What is pump controller?
Pump control is a system that includes features and protection functions aimed at optimizing the energy efficiency of water pumps and drivers, extending their operating life, and reducing maintenance costs. This system enhances the performance and safety of water pumps with functions such as continuous and variable speed control, over-temperature, waterless operation, dry running, frequency, and voltage protections.
Single Drive / Level Control Mode:
The system operates between upper and lower levels with filling and emptying digital inputs. When the filling digital input arrives, the drive starts operating, and when the digital input signal indicating the tank is full arrives, the drive stops. The drive starts operating when the emptying digital input arrives, and when the digital input signal indicating the tank is emptied arrives, the drive stops.
Single Drive / Low-Pressure Control Mode:
The input pressure sensor (AI1) measures the tank pressure. AI2 controls the pressure of the output line. If AI1 detects insufficient water, the pump stops. If there is enough water, the operation of the pump is allowed.
Single Drive / Well Pump Mode:
Includes startup and shutdown options for deep well pumps. In subsequent operations after the initial start (awakening or restarts), the drive is started at the end of the time in FB45. This can be considered as a check valve protection mode; time can be waited for the water in the pipe to drain.
Single Drive / Fire Pump Mode:
This is the feature of running asynchronous pumps continuously and uninterruptedly in case of fire. Errors are automatically reset infinitely. Two pump types, jockey pump, and fire emergency pump are supported. Jockey pump always keeps water leaks in the pipeline under control. It ensures that the pipeline is always kept at a certain pressure. The fire pump (the larger one) is responsible for pumping water into the system in case of fire. (Can work in PID mode or with a fixed frequency)
Single Drive / Fixed Speed Multi-Pump Control: (equal aging)
Multiple motors can be controlled with a single drive. (With or without equal aging) The number of pumps that drive models can control is as follows:
Single Drive / Fixed Speed Multi-Pump Control
There are 3 different options for Single Drive / Fixed Speed Pump Control:
No displacement in fixed motors
Fixed-speed motors with time-dependent displacement
Fixed-speed motors with sleep mode displacement
Multi-Drive / Variable Speed Pump Control
There are 3 different options in Multi-Drive / Variable Speed Pump Control;
1- Master drive and other drives with no fixed displacement
2- Master drive with time-dependent displacement (One of the slaves becomes the master at the end of the time without the system stopping)
3- Master drive with sleep mode displacement (One of the slaves becomes the master when the system goes to sleep) In this structure, a maximum of 15 drivers and pumps can be used, and communication is provided between the drivers with a special Canbus Port.
In case the master drive fails, the least used slave drive becomes the master without stopping the system. If the feedback sensor fails, it automatically switches to another connected feedback sensor, and the system continues to operate without stopping. There is no obligation to connect a feedback sensor for each drive.
Protection Functions / Water Pump Entry Permit
The entry to the part where the pump control software settings of the drive are made can be protected with a password. Different parameters are used from the existing encryption parameters of the drive. A password can be entered between 0000-9999.
Pump Jamming Function
The Pump Jam (Anti Jam) Function is used in situations where a solid/hard part comes to the suction part of the pump and the pump cannot rotate. It is used in single drive/single pump systems. If a current above 115% of the motor current is drawn for a certain period, this function starts operating if it is active in the circuit.
Leakage - Leak Function
Leaks in the pipes can be easily detected with the help of this function. When the feedback drops below a predetermined value, the drive increases to the maximum frequency, operates for a certain period, and then stops; after waiting for a certain period, it again increases to the maximum frequency and repeats this cycle for a certain number of times. If the feedback rises above the set value during this cycle, the system returns to normal. If the feedback does not reach the SET value at the end of the algorithm, the drive stops and gives a 69:EP6 error.
Waterless Operation Protection
Damage to the pump due to waterless operation can be prevented with the help of this feature. This protection feature is used in conjunction with devices that provide feedback, such as flow rate sensors or pressure sensors. When the feedback received from the sensors is below the determined minimum values, the system automatically stops, preventing waterless operation of the pump. This feature is of vital importance, especially in situations like drawing water from wells.
Over-Temperature Protection
This is a protection function that prevents the operation of the drive and the pump in case of excessive temperature. Temperature sensors are located in the critical areas of the drive and pump and automatically stop the system if the determined temperature values are exceeded. This prevents damage to the devices due to excessive temperature or operating at low efficiency.
Frequency and Voltage Protection
This protection feature comes into play in abnormal frequency and voltage situations that may be harmful to the drive and pump. In case of voltage and frequency fluctuations outside the determined values, the system automatically stops, preventing damage to the drive and pump. This feature provides important protection against fluctuations and interruptions in the power grid.
In conclusion, the features and protection functions mentioned above extend the usage time of water pumps and drives, increase energy efficiency, and reduce maintenance costs. Therefore, the presence of such features in pump control systems provides significant advantages for businesses and facilities.