I am currently seeking a smaller and more basic PLC system for controlling the timing of a fountain, as well as an analog pressure sensor to detect any blockages in the filter lines of a large outdoor water feature. Additionally, I am wondering whether a drop in pressure or an increase in amp draw would be more effective in safeguarding the pumps from damage caused by clogged filters. Recently, a group of individuals added foil confetti and Champagne corks into the fountain, leading to the pumps becoming clogged and running continuously until the next day. I am aware that Schneider offers cost-effective PLC solutions such as the Zelio Logic with complimentary programming software. Are there any other reputable competitors in the market that provide reliable alternatives for this application? I am specifically looking for options that are not cheap Chinese imitations.
Looking for affordable units with Analog I/O? Check out Horner's (XLe & more) selection and choose the right fit for your needs. Plus, enjoy free software with your purchase.
A digital flow switch is essential for the pump in all swimming pool facilities, eliminating the need for an analog one.
In my opinion, having redundancy to monitor both amp draw and flow is crucial in protecting your motor and pump. For instance, if your pump bearing starts to deteriorate, a flow switch may not immediately detect the issue, resulting in a delay in sensing low or no flow, whereas monitoring the amp draw can quickly detect spikes indicating a potential problem with the bearing. This dual monitoring system ensures early detection of issues to prevent damage.
Clogged filters can decrease amp draw significantly by reducing the amount of work done per unit time. This is because with a clogged filter, the volume (V) drops close to zero even though the pressure difference (∆P) increases.
I incorporated a current switch to monitor a blower on a plastic grinder. In the event the regrind bin becomes full, causing material to clog the pipe, the plastic within the grinder continues to grind until it reaches a melting point. This scenario can lead to significant downtime for cleaning. By detecting a drop in current within the blower motor, I was able to prevent potential overheating before it happened. Consider utilizing two current switches, with one dedicated to detecting issues like clogged filters or faulty bearings by sensing either a drop or rise in current. This proactive approach can help avoid costly downtime and equipment damage.
I've had good experiences using Allen-Bradley’s Micro800 series PLCs, which are also pretty cost-effective. They've proven to be robust and reliable in a variety of applications. Regarding your question about pressure sensor or amp draw, I'd suggest considering a combination of both. Decreased water flow will first register as a drop in pressure. But if overlooked, amp draw will increase because the pump will strain to maintain output against the reduced flow, which could potentially cause overheating and damage. Hence, employing both methods can provide an added layer of protection thereby catching any problems before they escalate.
In terms of PLC systems, you might want to consider Siemens. Their LOGO! series is compact, user-friendly, and has a wealth of functions for controlling timers and other protocols specific to automating applications. As for pressure tokens, Ashcroft or Emerson have some sturdy, long-lasting sensors worth checking out. Concerning the choice between monitoring pressure drop or amp draw, I'd suggest opting for amp draw as it directly relates to the load the pump is experiencing. A significant increase in amp draw is a clear indication of a clogged filter, mound of confetti, or some other obtrusion that's causing the pump to work harder than it should.
I can relate to your predicament, having troubleshot similar issues with public fountains. In terms of PLCs, you could explore Allen Bradley's Micro800 series, particularly if you're already within the Rockwell ecosystem. It's compact yet offers sufficient capabilities for your application. Siemens also offers great options like their S7-1200 series. As for the sensor question, I'd suggest that a drop in pressure would be a more accurate indication of filter blockages as it directly relates to the flow blockage. However, an increase in amp draw could indicate broader issues with the pump other than just a clog, so monitoring both would give you the most comprehensive overview of your system's wellbeing.
While the Zelio Logic from Schneider is a solid choice, you may also want to consider Siemens' Logo! series for basic PLC needs. It's quite user-friendly, cost-effective, and compact, working well for smaller projects like yours. As for your sensor dilemma, both a drop in pressure and an increase in amp draw will be indicative of blockages. However, monitoring current draw (amp) might provide a more immediate and precise detection of overwork due to blockages, hence safeguarding the pumps with more certainty. Ensure to get a sensor that can handle the range and type of pressure in your system. Finally, just make sure whichever solution you go for, it offers robust after-sales support and easy integration with existing systems.
✅ Work Order Management
✅ Asset Tracking
✅ Preventive Maintenance
✅ Inspection Report
We have received your information. We will share Schedule Demo details on your Mail Id.
Answer: - A smaller and more basic PLC system like Schneider's Zelio Logic is a cost-effective solution with complimentary programming software.
Answer: - An analog pressure sensor can be used to detect blockages in filter lines of a large outdoor water feature.
Answer: - It is recommended to monitor a drop in pressure to safeguard pumps from damage caused by clogged filters.
Answer: - Yes, there are other reputable competitors in the market that provide reliable alternatives for this application, avoiding cheap Chinese imitations.
Join hundreds of satisfied customers who have transformed their maintenance processes.
Sign up today and start optimizing your workflow.