Pump control cabinets. Pump control cabinet - device features and purpose Pump unit control cabinet

Service autonomous system water supply includes control over pumping equipment and serviceability of communications, conservation of the network during a long absence, rational automatic control.

Automation is easy to implement by installing a pump control cabinet in a specially designated area - a compact distribution station operating in several modes. We will tell you in detail how to correctly assemble and install it. By following our advice, you can correctly connect the equipment.

We have provided a standard configuration of the control cabinet. Described what additional functions can be installed and used. The information proposed for consideration was supplemented with useful illustrations and videos.

Technical stuffing different models differs, since control points have an individual functional focus.

Manufacturers offer ready-made standard circuits, but they do not always meet specific requirements, so there is such a service as manufacturing a custom-made control unit. To begin with, we will try to consider the general positions that unite all models.

Functional responsibilities of the control cabinet

The main function of any distribution station is to organize the operation of the equipment connected to it, including in this case– pumping. From one control panel (and this is convenient if the distance between objects is large), the motors of drainage, surface, and well pumps are effectively controlled.

The number of connected units may vary. The minimum connection is one well or one, which supplies water and ensures its availability for the entire water supply system (heating, fire extinguishing). In addition to it, a drainage pump is connected, which is necessary for pumping out water in domestic and emergency situations.

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Automatic switching on/off of pump motors makes life easier for private home owners, allowing free time spend time with your family, and not manually switching toggle switches.

A few more convenient functions that can be “entrusted” to automation:

control of network voltage necessary for uninterrupted operation of equipment;
protection of mechanisms from power outages and short circuits;
monitoring the water level in a well (or other reservoir) and responding to its shortage;
recording pressure surges and adjusting optimal parameters (stopping the engine when a critical point is reached, starting when the indicators level out);
remote control of well pumps, direct access to which is impossible;
load distribution between several units or emergency connection of a backup option.

As a result of centralized automatic control, productivity increases and service life increases. electrical equipment increases noticeably. Modern electronic systems allow you to program mechanisms and turn them on in a convenient mode (for example, only during the daytime).

Protection devices against voltage surges, phase failures, and incorrect connections protect mechanisms and prevent them from operating in emergency mode. They adjust the network parameters, and only after the parameters are equalized, they automatically connect the equipment.

Overload protection functions in much the same way. For example, there is a ban on simultaneous activation of two pumps, which leads to unnecessary costs and irrational use of equipment.

Almost all established systems have the ability to switch from fully automated control to manual control. This is necessary for maintenance, repair work, replacing worn or burnt out parts

Let's assume that if one pump fails, it can be easily removed and sent for repair by turning off the automation and using manual control.

Additional options and features

Various manufacturers include additional functions in the basic package that expand control capabilities. For example, the Alta Group company offers an AVR system - turning on backup power in automatic mode. The need for this function is explained by the fact that the operation of the pumping station is part of the life support system of the house, therefore, the network must operate in constant mode.

The operating principle of the ATS is as follows: as soon as the main power supply stops, the backup network is automatically introduced. It is valid until the main source resumes operation.

When you turn it on intelligent system checks the optimality of the parameters, and only if the response is positive, reconnects the main network. If the test analysis is unsatisfactory, the system will continue to operate from a backup source.

Low temperatures and high humidity are the enemies of the electronic content of the cabinet, so manufacturers offer the service additional insulation. It is relevant for the northern regions and for any areas if the equipment is located outdoors.

The so-called “warm package” is a layer of insulation laid with inside. Thermally insulated SHUNs are operated over a fairly wide temperature range - from -40ºС to +55 ºС

A fairly common addition that allows you to protect pump motors from overload is a soft start system. It consists of a careful, gradually increasing voltage supply mode, thanks to which the engine is protected from a sudden start and is put into operation slowly and carefully.

Modern dispatch function allows control from a distance. Remote warning systems are constantly connected to GPRS, radio modem or the Internet, thanks to which emergency situation The locking system is immediately activated and the signal is transmitted to the receiving device (phone or laptop).

A convenient option that allows you to set a specific program is possible through the use of a controller. In automatic mode, it is able to independently influence the operation of pumps, connect additional devices, and optimize the functioning of the system as a whole.

Indication involves the location of an electronic display on the cabinet lid with voltage and current readings, as well as statistical data: number of starts, engine operating hours, water volume

Another good option that allows you to obtain information about a system stop or an emergency situation is the installation of a light alarm and siren. When force majeure occurs, the flashing light lights up brightly, and a special sound device emits a loud, repeating signal.

Samples of electronic technical connection diagrams

Equipment assembly takes place in production conditions, are also compiled there circuit diagrams pump control cabinet. The simplest are the connection diagrams for one pump, although a set of additional devices can complicate the installation.

As a sample, let’s take SHUN-0.18-15 (Rubezh company), designed for manual and automatic control of electric drives of a pumping station. The control diagram looks like this:

Possible operating modes: circulation and drainage using an analogue sensor or pressure switch. Two variants of the operating algorithm involve simultaneous or alternate activation of pumps

Specifications:

Voltage – 1x220 V or 3x380 V, 50 Hz
Motor power of connected equipment – up to 7.5 kW per motor
Temperature range – from 0°C to +40°C
Protection degree: IP65

If an emergency occurs and the pump motor breaks down (due to a short circuit, overload, overheating), automatic shutdown equipment and connecting a backup option.

Cabinets Wilo SK

The SK-712, SK-FC, SK-FFS lines from Wilo are designed to control several pumps - from 1 to 6 pieces.

Several automatic circuits in the Wilo SK-712 cabinet greatly simplify the work pumping stations

Specifications:

Voltage –380 V, 50 Hz
Motor power of connected equipment – from 0.37 to 450 kW
Temperature range – from +1°С to +40°С
Protection degree: IP54

During operation, all technological parameters are displayed on the display. In the event of an emergency, an error code is displayed.

Conclusions and useful video on the topic

You can learn more about how pump control cabinets function in the following videos.

How to make the simplest SHUN with your own hands:

An example of the operation of a typical SHUN on a test bench:

The use of pump control cabinets allows you to efficiently use the resources of well or drainage equipment and save energy. Knowing the technical characteristics of your pumping station, you can purchase a basic SHUN model or place an order according to an individual scheme.

The pump control cabinet is used to service sewage and drainage pumps equipped with AC electric motors. The main task of the cabinet is to monitor fluctuations in system parameters and determine the best operating modes for electric motors. This reduces energy consumption and protects pump motors from unwanted and unacceptable operating conditions.

Applications and functions of pump control cabinets

The pump control unit performs several functions at once important functions. These include:

Starting and stopping the pump in automatic mode;
Manual start of pumping equipment for its maintenance;
Automatic start additional pump in case of breakdown of the main unit;
Automatic alternation of operation of several pumps for uniform operation time;
Protection of the pump motor from short circuit and overload;
Automatic protection of pumping equipment against dry running.

Thanks to the large list of tasks that the control cabinet solves, it is used in many areas of human activity. Most often it is used in production to control drainage pumps. Cabinets are also actively used to control lifting stations in production and construction. The shields are used by many utility companies and rescue services.

Standard set of blocks

Most models of switchboards used to control the pump have almost the same configuration. It consists of the following elements:

Rectangular metal body. On the front side of the housing there is a pump control panel. The dimensions and design of the case may vary, but it always contains the “Start” and “Stop” buttons;
Manual switch to turn on and off pump equipment;
Protective fuse;
A block with frequency converters that allows you to control the operation of asynchronous motors;
Automatic pump control systems that turn the unit on and off in scheduled and emergency modes;
A set of sensors that control pumps by pressure and water level;
Thermal relay;
Light signaling in the form of a set of light bulbs.

Each of the listed elements from the cabinet set plays an important role in the system. The functions of the control unit depend on the number of pumps. If there are more than two, then the device is responsible for alternately switching the units.

The temperature sensor protects the equipment from overheating - this is often required when working with a submersible pump in wells with low flow rates. The electronic pump control unit turns off the unit and turns it back on when certain operating conditions occur.

Assembly of the pump control cabinet is usually carried out in special conditions if there is necessary tools and materials. At the same time, it is quite possible to assemble the components into a single system with your own hands. To do this, you will need to study examples of electronic technical circuits, which will make it possible to understand the correctness and procedure for assembly. To consider examples, we will use the cabinet model 0.18-15 from Rubezh. This system is used for automatic and manual control of the pumping station. The control diagram for such a cabinet is shown in the image below.

The manufacturer of this model managed to implement 19 modifications, differing in the power of electric motors - from 0.18 to 110 kW. The following parts are located inside the cabinet body:

Automatic type switch;
Protective relay;
Contactor;
Controller;
Auxiliary power supply.

To connect the model to the electrical network, you will need to use a cable with a cross section of 0.3–0.4 mm 2. An example of a connection diagram is shown in the image below.

Installation of monitoring stations – what should you know?

All pump control cabinets have complex design and operate on electrical power. They must be installed, operated and maintained strictly in accordance with the instructions specified by the manufacturer. There are a number of rules that must be followed, regardless of the model and configuration of the cabinet. These rules include:

The system must be installed in a room that is protected from explosions;
Humidity and air temperature in the room must correspond to the parameters specified by the manufacturer;
The characteristics of the cabinet must correspond to the parameters of all elements of the equipment;
For connection, you should use a cable whose cross-section corresponds to the manufacturer’s recommendations.

Control stations that are used in everyday life are subject to the same requirements as industrial systems. Their installation should be carried out in a dry room, which will be convenient for servicing the units.

It is necessary to connect the equipment only after the final installation of the water supply system, wiring and insulation of contacts.

Equipment maintenance and technical support

Many manufacturing companies claim that the pump control cabinets they produce do not require any maintenance. At the same time, cabinets need regular checks of basic elements.

Before checking or replacing elements, the system should be disconnected from the electrical supply and prevent the possibility of being turned on again. You will also need to check the reliability of all fasteners and connections. To avoid mistakes during repairs, you need to carefully study the equipment operating instructions. It contains a list possible malfunctions and ways to eliminate them. For example, one of the typical breakdowns is the failure of the light to indicate that the cabinet is connected to the electrical network. There may be several reasons for this malfunction - lack of voltage and breakage of the circuit breaker. According to the instructions, the repair requires replacing the switch or adjusting the electrical supply.

If a malfunction occurs that cannot be solved on your own, you will have to contact a service center for help.

Having drilled for summer cottage well and having installed a water supply system with a submersible pump, you involuntarily ask the question: how to make the pump work more productively, last longer and have several operating modes? In addition, it would be nice to automate the water supply process, especially if there are two or more pumps. The solution is simple: install a distribution board or pump control cabinet.

Purpose and functions of control cabinets

The main purpose of distribution structures is control electric motors pumps of any type: drainage, submersible, well.

The drain pump control diagram shows the options for adjusting one, two and three drain pumps

Without a submersible pump, the operation of heating, water supply, and fire extinguishing systems is impossible, and a drainage pump control cabinet is necessary to automate the pumping of liquid.

If you have no experience working with control cabinets, it is better to entrust configuration and commissioning to a specialist

By installing a control cabinet for a well pump, the owner of the house will find rest and peace, since the operation of the equipment will then be controlled by electronic “stuffing”.

Both smooth and safe start of the electric motor and regulation will be ensured frequency converter. Parameters such as pressure, water level and temperature will also be monitored.

This diagram clearly shows where the pump control cabinet should be located and how it is combined with the water supply system

If a control cabinet for two pumps is used, its functions are even wider:

in an emergency with one pump, he quickly connects the second, backup one;
evens out the wear of units by regulating their shift work;
when one of the mechanisms is idle, it prevents it from silting;
makes it possible to manually block one of the pumps;
contains control programs for two or more units;

provides information on each mechanism separately.

The diagram shows the interaction between the control panel and the well pump with associated equipment

Standard composition of distribution cabinets

Depending on the number of units being serviced, the product may have different contents. For example, let's take a control cabinet for submersible pumps with asynchronous motors alternating current.

The dimensions of the cabinet depend on its contents and functions. Metal carcass installed on the wall or floor

Components:

external control panel;
controls (buttons, switches) of the system;
a frequency converter;
water pressure meter (for automatically regulating the operation of mechanisms depending on its level);
protection against “dry running”;
light signaling (light bulbs);
switches to protect the motor and frequency converter;
two load control modes: manual and automatic;

thermal relay.

Layout of components of a cabinet regulating the operation of one pump

Although the cabinet also requires manual control, most of the time it should operate in automatic mode.

