33

AV2V50100D 39

AV2V50150D 43

AV2V50200D 44

AV2V50250D 73

AV2V50300D 78

AV2V50400D 82

AV2V50500D 135

AV2V50600D 143

AV2V50750D 152

Table 3: Required Dissipation When Fins are External to the Enclosure

Step 6 - Maintenance Minimum Torque Values to Secure Cover

If you remove the cover of an IP55 AQUAVAR controller, it is imperative that the cover be closed and re-secured with sufficient tightness to maintain environmental integrity. The table below specifies the torque values for the bolts that secure the covers on the various models.

Step 7 - General Wiring Information Wiring Practices

When making power and control connections, observe these precautions:

• Follow all Federal, State, NEC codes and local codes.

• Never connect input AC power to the motor output terminals T1/U, T2/V or T3/W – or damage to the controller will result.

• Power wiring to the motor must have the maximum possible separation from all other power wiring. Do not run in the same conduit, this separation reduces the possibility of coupling electrical noise between circuits.

• Cross conduits at right angles whenever power and control wiring cross.

• Good wiring practice also requires separation of control circuit wiring from all power wiring.

Since power delivered from the controller contains high frequencies which may cause interference with other equipment, do not run control wires in the same conduit or raceway with power or motor wiring.

Considerations for Power Wiring Power wiring refers to the line and load connections made to terminals L1/R, L2/S, L3/T and T1/U, T2/V, T3/W respectively. Select power wiring as follows:

• Use only UL recognized wire. (Shielded or armored wire is recommended for power and motor wiring.)

• Wire voltage rating must be a minimum of 300 V for 230 Vac systems and 600 V (Class 1 wire) for 460 Vac and 575 Vac systems.

AV2 Enclosure Type Torque Value

English Metric 1-20 HP, 230 Vac input 12 in-lbs 1.35 Nm

IP55 1-20 HP, 460 and 575 Vac input 18 in-lbs 2.03 Nm 25-75 HP, 460 and 575 Vac input 12 in-lbs 1.35 Nm

• Use circuit breakers on the incoming power lines.

• Grounding must be in accordance with NEC and CEC. If multiple AQUAVAR controllers are installed near each other, each must be connected to ground. Take care to not form a ground loop. Maintain a common ground.

• Wire must be made of copper and rated 60 / 75ºC (unless otherwise specified in the table below). Refer to Tables 4, 5 and 6 for recommended wire gauges and temperature ratings.

Considerations for Control Wiring Control wiring refers to the wires connected to the control terminal strip. Select control wiring as follows:

• Shielded wire is recommended to prevent electrical noise interference from causing improper operation or nuisance tripping.

• Use only UL™ recognized wire.

• Wire voltage rating must be at least 300 V for 230 Vac systems.

Model Wire Size 208 Vac Wire Size 230 Vac Number AWG mm2 AWG mm2

AV2V2S010D 14 2.5 14 2.5

AV2V2S020D 12 4.0 12 4.0

AV2V2S030D 10 6.0 10 6.0

AV2V2S050D 8 10.0 8 10.0

AV2V2S075D 6 16.0 6 16.0

AV2V2S100D 4 25.0 4 25.0

AV2V20010D 14 2.5 14 2.5

AV2V20020D 14 2.5 14 2.5

AV2V20030D 12 4.0 14 2.5

AV2V20050D 10 6.0 10 6.0

AV2V20070D 8 10.0 8 10.0

AV2V20100D 81 10.01 8 10.0

AV2V20150D 61 16.01 61 16.01

AV2V20200D 61 16.01 61 16.01

(1) Use wire rated 90ºC in an environment where the ambient temperature is greater than 40ºC (122ºF).

Table 4: Recommended Wire Gauges (230 Vac Models)

Model Number Wire Size AWG mm2

AV2V50010D 14 2.5

AV2V50020D 14 2.5

AV2V50030D 14 2.5

AV2V50050D 14 2.5

AV2V50075D 14 2.5

AV2V50100D 12 4.0

AV2V50150D 10 6.0

AV2V50200D 8 10.0

AV2V50250D 8 10.0

AV2V50300D 8 10.0

AV2V50400D 61 16.01

AV2V50500D 41 25.01

AV2V50600D 41 25.01

AV2V50750D 21 35.01

(1) Use wire rated 90ºC in an environment where the ambient temperature is greater than 40ºC (122ºF).

Table 5: Recommended Wire Gauges (460 Vac Models)

Model Number Wire Size AWG mm2

AV2V40010D 14 2.5

AV2V40020D 14 2.5

AV2V40030D 14 2.5

AV2V40050D 14 2.5

AV2V40075D 12 4.0

AV2V40100D 12 4.0

AV2V40150D 10 6.0

AV2V40200D 101 6.01

AV2V40250D 81 10.01

AV2V40300D 61 16.01

AV2V40400D 61 16.01

AV2V40500D 31 35.0

AV2V40600D 21 35.01

AV2V40750D 11 50.01

(1) Use wire rated 90ºC in an environment where the ambient temperature is greater than 40ºC (122ºF).

Table 6: Recommended Wire Gauges (575 Vac Models)

Step 8 - Input Line Requirements Line Voltage

See the Power and Current Ratings table for the allowable fluctuation of AC line voltage for your particular model. A supply voltage above or below the limits given in the table will cause the drive to trip with either an overvoltage or undervoltage fault.

When supplying line voltages other than the factory default values (either 230 Vac, 460 Vac or 575 Vac depending on the model), set the Supply Voltage parameter to the appropriate value.

Exercise caution when applying the AQUAVAR controller on low-line conditions.

For example, and AQUAVAR controller will operate properly on a 208 Vac line – but the maximum output voltage will be limited to 208 Vac. Now if a motor rated for 230 Vac line voltage is controlled by this drive, higher motor currents and increased heating will result.

Therefore, ensure that the voltage rating of the motor matches the applied line voltage. If other than 60 Hz output is desired, proper V/Hz can be programmed into the AVII by setting the Nom Mtr Voltage and Nom Mtr Freq parameters.

Use of Isolation Transformers and Line Reactors The AQUAVAR controller is is perfectly suitable in most cases for direct connection to a power source as specified in this manual and the technical nameplate affixed to the unit. There are however a few cases where a properly sized isolation transformer or line reactor should be employed to minimize the risk of drive malfunctionor damage or nuisance tripping:

• As noted in Table 7, transformer sizing, when line capacity is greater than 10 times the KVA rating of the drive. Consult the factory for assistance in sizing the reactor.

• When power factor correction capacitors are employed on the drive’s power source.

• When the power source is known to be subject to transient power interruptions or significant voltage spikes.

• When the power source supplying the drive also supplies large devices such as DC drives that contain controller rectifiers.

Table 7: Transformer Sizing for the AQUAVAR Controller Controller HP 1 2 3 5 7.5 10 15 20 25 30 40 50 60 75

Transformer kVA 2 4 5 9 13 18 23 28 36 42 56 70 90 112

Phase Imbalance Phase voltage imbalance of the input AC source can cause unbalanced currents and excessive heat in the drive’s input rectifier diodes and DC bus capacitors. Phase imbalance can also damage motors running directly across the line.

Step 9 - Terminals Found on the Power Board Description of the Terminals

Diagram 4 shows the power terminals for the AQUAVAR controller. Table 8 describes the terminals.

Table 8: Description of Power Terminals

Terminal Description

TB1 Terminal Group GND Earth ground.

L1/R These terminals are the line connections for three-phase models. (Single-phase L2/S models will only have the L1/R terminal, with the other two terminals being L3/T replaced by a terminal labeled N.)

T1/U T2/V These terminals are for motor connections.

T3W

CAUTION!

