Pump equipment OEM
Integrate pressure control, alternation, contactor feedback and local operating records into a packaged two-pump supply unit.
PUMP-TANK-A01 · WATER CONTROL
Dual-pump water supply controller PCBA
A duty/standby controller for pump manufacturers, water-treatment equipment and cabinet integrators. Pressure and tank-level inputs coordinate one running pump and one standby pump, automatic alternation, fault handling and operating records.
- 24V
- 18–30V DC input
- 2 × 4–20mA
- Pressure + level inputs
- 2 pumps
- Duty / standby operation
- 200 × 150
- mm · 4-layer PCB
Applications
Designed around indoor clean-water auxiliary supply and direct-on-line contactor control. Match the pump curve, source-water level, system pressure and independent cabinet protection to the installation.
Tank-to-pressure-vessel supply
Coordinate source-tank level and delivery pressure. A low-level input inhibits pumping, while pressure hysteresis reduces unnecessary switching.
Water-treatment auxiliaries
Control clean-water feed and transfer auxiliaries. Independent level, pressure and motor-protection contacts remain in the cabinet.
Industrial washing & utility water
Provide local on/off pressure control for clean-water utility skids, with one pump operating and the other available for alternate duty.
Facility utility pump sets
Give maintenance teams local fault indications, accumulated runtime, starts and Modbus access to pump-set information.
Control-cabinet retrofit
Reuse suitable contactors, overload devices and hardwired interlocks, adapting the field wiring and parameter settings to the existing installation.
System architecture
24V powers the controller and low-voltage cabinet branches. Two 4–20mA channels acquire pressure and tank level; 24V digital inputs acquire permissions, feedback and overload contacts. Dry-contact outputs command external 24V DC contactor coils. Motor power remains in the cabinet.
Control functions
Alternation
Successful operating cycles alternate duty between pump 1 and pump 2; only one pump is commanded at a time.
Automatic fallback
Automatic operation can transfer to the available standby pump after a start failure or overload, respecting the full stop interval.
Pressure hysteresis
The baseline starts below 2bar and stops at 3bar. Settings are matched to the hydraulic system; this is on/off control.
Stop interval & feedback
The baseline stop interval is 30s, feedback confirmation 2s and pressure-rise observation 10s.
Fault interlocks
Low source level, overpressure, invalid or stale measurements, contactor feedback faults and storage faults inhibit operation.
Manual & reset behavior
Manual commands retain protections. Reset clears an eligible latched fault; a separate new enable command is required to run.
Electrical design
The board uses STM32G071CBT6, a 24V input power stage, two protected current-loop inputs, isolated RS485, local buttons and nonvolatile storage. Download the fixed component selections and editable KiCad source.
228 electrical components · 59 MPNs · 189 SMT / 39 THT · 12 mating plugs
Interfaces & wiring
| Connector | Pins | Function |
|---|---|---|
| J1 | 2 | 18–30V DC input |
| J2 | 5 | 3.3V-reference SWD |
| J3 / J4 | 3 each | Pressure / level 4–20mA loops |
| J5 / J6 | 5 each | Permission, source, pressure, feedback, overload, remote inputs |
| J7 / J8 | 2 each | Pump 1 / pump 2 dry contacts |
| J9 | 3 | Alarm changeover contact |
| J11 | 3 | RS485 A / B / isolated reference |
| J12 | 6 | Cabinet control / STOP-health wiring |
| J13 | 2 | Independent first-phase-contact load branch |
Use the pin-by-pin connector table and cabinet wiring guide. The PCB contacts switch 24V DC control coils; they do not switch the motor supply. Preserve the independent emergency-stop, phase, source-level, mechanical pressure and overload chain, plus contactor interlocking.
Firmware & records
Modbus RTU runs at 9600baud, 8E1, default slave 1. FC03 reads values, parameters and event data; FC06 queues control commands; FC16 writes complete parameter groups and the event selector. Unavailable pressure/level values are reported as null by the service client, with raw words and per-channel validity.
Nonvolatile records include configuration, pump starts, accumulated runtime, boot count and a 464-entry event ring. Event timing uses monotonic uptime plus boot count. Power-up does not restore an enable command.
Integration
The reference system selects two Grundfos CM5-5 pumps, Schneider LC1D09BL 24V DC contactors, GV2L08 / LRD08 motor protection, RM17TG20 phase monitoring, WIKA A-10 pressure and LH-10 level transmitters, and a MEAN WELL HDR-100-24 control supply. The system BOM includes valves, tank, vessel, wiring and installation accessories.
Board outline: 200×150mm, four copper layers, 1.6mm high-Tg FR-4 and ENIG. SMT and THT coordinates are separated. The DFM files specify a 0.125mm stencil and six U1 filled, planarized, copper-capped thermal holes. Use the board drawings for mounting, polarity, pin 1 and conductor separation.
Technical downloads
Download the complete technical archive or individual categories without registration. Files cover editable schematics and PCB, local libraries, component and system BOMs, Gerber/drill/placement data, firmware source and binaries, service tools, calibration, wiring and engineering records.
Complete technical files & sourceZIP · 18358.4 KB ↓KiCad, libraries & manufacturing filesZIP · 4035.6 KB ↓Firmware, tools & test sourceZIP · 1757.4 KB ↓System selections, cabinet wiring & accessoriesZIP · 26.9 KB ↓DFM & assembly filesZIP · 1435.0 KB ↓9-page schematic PDFPDF · 610.7 KB ↓228-position component BOMCSV · 64.0 KB ↓59-MPN procurement BOMCSV · 7.4 KB ↓47-line system BOMCSV · 5.2 KB ↓Mating plugs & accessoriesCSV · 1.0 KB ↓Connector pin assignmentsCSV · 3.7 KB ↓MCU pins & netsCSV · 3.7 KB ↓Modbus registers & commandsMD · 2.4 KB ↓Analog calibration procedureMD · 4.9 KB ↓Cabinet wiring guideMD · 12.1 KB ↓189-component SMT placementCSV · 12.1 KB ↓39-component THT placementCSV · 3.2 KB ↓U1 six filled-hole coordinatesCSV · 0.5 KB ↓STM32 firmware HEXHEX · 58.4 KB ↓STM32 firmware BINBIN · 20.7 KB ↓PCB top assembly drawingSVG · 1031.1 KB ↓Dual-pump water system diagramSVG · 1.6 KB ↓
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