When auto mode starts, the frequency converter smoothly drives the submersible pump motor until the water pressure reaches the set parameter. When active water extraction stops, the frequency decreases and the pump stops.

Custom control cabinets

Many manufacturers of pumps and pumping stations supply ready-to-use products. For example, the Grundfos concern produces a whole range of cabinets for automatically controlling the supply and pumping of water.

Grundfos products are very popular

But there is another option - making a product to order. What should you consider when ordering a control cabinet?

Number of electric motors and their parameters (power, speed, voltage).
Type of control (manual, automatic, remote).
Engine starting mode (direct, frequency converter, combined, smooth).
Environmental conditions (humidity, temperature).

Features of cabinet maintenance

Before you start using the automation, you should carefully study the instructions and diagrams supplied with the product. Any pump control cabinet diagram shows the location of the electronics, the structure of the device as a whole, interfaces for connecting pumps, and motor protection channels.

Electronic content diagrams for control cabinets show the location of all elements

Any manipulations with mechanisms - cleaning, inspection, repair - must be carried out with the power supply turned off (the “Power” light is not lit).

You should ensure the cleanliness of the ventilation grille filters; most often they are replaceable. The radiator of the frequency converter and the fan must also be cleaned of dust. In order for the connections to function without interruption, you need to tighten the mounting screws.

Its markings will tell you about the technical characteristics of the control cabinet.

Sometimes malfunctions occur in the system. Some of them can be eliminated on their own, others - by specialists or after consultation with the manufacturer. For example, the message “Alarm” appeared on the display - “low pressure”. This means that the “dry running” protection has responded - most likely, there is no water in the well. Until water appears, the pump will be blocked.

If you are the owner country house or dachas with autonomous water supply, then you’ve probably at least once wondered how to make pumping equipment work more efficiently and longer, and also have several convenient operating modes. In addition, sometimes two pumps are used at once to provide the house with water and water the garden, so it is necessary to coordinate and automate their operation. You will get the answer to all your questions when you find out what a pump control cabinet is and why it is needed.

The main purpose of distribution cabinets is to control the electric motor of one or several pumping units at once. In this case, the type of pump does not matter. This can be submersible equipment or a well or drainage pump.

Moreover, the purpose of pumping equipment may be different. For example, a submersible type unit is needed for efficient work heating system, arranging the water supply of a country house or creating a fire extinguishing system. But the drainage pump, together with the control cabinet, is useful for pumping liquid.

Worth knowing: the scope of use of control cabinets is quite extensive. They are successfully used at housing and communal services facilities, as well as industrial enterprises. In addition, cabinets are actively used by private individuals for arranging autonomous water supply.

If you install a control cabinet to coordinate the operation of the well pump, you will finally find long-awaited peace and relaxation, since from now on you do not need to monitor the operation of the equipment, all this will be done by the automation located in the cabinet. In this case, this device will be able to perform the following functions:

the equipment will ensure safe and smooth starting of the pump unit engine;
automation will be able to regulate the operation of the frequency converter;
in addition, the device will monitor the pressure in the system, the water level, as well as its temperature, which is very important for the timely switching on and off of pumping equipment.

The functions of control cabinets for two or more pumps are even more extensive:

if the unit notices that one of the pumps is operating in emergency mode, it will immediately connect the second pump to operation;
since the automation of the control cabinet will regulate the alternating operation of each pump, the overall wear and tear of the pumping units will occur later;
if one of the pumps long time will be without work, the equipment will be able to protect it from silting;
Thanks to this device, you can manually block the operation of one of the pumps;
cabinet automation has different programs for controlling several pumps;
if necessary, you can obtain complete data on the operation of each unit separately.

What's included?

The control cabinet for pumping equipment may have different contents depending on the number of pumps being serviced. We will look at the cabinet configuration using the example of a device that will serve submersible pump With asynchronous electric motors alternating current. The package includes the following components:

External panel for control and configuration.
Various switches and buttons for performing actions to control pumping equipment.
A frequency converter.
A device for measuring water pressure, which will allow you to automatically regulate the operation of pumping equipment.
A dry operation protection relay is necessary to ensure that the unit cannot operate after the water level drops, which can lead to its failure.
To notify about different situations and enabled functions, the cabinet is equipped with various light indicators (light bulbs).
Special switches that allow you to turn off the engine and frequency converters.
Thermal sensor.
Equipment for manual and automatic load control.

It’s worth knowing: in principle, the cabinet’s operation is designed to automatically control the operation of pumping equipment. But if necessary, you can switch to manual control mode.

Operating principle

The principle of operation in automatic mode looks like this:

When automatic mode is activated, the frequency converter smoothly starts the submersible pump motor.
It keeps it on until the water pressure in the system reaches the set maximum.
After this, the equipment turns off the pump.
The same thing happens during active water extraction - the pump operates until peak water consumption stops and the pressure rises. As a result, the frequency decreases and the unit turns off.

The equipment body is made of metal. There are cabinets designed for wall mounting, while other units are designed for floor mounting only. The main purpose of any product is to control system parameters and select the most suitable operating mode of the electric motor. Thanks to their use, it is possible to reduce energy consumption and prevent damage to the electric motor.

Cabinet Operation

Pump control cabinets are sold with detailed instructions and diagrams that are worth studying before you start using the product. The diagram accurately shows the location of the electronics, structure, pump connection points, as well as the location of engine protection devices.

Cabinet maintenance (cleaning, repair or inspection) must be carried out with the power supply turned off. In this case, the light labeled “network” should not be lit. The cabinets use replaceable filters for ventilation grilles. They need to be changed when they become dirty.

In addition, the fan and radiator of the frequency converter must be cleaned regularly. The fastening screws at the connection points must be tightened periodically. This will ensure uninterrupted operation of the equipment.

The operation of control cabinets is designed for positive temperature conditions, so these units should be installed only in heated rooms.

How to choose a cabinet?

Most well-known manufacturers of pumping equipment produce ready-to-use cabinets. However, if necessary, you can order its production with the operating parameters you need. To do this, it is necessary to take into account the following characteristics:

Options and total number engines. In this case, the rotation speed, power of the device and operating voltage are important.
Type of control (remote, manual or automatic).
In what mode should the engine start (using a frequency converter, direct mode, smooth or combined).
You also need to take into account the conditions in which the equipment will operate (temperature, humidity).

As for purchasing a finished control product, when choosing it you need to pay attention to the load performance and build quality, as well as the compatibility of the system with the equipment being serviced.

Tip: when choosing a cabinet, pay attention to the year it was manufactured. It’s good if it coincides with the production date of the pumping equipment. This way you can choose compatible models.

Popular models

Range of Grundfos cabinets quite extensive. It contains products with different configurations and technical characteristics. Some models have protection against dry running, low voltage and phase failure. However, they all can:
- manage pumping equipment;
- automatically start the unit after a long period of inactivity;
- control the water level and display data on the display panel;
- regulate the operation of equipment;
- such products can be used in the temperature range from -20 to +40°C;
- All equipment of this brand comes with a two-year warranty.

Alpha Control cabinets reliably protect pumping equipment from negative factors that cause units to fail. They can work with any pump models. These products are designed for connection to a 220 and 380 V network. The “D” marking in the designation will indicate that the model can be used to control two pumps.

They know well how difficult it is to ensure high-quality operation of pumping equipment and extend its service life without automatic system management. This compact and extremely useful technical unit has an improved version known as a control cabinet.

The main purpose of the cabinet is optimization of electric motor operation and, of course, energy saving.

Any equipment of this type is designed, first of all, for careful energy consumption due to balanced control of the pump motor. The cabinet can be used to display automation from several pumps at once. And the variety of models of this unit allows it to be used to work with the most different types pumping equipment - drainage, water supply (submersible and borehole), and even heating.

How does it work

The cabinet is a square or rectangular structure made of metal. On the cabinet door there is a front panel equipped with indicators and start buttons. The following components are located inside the housing:

a unit for monitoring electrical voltage on phases, equipped with sensors;
a safety device in the form of a relay in case of a short circuit (protects the electric motor winding and all cabinet components);
block for controlling pump operating modes;
contacts with terminals for connecting power supply (temperature and pressure sensors are also connected to them);
relay for automatic control of pump operation (programmable unit) - not all models have it.

Cabinets are manufactured of standard type or by special order.

After assembly, the device undergoes mandatory testing and only after that it is sent to the customer. In the future, the manufacturer will Maintenance and performs service repairs.

