SECTION XXXXX

SIMPLEX 2HP GRINDER PUMP CONTROL PANEL

PART 1 GENERAL 

1.01	SECTION INCLUDES

A.	This section includes all elements required to furnish and install a complete electrical control system to control, operate, and display information as indicated in the plans and specifications. The control system shall include all equipment, devices, wiring, and incidental materials to operate the system and display or relay information in accordance with these specifications. The intention of this section is to secure a complete control system that will operate equipment in accordance with narratives and requirements indicated in the plans, specifications, and manufacturer's literature for the equipment installed. All circuits and devices for protection of installed equipment shall be included in the lump sum bid.

1.02	SCOPE OF WORK

A.	The contractor shall furnish and install with each pump station, SJE-Rhombus VarioSpeed Grinder control panel model number VSGS-240-1-11.  The pump station control panel shall house the complete electrical system to operate the pump station. The control panel shall be manufactured by a UL certified panel facility and shall meet all UL508A standards (Industrial control equipment).  All components shall be UL recognized or listed including those supplied by the pump manufacturer. The control panel shall be built to meet NEMA Type 3R rating and shall in all respects conform to the National Electric Code and all other state and local codes which may apply.

1.03	REFERENCES

A.		NEMA 250 – Enclosures for Electrical Equipment
B.		NEMA ICS7 – Industrial Control and Systems Adjustable Speed Drives
C.		UL® 50 – Enclosures for Electrical Equipment
D.		UL 98 – Disconnect Switches
E.		UL 508 – Industrial Control Equipment
F.		UL 991 – Safety Tests

1.04	SUBMITTALS 

A.		The Engineer reserves the right to approve or disapprove any and all equipment based upon evaluation. Approval for fabrication and installation will be made only after submittal and review of all shop contract documents. The information required for approval shall include the following items and be provided to the engineer prior to the bid date.
1.	Electrical schematics
2.	Enclosure dimensional drawings
3.	Complete layout drawing with dimensions
4.	Manufacturer data sheet for all components
5.	Complete bill of material
6.	User operating manual
7.	Installation instructions
8.	Warranty certificate

1.05	SUBSTITUTIONS

A.	The Engineer will consider proposals for substitution of materials, equipment, methods and services only when proposals are accompanied by full and technical data and all other information required by the Engineer for the proposed substitution.  Substitution of materials, equipment, methods and/or services is not allowed unless such substitution has been specifically approved by the Engineer.

1.06	QUALITY ASSURANCE

A.	Control panel 
1.	Control panel shall be manufactured in a UL508A facility
2.	Factory shall conduct full operational tests with appropriate voltage applied to the panel.

1.07	WARRANTY

A.	 Warranty: 5-year for the control panel and float switches from date of manufacture. The warranty shall apply to being free to defects in material and workmanship.

PART 2 PRODUCTS

2.01	 ENCLOSURE AND CONDUIT

A.	The enclosure shall be weatherproof and rated for outdoor installations.  It shall be a wall mount type polycarbonate enclosure with a hinged door.  The door shall be secured by two large non-metallic latches.  The enclosure door shall be padlockable and house all the necessary control equipment and wiring with ample space for field equipment termination. The enclosure shall have a UL Type 3R rating and be UV resistant. The enclosure mounting feet and drip shield shall be molded as part of the enclosure.  The enclosure shall have two vents on the side to cool the internal components.  The vents shall be rated for outdoor use to prevent rain and larger insects from entering inside the enclosure. All electrical conduits shall be routed at the bottom of the enclosure.  Level sensors shall be routed in a separate conduit and not be combined with pump cables. All sensors and pump cables shall run continuously from the wet well to the control panel enclosure. Cable splicing in junction boxes shall not be allowed. The conduits coming from the wet well shall be sealed 12” below the enclosure with the use of sealant fittings and sealing compound. Only approved sealants shall be permitted to effectively restrict the passage of gases or vapors through the sealing fitting.

2.05 COMPONENTS AND REQUIREMENTS

A.	Incoming power
a.	The control panel shall be rated for 240V, 1-phase input power.
b.	A dedicated feed for the pump control panel shall be provided and shall be protected by a thermal-magnetic sized to 30A or higher.

B.	Pump
a.	Shall be rated at 2HP, 230/240V, 3-phase
b.	The Full Load Amps (FLA) shall not exceed 11.0A
c.	Reversing the rotation of the impeller shall be permissible and not cause damage or degradation of the pump

C.	Variable Frequency Drive (VFD)
a.	Shall be rated for 1-phase input and deliver 3-phase output
b.	Shall be able to control the pump to deliver maximum torque at low speed via vector control
c.	Shall be connected via Modbus to a graphic, color, easy to use HMI/Controller
d.	Shall have 5-year warranty

D.	HMI/Controller
a.	The controller shall have the following characteristics:
i.	LCD graphic/color display
ii.	High Brightness / Direct sunlight readable  
iii.	Removable/handheld for easy programming
iv.	Pump run indication (FWD or REV)
v.	Pump speed (Hz)
vi.	Motor current (A)
vii.	Float switch status
viii.	Elapse time meter/cycle counter
ix.	Message bar (Status & Alarm)
x.	Alarm history
xi.	Password protection
xii.	Rotary button for easy menu navigation and configuration
xiii.	HAND/OFF/AUTO selector switch
xiv.	Conformal coating
b.	The HMI/Controller shall be manufactured by SJE-Rhombus

E.	Audible and Visual Alarm
a.	An alarm horn shall be mounted on the side of the control panel, the LED beacon shall be mounted on the top. They shall be activated on High-level or common alarm from the controller.  If the audible alarm is silenced, the alarm light shall remain ON active until the alarm condition is cleared.  

