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`Hayward Industries, Inc.
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`EXHIBIT 1020
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`Hayward Exhibit 1020
`Inter Partes Review of
`US Patent No. 8,019,479
`
`

`

`
`
`nipower®
`HPL'I 'I o, HPL420
`Programming Suggestions for
`Centrifugal Pumps
`
`General Principles
`Centrifugal pumps are constant head -
`variable flow systems with a power
`consumption which basically tracks
`flow rate as shown in Fig. 1.
`
`Since power consumption tracks flow,
`power monitoring is an effective
`basis 'or monitoring and protection.
`
`
`
`
`
`For seal-less centrifugal pumps, it is
`partic larly important to protect against
`dry—running since without fluid, the rotor
`rubs directly against the stator housing.
`Whe
`dry running occurs, the power
`consumed by the pump immediately drops
`to a very low level — well below the zero flow
`powe and approaching the idle power of
`the rrotor. This characteristic makes power
`
`monitoring particularly useful for protecting
`seal-less pumps from dry—running.
`
`Figure 1
`
`Alarm functions required for centrifugal pump protection are:
`Low Power:
`
`— Dry-running due to lack of fluid, blocked inlet, air induction,
`— Operation below l\/lin. Safe Flow leading to over—heating and fluid vaporization,
`
`High Power:
`- Operation above Max. Safe Flow leading to cavitation and unstable operation,
`—
`lammed impeller.
`
`The Unipower HPLi 10 and HPL420 models both incorporate high/low power alarm
`functions suitable for pump protection applications. Please refer to the relevant
`data sheet for overall information and instructions; this guide is solely intended to
`
`provide suggestions on limit setting for centrifugal pumps.
`
`HAYWARD EXHIBIT 1020
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`Page 1 of 4
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`

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`Unipower Alarm Objectives
`for Centrifugal Pumps
`Once the Unipower system has been installed and basic set-up completed, there are five
`parameters which must be set for effective pump protection:
`
`Ts -
`
`Start Delay Timer: Delays active monitoring until the pump/motor have reached
`normal operating speed (or in the case of self—priming pumps, until prime is
`established).
`
`L1 - Max. Limit Alarm: Alarm when Max. Safe Flow is exceeded.
`
`L2 - Min. Limit Alarm: Alarm when I\/|in. Safe Flow is not met.
`
`Tr1 - Trip Delay for L1: Time duration for which an alarm condition must exist before
`alarm is declared; avoids nuisance tripping due to normal process fluctuations.
`
`Tr2-
`
`Trip Delay for L2: As above for the L2 Min. Alarm.
`
`Setting Ts Start Delay
`While Ts is active, monitoring is disabled so this parameter should be set as short as possible.
`
`For normal primed applications, a typical power vs. time plot is shown in Fig. 2. The motor
`is started at time i and the system settles to a running normal value at time 4.
`In this case,
`Ts is set at 3.5 seconds resulting in normal monitoring becoming active at time 4.5.
`
`Typical Ts values for primed centrifugal pump applications are in the range 1 to 5 seconds;
`default of 2 seconds is a good starting point.
`
`For self-priming applications, the pump starts by running dry until prime is established. This
`results in a period on start-up where the power is below the normal L2 Min. Power alarm
`level and an extended Ts period must be used.
`In these cases, set Ts to the value suggested
`
`by the pump manufacturer (contact WEN Technology if extended Ts options are required).
`
`Setting L1 - L2 Max. and Min. Alarm Limits
`The objective is to set these values to the Max. and Min. Safe Flow power values for the
`pump system. Unipower models HPLI IO and HPL420, however, are programmed in units of
`%kW; programming L1 — L2 in %kW for these models is achieved as follows:
`
`Empirical Peak Detect Method
`First disable the L1 & L2 alarms by setting them to 101% and 0% respectively.
`Run the pump and first open the outlet valve to normal full flow setting then close the
`outlet valve to the normal minimum flow setting. Return the valve setting to normal flow.
`
`Depress the A key and note the max. power experienced by the pump in %kW — set L1
`appropriately above (slightly) this value.
`
`Depress the V key and note the min. power experienced by the pump in %kW - set L2
`appropriately below (slightly) this value.
`
`HAYWARD EXHIBIT 1020
`
`Page 2 of 4
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`