EQUIPMENT DAMAGE HAZARD - NEVER USE POWER-FACTOR CORRECTION

CAPACITORS ON MOTOR TERMINALS T1/U, T2/V OR T3/W. DOING SO WILL

DAMAGE THE SEMICONDUCTORS. FAILURE TO OBSERVE THIS INSTRUC-

TION CAN RESULT IN INJURY OR EQUIPMENT DAMAGE.

G N

D

L1 /R

L2 /S

L3 /T

B– B + D B

T1 /U

T2 /V

T3 /W

Diagram 4: AQUAVAR Controller Power Terminals

Typical Power Connections Diagram 5 shows the terminal connections for line power and motor output. See Step 8 for input line requirements.

Note that when testing for a ground fault, do not short any motor lead (T1/U, T2/V or T3/W) back to an input phase (L1/R, L2/S or L3/T).

As shown in Diagram 5, it is necessary to provide fuses and a disconnect switch for the input AC line in accordance with all applicable electrical codes. The drive is able to withstand a 110% over load for 60 s. For maximum protection of the drive, use the fuses listed in Tables 9, 10 and 11 found below and on the next page. The recommended supplier is Bussman.

Table 9: Recommended Fuses (230 Vac Models)

Fuse Size 208 Vac Fuse Size 230 VacModel Number

JJS/JJN1 JJS/JJN1

AV2V2S010D 15 10

AV2V2S020D 20 20

AV2V2S030D 30 30

AV2V2S050D 45 45

AV2V2S075D 60 60

AV2V2S100D 80 80

AV2V20010D 10 6

AV2V20020D 15 10

AV2V20030D 20 15

AV2V20050D 30 25

AV2V20075D 40 35

AV2V20100D 50 40

AV2V20150D 70 60

AV2V20200D 70 60

(1) For sizes up to and including 30 A, KTK fuses may be substituted.

AV2V Drive

Motor

Fuses

Disconnect Switch

Th re e- Ph as e

A C

P ow er

L1/R

L2/S

L3/T

T1/U

T2/V

T3/W

GND

Diagram 5: Connections for Power Wiring

Table 10: Recommended Fuses (460 Vac Models)

Fuse Size 380 Vac Fuse Size 460 VacModel Number

JJS/JJN1 JJS/JJN1

AV2V40010D 6 6

AV2V40020D 6 6

AV2V40030D 10 10

AV2V40050D 15 15

AV2V40075D 20 20

AV2V40100D 20 20

AV2V40150D 40 35

AV2V40200D 50 40

AV2V40250D 60 50

AV2V40300D 70 60

AV2V40400D 80 60

AV2V40500D 90 90

AV2V40600D 110 110

AV2V40750D 150 150

Table 11: Recommended Fuses (575 Vac Models)

Fuse Size 575 VacModel Number

JJS/JJN1

AV2V50010D 6

AV2V50020D 6

AV2V50030D 10

AV2V50050D 10

AV2V50075D 15

AV2V50100D 20

AV2V50150D 30

AV2V50200D 35

AV2V50250D 50

AV2V50300D 50

AV2V50400D 70

AV2V50500D 70

AV2V50600D 80

AV2V50750D 100

1. The wires routed from the terminal block U, V, W, and ground screw, should now be connected to the motor leads using the motor nameplate and Diagram 6 for reference. Always refer to motor wiring nameplate.

2. Pressure Transducer Installation and Wiring It is recommended that the transducer be mounted in the discharge piping. The location should be in a non-turbulent, straight piece of pipe. See layout on page 5. Locate the adapter for the pressure transducer, if needed.

220 Volt 460 Volt

AQUAVAR

W U

V

GROUND = PE

AQUAVAR

GROUND = PE

Diagram 6

BROWN – 3

WHITE – 2

+ 5VDC

SIO +

SIO -

15 V IN (4-20 mA)

RS-485

connected to drive “Run Signal” fault signal

Current Signal Input (4-20 mA)

Analog signal output (0-10V) connected to drive

Motor thermo or PTC * low Water or jumper * external on or jumper *

Ub (max 100 mA) actual value signal shieldingX1

X2 Multi-pump

Transducer connection

X5

NO

CC

NC

NO

CC

NC

Digital Input Voltage Signal Input (0-10Vor 2-10V)

1X1

X6 4 3 2 1

RS485

6 – CONNECTED TO DRIVE

5 – CONNECTED TO DRIVE JUMPER

4 – CONNECTED TO DRIVE JUMPER

3 – CONNECTED TO DRIVE

2 – ANALOG OUT (PRESSURE)

1 – RETURN SIGNAL

X9

* NOTE: Jumpers are installed from the factory.

Must remove to wire motor thermal, low water switch or external ON/OFF if used.

- 24 VDC

+ 24 VDC

+ 24 VDC

FAULT RELAY

Diagram 7

3. Place the square gasket over the end of the transducer, plug the cable connector on, and tighten the screw.

• The transducer is supplied with 1⁄4” NPT threads for direct mounting in the discharge piping.

4. Now select one of the remaining ports in the AQUAVAR controller to route the transducer cable.

Route the transducer cable through the strain relief, cut to length and connect to locations X1 #2 and #3 as shown in Diagram 7. (Note: Control board is mounted to the inside front cover of the drive enclosure.) The brown wire is connected to X1 #3 and the white wire to X1 #2.

Tighten strain relief.

5. Terminals Found on the AV II Drive Control Board (Internal Drive) Description of the Control Terminals: Figure 8 shows the control terminals found on the I/O board of the AV II drive. (The actual control board cannot be accessed by the user.) These terminals are prewired by the factory with color coded wires below.

Note that due to labeling constraints, the labels for some terminals start on the left (either on the side or top of the terminal block), are interrupted by the terminal screw, and then finish on the right (either on the side or top of the terminal block). For example, terminal A11 is labeled with A on the left side of the block and 11 to the right of the terminal screw on top of the block. Similarly, terminal NC2 is labeled with N to the left of the terminal screw on top of the block and then C2 on the right side of the block.

As is shown in the figure, the terminals are divided into four terminal blocks, each of which pulls apart for ease of field wiring:

• TB1 - analog input, analog output and digital output terminals.

• TB2 - output relay 1 (R1).

• TB3 - output relay 2 (R2).

• TB4 - digital input terminals.

Table 12 starting on the next page describes the control terminals.

Cable connector will fit on one way only! Do not force on or damage may occur.

TB1

A0

CM

A1

PQ

C1

DIP Switches

A0

A1

DQ

R

TB2

Yellow Wire

White Wire

Black Wire

On side of terminal block TB4

TB3

EN

C2

C2

O2

On side of terminal block

Black Wire

Jumper

Orange Wire

Blue Wire

Red Wire

Enhanced Keypad

Port

Diagram 8

Table 12: Description of AV II Drive Control Terminals (Internal Drive)

Terminal Description TB2 Terminal Block

Common terminal for the first auxiliary relay. The function of the relay is RC1 set by parameter R1 Configure. The default setting is for the relay to activate when a fault is detected (Drv Flted).

NC1 Normally-closed contact for the first auxiliary relay. It will open when the relay is activated.

NO1 Normally-open contact for the first auxiliary relay. It will close when the relay is activated.

TB3 Terminal Block (Drive Run Contacts) Common terminal for the second auxiliary relay. The function of the relay

RC2 is set by parameter ROUT R2 Config. The default setting is for the relay to activate when the drive is running.

The contact ratings are 115 VAC at 1 A or 230 VAC at 0.5 A.

NC2 Normally-closed contact for the second auxiliary relay. It will open when the relay is activated.

NO2 Normally-open contact for the second auxiliary relay. It will close when the relay is activated.

TB4 Terminal Block Enable terminal. A jumper is placed between this terminal and the +2 terminal at the factory. You may replace this with a contact if desired. The

EN circuit from EN to +24 must be closed for the drive to operate.