F.	Float switches
a.	Three mechanical control float switches shall be supplied with the control panel to operate the pump based on the level in the wet well.
b.	Component shall be SJE-Rhombus, MilliampMaster™

G.	Circuit Breakers
a.	The pump circuit breaker shall be a thermal-magnetic molded case circuit breaker rated to 240V and sized according to the NEC and the load requirements of the control panel.  
b.	Component shall be Schneider Electric / Square D, QOU, 2-pole, 25A

2.08 SEQUENCE OF OPERATION 

A.	General 
1.	The wet well level shall be monitored by the three float switches.  
a.	STOP float switch
b.	START float switch
c.	HIGH-LEVEL alarm float switch
2.	Two-float switch operation shall be possible by combining the STOP and START float operation with the use of a single wide-angle float switch.
B.	Pump Operation 
1.	The controller shall monitor the position of the pump HAND/OFF/AUTO selector switch on the HMI.  
2.	In the HAND mode the pump shall run regardless of the status of the float switches for the duration of the HAND Run time value and switch to the OFF mode when done.  The value for this timer shall be set to five minutes by default.  The user shall be able to stop the pump at any time by selecting the OFF mode on the HMI.  If placed in the OFF mode, the pump shall not run. The user shall be able to control the speed (Hz) and rotation of the pump in HAND mode.  This function shall assist the user to manually unclog the pump before pulling it out if necessary. 
3.	In AUTO mode, the pump operation shall be based on the status of the float switches.  As the level of the wet well rises above the STOP float, the pump does not run.  If the level rises above the STOP and START floats the pump shall start and run continuously until the level drops below the STOP float.  When the level is below the STOP float the pump shall not run in AUTO mode. Should the level rise above the HIGH-LEVEL float, the alarm will sound, and the beacon will turn on.  If the level drops below the HIGH-LEVEL float, the horn and beacon will stop, but alarm shall remain in the alarm log. 
4.	In AUTO the pump shall run if the HIGH-LEVEL float is activated and continues to run until the STOP float is OFF.  If the STOP float is OFF and the HIGH-LEVEL float is ON, then the pump will run until the START float is OFF.
C.	Auto-reversing function
1.	The control panel shall be able to reverse the pump rotation on start to clear any debris accumulated in the cutter and impeller. In addition, the controller shall be able to detect high-amp conditions during pump run, indicative of clogging and shall automatically reverse the rotation. This shall be done momentarily and repeatedly until the binding material has been shredded to a size that can easily pass through the pump. This control method shall reduce clogging and potential failure resulting from a locked rotor.
D.	Pump and Pump System Protection
a.	The controller shall provide the following protection:
i.	Electronic Motor overload 
ii.	Run Dry detection
iii.	Maximum cycle run time
iv.	Motor over temperature 
v.	Float out-of-sequence detection and fallback operation

2.09 Quick Start Wizard / Data logging
A.	Quick start wizard shall be available for easy setup and include the following steps:
a.	Enter motor amps (FLA)
b.	Enter motor horsepower (HP)
c.	Enter motor voltage (V)
d.	Perform motor auto-tuning 

B. System Status and Data logging
1.	The controller panel shall provide the following data:
a.	Pump run status (Start/Stop)
b.	Pump run times
c.	Pump cycles
d.	Pump Running Amps
e.	Pump Speed in Hz
f.	Pump rotation (FWD or REV)
g.	Alarm conditions
h.	A record of the last 10 faults

PART 3 EXECUTION

3.01 GENERAL  
	
	A. 	All work shall be done in accordance with appropriate Divisions and Section and shall be 			performed in a workmanship manner.

3.02 FABRICATION

A.	All control panels shall be shop assembled and factory tested prior to delivery to the site. 				Final as-built drawing shall be made to reflect all adjustments and modifications made to 				the system after start-up has been completed satisfactorily. All equipment and devices 				shall be mounted, adjusted, calibrated, and operated exactly as recommended by the 				manufacturer of each component.

3.03 EQUIPMENT INSTALLATION AND MAINTENANCE

	A. 	All equipment shall be installed in accordance with approved drawings and the manufacturer’s 				written instructions.

3.04 START UP

A.	Startup shall be done in accordance with manufacturer’s written instructions and be completed by qualified electrician or SJE-Rhombus-Authorized Distributor.

3.05 MAINTENANCE

A.	A preventative maintenance program shall be established to optimize performance and reduce failure.
1.	Control panel
a.	Check for physical damage, water intrusion or corrosion from gas
b.	Check field wiring in terminal blocks, ensure all connections are tight and secure
c.	Check alarm history
d.	Check motor running amps
e.	Reverse the motor rotation in HAND mode to clear any debris. Check amps again
2.	Float switch switches
a.	Check cable for damage
b.	Check for build-up on the float
c.	Check activation point and operation
3.	Pump / Valve
a.	Perform maintenance as recommended by the pump manufacturer
b.	Verify the operation of the check valve

3.06 SPARE PARTS

A.	The following spare parts shall be kept in a cool and dry location by the maintenance team:
1.	VFD (Pre-programmed and pre-wired to quick connector). 
2.	Float switch. 
3.	LED Beacon
4.	Horn
B.	One (1) spare unit shall be kept on the shelf for every twenty (20) units installed.

END OF SECTION

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