Product Introduction
I. Product Overview:
This intelligent stabilized pressure pump control box is a core automatic control device specially designed for fire water supply systems and water supply pipe network pressure stabilization. Strictly adhering to relevant fire protection and electrical specifications, the product integrates advanced control logic and reliable protection functions. Its core mission is to monitor the pipe network pressure in real time and accurately maintain the system pressure within the user-set safe range by automatically starting and stopping the water pump, ensuring the constant pressure and stable operation of the system. Its "one in use and one standby" dual-pump redundancy design ensures that the standby pump can be put into operation without delay when the main pump fails, greatly improving the reliability and continuity of the entire system.
This intelligent stabilized pressure pump control box is a core automatic control device specially designed for fire water supply systems and water supply pipe network pressure stabilization. Strictly adhering to relevant fire protection and electrical specifications, the product integrates advanced control logic and reliable protection functions. Its core mission is to monitor the pipe network pressure in real time and accurately maintain the system pressure within the user-set safe range by automatically starting and stopping the water pump, ensuring the constant pressure and stable operation of the system. Its "one in use and one standby" dual-pump redundancy design ensures that the standby pump can be put into operation without delay when the main pump fails, greatly improving the reliability and continuity of the entire system.
II. Structural Composition:
The control box is a complete power distribution and control system integrating primary and secondary circuits, mainly composed of the following parts:
1. Cabinet
- Material: High-quality cold-rolled steel plate (with spray anti-corrosion treatment) or stainless steel (SS304/SS316), featuring good mechanical strength and anti-corrosion ability.
- Protection Level: Usually IP55, effectively preventing dust intrusion and water spray from any direction, suitable for installation in humid environments.
The control box is a complete power distribution and control system integrating primary and secondary circuits, mainly composed of the following parts:
1. Cabinet
- Material: High-quality cold-rolled steel plate (with spray anti-corrosion treatment) or stainless steel (SS304/SS316), featuring good mechanical strength and anti-corrosion ability.
- Protection Level: Usually IP55, effectively preventing dust intrusion and water spray from any direction, suitable for installation in humid environments.
2. Primary Circuit (Main Circuit)
- Isolating Switch/Circuit Breaker: Serves as the main power switch, providing safe electrical isolation and comprehensive short-circuit protection.
- Contactors: Two in total, controlling the power on/off of the two water pump motors respectively to execute start and stop commands.
- Thermal Overload Relay or Intelligent Motor Protector: Provides protection for each water pump against overload, phase loss, locked rotor, etc., ensuring motor safety.
- Isolating Switch/Circuit Breaker: Serves as the main power switch, providing safe electrical isolation and comprehensive short-circuit protection.
- Contactors: Two in total, controlling the power on/off of the two water pump motors respectively to execute start and stop commands.
- Thermal Overload Relay or Intelligent Motor Protector: Provides protection for each water pump against overload, phase loss, locked rotor, etc., ensuring motor safety.
3. Secondary Circuit (Control Core)
- Programmable Logic Controller (PLC) or Dedicated Control Module: The "brain" of the control box, which receives external signals, executes preset logic, and outputs control instructions. It realizes functions such as pressure control, dual-pump switching, and fault switching.
- Intermediate Relays and Auxiliary Components: Used for signal expansion and circuit isolation to enhance system reliability.
- Programmable Logic Controller (PLC) or Dedicated Control Module: The "brain" of the control box, which receives external signals, executes preset logic, and outputs control instructions. It realizes functions such as pressure control, dual-pump switching, and fault switching.
- Intermediate Relays and Auxiliary Components: Used for signal expansion and circuit isolation to enhance system reliability.
4. Pressure Detection and Feedback Device
- Remote Pressure Gauge or Pressure Transmitter: A sensor installed on the pipe network, which converts the real-time pipe network pressure value into an electrical signal (4-20mA or 0-10V) and feeds it back to the control center, serving as the basis for control logic.
- Remote Pressure Gauge or Pressure Transmitter: A sensor installed on the pipe network, which converts the real-time pipe network pressure value into an electrical signal (4-20mA or 0-10V) and feeds it back to the control center, serving as the basis for control logic.
5. Human-Machine Interface (HMI)
- Door Panel Layout:
- Mode Changeover Switch: Standard three-position knob switch with "Manual", "Auto", and "Stop".
- Operation Buttons: Dedicated "Start" and "Stop" buttons in manual mode (independent for each pump or shared).
- Status Indicators: Power indicator, running indicators (independent for each pump), stop indicator, automatic status indicator, fault alarm indicators (independent for each pump).
- Door Panel Layout:
- Mode Changeover Switch: Standard three-position knob switch with "Manual", "Auto", and "Stop".
- Operation Buttons: Dedicated "Start" and "Stop" buttons in manual mode (independent for each pump or shared).
- Status Indicators: Power indicator, running indicators (independent for each pump), stop indicator, automatic status indicator, fault alarm indicators (independent for each pump).
6. Other Optional Configurations
- Automatic Transfer Switch (ATS): Provides uninterrupted power supply for first-class load occasions.
- Remote Monitoring Interface: RS485 communication interface (supporting protocols such as Modbus), facilitating access to building automation (BA) or fire control center systems to realize remote status monitoring and start-stop control.
- Audible and Visual Alarm: Issues audible and visual warnings when a fault occurs.
- Automatic Transfer Switch (ATS): Provides uninterrupted power supply for first-class load occasions.
- Remote Monitoring Interface: RS485 communication interface (supporting protocols such as Modbus), facilitating access to building automation (BA) or fire control center systems to realize remote status monitoring and start-stop control.
- Audible and Visual Alarm: Issues audible and visual warnings when a fault occurs.
III. Working Principle
The control system takes the pipe network pressure as the controlled variable, forming a closed-loop feedback system.
The control system takes the pipe network pressure as the controlled variable, forming a closed-loop feedback system.
1. Pressure Sampling: The pressure sensor continuously detects the actual pressure value of the pipe network (P_actual) and converts it into a standard electrical signal, which is transmitted to the controller.
2. Signal Processing and Judgment: The controller has two preset key pressure points internally:
- Stabilized pressure pump start pressure value (P_low): The minimum allowable pressure of the system.
- Stabilized pressure pump stop pressure value (P_high): The target pressure that the system needs to maintain.
The controller compares `P_actual` with `P_low` and `P_high`.
- Stabilized pressure pump start pressure value (P_low): The minimum allowable pressure of the system.
- Stabilized pressure pump stop pressure value (P_high): The target pressure that the system needs to maintain.
The controller compares `P_actual` with `P_low` and `P_high`.
3. Automatic Operation Logic:
- Normal Pressure Stabilization: When `P_actual` ≤ `P_low`, the controller judges that the system pressure is insufficient and immediately sends a start signal to start a main pump for pressurization.
- Reaching Target: After the water pump runs, `P_actual` gradually rises. When `P_actual` ≥ `P_high`, the controller sends a stop signal, and the water pump stops running.
- Cycle Reciprocation: After that, the system enters the "shutdown and pressure maintenance" state until the pressure drops to `P_low` again, starting the next cycle.
- Fault Switching (One in Use and One Standby): In "Auto" mode, the control system regularly rotates the main and standby pumps to balance wear. When the running water pump has faults such as overload, phase loss, or short circuit, the thermal relay or intelligent protector acts. The controller will immediately cut off the faulty pump and automatically switch to the standby pump seamlessly, while lighting up the corresponding "fault" indicator, ensuring the continuous and stable system pressure.
- Normal Pressure Stabilization: When `P_actual` ≤ `P_low`, the controller judges that the system pressure is insufficient and immediately sends a start signal to start a main pump for pressurization.
- Reaching Target: After the water pump runs, `P_actual` gradually rises. When `P_actual` ≥ `P_high`, the controller sends a stop signal, and the water pump stops running.
- Cycle Reciprocation: After that, the system enters the "shutdown and pressure maintenance" state until the pressure drops to `P_low` again, starting the next cycle.
- Fault Switching (One in Use and One Standby): In "Auto" mode, the control system regularly rotates the main and standby pumps to balance wear. When the running water pump has faults such as overload, phase loss, or short circuit, the thermal relay or intelligent protector acts. The controller will immediately cut off the faulty pump and automatically switch to the standby pump seamlessly, while lighting up the corresponding "fault" indicator, ensuring the continuous and stable system pressure.
