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Booster Pump Controller

Booster Pump Controller
Features of Booster Pump Controller Unit

Features of Booster Pump Controller Unit

The booster pump controller unit is the electric pumps controller, which can manage up to two pumps for constant pressure with the variable speed drive technology that give you a lot of more advantages than the conventional system.

CONSTANT PRESSURE CONTROL*

 

The system uses an inverter (frequency converter) to vary speed of the pump for constant pressure at your outlet.

HIGH CAPACITY IN AFFORDABLE PRICE*

 

The system has two pumps capacity, but uses only one inverter to control the pressure. That makes the system cost just a little bit more than one pump (with one inverter) system, but a lot of less than two pumps (with two inverters) system.

EXTENDED PUMP LIFE-TIME*

 

The mechanical stress on the pump and water hammering during stopping are reduced because of the variable speed pump technology. Moreover, the system try to share load equally to both pumps (ALT sub-mode only - see details in next section).

ENERGY SAVING*

 

Thanks for the integral inverter, the pump consumes the power just only its need (as low as possible) and the system also try to stop the pumps when there is low or none of water demand.

NOISE REDUCTION*

 

The pump works at smooth variable speed that gives a reduced noise level.

*AUTO MODE ONLY

Features of Booster Pump Controller Unit

Features of Booster Pump Controller Unit

PUMP PROTECTION

 

The system contains pump protection including:

- Overload Protection

- Phase Loss Protection

- Dry Running Protection (when use with a float switch)

2 MODES OF OPERATION

 

The system has 2 modes of operation including MANUAL MODE and AUTO MODE (see more details in the next section).

EASY TO USE

 

The users can adjust the pressure (set point) via the build-in potentiometer and the users can see the setting value directly on the 7- segment display on the integral inverter. The system also has the easy- to-use keypad (see the figure below) on its panel for system operating and fault alarm.

easy- to-use keypad (see the figure below) on its panel for system operating and fault alarm.

Keypad on the front panel

Operating Modes

Operating Modes

There are 2 modes of operation:

MANUAL MODE

 

The users can run/stop the pumps manually via the buttons on the keypad. However, the integral inverter is not used in this mode.

AUTO MODE

 

The inverter controls the pump’s speed in this mode and the users can select 3 sub-modes including:

1. P1: The system uses pump no.1 only. If the pressure changes from the setting value, the inverter adjusts the speed of pump no.1 to keep the pressure at the setting value.

2. P2: Same as P1, but use pump no.2 instead of pump no.1.

3. ALT (Alternate): In this sub-mode, the system controls the usage of both pumps automatically. The sequence of this sub-mode is described below. When the pressure changes from the setting value, The system try to auto-select one pump to run first. If the capacity of one pump is sufficient to keep the pressure at set value, the system keeps running only one pump. Otherwise, the second pump starts by 3 phase supply (direct online) when the first pump’s speed is maximum (50 Hz frequency) for a while. When the demand of water drops, the inverter-controlled pump (first pump) reduces its speed to keep the constant pressure condition. If the pump’s speed is reduced to zero (0 Hz frequency) for a while, the direct online pump (second pump) stops and the inverter-controlled pump increases its speed to keep the pressure at constant. In addition, if the demand of water terminates, the system stops and change the first pump that will run on the next time (next request for water) to share the usage equally to both pumps.

System’s Components and Wirin g Dia g ram

System’s Components and Wiring Diagram

Fuse

Inverter

System’s Components and Wirin g Dia g ram Fuse Inverter Main Circuit B r e a
System’s Components and Wirin g Dia g ram Fuse Inverter Main Circuit B r e a

Main

Circuit

Breaker

g ram Fuse Inverter Main Circuit B r e a k e r Cooling Fan Phase

Cooling

Fan

Phase Circuit Relays Wiring Terminals
Phase
Circuit
Relays
Wiring Terminals

Protection

Magnetic

Contactors

Overload

R

S

R S T N U1 V1 W1 U2 V2 W2 V12 CM Ci A1 A2

T

N

U1

V1

W1

U2

V2

W2

V12

CM

Ci

A1

A2

W1 U2 V2 W2 V12 CM Ci A1 A2 Power Supply Pump NO.1 Pump NO.2 Pressure
W1 U2 V2 W2 V12 CM Ci A1 A2 Power Supply Pump NO.1 Pump NO.2 Pressure

Power Supply

Pump NO.1

Pump NO.2

Pressure

Float

Transmitter

Switch

Main

Controller

Board

System Connection Scheme

System Connection Scheme

Booster

Pump

Controller

Unit

4 2 1 3 2 2 5 2 1 3 2
4
2
1
3
2
2
5
2
1
3
2

REF.

