How to use pump monitoring with pressure (depth) control when using an EMX4 with a smart card

Scope

Pump monitoring with pressure (depth) control when using an EMX4 with a Smart Card.

Pumps are used in a wide range of industries where liquids tend to be moved. Pump monitoring is a widely necessary feature in a wide range of applications for obvious reasons like automation, energy conservation and thereby reducing expenses and limiting maintenance. This case study highlights an efficient solution proposed by the use of EMX4 soft starters with a smart card for pump monitoring with pressure (depth) control.

Solution

Let’s demonstrate the solution via a scenario as mentioned below,

Soft starter runs a pump to fill a water tank when the water level is below 2 meters and stops the pump when the water level reaches 5 meters
Use programmable input A to select between auto and manual.
Auto: soft starter automatically starts or stops according to the water level
Manual: soft starter accepts start and stops commands from the digital inputs

Electrical Schematic

1	Digital inputs	K1	Main contactor
A	Manual start	10, 11	Reset
B	Manual stop	11, 12	Start/Stop
C	Automatic operation (level-controlled)	13, 14	Programmable input A (set = Command Override: Digital)
2	Control voltage	33, 34	Main contactor output
3	Three -phase supply	B33 (-), B34 (+)	Flow protection
4	Smart card
5	Maximum water level
6	Flow sensor	B23 (-), B24 (+)	Pressure control
7	Pressure sensor
8	Minimum water level

Level Chart Interpretation

1	High Pressure Trip Level	A	Pump on (wake)
2	Pump Sleep (Stop Pressure Level)	B	Pump off (sleep)
3	Pump Wake (Start Pressure Level)	C	Falling fluid level
4	Low Pressure Trip Level	D	Rising fluid level

Calculation

To be simple assume 100 kPa equals the pressure of water at depth of 10 meters

Pressure transducer with 4-20mA output and 100 kPa gauge, and placed at water level 1 meter

At a water level of 2 meters, the pressure is 10 kPa

At a water level of 5 meters, the pressure is 40 kPa

Parameter settings

30A (Pressure Sensor Type): Analog
30B (Pressure Units): kPa (default)
30C (Pressure at 4 mA): 0 kPa (calibration)
30D (Pressure at 20mA): 100 kPa (calibration)
33A (Pressure Control Mode): Falling Pressure Start
33B (Start Pressure Level): 10 kPa
33C (Start Response Delay): 500ms (default)
33D (Stop Pressure Level): 40 kPa
33E (Stop Response Delay): 500ms (default)
36A (Pressure Sensor): Soft Trip and Log (default, selects the soft starter’s response if it detects a fault with the pressure sensor)
1A (Command Source): Smart Card
7A (Input A Function): Command Override: Digital
(Override the setting of 1A and sets the command source to the digital input when input A is active)

The above figures represent the Smart Pump Card for EMX4i/e (Part #: SCCPC01)

Configuration

The Pumping Smart Card's operating parameters are programmed and saved in the soft starter. Parameters can be set in the main menu or uploaded via the USB Save and Load function.

Smart card function parameters are only visible in the parameter list if the smart card is installed. Create a parameter file in WinMaster and load it into the starter using USB Save & Load to configure smart card settings in the starter before the card is installed.

Operation

With the EMX4 and smart card option combined, you can achieve protection, monitoring, and control all in one. The smart card can start and stop the EMX4 automatically in response to rising or falling pressure or depth.

To control the soft starter with the Pumping Smart Card:

Change the value of parameter 1A Command Source to 'Smart Card' or 'Smart Card + Clock'.
Set parameter 33A Pressure Control Mode as required.
Enable parameter 4A Auto-Start/Stop Mode to use clock-based scheduling.

Pressure Protection

When the starter is in the start, run, or stop mode, pressure protection is activated.

A	Off (Ready)
B	Start Signal
C	Pressure protection active
D	Protection event (parameter 32A High Pressure Trip Level, 32D Low Pressure Trip Level)
E	Protection response (parameter 36A Pressure Sensor, 36D High Pressure, 36E Low pressure)
1	Pressure protection start delay (parameter 32B High Pressure Start Delay, 32E Low Pressure Start Delay)
2	Pressure protection response delay (parameter 32C High Pressure Response Delay, 32F Low Pressure Response Delay)

When the pressure level reaches the programmed trip level, the smart card will trip the starter. When the trip is reset (including auto-reset), if the pressure level is outside the expected operating range, the starter will not trip again.

According to the measured pressure, the smart card can start or stop the starter (wake or sleep the pump). This can be used for direct pressure-based control or to indicate water depth using the pressure measurement.

Other sensors can also be used for security and monitoring.

Terminals B23 and B24 on the smart card are used for pressure control. Use a 4 - 20mA analog sensor.

Benefits

Not only is the EMX4 smaller, more powerful, and packed with new control and protection features, but its game-changing Smart Card capability transforms it from a super smart motor controller to a complete system controller.

By improving and making intuitive the display and connectivity functions, it is easier to access the right information when you need it, increasing your overall efficiency.

The EMX4 has starter, motor, and system protection functions, as well as alarms to warn you of any potential problems. In the event that the worst happens, the Power Through and Emergency Run functions allow you to continue running.

EMX4 – The Most Energy-Efficient Outcome For Fixed Speed Applications

There is assistance available!

All of the tools you need to troubleshoot starting and starter issues can be accessed in the palm of your hand via the AuCom Pocket Technician app. Simply search “AuCom” in App Store or Google Play.

Easily extract useful data from EMX4 soft starters to aid in problem diagnosis. With the click of a button, you can review the information for yourself or share it with your local support team.