Note that unlike all other terminals, this terminal cannot be configured for “pull-down logic.” That is, a high input to this terminal is always regarded as true – and must be present if the drive is to operate.

Digital inputs. The function of a digital input is configured by the

D3 to D10 parameter with the same name as the digital input in the DI Configure parameter group.

Digital input. In 3-wire control, this must be a Stop input. In 2-wire

D2 control, it may be configured to another function with parameter D2 Configure.

D1 Digital input. This must be a Start or Run input.

6. For multi-pump systems: Use a three core shielded cable to connect terminals 1, 2, and 3 on X5 between the AQUAVAR controller units. These are the RS-485 interface connections.

(See Diagram 11 and 13). Note: either RS485 port can be used.

• Connect pump one to pump two, two to three, and three to four (maximum is 4 pumps).

7. External pressure switch or float switch- (if used) to check incoming pressure and low/no suction. Connect to terminal block X1 at the 6 and 7 location. Refer to Diagram 11.

When using a suction pressure switch, set the cut off at the maximum NPSH required by the pump.

8. External on/off If used to turn the AQUAVAR controller on or off from an external panel or controller, connect to terminal block X1 at the 4 and 5 location (refer to Diagram 7, page 24).

9. Analog output of pressure A meter can be connected to X9 pins 2 and 1 for remote display of actual system pressure.

The meter must be 0-10 VDC volt with no more than 2 mA.

10. Second Sensor Input The ground pin (X1-10) used for analog output can also be used to bridge a connection for a second sensor. This can be digital (on/off) such as a switch which would be connected between X1-10 and X1-14. Another choice is a sensor with a voltage signal of 0-10V or 2-10V which would be connected to X1-10 and X1-13. A final choice is a 4-20 mA current sensor which would be connected to pins X1-10 and X1-12.

Power supplies using G.F.I. breakers will cause nuisance tripping which will result in the AQUAVAR controller displaying an “undervoltage” fault.

If an external switch is NOT used, install a jumper wire between X1 Locations 4 and 5.

Diagram 9

Pump Priming Refer to your pump operation manual for instructions on pump priming. You will need to unscrew the pressure transducer and adapter if you used the pump fill plug for mounting. When priming is complete, replace the pressure transducer and check for leaks!

Run Test

Instructions

1. Check all wiring.

All motors used with the AQUAVAR controller are three phase. You will need to check the direction of rotation of the motor shaft. If you have followed all of the previous steps carefully, you should now be ready to apply power to the AQUAVAR controller unit.

2. Close discharge valve.

Make sure the discharge valve is closed.

Apply power to the AQUAVAR controller. The first screen appears for 2 seconds and shows the software version and manufacture date. The next screen will appear automatically *If auto start is preprogrammed “ON”, pump will start immediately.

3. Check Power Light Check the AQUAVAR controller panel. The “power on” light should be illuminated and the display should say “No Autostart - disable inverter.” If either of these conditions is not present, turn off all power to the AQUAVAR controller and recheck all connections.

To change the display language on the AQUAVAR controller, press the “ ” key and the up arrow key at the same time. A scrolling line will appear on the bottom of the screen and tell you which button to push for the language you want. After selecting the language, press the up arrow to return to the main display.

WARNING!WARNING

DO NOT APPLY POWER TO THE AQUAVAR CONTROLLER OR PUMP UNTIL ELECTRI-

CAL CONNECTIONS HAVE BEEN REVIEWED BY A QUALIFIED ELECTRICIAN AND

MEET ALL APPLICABLE STATE AND LOCAL REQUIREMENTS.

Screen

NO AUTOSTART - DISABLE INVERTER

ITT Industries SW:120 Date: 10/30/00

4. Check Display.

* If these conditions exist, proceed.

If NOT, check all wiring.

5. Drive Component Keypad (Internal Drive) The AQUAVAR II units have an additional keypad inside the cabinet. You will need to use this keypad one time for initial system set up. Once set, all other functions are programmed with the main display on the front panel. Below are the instructions for initial programming of the internal keypad.

Th…