In water infrastructure, reliable and energy-efficient pump control is essential. Applications like water supply, dewatering, and flood protection require robust and flexible automation. Pumps with power ratings from 160 kW up to 630 kW are dynamically regulated using frequency converters. Process parameters such as flow, pressure, and tank level are continuously monitored by sensors and processed in real time.
Typical use cases include:
Water distribution in municipal or industrial networks
Dewatering in mining and construction sites
Flood control and large-scale irrigation systems
The system is based on the ctrlX CORE X3, which executes the control logic, processes sensor data, and manages communication with SCADA systems via Modbus TCP or MQTT. Programming is done using Structured Text (IEC 61131-3) with the ctrlX PLC App, or optionally via Node-RED for rapid development.
Frequency converters handle speed regulation of the pumps, adapting in real time to demand conditions. Sensor data is collected through the ctrlX I/O system. Pressure, flow, temperature, and level values ensure safe and efficient operation, including dry-run protection and performance optimization.
With support for open communication standards, the solution can be seamlessly integrated into existing automation infrastructures and remotely monitored via web-based HMI or cloud dashboards.
Key Features & Benefits
Energy-efficient control through intelligent speed regulation: By dynamically adjusting pump speeds based on real-time process data, the system reduces energy consumption significantly. This not only lowers operating costs but also extends equipment lifespan through smooth and precise operation.
Fast commissioning and integration into existing systems: Thanks to the preconfigured ctrlX CORE setup, modular I/O structure, and open communication protocols like Modbus TCP and MQTT, the solution can be deployed quickly—ideal for both retrofit projects and new installations.
Remote diagnostics and scalable system design: Remote access via secure VPN and web-based HMI enables real-time monitoring, parameter adjustment, and failure diagnostics. The modular architecture allows the solution to scale across various pump stations and application sizes.
Build your Application with Bosch Rexroth Products
This application is realized with the following components: