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Booster Pump Controller

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


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 7segment display on the integral inverter. The system also has the easyto-use keypad (see the figure below) on its panel for system operating and fault alarm.

Keypad on the front panel

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 pumps 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 pumps 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 pumps 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.

Systems Components and Wiring Diagram


Fuse Inverter

Main Circuit Breaker

Cooling Fan

Phase Protection Circuit

Magnetic Contactors

Main Controller Board

Overload Relays Wiring Terminals

U1

V1

W1

U2

V2

W2

V12

CM

Ci

A1

A2

Power Supply

Pump NO.1

Pump NO.2

Pressure Transmitter

Float Switch

System Connection Scheme

Booster Pump Controller Unit 4

REF. 1 2 3 4 5

COMPONENT Pump On/off valve Check valve Pressure transmitter Surge tank

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 Signal Terminal

Trip Contact Terminal

Set Point Trimpot

Keypad Connector

220Vac Input

Terminal for Pump's Magnetic Contactors

Main controller Board Layout

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
A-03 A-04 A-09 *A-10 *A-11 *A-25 C-06 *C-25 E-00 E-06 E-07 Note : A-10, A-11 and A-25 : Depend on Pump size and usage

Default value
1 1 120.00 5.0 5.0 3 7 2 1 100.0 1.0

Value for Booster Pump


2 2 50.00 0.5-2.0 0.5-2.0 3-9 12 5 3 110.0 0.5

Description
Start/Stop by external command External command from terminal Vi (0-10 Vdc) Maximum frequency acceleration time deceleration time Switching frequency Terminal I5 = FR (Free Run) Analog output signal VO (Show motor speed) Control mode (PID+Speed mode) PID proportional band (PB) PID Integral time (Ti)

00 18 WIRING DIAGRAM CIRCUIT 19 20 21 22 23 24 25 26 27

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02

03

04

05

06

07

08

09

10

11

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13

14

15

16

17

00

01

02

INPUT POWER SUPPLY AC 380V,3PHASE,50/60Hz R S T N E

VOLT
V
NO CMR

FAN2 FAN1
+12 LEVEL OL1 OL2 PL KEY PAD
LS O/L2

03
A2 O/L1 A1

MCB
R S T

F1-4 PHASE PROTECTION


L N

04

05

06

CONTROL BOARD BTP-R2


N P1_DIR
K2

07

INVERTER FRECON
P1_INV
K1
Ci +12 CM

+12 NO Fout Vi FR CM

08

R S T U V W
Pressure Transducer

CMR NO Vo Vi I5 CM +12 Ci

P2_DIR
K4

P2_INV
K3

09

10

K1

K2

K3

K4

C474/630V

11

12

K1

K2

K3

K4 CONTROL TERMINAL R S T N INPUT SUPPLY E U1 V1 W1 U2 PUMP NO.1 V2 W2 Ci +12 CM PUMP NO.2 PRESSURE TRANSDUCER ON A1 A2

13

LS

14

O/L1 AMP NO.2


A

AMP NO.1

O/L2

15

OFF
U2 V2 W2 PUMP NO.2 GROUND TANK

16

U1 V1 W1 PUMP NO.1

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A.P.Y. ENGINEERING CO.,LTD MACHINE FILE:

USER : DESG. DRAW APPR. NAME

Mr.Krungsri Mr.Sawai Mr.Wichit

OCT/27/2009 OCT/27/2009 OCT/27/2009

SCALE DATE REV. DATE SHEET


01/01 None

BOOSTER PUMP

NAME: WIRING DIAGRAM BOOSTER PUMP DWG. NO. A.P.Y. ENGINEERING CO.,LTD