SECTION XXXXX

DUPLEX 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 Duplex control panel.  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 stainless steel 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 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. The enclosure shall have an inner door with the level controller, the VFD HMIs, and the HAND /OFF/AUTO selector switches. 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 sealant shall be permitted to effectively restrict the passage of gases or vapors through the sealing fitting.

2.05 COMPONENTS AND REQUIREMENTS

A.	Pump requirements
a.	Shall be rated at 208, 230, or 240V, 3-phase.
b.	The motor rated voltage shall match the incoming voltage
c.	The Full Load Amps (FLA) shall not exceed the rating of the control panel
d.	Reversing the rotation of the impeller shall be permissible and not cause damage or degradation of the pump

B.	Variable Frequency Drives (VFDs)
a.	Shall be able to control the pump to deliver maximum torque at low speed via vector control
b.	Shall be connected via Modbus to a graphic, color, easy to use HMI
c.	Each VFD shall have an HMI mounted on the Inner door.
d.	Shall have 5-year warranty

C.	VFD HMIs
a.	The HMI 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.	Call to run indication (from the level controller)
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.	Conformal coating
b.	The HMIs shall be manufactured by SJE-Rhombus

D.	Audible and Visual Alarm
a.	An alarm horn shall be mounted on the side of the control panel, the LED beacon shall be mount 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 until the alarm condition is cleared.  

E.	Level Controller
a.	A microprocessor-based pump controller shall be provided to monitor wet well level via a submersible level transmitter and provide Duplex pump down control. The pumps shall start and stop as required to maintain an acceptable level.

b.	When the level in the wet well rises to the lead pump start set point, the lead pump shall start. If the capacity of the lead pump is greater than the demand, the lead pump shall stop when level drops below the stop set point.

c.	If the capacity of the lead pump is less than the demand, the lag pump shall be called to start. If the capacity of both pumps running in parallel is greater than the demand, the lag shall stop when the level drops below the lag pump stop set point. The lead pump will continue to run.

d.	The pumps shall operate in the pumping sequence if manually selected or shall alternate after each complete operating cycle if alternation is enabled.

e.	The Lift Station Pump Controller shall be a SJE Inc Model TPC-X, off-the-shelf, preprogrammed, and dedicated to pumping application.  The microprocessor-based controller shall be capable of monitoring the tank level and automatically control one to three pumps. PLC systems using a one-of-a-kind, non-standardized, custom programming generic controllers represent additional complexity and unproven operation and thus are not in conformance to the intent of these specifications and will not be acceptable.

f.	Controller shall be configured for the number of pumps to be controlled at this lift station as per these specifications. 

g.	Controller Display:  The controller display shall consist of a text/graphical display, dedicated alarm and pump status indicators, operator navigation buttons and rotary selector wheel providing quick and easy system navigation. The display shall be capable of showing all system status and configurable parameters as herein defined. 
i.	The operator interface shall have a display area not less than 2.7” with 64 x 256 pixel resolution.
ii.	The display shall be based on OLED technology offering increased energy saving and wide viewing angles. 
iii.	The controller shall be configured with a main level (Home) display that shows the current level in feet and represent the level in bar graph form, which dynamically updates based on the level in the wet well. The level display shall have the ability to show up to 4 digits providing needed resolution. The main display shall provide indication of lead pump, active alarm indication and show the most current active alarm text message.
1.	When communication is activated, the Main level display shall include a communication active status indicator confirming recent connection to master device.  

h.	Inputs/Outputs (I/O):  The controller shall come standard with herein specified predefined inputs and outputs having a total I/O compliment of 11 discrete inputs, 6 discrete outputs 1 analog input and 1 analog output.

i.	As a minimum, in its base configuration, the controller shall be capable of accepting the following input status signals: 
i.	Pump 1, 2 & 3 Running or Disable (Selectable)
ii.	Pump 1, 2 & 3 Seal Failure
iii.	Pump 1, 2 & 3 Over-temp
iv.	High Level Float
v.	Alarm Horn Silence/Reset

j.	The controller shall provide outputs for pump operation and alarm signals. Outputs shall be contact closure rated at 250 VAC @ 3 Amps. As a minimum, in its base configuration, the controller shall be capable of providing the following output signals:
k.	Pumps 1, 2 & 3 Call
l.	Alarm Horn
m.	High Level
n.	Low Level

o.	The controller shall monitor 4-20 mA signal input representing wet well level. The analog input shall have 14-bit resolution or higher. 
i.	The controller shall include built-in 24 VDC power supply for powering an external loop powered process transmitter.

