Pumping station control boxes

Control Boxes and Monitoring

  1. pl
  2. en
Polish pump and pumping stations factory

Controler
SP-62

Rainwater pumping station control

Household pumping station control

Sewage pumping station control

METALCHEM-WARSZAWA S.A. supply and control boxes

Main power & control

Sterownik do przepompowni

RZS power supply and control boxes manufactured by METALCHEM-WARSZAWA are used to automatically control the operation of pumping stations for power pumps from 1.1 ÷ 22 kW of own production or any power for pumps from other manufacturers. Control boxes are available in a relay-contactor version and based on a microprocessor controller.

Control boxes have a "Declaration of Conformity" with harmonized directives and standards in force in the European Union. The design of the control boxes provides IP-65 protection when closed and IP-21 when the enclosure door is open. The cabinet housing is made of non-flammable polyester material. As a standard, the control boxes is mounted on a plastic pedestal, which is mounted on a previously poured concrete pedestal located next to the pumping station. In the case of a considerable distance from the pumping tank, a cable connector should be used to extend the pump and signal sirens. Power supply should be made in the TN-S network system.

We distinguish between RZS control systems:

  • work system with one pump,

  • work system with two pumps,

  • work system with three pumps,

  • special work systems, according to customer requirements.

The control systems start the electric motors of pumps (made by Metalchem):

  • direct for engine power from 1.1 kW to 4 kW,   

  • intermediate (star-delta) for engine power from 4 kW to 22kW,   

  • based on Soft-Start systems for engine power from 1- 22 kW,   

  • any other for pumps from other manufacturers.

Monitoring
MRT-GSM
(computer/internet)

Control boxes
with microcontroller

Monitoring
MRT-GSM
(one direction SMS)

Control boxes
Contactors-relays

Relay-contactors Control boxes

rozdzielnica na przekaźnikach

The relay-contactor control boxes are the simplest control systems for pumping stations, their advantage is simplicity of construction and quick repair option. However, this is associated with a limited number of control functions compared to control boxes containing microprocessor controllers. 

Standard equipment of relay-contactor control boxes:

  1. Switch Main power -0- Chiller.   
  2. 32A genset plug.   
  3. Electric shock protection - residual current circuit breaker.   
  4. Overload protection for each pump.   
  5. Sensor of phase decay and asymmetry.   
  6. Circuit breakers for the control system.   
  7. 230VAC / 10A socket.   
  8. Electromechanical counters of pump operating hours.   
  9. Electromagnetic relays.   
  10. Time relays for indirect start pumps.   
  11. Blocking of pump activation in case of opening the circuit (1-2) protecting the pump (the circuit is opened in case of damp or motor overload).   
  12. Optical-acoustic signaling device.   
  13. STOP - START buttons.   
  14. Operation selection mode AUTO - 0 - MANUAL.   
  15. Control lights.



Additional equipment:

  1. Repair outlet 3x400VAC / 16A or 32A.
  2. 24VAC / 6A socket.
  3. Voltmeter.
  4. Ammeters.
  5. Leading individual potential-free signals to a strip.
  6. Heater with thermostat.
  7. Surge arrestor class T2 (C) - four poles.
  8. Twilight automaton.
  9. MRT-GSM communication modem.
  10. Individual according to customer specifications.
licznik czasu pracy pomp
Gniazda w rozdzielnicy

Control boxes with microconroller

Szafy sterujące na mikrpkontrolerze

Control boxes  with microprocessor controllers are currently the widest group of control boxes used in pumping station control, regardless of their types. Controllers available on the market can be divided into general purpose controllers and controllers intended only for pumping stations. Most of our control boxes are built based on the SP62 controller and its earlier versions SP12; SP22; SP32; SP42 and SP52. The SP62 controller is our latest controller and is characterized by a color touch liquid crystal display, a built-in SIM card slot and an RS485 connector. At the customer's request, we can make control boxes with other freely programmable controllers available on the market as; Eaton, Siemens, Unitronics, etc ..

Wentylacja w przepompowni

The basic functions of the control box:

  1. Pump control Automatic or Manual.Alternating pump operation.

  2. Offset of pump activation after power failure and after exceeding the alarm level.

  3. Switching the lead pump to the other one if it would fail.In the case of continuous operation, change of pump operation every 20 minutes.

  4. In manual mode it is possible to pump the liquid to the dry-running level.

  5. Arrears function (short work with long wait and low inflow).

  6. Possibility of blocking the simultaneous operation of two pumps after exceeding the alarm level.

 

Standard equipment of control box based on a microprocessor controller:

  • Switch Main Power -0- Chiller.
  • 32A genset plug.
  • Microprocessor controller with built-in GSM / GPRS modem and color touch screen i (SP62).
  • Electric shock protection - residual current circuit breaker.
  • Overload protection for each pump.
  • Sensor of phase decay and asymmetry.
  • 230VAC / 10A socket.
  • Counters of working hours and number of starts for each pump.
  • Blocking of pump activation in case of opening the circuit (1-2) protecting the pump (the circuit is opened in case of moisture or overload of the motor).
  • Optical-acoustic signaling device.
  • Emergency control switch (bypassing the controller).
  • Automatic or Manual control (Start / Stop).
  • Surge arrestor class T2 (C) - four poles.

 

Additional equipment:

  • Repair outlet 3x400VAC / 16A or 32A.
  • Current transducer (current measurement of pumps in one phase),
  • 24VAC / 6A socket.
  • Voltmeter.Ammeters.
  • Leading individual potential-free signals to a strip.
  • Heater with thermostat.
  • Surge arrestor class T1 + T2 (B + C) - four poles.
  • Twilight automaton.
  • Individual according to customer specifications.
Wyłącznik główny w szafce
podłączanie szafy sterującej

SP62 microcontroller and its possibilities

Kontroler przepompowni
  1. Pump start 1   
  2. Pump stop 1   
  3. Level bar   
  4. Pump start 2   
  5. Pump stop 2   
  6. Daily pump running counter 2   
  7. Pump icon 2   
  8. Pump time counter 2   
  9. Pump start counter 2   
  10. Pump operating status 2   
  11. Pump current 2   
  12. Power supply 3x400V   
  13. GSM signal strength   
  14. Waste water level in the tank   
  15. Internet login status   
  16. Float condition max   
  17. GSM login status   
  18. Float condition min   
  19. Pump current 1   
  20. Pump start counter 1   
  21. Pump icon 1   
  22. Pump time counter 1   
  23. Repair cycle counter p1

The colors of the pump icons mean:

blue / black - pump is OK, not working
green - the pump works in automatic mode   
yellow - the pump is operating in manual mode   
red - pump in a state of failure    white - pump stopped

SP-62 is a controller designed specifically to operate two-pump pumping stations.

Thanks to this, the number of elements of the supply and control switchgear is limited to a minimum.

The SP-62 controller contains all possible algorithms for controlling a pumping station with two pumps.

It is equipped with an operator's touch panel, which shows the current status of the pumping station:

  • Status of float level switches.   
  • Current level of sewage in digital and analogue form (bargraph).   
  • GSM network login status (GPRS, INTERNET)   
  • Signal level of the CSQ cellular network in the range of 0-31.   
  • Pump current (I).    Number of pump starts (CYCLES).   
  • Pump running time counter (PR TIME).

 

Controller configuration is made using 10 screens equipped with a numeric keypad.

 

Operating modes of the SP-62 controller:

  1. Manual control using buttons on the START, STOP screen, pump icon yellow.   
  2. Automatic control via level control devices (floats, hydrostatic probe and others), pump icon green.   
  3. Control of pumps with direct start.   
  4. Pump control with indirect start with star-delta switching.   
  5. Level control using four floats.   
  6. Level control using five floats (rainwater pumping station).   
  7. Level control with a hydrostatic probe and two floats.   
  8. Control with blockade of simultaneous operation of pumps (limitation of pumping power).   
  9. Control using a hydrostatic probe and floats.   
  10. Control with control of sewage retention time in low-flow pumping stations.   
  11. Control limited to 20 minutes of continuous pump operation time to avoid overloading.   
  12. Control with cyclical simultaneous activation of both pumps during operation below the alarm level in order to increase the expenditure for cleaning the pipeline of deposits.

 

The SP-62 controller controls:

  1. The presence of all phases L1, L2, L3, inscriptions in green, failures  inscriptions in red.   
  2. Phase-to-phase voltages.   
  3. Values ​​of phase shifts, FOLD COLOR green indicates the correct phase sequence, red indicates the wrong phase sequence.   
  4. Thermal sensor circuit.   
  5. Humidity sensor circuit.   
  6. Motor circuit breaker.

