I. Overview The original industrial pump was equipped with a direct-on-line (DOL) starting method, where the motor was only protected by a fuse, without any additional protection mechanisms such as over-voltage, under-voltage, over-current, or three-phase imbalance protection. In the event of these faults, the motor could be severely damaged or even burnt out. To address this issue, the upgrade plan involves replacing the existing control system with a French Schneider Electric ATS46 soft starter to enhance motor protection. Additionally, a Siemens S7-200 programmable logic controller (PLC) will replace the original control circuit, providing more advanced and reliable control functionality. 1. Manual and Automatic Switching Function When in automatic mode, the system can select between single-pump or dual-pump operation based on the number of units running. In single-unit operation, the system automatically controls the pump based on water level signals to maintain the desired level. If the water level drops below the low-level threshold, the pump is softly started. When the water level rises above the high-level threshold, the pump is automatically stopped. The system also cycles the pumps based on operating time, ensuring balanced usage between the two pumps. In dual-pump operation, the system maintains one pump running while the other starts and stops automatically based on the water level signals to keep the level stable. In manual mode, the system retains the original control functions. Operators can manually switch between the self-cast, standby, or running states using the control room selection switch. Pumps can be started or stopped via the control panel or local power box. Both pumps remain interlocked during manual operation, which is ideal for maintenance or single-pump testing. 2. Interlocking Between Two Pumps If one pump fails, the system triggers an alarm to notify maintenance personnel. After a set delay, it automatically switches to the other pump to ensure continuous operation. 3. Remote and Local Control Options 4. Multiple Status Indications The control cabinet includes a digital ammeter for real-time motor current monitoring, making it easy to observe performance. It also provides indicators for pump operation, stop, and fault status, along with a control power indicator. The system displays automatic start/stop commands and fault alerts, accompanied by an audible alarm for immediate attention. III. Working Characteristics of Schneider Soft Starter Schneider Electric is a global leader in automation solutions and has been present in the Chinese market for over 20 years. As one of the first international automation companies to enter China, it has built a strong network of services and support, offering comprehensive assistance from system design through installation and operation. 1. Model: ATS46C14N Soft Starter 2. Key Features of the Schneider Soft Starter: Altistart46 can control the start and stop of three-phase asynchronous squirrel-cage motors. It offers: - Control of motor behavior, especially during start-up and shutdown - Thermal overload protection for both the motor and the starter - Mechanical protection by reducing torque surges and current impact - Acceleration torque control across the entire speed range - Adjustable motor torque according to application needs - Reduced motor wear and tear - LCD display for easy parameter setting and alarm information retrieval, including current values 3. Protection Features of the Soft Starter: - 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 - Continuous load current trip limit: 50% ~ 300% In, minimum 10 seconds - Stall protection: 5 × In (nominal current setting) for 200ms - Maximum setting: 5 × ICL (starter current rating) - Underload protection (for deep well pumps): 20% ~ 100% of rated torque - Preheat function: 10% ICL to prevent condensation - Torque limit: 200% of Tn (adjustable), active only during acceleration - Mechanical overload: analog output for early warning - Delayed start time: 1 second to 999 seconds packaging box with logo, logo printed paper box, paper stroage box, packaging box for medicine Zhuhai Yingwei Packing Products Co., LTD , https://www.yingweipacking.com
II. System Functions
October 07, 2025