Part_4_-_Toe_Seep_Modifications_Plans_and_Specs_4-7-2015.pdf
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- Solicitation number
- DQ1 FAAA FEEA2015000000000001 4
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- Rio Grande County, Denver City, Colorado
About this file
This file is a technical manual excerpt detailing the operational procedures and maintenance requirements for a Panasonic Sigma Programmable Logic Controller (PLC) supplied with a pump station system. The document provides comprehensive guidance on PLC overview and operating principles, checkout procedures, maintenance protocols, and troubleshooting protocols for pump station operations. The Panasonic Sigma PLC is a compact, integrated controller that monitors and processes flow and pressure data to manage start/stop/sequencing of system pumping operations, while also providing data logging and system diagnostic capabilities. The controller features discrete inputs and outputs connected via din connectors, expandable I/O capabilities through expansion cards, and communication ports (Com 1 and Com 2) for external software connectivity such as Watervision applications. The manual emphasizes critical safety procedures, including ensuring the door-mounted Main Disconnect Switch is in the OFF position before inspection and exercising extreme caution when power is applied during open-door maintenance.
The technical specifications and maintenance guidance address routine system components including pumps and motors, with detailed troubleshooting steps for common operational issues such as pump failure to engage in automatic or manual modes, pressure reading inaccuracies, motor overload conditions, and temperature sensor failures. The document includes a comprehensive symptom-cause-corrective action matrix that covers eight primary failure scenarios, ranging from low pressure alarms and blown fuses to high temperature conditions. The PLC was factory-programmed to meet specific system requirements and does not require additional user input, though system settings such as regulate set points and valve operations can be modified through the display unit. The manual references the complete Sigma User Manual for detailed installation, operation, and specifications information, and emphasizes the importance of consulting individual component manufacturer documentation to ensure efficient, trouble-free system operation.
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THE PANASONIC PLC
Overview & Operating Principle Panasonic Sigma PLC
The Panasonic Sigma Programmable Logic Controller supplied with this pump station monitors & processes information such as flow and pressure data to provide output for start/stop/sequencing of system pumping operations. Additional functions include data logging and system diagnostic capabilities. Controller, I/O, power supply & communications functions are in a compact, integrated package mounted within the control enclosure.
Referring to the image of the PLC in Figure 1, the 24VDC power is brought into the PLC on the bottom of the PLC housing. The discrete inputs (selector switches, pushbuttons, temp. Sensors, etc) are wired to the PLC’s top din connectors labeled with an (X). The discrete outputs (indicator lights, motor starters, electric butterfly valves (EBV’s) etc.) are wired to the PLC’s top din connectors labeled with an (Y). Additional I/O required will be in the form of expansion card that will reside along either side of the PLC.
The communication ports -- com 1 and com 2 are located on the bottom side of the unit.
These communication ports will be used for connecting to the PLC with software packages like Watervision.
THE PANASONIC CHECK OUT PROCEDURE
1. CAUTION! Before entering the electrical control enclosure to inspect the PLC, ensure that door-mounted Main Disconnect Switch is in the OFF position.
2. IMPORTANT! Ensure that the “black” din connector terminal blocks are securely attached to the PLC. Each block is attached to the PLC base via two clips located at the top. See Figure 1.
Exercise EXTREME CAUTION for the following steps require Power be applied to the enclosure while the door is open.
3. With the Station control power ON, check status display panel located on front of the PLC. Light-emitting diodes (LED) indicate health and status of the CPU, battery, communication ports & fixed I/O points. LEDs on the left side of the unit indicate the following status:
• COM 1
A “flashing” GREEN LED indicates that com port #1 is active and communicating with an external device.
• COM 2
A “flashing” GREEN LED indicates that com port #2 is active and communicating with an external device.
THE PANASONIC CHECK OUT PROCEDURE
(Continued...Page 2 of 2)
4. The Panasonic Sigma Programmable Logic Controller supplied with this Pump Station has been programmed at the factory to meet specific requirements, and therefore does not require additional user input. However, changes to system settings such as regulate set point, VFD/EBV operation, etc. can be made through the display unit (See Section Three - Tab 7).
5. If the user wants to become more familiar with PLC operation, installation, or specifications, the Sigma User Manual (see Section Five -Tab 26) provides detailed information about the unit.
Figure 1:
Tab 7).
MAINTENANCE PROCEDURES
For details and specifications about your Pump Station components, consult the information provided in this Manual. These manuals are supplied by the manufactures of the individual components used to build your pumping system. It is important that you read and understand the different requirements of each one of these components to ensure efficient, trouble-free system operation.
The most common components needing routine maintenance include:
Pumps Motors
TROUBLESHOOTING GUIDE
--- WARNING !! ---
This equipment contains LIFE THREATENING VOLTAGES.
Exercise EXTREME CAUTION when working on or near this part of the station. Never open the electrical enclosure until you have
TURNED OFF all power to the station.
NOTE: When checking fuses for continuity, make sure that ALL power is OFF. If the fuses are good, check the electrical power for CORRECT Voltage Levels before replacing suspected bad components. Since this must be done with power ON, exercise EXTREME
CAUTION.
(1) -----------------------------------------------------------------------------------
SYMPTOM: Pumps will NOT come on in AUTO mode -- even though The Pressure in the system is LOW.
PROBABLE CAUSE: CORRECTIVE ACTION:
Low Pressure Alarm Check for Cause(s) of LOW PRESSURE Condition exists. Alarm and correct.
The Pressure Reading on Calibrate the Pressure Display to match the the Display is not Accurate. Liquid-Filled Gauge.
Troubleshooting Guide (Continued...Page 2 of 2)
(2) -----------------------------------------------------------------------------------
SYMPTOM: Pumps will NOT run in either MANUAL or AUTO.
PROBABLE CAUSE: CORRECTIVE ACTION:
No Power at Pump Motor(s). Turn ON Main Power. Turn ON Panel Power.
Phase Monitor NOT on. Ensure Correct Phase & Voltage Level.
Duplex Outlet/GFCI Tripped. Press RESET on GFCI Unit.
An Overload Relay has tripped. Check OVERLOAD Relays. RESET if Tripped.
Blown Motor Fuse(s) Replace FUSE(s).
Blown Transformer Primary, or Check for loose wires or shorted wires and Secondary Fuse(s). Replace FUSE(s).
(5) -----------------------------------------------------------------------------------
SYMPTOM: Pump runs in AUTO mode, but ALARMS.
PROBABLE CAUSE: CORRECTIVE ACTION:
Alarm Condition -- Low/High Correct & Clear Alarm Condition.
Pressure, etc...
Tripped Motor Overload Relay. Check & RESET Overload(s).
(8) ---------------------------------------------------------------------------------- SYMPTOM: The Station Alarms on HIGH TEMPERATURE.
PROBABLE CAUSE: CORRECTIVE ACTION:
The Water Temperature of the Check for Loss of PRIME; or for a LEAK in Pump Inlet is above 120 degrees. The Suction Line.
Defective Temperature Sensor. Replace TEMPERATURE SENSOR.
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