USDA Forest Service
1.01 USFS REGION 6 CONTROL SYSTEM COMPONENT PARTS PHOTOS:
A.
B.
Shown below are pictures of control system components used in R6 USFS Control panels:
Free Siemens control system training http://www.sea.siemens.com/step/default.html
1. Typical USFS Water system well pump to tank
control panel. Parts shown on pages below are
used in this panel.
Battery Box
Test Swtch Box
GFI
Thermostat
Main Breaker
Fuses
Circuit Breakers
Time delay relays
DC Relays
AC Relays
Diode
24VDC Power Supply
Coyote low flow protector
Motor Circuit Protector
Well Pump Motor Starter
Chlorinator Motor Starter
Pump Motor start Capacitors
Strip heater
Telephone Jack for troubleshooting
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Lightning protectors for control cable
Service Lightning protector
Control transformers
Control Systems Parts Photos
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USDA Forest Service
2.
Control panel Front Door
Main Breaker
Sonalert
AC Power on Light
DC Power on Light
Genreal alarm light
Alarm reset pushbutton
Set point controller
Alarm battery test pushbutton
Low flow alarm light
Tank Low Level Alarm
Running time meter
Operation counter
Tank Hi Level alarm
Well Pump Low Flow
Well Pump Fault
Well pump run light
Well pump Overload/ breaker trip
Well pump HOA selector switch
Chlorinator HOA selector switch
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Control Systems Parts Photos
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USDA Forest Service
3.
4.
5.
6.
.24Volt DC Power supply
http://www.power-one.com/
.Transient Voltage Surge Suppressor
http://www.itvss.com/
Carbon Lightning protector for control cable
with black arcs from lightning strike
lightning Protector blocks with gas tube or
carbon gap in pre 1980’s panels. Panels newer
than 1980 have gast tube protectors
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Control Systems Parts Photos
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USDA Forest Service
7.
. lightning Protector blocks with gas tube or
carbon gap in pre 1980’s panels. Panels newer
than 1980 have gast tube protectors. This
model has been in use since about 1980
8.
.24 Volt AC Relay plug in Deltrol 3PDT 10A.
Most common control relay used in all panels.
Note LED on base for indication that relay is
energized.
9.
24VAC Time Delay Relay 2PDT 10A Time
Mark.. Time is set by dip switches 1-1023
seconds range.
http://www.time-mark.com/index.php
10.
24VDC relay used in water systems and sewage
pump stations for low current application over
telephone cable for several miles for water
tanks and intrinsically safe areas. Early units
1975 – 1990 Potter Brumfiled. 1990 – 2000
Midtex. 2000 now. Circuit Works.
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Control Systems Parts Photos
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USDA Forest Service
11.
Motor Circuit Protector used for all motors with
instantaneous trip small red dial lower left
corner is adjustment point for trip current.
Wires coming out of left side are for breaker
trip alarm. New units are Cutler hammer
older units are Westinghouse.
http://www.cutlerhammer.eaton.com/unsecure/cms1/TB0120000
1E.PDF
12.
Motor Circuit Protector used for all motors with
instantaneous trip small red dial lower left
corner is adjustment point for trip current.
Wires coming out of left side are for breaker
trip alarm. Older units are Westinghouse.and
are black
13.
Enclosed Motor Starter in metal box for shock
protection, MCP motor circuit protector
mounted above for each motor.
http://www.sea.siemens.com/contrlbu/upld/files
/p57-58.pdf
14.
Internal contacts of motor starter, Note burned
contacts. Never file contacts. If they are
burned replace all 4 sets of contacts and the
springs.
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15.
Two control transformers mounted in lower
part of picture. 240VAC/ 120VAC and
120VAC/24VAC for control voltage.
16.
Test Switch panel for all floats, pressure
switches, and other sensors to come into panel
to allow operator to simulate sensor operation
without disconnecting any wiring. Positions
are:
Close: simulates sensor closing
Open: Opens sensor circuit
Auto: Automatic operation
17.
Temperature switch and guage for monitoring
blower pressure and temperature.
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Control Systems Parts Photos
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USDA Forest Service
18.
Digital water or sewage flow meter. Yokogawa.
Unit has 4-120ma output to run strip chart
recorder and has gallon totalizer in display and
instantaneous flow.
19.
6 dial Time Clock for multiple system
20.
System pressure guage, and shut off and bleed
valves. Make sure gauges are shut off and that
they are at 0 pressure when not reading to make
them last longer and more accurate. Do not let
gauges monitor system pressures constantly,
only when you look at them.
21.
Diode Used in system power supply
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USDA Forest Service
22.
24V VDC Gell Cell Battery for battery backed
up alarm. These last 3-4 years. Note split case
on this unit. Replace every 3-4 years.
23.
0.5 A Fuses used in all small ameperage
circuits on telephone cable going outside of
panel and in intrinsically safe circuits.
