How to Monitor Pump Performance with a Panel PC, HMI & Ethernet I/O

An Acromag Solutions Video Application Note

Pumps are integral to a wide variety of industries and processes. When you monitor pump performance, you can lower operating costs, improve process throughput, and reduce downtime and schedule maintenance. An automation system is needed with local displaying of real-time parameters, analytical calculations, data storage, trending, set warning and shutdown alarms, issue event driven messages, as well as network communications. Additionally, with vibration monitoring and proactive maintenance, machine condition monitoring can be implemented.

Click on the AcroMaggie video below for further information on the benefits and steps involved to monitor pump performance with a panel PC, HMI and Ethernet I/O.

System Requirements for Monitoring Pump Performance with a Panel PC, HMI & Ethernet I/O:

  • An industrial panel PC with either Windows┬« or Linux┬« OS and a suitable HMI for distributed control and process automation.
  • Ethernet I/O to interface the pump sensors with the HMI.

Converting pump analog signals to Ethernet facilitates an easy connection to the PC, simplifies wiring, and minimizes electrical noise in harsh environments.

Implementing the Solution:

1. To optimize the pump performance, add the following sensors with 4-20mA output:

  • Current transformer (CT) to monitor electrical power.
  • Flowmeter to monitor flowrate.
  • Pressure transmitter to monitor both suction pressure at the inlet side and discharge pressure at the output side.
  • Hall Effect speed sensor with frequency output to signal conditioner TT339-0700, )converting to 4-20mA as a result), to monitor pump-specific speed.

2. Create an Ethernet connection from the XT1211-000 to the Panel PC for Modbus TCP/IP communications. The HMI will Poll the XT, then read back the pump parameters to display and perform calculations.

3. Add a device driver to the PC OS:

  • For a PC running Windows: add either a Modbus TCP/IP ActiveX Control or .NET Control
  • For a PC running Linux: add an Ethernet Modbus C Library utility so you can build Modbus TCP/IP commands

TT339-0700: Transmitter, Frequency/Pulse/PWM Input, 12-32V DC Loop/Local Power

XT1211-000: Ethernet I/O Module, 8-Channel Differential Analog Current Input

Click here to see the full application note in PDF.

Learn more: What is Ethernet/IP?