Automation

TorqueMaster

New T1-16S PLC

I/O Exp Case
1 Card 16 Discrete/1 Analog

16 I/O PLC I/O Exp Case

4 Cards Discrete/Analog

TorqueMaster
DIGITAL PUMP CONTROL SYSTEM

Introducing To

Torque Control Energy Savings Technology

Replace Conventional Speed Control for Lift Station Applications

PRODUCT OVERVIEW
Operates motor at most efficient point on the
pump curve Uses Noise Free RS485 digital communications link to ASDs Accurately controls motor torque, not motor speed Allows operation in triplex, duplex, or simplex modes All system information displayed on color touch screen Reduces cavitation, heat generation, and vibration Saves energy

PRINCIPLE OF OPERATION

Torque Control allows multiple pumps to operate at different speeds to balance the flow and pressure equally thus greatly increasing the GPM throughput compared to the same amount of energy consumed using Speed Control of the pumps (ie more GPM less energy)

Typical Energy Savings Using

TorqueMaster

Conventional On-Off Control

Energy Usage

Speed Control

Torque Control
Gallons per hour

Startup

Normal Operation

Max Operation

Note: Actual energy savings depends on the design and current overall efficiency of the existing system. The less efficient the current system the more energy savings realized by TorqueMaster.

How TorqueMaster Saves Energy

TorqueMaster continually adjust system parameters to
maintain the throughput at the optimum point on the system curve

The ASDs (Toshibas Adjustable Speed Drives) manage the

pumps acceleration/deceleration time and speed as the overall system efficiency curve changes due system imbalances (discussed later)

Accordingly, energy savings up to 50% can be realized

with TorqueMaster

Conditions That Cause System Imbalance (Efficiency to Change)

Lift station efficiency changes as system goes from simplex to duplex
to triplex control during abnormal flow conditions

Lift station changes in design efficiency as other lift stations upstream

or downstream come on line

Individual efficiency changes in pumps as impellers wear Changes in lift station efficiency as piping changes are made Changes in efficiency due to varying flows or pressure drops caused
by scaling or coating of process piping

Only Torque Control Can Correct These Conditions That Causes Increase Power Consumption And Maintenance

How TorqueMaster Does It!

RS485 Communication to ASDs

Toshiba Drives sends to TorqueMaster: The Hertz (RPM), amps, availability, and trip code. TorqueMaster sends to each drive: Run, Stop, Max speed, Max torque setting, and a Watch dog timer pulse to keep the drive from shutting down if not updated by TorqueMaster every 20 seconds Result
Each ASD will reduce/increase pump speed to the maximum torque setting dictated by TorqueMaster

What Is TorquMaster ?
The Inside Story
T1 Analog Input Card

EEPROM with Backup Program

Color Touch Panel NEMA 4X Polyester Modular Enclosure

Super T1-40 PLC

INTERNET ADVANTAGES

Event Actuation
Allows for alarm conditions to be transmitted to the master station immediately, providing faster notification than a conventional polling type system

Scheduled Actuation
Provides complete scheduled status reports automatically from the remote station

Remote Operations
Complete control and operation from the master or secondary location

UDP/IP Protocol
Ensures correct date reporting, garbled transmissions are not accepted

Main display

Also available as PumpMaster

Duplex pump Controller
Cost effective version

Duplex level & logic control for contactors/ASDs using relay

outputs

PumpMaster uses a Toshiba LCD display and physical switches Compatible with all brands of ASDs Uses conventional pump speed control

TorqueMaster Controlling Three Toshiba G3 Drives Installed in Pumping Station