COMPONENT

1

Pump

2

On/off valve

3

Check valve

4

Pressure transmitter

5

Surge tank

A.P.Y. ENGINEERING CO., LTD. 9/1 Moo 4 Soi Suksawat 62, Suksawat Rd., Kwang Bangmod, Khet

A.P.Y. ENGINEERING CO., LTD.

9/1 Moo 4 Soi Suksawat 62, Suksawat Rd., Kwang Bangmod, Khet Thoong Kru, Bangkok 10140 Tel. +66(0) 2818-2995 (AUTO), FAX: +66(0) 2818-2996, 2818-2997

Set Point Trimpot

Inverter Signal Terminal

Trip Contact Terminal

Point Trimpot Inverter Signal Terminal Trip Contact Terminal 220Vac Input Terminal for Pump's Magnetic Contactors

220Vac Input

Terminal for Pump's Magnetic Contactors

Main controller Board Layout

Keypad Connector

A.P.Y. ENGINEERING CO., LTD. 9/1 Moo 4 Soi Suksawat 62, Suksawat Rd., Kwang Bangmod, Khet

A.P.Y. ENGINEERING CO., LTD.

9/1 Moo 4 Soi Suksawat 62, Suksawat Rd., Kwang Bangmod, Khet Thoong Kru, Bangkok 10140 Tel. +66(0) 2818-2995 (AUTO), FAX: +66(0) 2818-2996, 2818-2997

Inverter's Parameter Setting for Booster Pump Before using the inverter ix as a Pump Controller, some parameters of the inverter ix must be changed from the default (Factory) setting. The list of the parameter that must be changed are shown as in the table below.

Function

Default value

Value for Booster Pump

Description

A-03

1

2

Start/Stop by external command

A-04

1

2

External command from terminal Vi (0-10 Vdc)

A-09

120.00

50.00

Maximum frequency

*A-10

5.0

0.5-2.0

acceleration time

*A-11

5.0

0.5-2.0

deceleration time

*A-25

3

3-9

Switching frequency

C-06

7

12

Terminal I5 = FR (Free Run)

*C-25

2

5

Analog output signal VO (Show motor speed)

E-00

1

3

Control mode (PID+Speed mode)

E-06

100.0

110.0

PID proportional band (PB)

E-07

1.0

0.5

PID Integral time (Ti)

Note :

A-10, A-11 and A-25 : Depend on Pump size and usage

00 01 02 03 04 05 06 07 08 09 10 11 12 13 14
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
00
WIRING DIAGRAM CIRCUIT
01
INPUT POWER SUPPLY
AC 380V,3PHASE,50/60Hz
02
03
R
TNES
VOLT
FAN2
V
MCB
A2
NO
CMR
FAN1
F1-4
LS
O/L1
O/L2
A1
R
04
05
PHASE
S
PROTECTION
T
LEVEL OL2 PLOL1+12
L
N
KEY PAD
CMR
+12
CONTROL BOARD
06
07
NO
NO
INVERTER
Vo
Fout
BTP-R2
-
0 - - -
0
Vi
Vi
FRECON
I5
FR
CM
CM
+12
N
P1_DIR
P1_INV
P2_DIR
P2_INV
08
09
R
TUVWS
Ci
Ci
+12
CM
Pressure Transducer
K2
K1
K4
K3
10
K1
K2
K3
K4
C474/630V
11
K1
K2
K3
K4
12
13
CONTROL TERMINAL
R
W2S
N Ci +12 CM A1 A2T
E
U1
V1
W1
U2
V2
PRESSURE
INPUT SUPPLY
LS
TRANSDUCER
PUMP NO.1
PUMP NO.2
ON
14
15
O/L1
O/L2
AMP NO.1
AMP NO.2
A
A
OFF
GROUND TANK
16
17
U1
V1
W1
U2
V2
W2
PUMP NO.1
PUMP NO.2
USER :
DESG.
Mr.Krungsri
OCT/27/2009
NAME:
SCALE
WIRING DIAGRAM BOOSTER PUMP
A.P.Y. ENGINEERING CO.,LTD
MACHINE FILE:
DRAW
Mr.Sawai
OCT/27/2009
None
APPR.
Mr.Wichit
OCT/27/2009
DWG. NO.
SHEET
BOOSTER PUMP
DATE A.P.Y. ENGINEERING CO.,LTD DATENAME
REV.
01/01