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`PW»)
`
`P=f(t)
`
`100%
`
`
`
`
`Ll
`Max. Limit
`
`L2
`Min. Limit
`
`
`
`PowerOn
`
`Relay On
`MotorOn
`
`Figure 2
`
`Emplrlcal Mm. Safe Flow Settlng
`An accurate setting of the critical l\/|in. Safe Flow trip point in %kW can be achieved with
`a slight variation on the above procedure.
`
`Instead of running the pump with the outlet valve set at normal minimum flow, close the
`outlet valve completely and record the power value in %kW with the valve closed — Zero
`Flow %kW (ZF%kW).
`(Be sure to re-open the outlet valve immediately)
`
`From the pump curve, note the power consumption at Zero Flow (ZFP) and at Min. Safe
`Flow (MinP). Use this data to establish the Min. Safe Flow setting for the Unipower unit
`as follows:
`
`Min. Safe Flow (%kW)=ZF°/okW x MinP / ZFP (%kW)
`
`Set L2 to this calculated l\/lin. Safe Flow value in %kW.
`
`Note: This method is quite accurate for setting Min. Safe Flow. However, for basic
`protection from dry—running, any L2 setting which is equal to or above the zero flow —
`dead-headed — power of the pump will be effective.
`
`Setting Tr1 - Tr2 Trip Delays
`The Trl
`- Tr2 Trip Delay timers ensure that the measured power remains above or below the
`respective LI
`- L2 Limits continuously for the time set by the Tr timer; see Fig. 2. As such,
`they reduce sensitivity to short duration process fluctuations and are used to reduce nui-
`sance tripping of the system.
`
`Setting these parameters is empirical. The default values for the Unipower systems are 0.1
`seconds. For pumping applications, it is usual to use a longer Tr time and values in the
`range 1 to 5 seconds are typical.
`
`HAYWARD EXHIBIT 1020
`
`Page 3 of4
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`

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`Settlng Protection
`Once the settings have been determined and set, protect the program by setting DIP
`Switch 1 to the “ON” position.
`
`Q: Why are the HPL110 and 420 models not programmed in units of HP?
`
`A: The Unipower motor load monitors measure the input power to the motor whereas
`pump curve data is related to motor output power. And quite a bit more data must be
`entered and processed in order to display and function in engineering units.
`
`Programming based on observed %I<W values is an easy and safe method without
`requiring a detailed knowledge of the motor efficiency curve.
`
`Two options exist for programming from the pump curve in real units of power
`The first option is Unipower model PCU4123 which is programmable in units of kW
`and includes a scaling function which can be used for motor efficiency correction.
`
`The second option is to convert %kW into kW using the equation:
`
`P [100%kW] = i/3 . U .|
`
`is the
`where U is the rated voltage of the unit (e.g. for HPL110/460. V is 460V) and I
`effective primary current (see System Configuration section in Installation Manual).
`Remember that this is the input power to the motor; to convert to output power,
`
`adjust these values based on the efficiency curve for the motor.
`
`A conversion chart for your application can be supplied based on receiving aII the
`information Iisted in the setup log sheet found on the back of the Installation Manual:
`
`for Limits L1 and L2. give the desired Max. and Min. Safe Flow ratings in units of HP or
`kW (please denote which are being given).
`
`Document Number: W199EOO3
`© 1999 Wen Technology. Inc. Raleigh. NC USA
`
`
`WENiechnoIogy
`
`8411 Garvey Drive / Suite 117
`Raleigh, North Carolina 27616
`(919) 954—1004 I Fax (919) 954-1009
`www.wentec.com
`
`HAYWARD EXHIBIT 1020
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`Page 4 of 4
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