24.
Red Indicator light with 10 segment LED
Lamp. IDEC 24VAC or 24VDC life 500,000
hours and does not burn out, will retrofit all
panels built since 1975.
Colors:Red, Green, White.
Red lights are all alarms
25.
White Indicator light with 10 segment LED
Lamp. IDEC 24VAC or 24VDC life 500,000
hours and does not burn out, will retrofit all
panels built since 1975.
Colors:Red, Green, White.
White lights are for system Power
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26.
Green Indicator light with 10 segment LED
Lamp. IDEC 24VAC or 24VDC life 500,000
hours and does not burn out, will retrofit all
panels built since 1975.
Colors:Red, Green, White.
Green lights are for motors on or for other
items such as solenoid valves open.
27.
3 Phase Monitor relay, used for protection of
motors from phase loss, Phase reversal, low
voltage, high voltage. Note adjustments for
voltage and for time delay on dropout.
28.
Control panel shut off and bleed valves used for
incoming air lines to shut off and bleed
pressure switches and gauges.
29.
Pressure Switches, Mercoid mercury switches
30.
Operation Counter, counts each time motor
starts,
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USDA Forest Service
31.
Running time Meter Records motor run time to
0.1 hour. Energizes every time motor turns on.
32.
Hand – Off –Auto Selector Switch Used for
operational control of motors and other devices
such as solenoid valves.
33.
Contact blocks on backs of selector switches
and pushbuttons. These switches turn on
motors and other devices thru relays.
34.
Strip Chart recorder used for recording flows
and levels. 4-20ma Rustrack 288 recorder
35.
Setpoint Controller universal controller used for
water tank and sewage pu p station level
controls, temperature, flow PH DO or any other
kind or monitoring alarming and digital
readout. Yokogawa UT320 4-20ma input, hi/lo
alarms and on off control and PID loop control
in one unit about $350
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USDA Forest Service
36.
Stainless Steel water tank level switch used in
potable water tanks made by GEMS Co. Gems
Level Switch Model LS-750 part # 197433.
needs 24VDC low current relay to operate.
Will interchange with any mercury float in
current tanks. Has both NO and NC
connections.
37.
Water Tanks or sewage Level transducer
Made by Gems Sensors 4-20 ma 2 wire
transmitter used in potable water tanks and
sewage systems and deep wells to measure and
control pumps with setpoint controller shown
above
38.
Rotofloat Brand mercury float switch to be
used in sewage pump stations only. Not for
potable water. Used for turning on pumps.
Available in NO and NC versions.
39.
Control panel circuit breakers. Ususally from
1 A to 20A. Breakers on right are
Westinghouse. Small breakers on left are less
than 10A and are not used in current deisgns
and are connectron brand.
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40.
Control panel terminal strips for connection of
motors and other sensors, usually located on
panel bottoms.
41.
Poewr panel in control buildings for circuilt
breaker protection of builind loads, lights
outlets heaters. This is NOT USED for motor
circuilt breakers as standard panel breakers are
not specifically designed for motor protection.
MCP instantaneous breakers are used for motor
protection.
42.
24Hr 96 pin time clock ususlly used for control
of lighting or other timed applications such as
backwash in some treatment units.
43.
Diode and heat sink used in battery back up
charging circuits.
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44.
Typical panel layout for motors, with running
time meter, operation counter, overload/breaker
trip light, run light and hand – off – auto
selector switch. 1 line of controls for each
motor.
45.
Air operated diaphram valve where automatic
control of valving is required used in
conjunction with 24VAC pilot air operated
solenoid valves.
46.
24VAC air solenoid valves, used to switch
compressed air for large air operated diaphragm
valves or butterfly valves. Control panel sends
24VAC signal to open valve to allow air to
open larger valve.
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47.
Flow Switch Mcdonnel Miller FS7-4SV
stainless steel flow switch used for pump low
flow protection. Switch closes on no flow
starting a time delay. If pump does not move
water in 10 seconds locks pump off and sounds
alarm.
48.
Chlorine Solution Tank Low level Alarm
Switch US Flite U 21780 float switch. Mounts
on lid of chlorine solution tank. When tank is
6” from empty switch closes causing alarm in
control panel, and shutting off well pump and
chlorinator.
49.
Same as above with picture inside chlorine
tank.
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50.
Frankline Subtrol This unit is made by
Franklin electric to protect submersible well
pumps from running dry or from rapid cycling.
If no flow is detectrd, unit shuts pump off for a
time then restatrts. Unit works by measuring
motor current. No probes are required to us
this in a well.
51.
Intrinsically safe barriers for sewage pump
stations
Data signal protectors for transient protection
of 4-20ma transducers.
52.
Rubber Switchboard matting on floor in fornt
of each panel for shock protection. Minimum
5KV insulation value.
2.
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