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KSB waste water pumps in a collecting tank
6 min read

How to digitalise water and waste water pumps successfully

A particular challenge is posed by submersible motor pumps and submersible mixers, like Amarex or Amamix: As per design, they work under water, which makes condition monitoring so much harder than for dry-installed pumps. AmaControl protection module provides intelligent help: It supplies precisely the information required for comprehensive monitoring – and it also connects the system with the digital world.

A particular challenge is posed by submersible motor pumps and submersible mixers, like Amarex or Amamix: As per design, they work under water, which makes condition monitoring so much harder than for dry-installed pumps. AmaControl protection module provides intelligent help: It supplies precisely the information required for comprehensive monitoring – and it also connects the system with the digital world.

The demands placed on pumping systems are rising continuously

Operators of water management systems are faced with ever greater challenges: operating reliability, energy efficiency and, last but not least, digitalisation are fields in which manufacturers and operators have to advance continuously. Here is an example: As a result of the population successfully taking measures to save water, the solids load in the waste water has increased steadily over the last few years. Pump manufacturers had to react to this trend and enhance their systems to be able to offer suitable protection and counter measures. Another example is the growing danger of cyber attacks on relevant infrastructure. Here, too, pump systems have to be protected adequately. At the same time, where possible, all components are required to be networked with each other and centrally controlled – a difficult balancing act that is necessary to operate pump systems reliably and make use of the opportunities of digitalisation.

KSB has now made networking of submersible motor pumps and mixers even easier – with AmaControl. The module makes the measured values and operating data of the pump available via an integrated Modbus interface. This is how operators receive information and warnings at an early stage, enabling them to react before a failure occurs.

To prevent cyber attacks the pump protection module does not allow system parameters to be changed via the Modbus interface. For safety reasons, such settings can only be made directly at the module.

AmaControl uses the motor input power as a significant condition indicator

One of the key parameters of a pump is the motor input power, which can tell us a lot about the operating point and condition of the pump. Measuring the effective power, reactive power and apparent power as well as the power factor cos 𝜑 has therefore been implemented as a major new feature of AmaControl. In addition, the integrated storage of the protection module contains meters for the effective power and reactive power input.

Another major benefit: AmaControl can also measure the motor input power when a frequency inverter is installed. A current transformer is used in this case, offering the highest possible measuring accuracy of amplitude and phase over a large effective and carrier frequency range. The phase error is situated in the range of 20 to 100 Hz at < 1 º, which results in a particularly high accuracy of effective power.

As the power increases or decreases the device can detect dry running, closed gate valves or rotor blocking in the motor due to clogging. The combination of other sensor data, e.g. motor temperature, bearing temperature and vibrations, serves to find possible faults, thus providing additional protection.

The KSB INTspector app: valuable support with digitalisation

Clearly structured and easy to use: The KSB INTspector app gives you a detailed insight into all relevant operating data.

Everything under control with a single app

Regarding digitalisation, too, AmaControl takes a decisive step further: With the KSB INTspector app the user can access the AmaControl data directly. Based on exact operating data, fault lists with time stamp, a fault counter, informtion on operating hours, start/stop cycles, current measured values and other data, the pump condition can be analysed accurately. Via the live diagnosis all measured values can be recorded over a prolonged period of time and saved directly on a smartphone, tablet or laptop. This saves users having to purchase complex measurement equipment. Instead, they can simply use their end device as a data logger. Users also have full control over their systems by making settings directly in the app.

Three versions of the all-in-one AmaControl protection module for water and waste water products

The right module for every system: AmaControl is available in three different versions.

AmaControl finds a suitable connection, no matter where

In the parameterisation, users can set each input in the module individually. If an input is not being used, it is set to "deactivated". The values for warnings, setpoints and tripping as well as for triggering and re-starting delays or for interlocked tripping without automatic re-start can be set for each input. This allows each value to be set specifically for the application. Users can also create entire parameter data sets, save them and re-load them via the app. A number of default parameter sets are available from KSB, saving time for recurring applications.

In addition to inputs for voltage and current, depending on the specific version, AmaControl offers further inputs for temperature, leakage, float switches as switching contacts and analog input, e.g. for vibration sensors. Phase monitoring comprises phase sequence, phase failure and phase asymmetry as well as overvoltage and undervoltage. It can also be used in single-phase supply systems.

A relay each for alarm and warning add to the operating reliability. With cos 𝜑, operating hours, frequency of starts, short circuits and sensor interruptions can be monitored. The device determines and shows the input of apparent power, effective power and reactive power. It further meters the effective power and reactive power.

Small module, high operating reliability

With its multitude of inputs, functions and options KSB's very compact AmaControl module fits perfectly into the protection concept of modern pumping systems – and supports the operator in meeting the rising requirements on operating reliability, efficiency and digitalisation.

Used products

Amacontrol

Amacontrol

Protection module for water and waste water products as all-in-one device. Depending on the variant, it can be used for motor temperature measurement, bearing temperature measurement, leakage measurement, vibration measurement, voltage measurement and current measurement as well as for diagnosing a pump, pump system or submersible mixer to ensure trouble-free and reliable operation.

Amarex

Amarex

Vertical single-stage submersible motor pump for wet installation, with vortex impeller (F-max) or open dual-vane impeller (D-max), stationary or transportable version. Single-stage, single-entry close-coupled pump sets which are not self-priming. ATEX-compliant version available.

Amarex KRT

Amarex KRT

Horizontal or vertical single-stage submersible motor pump in close-coupled design, with various next-generation impeller types, for wet or dry installation, stationary or transportable version, with energy-saving motor and models for use in potentially explosive atmospheres.

Amamix

Amamix

Horizontal submersible mixer with self-cleaning ECB propeller, close-coupled design, direct drive. ATEX-compliant version available.

Amaprop

Amaprop

Horizontal submersible mixer with self-cleaning ECB propeller, close-coupled design, with coaxial spur gear drive. ATEX-compliant version available.

Amaline

Amaline

Wet-installed horizontal propeller pump with submersible motor, equipped with direct drive or spur gear, ECB propeller with rigid, fibre-repellent blades, bolt-free connection to the discharge pipe. Explosion-proof version available.

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