p.	The controller shall provide a 4-20 mA output that is scalable to reflect the process level. The output signal shall be fully scalable and not less than 12-bit resolution.

q.	System Configuration: The controller shall have built in intuitive menu structure allowing quick and easy navigation and access to system data, status and adjustment of operator configurable parameters for system automation. The controller shall limit the operator adjustments to only the active components of the system. The controller shall allow system viewing and configuration of the following status and parameters: 
i.	Alternation – When editing the alternation, the display shall show only the active pumps to prevent sequencing in unavailable pumps. 
1.	Operator selection of a fixed pump sequence and or alternation mode to equalize pump wear.  
2.	The alternator shall have the capability of being put into fixed sequence mode at any time.
ii.	Level Set-points – When editing the set-points the display shall show the available level range to prevent adjustments outside the operating range of the system. 
1.	Establish pump on/off level set-points for each active stage (Lead, Lag, Lag2)
2.	Establish Low and High Alarm levels. 
iii.	Counts and ETMs (Elapsed Time Meter) – The controller shall monitor and accumulate the following items:
1.	Motor/pump starts for each motor/pump – This parameter shall be operator resettable to zero.
2.	Motor/pump accumulated run time for each motor/pump
3.	High Level Alarm occurrences – This parameter shall be operator resettable to zero.
4.	Low Level Alarm occurrences – This parameter shall be operator resettable to zero.
5.	High Level/Backup Float Alarm occurrences – This parameter shall be operator resettable to zero.
iv.	The controller shall allow for level simulation via the front panel display. The simulation shall allow the operator to simulate wet well level and verify that operational parameters are working as intended. 
v.	Level transmitter Input Range – The controller shall allow for configuration of the process variable input received from an external level/pressure transmitter. The controller shall allow the following operator adjustments:
1.	Transmitter Range – Allowable range shall not be less than 0-999.9. 
2.	The process input shall be viewable as inches, feet, centimeters, PSI, KPa, and bar. 
3.	Level Offset to allow compensation for actual transmitter/level transmitter placement. – Allowable range shall not be less than 0-999.9.
vi.	The controller shall allow for the operator selection of pump up (filling) or pump down (empty) modes of operation.  
vii.	The controller shall allow for the operator selection of the number of active pumps. The controller shall be settable for 1, 2, or 3 pumps. 
viii.	The controller shall be operator configurable to limit the number of pumps allowed to operate at one time. 
ix.	Pump on delay adjustment (0-250) shall allow for the time (in seconds) between pump starts. The set time will provide stagger starting of the pumps based on the set time. Setting the time to 0 (zero) will allow all pumps to turn on at the same time. 
x.	Pump off delay adjustment (0-250) shall allow for the time (in seconds) between pump stops. The set time will provide stagger stopping of the pumps based on the set time. Setting the time to 0 (zero) will allow all pumps to turn off at the same time.
xi.	Set-point Dwell time adjustment (0-99 Seconds) shall be provided to prevent nuisance pump operation or alarm activation based on momentary fluctuations of the input signal or to allow for temporary process variable swings from affecting system operation. 
xii.	Motor/pump failure to start delay shall be provided and operator adjustable (0-99 seconds). This parameter shall be active when the controller is monitoring externally produced pump/motor run signals. When active, the controller shall determine pump failure to start when the external run input is not present after the adjustable time delay. If the motor fails, an alarm shall be produced and displayed.  
xiii.	In pump down applications, the controller shall calculate station flow based on volumetric calculation as established by user entered vessel/wet well parameters. When operating in telemetry mode, these parameters shall also be adjustable remotely over the telemetry link. The station flow rate and totals shall be displayed on the operator display panel.  
xiv.	Telemetry communications via Modbus RTU shall be available for remote communication:
1.	Address: Node 1
2.	Baud Rate: 9600 baud
xv.	A Station Data display shall be provided allowing operator entry of the stations basic design parameters. As a minimum the following parameters shall be displayable: 
1.	Pump Horsepower
2.	Pump Voltage
3.	Pump FLA
4.	Tank Diameter (If Applicable) 

r.	The controller shall monitor pump status and alarms.
i.	Controller shall allow for monitoring of external switches indicating pump run or pump disable. The function shall be operator settable. 
1.	In the Run Feedback selection, the controller shall use this input for monitoring motor start and determining motor failure to start alarms. When activated the operator mounted pump run indicator light shall be illuminated.
2.	 In the pump disable mode, the controller shall prevent the associated pump from running. 
ii.	The controller shall monitor pump seal failure. The input shall detect a contact closure from an external pump protection module or be able to monitor the seal probes directly. When active, an alarm shall be produced. The motor shall continue to operate. 
1.	When monitoring seal fail directly via motor mounted probes, the seal failure alarm shall activate when the seal probe resistance drops below 50K Ohms.
2.	The seal fail monitoring shall be operator selectable for normal or inverted operation. 
iii.	The controller shall monitor pump/motor over-temp. The input shall detect a contact closure input from external pump thermos-switch contacts or pump protection modules. When the over-temp thermos-switch is activated, an alarm will be produced, and the motor call signal will be disabled until the condition is cleared.  
1.	The controller shall be configurable for automatic return to operation when the condition clears or require manual reset before allowing the pump/motor to restart. 

s.	The controller shall have built in diagnostics to facilitate on site user troubleshooting. The controller shall support the following diagnostics:
i.	Digital input open/closed status. 
ii.	Relay output on/off status
iii.	Analog Input raw input signal in mA
iv.	Analog Output signal in mA. 

t.	The controller shall have a built-in backup system. 
i.	The backup system shall be configured to allow operation of pumps in the event of primary level sensor failure. In this mode, the high-level float switch input shall be monitored to detect high level. Upon detection of a float switch high level, the controller shall indicate an alarm and will operate pumps on the high level-float input. The pump(s) will remain on after the level drops below the high-level float activation point for a user adjustable time to prevent short cycling. The adjustable time range shall be 0-999 seconds. 
ii.	A Float switch (as specified elsewhere in these specifications shall be provided to initiate high level alarm and activate the backup system. The float shall be set at an elevation above controller high level alarm set-points. 

u.	Controller Communications - The controller shall be supplied as telemetry ready.   
i.	The controller shall have an RS-485 serial port 
ii.	Communications protocol shall be configured based on MODBUS RTU open standard protocol.
iii.	When enabled, this communication feature shall allow the controller to:
1.	Interface directly with PanelLink™ cloud based remote monitoring gateway as specified elsewhere in these specifications. 

v.	Power and Environmental: The controller shall operate on 24 VDC power source. Controller shall be able to operate in an environment with 5 – 95% humidity noncondensing and have a temperature operating range of not less than 0 to 122 Deg. F.  

F.	Submersible Level Transmitter
a.	The level transmitter shall be designed for continuous level monitoring. It shall measure the hydrostatic pressure of the water above the sensor and outputs a 4-20 mA signal proportional to the water level. It shall be of robust design with a built-in internal stabilizing weight to provide a reliable and low maintenance solution for wastewater level control applications.
b.	The transmitter wetted components shall be designed with nonconductive materials to provide an electrical isolation barrier. The pressure sensor shall be isolated from process material by a protective VITON® diaphragm. A stainless-steel mounting bracket and cord strain relief shall be included.
c.	Component shall be SJE-Rhombus, Sub-X™

G.	Back-up float switch
a.	One mechanical control float switch shall be supplied with the control panel to operate the pumps as a back-up to the level transmitter. The float shall operate the pump when activated as a high-level alarm.
b.	Component shall be SJE-Rhombus, MilliampMaster™

H.	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

I.	Pump Terminal Blocks
a.	The terminal blocks for motor lead terminations shall be mounted on an angled and raised bracket to provide easy access for field wiring terminations.  
b.	Components shall be by Phoenix Contact, Part UT-4 for control connections and UT-6 for pump connections

2.08 SEQUENCE OF OPERATION 

A.	General 
1.	The level controller shall call the VFDs to run the pump as the level in the wet well rises 
B.	VFD Auto-reversing function
1.	The VFDs shall be able to reverse the pump rotation on start to clear any debris accumulated in the cutter and impeller. In addition, the VFDs 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.
C.	Pump and Pump System Protection
a.	The VFDs shall provide the following protection:
i.	Electronic Motor overload 
ii.	Run Dry detection
iii.	Maximum cycle run time

2.09 VFD 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. VFD System Status and Data logging
1.	The VFD HMI 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. Checks amps again
2.	Level transmitter
a.	Check cable for damage
b.	Check for build-up on the sensor
c.	Check the vented tube for moisture
3.	Float switch
a.	Check cable for damage
b.	Check for build-up on the float
c.	Check activation point and operation
4.	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.	Level transmitter
3.	Float switch. 
4.	LED Beacon
5.	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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