 

The SP-62 controller is equipped with a GSM modem and can monitor the operation of the pumping station :

  1. On the website sending total data on the www server.
  2. In a computer equipped with the SCADA program with the service of connecting and sending data from the GPRS package.

In a mobile phone with a smartphone application with the function of connecting control.

Description of the SP-62 controller operation

  1. Automatic alternating pump control depending on the level of wastewater in the tank.
  2. In the event of a pump failure, the control switches automatically to a functioning pump.
  3. After detecting an open circuit (1,2) protecting one of the pumps, the controller will display the icon of the given pump in red. To restore the pump to work, remove the cause of the failure and clear the alarm in the controller with the "START" button.
  4. Switching contactors with a time delay during automatic or manual operation enables the controller to operate in a direct start system and in a system with star-delta switching.
  5. Timer functions:
  •  Counting the P1 pump running time.
  • Counting pump operation time P2.
  • Counting the P1 pump operation time in the 1000 hour repair cycle.
  • Counting the P2 pump operation time during the 1000 hour repair cycle.
  • Adding up the P1 pump running time over 24 hours to determine the time overload of the pump.
  • Adding up the P2 pump running time over 24 hours to determine the time overload of the pump.
  • Counting the controller working time.
  1. Counting the number of P1 pump starts.
  2. Counting the number of pump starts P2.
  3. Alarm signaling:
  • Audible for 1 minute.
  • Light going on until the failure disappears.
  1. Turning the beeper on or off is done using the screen pump 1 configuration, which is started by pressing the lower part of the pump 1 icon, the active field is marked with a white frame.
  1. The optical signaling device is switched on or off by means of a screen pump 2 configuration, which is started by pressing the bottom part of the pump 2 icon, the active field is marked with a white frame.
  1. If the seizure function is set in the controller menu, and the cabinet is adapted to monitor the so-called burglary, then after opening the cabinet or hatch, the optical-acoustic signaling will be activated. burglary. Turning off the light and sound signaling device is done by pressing the lower part of the pump 2 icon (if the screen is in sleep mode, it should be activated). The alarm will be reactivated after closing the cabinet / hatch (15 sec.)
  1.  The configuration of pump 2 is started by pressing the bottom part of the pump 2 icon, the active field is marked with a white frame.Setting the control levels is achieved thanks to the screen activated by pressing the inscription area H = (level value) cm in the upper right corner. Procedure: delete the current value (<=), enter a new one from the keyboard and confirm with OK.

 

Note: The minimum level must be at least 10 cm higher than the probe suspension.

Konfiguracja sterownika

Pump 1 configuration settings screen:

 

1.  The setting is currently being changed

      it is marked with a yellow background.

 2.  The red button is for deleting numeric settings.

 3.  Green consent button for approval settings.

 4.  The "WY" button is used to go to home screen.

Level settings screen.

The "KON1" button is used for advanced settings protected by a pin.

The change of the level value should be preceded by deleting the current value with the red button, and then the new value should be entered and confirmed with the green button.

Attention:

The minimum level value must be at least 10 cm higher than the probe suspension value.

Emergency control

In case of controller failure, the switch located on the inside door of the cabinet should be set to the "emergency control" position.

In the above case, the pumping station is controlled in emergency mode, switching on takes place after exceeding the "alarm" level - raising the float, while the pumps are switched off after leaving this float.

In emergency mode, both pumps are switched on simultaneously. In order to work only one selected pump, the other should be put down, i.e. turned off with the motor switch.

ATTENTION: In emergency mode, the humidity and temperature circuit 1-2, and the alarm float are supplied with 230VAC.

A damaged controller should be removed from the cabinet and sent to the service center to remove the fault.

After removing the controller fault and installing it in the cabinet, set the switch located on the inside door of the switchgear in pos. "Normal control".

 

Possible events and their elimination:

Motor circuit breaker - The cause of the thermal motor circuit breaker tripping is the motor overload caused by clogged pump or mechanical blockage of the pump rotor. Overloading the motor causes the motor to consume more current than the nominal one set on the motor breaker. Take out the pump and clean the impeller (rags, cords etc.). Another cause of overloading may be pumping liquids with a density and viscosity greater than the permissible.