Control can be performed manually or automatically.

In the latter case, the cabinet independently controls the pump - it measures the pressure in the water supply and the temperature of the engine, and also turns it off and connects it to the power supply.

Manual control involves preliminary testing using a simplified scheme and starting the pump without automation.

The control cabinet is designed:

to extend the life of equipment;
connecting a backup pump in case of an emergency, if there is one in the system;
preventing siltation of equipment during downtime of the water supply system;
engine protection in emergency and incorrect operating modes;
control of a system of several pumps in program mode;
transmission of technical information to the operator through the information front panel.

Varieties

Cabinets are divided into several main ones technical varieties according to their area of application.

To ensure the operation of drainage and sewer type pumps The system ensures the selection of the best operating mode for engines for their uninterrupted operation and long service life. The start-up is automatic. Short-term testing of the system is mandatory. Protection against dry running and overheating is provided. The cabinet can also be used to operate fire pumps.
For controlling submersible pump types. The equipment is designed primarily to operate firefighting or irrigation pumps. The cabinet operates at temperatures up to +50 degrees and air humidity of 80%. Equipped with an alarm installed in a room with staff on duty.
To ensure the operation of well pumps. Pumps of this type work not only with drinking water, but also serve for pumping process water and other liquids. Control cabinets borehole type pumps, installed in breweries, dairies, and bottling plants mineral water, V autonomous water pipelines, farms(to control watering and irrigation of fields).
To control a deep-well type pump. Equipment operating at great depths, for example, in artesian springs, requires the most careful control, which is carried out by the control cabinet. The task of the automatic unit is to ensure maximum smooth start to avoid water hammer and engine failure. The pump motor shaft speed and winding temperature are also monitored and maintained optimal pressure in the pipeline.

Correct operation

Installing the control cabinet is only half the battle. From him correct operation will depend on how reliably the pumping equipment is protected. Included with the device technical certificate and instructions, which all experts strongly recommend to study before starting operation.

Scheduled or service inspections should be carried out regularly. At this time, the connection interfaces are checked and the correctness of their use is verified with work instructions.
Special attention is given to the front panel where the scoreboard is located. Notifications of all problems are displayed on it.
The fan and cooling radiator of the cabinet are regularly cleaned of dust. You should also change a dirty filter on time.
During a routine inspection, all mounting bolts are checked. Slack is removed if found.

Replacement of failed control units is carried out by specialists using a warranty or post-warranty service coupon.

It is not recommended to replace something yourself - equipment after repair must be tested on special stands, and this cannot be done at home.

Model overview

SHUPN-2

Typical cabinet for controlling two pumps (including standby). Used to interact with submersible units used in fire extinguishing and agricultural irrigation systems. Power up to 55 kW, working temperature from -10 to +50 degrees. Nominated by the manufacturer special requirements To environment. The air should not contain aggressive gases and not be saturated with conductive dust. Relative humidity up to 80% is acceptable. The cabinet is designed for a service life of ten years. Retail price 31,600 rubles.

SCHOON

Produced by the Ecotechnologies company, which has been presenting the product on the domestic market since 2005. The equipment warranty is two years. The cabinets are designed to work with drainage pumps and sewage pumping stations. Can control fire tanks. The unit is controlled in two modes - automatic and manual.

You can connect two pumps - backup and main. If the main pump fails, the backup pump will be activated automatically. Automatic alternation of pumps is provided to ensure uniform operating time and prevent winding overheating. At the request of the customer, the unit is modernized. For example, a GPRS module is installed, which ensures the forwarding of SMS messages in the event of an emergency. The permissible power of each pump is from 4 to 11 kW, depending on the cabinet model. average cost budget model from 10,900 rubles.

SHKANS-0055

A standard type of control cabinet produced by the Uralelectra company from Yekaterinburg. Equipment power from 400 Watt to 55 kW. The cabinet is designed to work with one or more deep-well pumps, as well as pumping stations. Up to three pumps can be connected simultaneously. Pumping stations are started automatically. During operation, the pressure is adjusted in plumbing system and protection of pump motors from overheating. Provided light alarm in case of an emergency stop. Price is negotiable. To order equipment, you can use the online store located on the manufacturer’s website.