SJE RHOMBUS 32S Lift Station Control Panel Instructions
- June 3, 2024
- SJE RHOMBUS
Table of Contents
SJE RHOMBUS 32S Lift Station Control Panel
This control panel must be installed and serviced by a licensed electrician in
accordance with the National Electric Code NFPA-70, state and local electrical
codes.
All conduit running from the sump or tank to the control panel must be sealed
with conduit sealant to prevent moisture or gases from entering the panel.
NEMA 4X enclosures are for indoor or outdoor use, primarily to provide a
degree of protection against corrosion, windblown dust and rain, splashing
water and hose-directed water. Cable connectors must be liquid-tight in NEMA
4X enclosures.
Check the incoming power: voltage, amperage, and phase must meet the
requirements of the pump motor being installed. Always check the pump
identification plate for electrical requirements.
Installation
The 32S Lift Station Control Panel is designed to operate via a four float system. The four float system should include fl oats for: pump(s) stop, lead pump start, lag pump start, and high level alarm.
CAUTION:
Please reference the schematic provided with the control panel for proper
installation.
Installation of Floats
CAUTION: If control switch cables are not wired and mounted in the
correct order, the pump system will not function properly.
WARNING: Turn off all power before installing floats in pump chamber.
Failure to do so could result in serious or fatal electrical shock.
- Use float label kit to identify and label cables on both float and stripped ends (stop, lead, lag, alarm, etc.). See schematic for float connection.
- Determine your normal operating level, as illustrated in Figure 1.
- Mount float switches at appropriate levels. Be sure that floats have free range of motion without touching each other or other equipment in the basin.
Installation Instructions
Mounting the Control Panel
-
Determine mounting location for panel. If distance exceeds the length of either the fl oat switch cables or the pump power cables, splicing will be required. For outdoor or wet installation, we recommend the use of a Neman 4X junction box with liquid-tight connectors to make required connections. You must use conduit sealant to prevent moisture or gases from entering the panel. Do not mount the junction box in the wet well.
-
Determine conduit entrance locations on control panel.
NOTE: Be sure the incoming power, voltage, amperage, and phase meet the requirements of the pump motors being installed. Always check the pump identification plate for electrical requirements. -
Drill proper size holes for type of connectors being used.
NOTE: If using conduit, be sure that it is of adequate size to pull the pump and switch cables through. -
Attach cable connectors and/or conduit connectors to control panel.
FOR INSTALLATION WITHOUT A SPLICE, GO TO STEP 8;
FOR INSTALLATION REQUIRING A SPLICE, FOLLOW STEPS 6-7. -
Determine location for mounting junction box according to state and local code requirements. Mount the junction box to proper support.
-
Run conduit to control panel or to junction box if required. Drill proper size holes for the type of conduit used. Use one conduit for fl oat switch cables and a separate conduit for pump cables. Do not run pump and float cables in the same conduits.
*For pumping applications that could require two pumps to run simultaneously during high in-flow conditions, mount the LAG fl oat lower than the ALARM float . In this configuration however, there will be no alarm if one pump fails. -
Identify and label each wire before pulling through conduit into control panel and junction box. Make wire splice connections at junction box if necessary.
-
Firmly tighten all fittings on control panel or junction box if required.
-
In the control panel, insert the appropriate overload modules (purchased separately) in the motor starter.
-
Adjust the dials to match motor full load amps.
-
Turn motor starter switch to the ON position. See Figure 4 – Panel Layout.
CAUTION: Resetting the motor starter with power applied may cause the pump to run unexpectedly. -
Connect pump wires directly to the motor starter terminal positions T1, T2, and T3.
NOTE: Three-phase motors will run in either direction. Check pump motor before installation for proper rotation. To reverse the rotation, swap pump cable connections on any two terminals T1-T2-T3. -
Connect “power-in” conductors to proper locations: 208/230/460 VAC on the 3 position terminal block. See Figure 2. Verify that the appropriate voltage tap on the transformer primary matches the incoming voltage.
CAUTION: The transformer is wired from the factory for 460VAC. If incoming power is 230VAC or 208VAC, the wire connections to the transformer must be changed for proper operation. Not doing so could result in damage.
VERIFY CORRECT OPERATION OF CONTROL PANEL 6AFTER INSTALLATION IS COMPLETE.
Operations
The 32S panels are designed to operate with four floats for pump sequencing. The standard float functions are pump(s) stop, lead pump start, lag pump start and alarm float.
Float Operation (in AUTO mode)
As the liquid level rises above the STOP float the panel will remain inactive.
As the level rises above the LEAD start float, the lead pump will start and
remain ON until the level drops below the STOP level. If the level continues
to rise past the start LEAD float and above the start LAG float, the second
pump will start and both pumps will remain ON until the level drops below the
STOP float.
