Control system for pump sets (up to 6 pumps)

An advanced automation system designed for comprehensive management and process optimization of multi-pump sets. The system features **complete flexibility in drive architecture configuration** and total hardware independence – the automation loop can interface with **any variable frequency drive (VFD)** available on the market. The system can be programmed to operate with a single VFD sequentially switched between subsequent units ("running inverter" topology), as well as in an advanced multi-drive structure where each of the 6 pumps is equipped with its own dedicated frequency inverter.

The control loop provides precise parameter stabilization based on signals from field instruments and transmitters (pressure, differential pressure Δp, flow rate). A dedicated, intelligent machine rotation algorithm **guarantees perfectly equal running time for each pump in the set**, preventing uneven operational wear of components. In the event of a frequency inverter failure, the built-in **redundancy (bypass) function** automatically maintains network supply continuity in emergency mode.

Functional and Technical Specification:

• ✓ Topology and Hardware Flexibility: Controls up to 6 pumps configured with a single sequential VFD or up to 6 independent drives operating over the network. Compatible with frequency inverters from any manufacturer.
• ✓ System Power Supply: Standard three-phase 3x400V AC.
• ✓ Balanced Loading: Advanced algorithm for staging and de-staging subsequent sections, ensuring identical running hours and equal mechanical wear for every pump.
• ✓ Flow Compensation: Automatic pressure control based on a programmable, 8-point pipeline characteristic curve.
• ✓ Hysteresis Loop: Precise definition of the hysteresis loop width to eliminate hydraulic shock (water hammer) when staging subsequent steps.
• ✓ Dry-run Protection: Active monitoring of suction and discharge pressure (before and after starting the pumps) with a programmable time delay for dry-run evaluation.
• ✓ Stagnation Protection (Anti-blocking): Cyclic, forced pump starting based on a real-time clock (RTC) schedule to prevent impeller seizing during low-demand periods (e.g., summer operation mode).
• ✓ Drive Parameterization: Individual definition of minimum speed limits for pumps driven by frequency inverters.
• ✓ Diagnostics and Security: Non-volatile event log archiving alarm states with precise timestamps, accurate running hours counters, and parameter protection via access code.
• ✓ Output Signals: Two galvanically isolated (opto-isolated) analog outputs 4-20mA, proportional to measured values (pressure, differential pressure, flow, active power).
• ✓ Integration and Communication (Optional): Profibus, Ethernet, Profinet, CANopen network interfaces for interfacing with nadrzędnymi SCADA / BMS systems, along with remote GSM transmission.

Application Capabilities Scope:

• ✓ Full process visualization: generation of pressure and flow trends vs time directly on the operator panel.
• ✓ Full control and tuning of the built-in PID controller structure parameters.
• ✓ Continuous limiting and monitoring of maximum pressure to protect the distribution pipeline infrastructure.