Overview¶
The Pumping Library is intended for smaller pump stations (or pump skids) and medium sized stations. It contains the block for the basic functionalities as well as advanced functions for very different applications.
This version named PUMP_AC500_V23.lib for Control Builder Plus V2.3 is usable for 1-3 pumps and is intended for configurations as it can be seen in the below picture. It is best suited for the use of frequency converters/drives for each pump but also for the traditional setup with one drive and 1-2 switched outputs for the pumps.
The minimal sensor equipment for boost control applications is a pressure or flow sensor, for level control a level sensor. The pressure sensor can be at input and or/output, the flow sensor should be at the output. Often additionally also at the input a sensor, typically pressure, is placed for advanced protection and diagnosis.
The two main pumping applications in water and waste water are:
- Boost, typically pressure boost control: Used in network feeding, but also flow boost control for irrigation, water transport, cooling and washing applications.
- Level control: Used for tank or reservoir filling or emptying applications e.g. also lift applications e.g. in waste water networks.
For both applications a special application block is available, which has all the needed basic functionality, so that with minimal programming and mainly configuration an application can be setup.
Further auxiliary and optimization Function Blocks are part of the library, which help in putting additional advanced functionality with again minimal programming effort.
This Function Block type concept helps in always having the necessary functionality without using too much PLC resources (memory) and keeping the applications as simple as possible. Therefore the Pumping Library can be used throughout the AC500 Platform, starting from the small AC500-eCo.
Example
A simple but typical application for small pump station or pump-skid (suitable e.g. also for AC500-eCo with 3 pumps)
The station itself is configured by the Function Block STATION_CONFIGURATION with an ID, name and number of used pumps.
The main application Function Block is PUMP_BOOST_CTRL or PUMP_LEVEL_CTRL.
When using the Function Block PUMP_BOOST_CTRL: The actual pressure is read from the sensor and sent to the Function Block PUMP_PID. The PID corrections are given to the Function Block PUMP_BOOST_CTRL.
When using the PUMP_LEVEL_CTRL: The actual level is read from the sensor. It is not sent to PUMP_PID, it is sent directly to the Function Block PUMP_LEVEL_CTRL which does a fill or an empty operation.
The Function Block PUMP_INTERFACE is used for detailed configuration of each pump and for interfacing to the drives/actuators. The Function Blocks PUMP_INTERFACE allow a variety of actuators: One drive with direct-on-line “DOL” pumps, hard- or soft-switched; all drive controlled pumps; discrete or bus connection to the drives.
The number of Function Blocks PUMP_INTERFACE is depending on the number of pumps. 1 pump = 1 Function Block PUMP_INTERFACE, 2 pumps = 2 Function Blocks PUMP_INTERFACE etc.
Note
The parameter and status exchange between the different blocks is done by a structured variable (symbolized by the light blue layer in the above picture) which is connected to all blocks with control functionality. It contains substructures depending on the function and use.
This concept minimizes memory usage, the connection work and still allows advanced diagnosis if necessary.