4. Manual Mode: When switched to "Manual" mode, automatic control is invalid. Operators can independently start or stop any water pump through the panel buttons, which is mainly used for equipment debugging, maintenance, or emergency operations.
IV. Installation and Maintenance Points
Installation Points:
1. Environment Selection: The control box should be installed in a well-ventilated, dry place without severe vibration, corrosive gas, and convenient for operation and observation.
2. Foundation Fixing: According to the cabinet size and installation method (wall-mounted or floor-standing), use expansion bolts to fix it reliably to ensure stability.
3. Cable Access:
- Power incoming lines, water pump motor lines, and pressure sensor signal lines must be introduced through pipes separately.
- Strictly wire according to the terminal block diagram and electrical schematic diagram to ensure that the power supply voltage matches the rated voltage.
- The signal line of the pressure sensor should use shielded wire and be grounded at one end to prevent interference.
4. Grounding Safety: The grounding terminal of the cabinet must be reliably connected to the on-site good protective grounding system, and the grounding resistance should comply with national standards.
Installation Points:
1. Environment Selection: The control box should be installed in a well-ventilated, dry place without severe vibration, corrosive gas, and convenient for operation and observation.
2. Foundation Fixing: According to the cabinet size and installation method (wall-mounted or floor-standing), use expansion bolts to fix it reliably to ensure stability.
3. Cable Access:
- Power incoming lines, water pump motor lines, and pressure sensor signal lines must be introduced through pipes separately.
- Strictly wire according to the terminal block diagram and electrical schematic diagram to ensure that the power supply voltage matches the rated voltage.
- The signal line of the pressure sensor should use shielded wire and be grounded at one end to prevent interference.
4. Grounding Safety: The grounding terminal of the cabinet must be reliably connected to the on-site good protective grounding system, and the grounding resistance should comply with national standards.
Maintenance Points:
1. Daily Inspection:
- Check whether the cabinet has abnormal noise or odor.
- Observe whether the indicator light status is normal.
- Check whether there is condensation, dust, or foreign objects inside the cabinet.
1. Daily Inspection:
- Check whether the cabinet has abnormal noise or odor.
- Observe whether the indicator light status is normal.
- Check whether there is condensation, dust, or foreign objects inside the cabinet.
2. Regular Maintenance (recommended monthly or quarterly):
- After power failure, use dry compressed air or a soft brush to clean internal dust, especially on components such as contactors and relays.
- Manual Inspection: In the power-off state, manually operate the main electrical components (such as circuit breakers and contactors) to check whether they act flexibly without jamming.
- Tightening Check: Re-tighten the power terminals of the primary circuit (must be done after complete power failure!) to prevent loosening and heating caused by vibration.
- Function Test:
- Switch to "Manual" mode, start and stop the two pumps respectively, and confirm that the rotation direction is correct and the operating current is normal.
- Switch to "Auto" mode, simulate pressure changes (such as slow pressure relief), and observe whether the pump start and stop pressure points are accurate and the action logic is correct.
- Simulate faults (such as manually triggering overload) to test whether the automatic input function of the standby pump is effective.
- After power failure, use dry compressed air or a soft brush to clean internal dust, especially on components such as contactors and relays.
- Manual Inspection: In the power-off state, manually operate the main electrical components (such as circuit breakers and contactors) to check whether they act flexibly without jamming.
- Tightening Check: Re-tighten the power terminals of the primary circuit (must be done after complete power failure!) to prevent loosening and heating caused by vibration.
- Function Test:
- Switch to "Manual" mode, start and stop the two pumps respectively, and confirm that the rotation direction is correct and the operating current is normal.
- Switch to "Auto" mode, simulate pressure changes (such as slow pressure relief), and observe whether the pump start and stop pressure points are accurate and the action logic is correct.
- Simulate faults (such as manually triggering overload) to test whether the automatic input function of the standby pump is effective.
3. Annual Maintenance: It is recommended that professional electrical personnel conduct a comprehensive inspection, including testing the function of the protection circuit and calibrating the accuracy of the pressure sensor.
Selection Tips: *When selecting or ordering, please provide key parameters such as water pump motor power, rated current, control voltage, pressure setting range, and sensor type to ensure the best matching of the product.
V. Sample diagrams are for reference only.