Another unusual and interesting task has been solved. “Akvoservis” created a diagnostic stand for pumping equipment. They handled all the hydraulic components and assembly of the control panel themselves, while our task was the top level: the human-machine interface (programming the controller and operator panel). Here’s the result:

The pump under diagnosis is connected to the UBA-302 motor protection block, which is designed for continuous monitoring of network voltage parameters and the active phase/line currents of a three-phase motor at 380 V, 50 Hz. Additionally, a pressure sensor and a flowmeter are connected to the analog inputs of the UBA. The operator panel displays current motor and process parameters (flow and pressure) and connects to the UBA via an RS-485 (Modbus) interface.

The panel displays two switchable screens: “Main” and “Pump Test Card”.

The “Main” screen displays the current main parameters of the stand:

• Motor line voltages;
• Motor phase currents;
• Motor starting current;
• Flow rates;
• Pressure.

“Pro Electro Co” uses the UBA-302 in automation panels for pump stations.

According to the technical specifications, it is necessary to ensure uninterrupted, autonomous operation of equipment at 13 water wells located in different places, which work on a common reservoir. Each pump station’s control system must provide several operating modes – setup, manual, automatic, and remote, transmit data about pump unit status, well level, currents, voltage, energy consumption, etc., to the central dispatch point of the cluster pump station, and also provide remote control of the pump station. Given that the pump stations are located quite far from each other and from the dispatch point, data transmission and control can only be achieved through wireless communication. The pump must be activated using a soft start device UPS. Additionally, a backup device must be installed in case the UPS fails.

To implement this task, a standardized cabinet set was developed, suitable for pumps of various power ratings. The core of each set is the Simatic S7-1200 controller (Siemens), responsible for collecting, analyzing, and transmitting data from various devices and sensors to the dispatch panel, as well as issuing commands to executing mechanisms. Motor starting and control are managed by a soft start device from the 3RW series (Siemens), with additional motor protection provided by the UBA-302, which transmits pump operation data to the controller via an RS-485 interface. Since each pump station needed to operate without maintenance personnel, provisions were made for automatic emergency shutdown in case of flooding, pump failure, or other emergency situations.

“NVO Parma Electronics” is a supplier of innovative motor control stations “PELKS”. They equip direct start control stations “PELKS-01” with UBA-302 for protection against electrical and mechanical overloads, with optional remote monitoring capability.