I. Overview The original industrial pump was designed to start directly at full voltage, with only a fuse protecting the motor. It lacked comprehensive motor protection features such as over-voltage, under-voltage, over-current, and three-phase imbalance protection. In the event of these faults, the motor could suffer serious damage or even burn out. To address this, the upgrade plan involves replacing the existing control system with a French Schneider Electric ATS46 soft starter, which provides enhanced motor protection. Additionally, a Siemens S7-200 programmable logic controller (PLC) will replace the original control circuitry, improving reliability and functionality. II. System Functions 1. The system includes a manual/auto switching function. When in automatic mode, it can be configured for single-pump or dual-pump operation based on the number of units in use. In single-unit mode, the system automatically controls the pump based on water level signals to maintain a set level. If the water level drops below the low-level threshold, the pump starts via soft-start; when the level rises above the high-level threshold, the pump stops. The system also cycles the two pumps automatically based on running time, ensuring balanced usage. In dual-pump mode, the system maintains one pump in operation while the other starts and stops based on water level signals to keep the level stable. When in manual mode, the system retains its original control functions. The operator can select the pump’s state—auto, standby, or manual—via a switch in the control room. Pumps can be started or stopped manually from the control panel or on-site power box. Both pumps remain interlocked during manual operation, making it suitable for situations requiring manual intervention or maintenance of a single unit. 2. The system supports interlocking between the two pumps. If one pump fails, an alarm is triggered, notifying maintenance personnel. After a delay, the system automatically switches to the second pump to ensure continuous operation. 3. The system offers both remote and local control capabilities, allowing operators to manage operations from different locations. 4. A variety of status indicators are included in the control cabinet. These include a digital ammeter showing motor current, pump operation and fault indicators, a control power indicator, system run/stop status, and fault indication with an audible alarm for immediate attention. III. Working Characteristics of the Schneider Soft Starter As a global leader in automation, Schneider Electric has been a pioneer in the Chinese market for over 20 years. With a strong network of service centers across China, they provide reliable support from system design through to operation. The Altistart ATS46 soft starter is specifically designed for controlling the start and stop of three-phase asynchronous squirrel-cage motors. It offers several key benefits, including: - Control of motor behavior during startup and shutdown; - Thermal overload protection for both the motor and the starter; - Mechanical protection by reducing torque surges and current impact; - Full-range acceleration torque control; - Adjustable motor torque to match application needs; - Reduced motor wear and tear; - An LCD interface for easy parameter setting and alarm monitoring, including real-time current readings. The soft starter also includes multiple protection features: - Short-circuit protection (13ICL-20ms); - Thermal protection after bypass; - Immunity to electrical disturbances; - Detection of rotating loads; - Short-term power-off protection (<200ms); - Overload protection with adjustable trip limits (50% to 300% of rated current, minimum 10s); - Stall protection (5 × In for 200ms); - Underload protection (20% to 100% of rated torque for deep well pumps); - Preheat function (10% ICL to prevent condensation); - Torque limit (up to 200% of Tn, adjustable during acceleration); - Mechanical overload pre-alarm via analog output; - Delayed start time (1s to 999s). Paper packaging box,custom paper box,gift box,cardboard gift box Zhuhai Yingwei Packing Products Co., LTD , https://www.yingweipacking.com
October 07, 2025