Lag Time Delay Relay
The Lag Time Delay Relay provides a delay for the lag pump start up after the
lead pump start up in case of a power failure to prevent an increased load on
the incoming line power. Normal settings should be 3-5 seconds delay to allow
the lead pump enough time to get up to speed.
Alarm Operation
The alarm will activate and remain ON if the alarm float is tipped to the ON
(close) position. The alarm can be tested by pressing the Test/Silence push
button.
Alarm System (Horn and Beacon)
When an alarm condition occurs, a red light and a horn activate. If the
silence push button is pressed, the horn will be silenced. When the alarm
condition is cleared, the alarm system is reset. The alarm system can be
tested by pressing the same push button.
HOA Switch
A HAND/OFF/AUTO switch is provided for each pump. In the HAND mode, the pump
will run regardless of the fl oat switch positions. It will stop only if
manually stopped and or an overload trip or motor thermal cutoff condition has
occurred. In the OFF position, the pumps will not RUN. In the AUTO position,
the pumps will only run if the float switches are activated in the correct
sequence.
Overload Module
A motor overload module must be ordered for each pump (purchased separately)
to provide motor overload protection, branch circuit protection and a means to
disconnect the pump. The overload dial on the module must be set to match the
motor Full Load Amps (FLA).In the event of an overload trip, the module must
be reset by first turning the selector handle counterclockwise to the OFF
position and then turning the handle clockwise to the ON position.
Alternating Relay
The alternating relay alternates pump operation to equalize pump wear.
Elapsed Time Meter
Each pump has an elapsed time meter which records the pump called to run times
in hours: tenths of an hour.
Pump Run Lights
Each pump has a run light. The run light will be ON in either the hand or the
automatic mode when the pump is called to run.
Dry Auxiliary Contacts
Normally open – Contacts are open under normal conditions and closed when
alarm condition is present. Automatically reset once alarm condition is
cleared.
Seal Failure Circuit and Indicator Light
The seal fail circuit is resistance sensitive and will sense the presence of
water in the pump seal chamber. When water is sensed, the control circuit will
illuminate the appropriate indicator light on the control panel. If a seal
fail occurs, turn off the pump and consult the pump manufacture for proper
repair or maintenance. Disregard if pumps are not equipped with seal fail
leads.
Thermal Cutout
The thermal cutout is wired in series with the magnetic contactor coil. If the
pump’s thermal switch opens on high temperature, the contactor will turn off
and stop the pump. When the thermal switch cools and closes, the magnetic
contactor will turn on if the pump is called to run.
If the pumps are not supplied with a thermal sensor, jumper wires must be placed on the terminal block from H1 to H2 and H3 to H4. Not doing so will result in the pumps not operating.
Troubleshooting
Alarm Beacon and Horn
Pressing the alarm silence/test push button or activating the alarm fl oat
should fl ash the alarm beacon and turn on the alarm horn. If the beacon does
not fl ash or the horn does not sound, replace them with the same type.
Alternating Relay or Device
The alternation can be sequenced by lifting the fl oat switches or making
jumper wires to simulate the fl oats closing. Consult factory when in doubt
about testing procedures or results.
Float Controls
Check the floats through their entire range of operation. Clean, adjust, or
replace damaged floats.
Checking the float resistance – The float resistance can be measured to
determine if the float is operating correctly or is defective. Use the
following procedure to measure the float resistance:
- Isolate the float by disconnecting one or both of the float leads from the float terminals.
- Place one ohmmeter lead on one of the fl oat wires, and the other ohmmeter lead on the other fl oat wire.
- Place the ohmmeter dial to read ohms and place on the R X 1 scale. With the float in the “off ” position, the scale should read infinity (high resistance). Replace the float if you do not get this reading. With the float in the ON position, the scale should read nearly zero (very low resistance). Replace the fl oat if you do not get this reading.
NOTE: Readings may vary depending on the length of wire and accuracy of the measuring device.
Fuses
Check the continuity of the fuse. Pull the fuse out of the fuse block. With
the ohmmeter on the R X 1 scale, measure resistance. A reading of infi nity
indicates a blown fuse and must be replaced. Replace fuse with same type,
voltage and amp rating.
Transformer
The 32S panel can be configured to operate at 208VAC, 230VAC, or 460VAC. It is
factory set for 460VAC operation. Check the available incoming supply voltage
to the 32S control panel prior to installation. Verify that the connections on
the transformer are correct and will match the available incoming voltage.
Measure the voltage between terminals 1 and S2 with a Voltmeter. It must read
115VAC (+/- 15%) for proper operation.
SJE-RHOMBUS® FIVE-YEAR LIMITED WARRANTY
Five-Year Limited Warranty.
For complete terms and conditions, please visit
www.sjerhombus.com.
NOTICE!
Products returned must be cleaned, sanitized, or decontaminated as necessary
prior to shipment to ensure that employees will not be exposed to health
hazards in handling said material. All applicable laws and regulations shall
apply.