After activation of the motor switch or both, the optical-acoustic signaling is switched on and information on the controller is displayed. If the pump impeller is clean and the motor switch is still activated, check the motor windings and check the continuity of the humidity-temperature circuit 1-2.

Humidity-temperature circuit 1-2 - The reason for circuit 1-2 opening may be water entering the engine compartment or overheating. If the failure persists, the pump should be repaired. Each opening of circuit 1-2 of the first or second pump causes an optical-acoustic signaling device and information on the controller will be displayed.

Dry running - One of the reasons for the dry running level may be that the liquid is pumped below the minimum level / pump off level, or the level switch hangs. It is necessary to check the liquid level in the tank and the status of the signaling devices (floats), whether any has hung or is not covered with fats, which can prevent the signaling devices from working properly (they must be cleaned).

Alarm level - Reasons for reaching the alarm level may be a power outage or blockage of the discharge system. Reaching the alarm level joins the work of the second pump, and at the same time the optical-acoustic signaling is switched on.

The pump is running but not pumping - One reason for not pumping liquids with the pumps running may be clogging the discharge line or closing the shut-off valves on the discharge line. In this case, the pipeline should be checked for patency and the valve opening degree.

Another cause may be pump airing, in this case turn on the pump, lift it up and then lower it (the liquid in the tank should be above the dry-running level).

ATTENTION:

All work related to the installation and maintenance of the switchgear must be carried out by a person with permissions required by law and other internal regulations.

Maintenance works should be carried out after prior disconnection of the switchgear from the mains and maintaining the safety conditions applicable to electrical devices. All activities related to work on the switchgear should be carried out by personnel trained in health and safety.

 

 

Suggested protection values ​​for specific powers of electric motors for pumps.

 

    

Pump motor power

[KW]

Security
Anti-shock for 2 pumps
Off. RCDs
In/IΔn
[A/A]

Range of thermal settings of motor switches for 1 pump
[A]

Security
in a connection cabinet for 2 pumps
In
[A]

 

Start

 

Comments

1,1

25/0,03

2,5 – 4

C16

Direct.

 

1,5

25/0,03

4,0 – 6,3

C16

Direct.

 

2,2

25/0,03

4,0 – 6,3

C16

Direct.

 

3,0

25/0,03

6,3 – 10

C20

Direct.

 

4,0

25/0,03

6,3 – 10

C25

Direct.

MSK1

4,0

25/0,03

10 – 16

C25

Indirect

MS5

5,5

40/0,03

10 – 16

C32

Indirect

 

7,5

40/0,03

10 – 16

C40

Indirect

 

9,5

63/0,03

16 - 20

C63

Indirect

 

11,5

63/0,03

20 - 25

C63

Indirect

 

12,5

63/0,03

24 - 32

C63

Indirect

 

15,0

80/0,03

24 - 32

C80

Indirect

 

18,5

100/0,03

32 - 40

C100

Indirect

 

22,0

100/0,03

40 - 52

C100

Indirect

 

 

Failures, faults and possible solutions to problems:

 

In the event of a controller failure, set the switch on the inside door of the cabinet to the "emergency control" position.

In the above case, the pumping station is controlled in emergency mode, switching on takes place after exceeding the "alarm" level, while switching off takes place after leaving the "alarm" float. In emergency mode, both pumps start simultaneously. In order to operate only one selected pump, the other should be put aside, i.e. turned off by a motor switch. In emergency mode, the humidity and temperature circuit 1-2, and the alarm float are supplied with 230VAC

 

Sewage pumping station control

Poziomy załączania pomp

Typical levels of control in sewage pumping stations:

  • Alarm level - pumping station level exceeded, pump II starts, acoustic-optical signaling and in the case of monitoring a signal sent to the user,
  • Max level - the level of pump I starts at normal pumping station operation,
  • Min level - the level at which the pumps turn off, equivalent to emptying the pumping station from sewage,
  • Dry running level - pump protection against dry application and motor overheating - achieved by manual control.
Przełącznik pływakowy poziomu

Typical levels of control in rainwater pumping stations:

  • Alarm level - pumping station level exceeded, pump II starts, acoustic-optical signaling and in the case of monitoring a signal sent to the user,
  • Pump II level - level of pump II activation at normal pumping station operation and increasing inflow,
  • Pump I level - level of pump I activation at normal pumping station operation,
  • Min level - the level at which the pumps turn off, equivalent to emptying the pumping station from sewage,
  • Dry running level - pump protection against dry application and motor overheating - achieved by manual control.
Wyłącznik pływakowy

Typical levels of control in home pumping stations:
(When using control boxes)

  • Alarm level - pumping station level exceeded, pump II starts, acoustic-optical signaling and in the case of monitoring a signal sent to the user,
  • Max level - the level of pump I starts at normal pumping station operation,
  • Min level - the level at which the pumps turn off, equivalent to emptying the pumping station from sewage,

 

Pumping station monitoring

Monitoring SMS

For facilities for which direct supervision is not possible, we offer switchgears with a built-in MRT-GSM or MRM-GPRS wireless monitoring system using a cellular network.

One-way Monitoring MRT-GSM

Przepompownie android

Emergency messages and their cancellations are sent as SMSes to the indicated mobile phone.

The system establishes communication with the service every 24 hours (communication test - report on pump operation time). In the absence of a message, check the operation of the controller.

The system has the ability to automatically switch the functions of the microprocessor controller to battery powerin case of power failure (the "Power failure" SMS message is sent and the controller goes into the so-called "sleep" state).

It is possible to block and unblock the controller functions (pumping station operation) from a mobile phone with the android system (smartphone) dedicated to the Metalchem-Warszawa S.A. program.

Pumping station monitoring is a modern tool for controlling and supervising pumping stations. In addition to observing the ongoing work of the object allows you to prevent major failures and downtime. Based on the work history and changes in the parameters of individual pumping station elements, it is possible to determine, for example, damage or clogged pumps, float or control failures, uncontrolled sewage discharge or burglary and devastation of the facility. Signals reaching the operator allow him to concentrate his resources and resources on objects requiring immediate service instead of visiting all objects in order to review them. This saves a lot of resources and time while reacting in advance of the failure.Let's imagine a situation when during a heavy rainstorm some objects fail or levels in pumping stations are exceeded and threaten to pour sewage from the tank. An operator supervising several objects at the same time would have to drive from one object to anotherand check what happens to the pumping stations (sometimes these objects are distant from each other by many kilometers). For example, if the float of the pump activation level hangs up, or the pumps become clogged and stop working, the level of sewage may increase and the area or property may be flooded. Penalties for environmental pollution can be very severe, and wastewater removal from the site is not easy and pleasant. In the event of monitoring, the operator would receive a signal that the alarm condition was exceeded in the tank and the pumps were not operating properly. He would know that he must react immediately and operate in this particular pumping station. Of course, it is better to prevent it than to repair and remove the effects of failure afterwards.

In our offer we distinguish two types of MRT-GSM one-way monitoring based on SMS communication and two-way MRM-GRPS based on GPRS data transmission. You can read more about the possibilities of monitoring provided by our company in the descriptions of individual types below.

Sieć monitoringu pompowni
Przepompownie apka sterująca

Bidirectional MRM-GPRS monitoring

Zarządzanie pompowniami

The pumping station communicates with the dispatching station via a GPRS modem using a cellular network.

The graphic visualization program of monitored objects enables:

- observation of the current state of the objects,

- analysis of pump operation time, failures, (pumps, power supply, communication), current level of sewage, communication status, detection of burglary (opening of the switchgear door) for each facility.

The user can also view the operation of the pumping station via the internet - a web browser.

Wizualizacja przepompowni
Sterownik GSM do przepompowni
Historia pracy przepompowni online

Careful analysis of the history and individual graphs makes it possible to predict the most common failures such as float suspension, hydrostatic probe failure, clogging of the discharge pipeline or pump. There are also known cases when our monitoring helped detect illegal sewage discharges to pumping stations or sewage manholes. By visualizing pumping station operation times and making the appropriate calculations, you can easily identify "bottlenecks" in the network that need to be improved so that your network works flawlessly and its maintenance can be done thoughtfully and at the lowest possible cost.


|Metalchem-Warszawa Spółka Akcyjna|Adress: Studzienna 7a st., 01-259 Warsaw, mazowieckie dist., Poland|NIP 527-020-40-40|BDO 000029119|
|Contact: phone +48 228371270|email: metalchem@metalchemsa.pl|www.metalchemsa.pl|
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