The project was carried out in 2003 and refers to the automation of water pumps with PLC Simatic S7-200 for monitoring, diagnosis, local and remote control via the internet using fiber optics and Modbus TCP protocol, widely used industrial communication protocol that enables devices to exchange data over Ethernet networks through TCP/IP protocol. The automation was made for hydrophore systems designed to supply water to residential and commercial buildings, refineries, chemical plants, electric substations, hydropower plants etc.

The installation subject to automation consists of two water pumps. The pump motors are driven by three-phase electric motors (1m1 and 2m1) with a power of maximum 2 KW, powered by separate electrical networks (Bar1 and Bar2 respectively). Certain electrical and mechanical defects are monitored.

The functions of the automation installation are the following:
-command and protection of the pump motors
-uniform operation of the electric motors by controlling them alternately
-protection of the electric motors against overload and phase loss
-protection of the electric motors against insulation loss to ground due to water infiltration
-water level measurement via submersible transducer and analog input module
-local communication via MODBUS and PROFIBUS-DP and remote via optical fiber
-The PPI port of the S7-200 is RS485 and can be directly used for the MODBUS communication
-use of CP243-1 module for Industrial Ethernet and MODBUS TCP
-Ethernet to Fiber Optic converter EKI-2541
-local and remote signaling of the function and fault states for each pump
-possibility of testing the functionality of the pumps through a local start command while maintaining all the protections necessary for the safety of the installation
-memorization of the number of starts and the total operating time for each pump

Warning1: Without any doubt, this project is not for amateurs and hobbyists. The components and system described in this documentation may be built, installed and operated only by personnel qualified for these specific tasks. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. It is mandatory to follow all the applicable safety regulations for work in 400 V voltage environments.

Warning2: I have been using 750W submersible pumps for my well since 1980. In the area where I lived, the groundwater was 7m deep. I gave up after 1990, when I found out that the groundwater was contaminated with nitrites and nitrates. It is advisable to have a chemical analysis of the water taken from the well to check if it is drinkable.

Disclaimer: The information on this web site is provided "AS IS", without warranty of any kind. The author has made the best efforts to ensure the design and the information provided are reliable. Under no circumstances shall the author be liable for any direct, indirect, incidental, special or consequential loss, damage, expense or injury incurred or suffered which is claimed to resulted from use of this site, even if expressly advised of the possibility of such loss, damage, expense or injury, including, without limitation, any fault, error, omission, interruption or delay with respect thereto.

Links:
[1] - PLC S7-200 CPU226
[2] - EM231 Analog Input Module
[3] - TD200 Text Display
[4] - SITOP 2.5 A Power Supply
[5] - EM277 PROFIBUS-DP Module
[6] - CP243-1 MODBUS TCP
[7] - EKI-2541 Ethernet to FO
[8] - PROFIBUS OLM