Synthesis™ Multi-pump

Synthesis™ Multi-pump Control regulates the pressure of a fluid delivery system using a single drive that orchestrates a series of pumps. The program seamlessly integrates motor-control, logic, and process-control functions into a single, compact solution. With its sophisticated pump-modeling technology, the controller leverages the computing power of its digital signal processor (DSP) to provide superior control, optimal efficiency, and comprehensive protection for the pumping system.

Synthesis™ Multi-pump Systems are available as stand-alone components or turn-key packages. Various packaging options are available. Custom integration can be provided to meet any requirements.

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Synthesis™ Multi-pump Control

Multiple Pumps

Multi-pump systems can operate up to eight pumps as well as a jockey or priming pump. One pump is a variable-speed master while the remaining auxiliary pumps operate at a fixed speed.

Variable-Speed Drive

The master pump is controlled by a flux vector AC drive from UNICO’s Series 1000 family. Drives are available from 11/2 to 500 hp and are UL and C-UL listed. Input power can be 230 or 460 VAC single- or three-phase or 575 V AC three-phase.

Starters

Auxiliary pumps are controlled using motor starters or soft starters. Starters can be customer-supplied or provided with the packaged system.

Bypass Control

Manual bypass control is available with packaged systems.

Power Conditioning

A variety of options is available for conditioning the incoming line, including AC line reactors, isolation transformers, twelve-pulse transformers, and harmonic filters.

Environmental Options

Systems can be packaged in NEMA 1, 4, 3R, or 12 enclosures for indoor or outdoor use. Customization is available for special environmental requirements.

Services

Comprehensive start-up assistance, service, and training are available.


Synthesis™ Multi-pump Systems

Multiple Pumps

Multi-pump systems can operate up to eight pumps as well as a jockey or priming pump. One pump is a variable-speed master while the remaining auxiliary pumps operate at a fixed speed.

Variable-Speed Drive

The master pump is controlled by a flux vector AC drive from UNICO’s Series 1000 family. Drives are available from 11/2 to 500 hp and are UL and C-UL listed. Input power can be 230 or 460 VAC single- or three-phase or 575 V AC three-phase.

Starters

Auxiliary pumps are controlled using motor starters or soft starters. Starters can be customer-supplied or provided with the packaged system.

Bypass Control

Manual bypass control is available with packaged systems.

Power Conditioning

A variety of options is available for conditioning the incoming line, including AC line reactors, isolation transformers, twelve-pulse transformers, and harmonic filters.

Environmental Options

Systems can be packaged in NEMA 1, 4, 3R, or 12 enclosures for indoor or outdoor use. Customization is available for special environmental requirements.

Services

Comprehensive start-up assistance, service, and training are available.

Multiple Pumps

The application can control from one to eight pumps. The speed of the master pump is controlled by the drive in response to system pressure feedback. The remaining pumps operate at a fixed speed and are controlled by the master using motor starters. As demand fluctuates within the system, the master stages the auxiliary pumps to maintain constant pressure and maximize efficiency.

Pump Curve

UNICO’s Pumping System Intelligence™ (PSI) technology mathematically models pump operation to achieve optimal performance, efficiency, and pump life. With just a few points from a pump’s published performance curve, the drive can dynamically calculate key variables such as developed head, flow, and efficiency to determine the most efficient staging under all operating conditions. By knowing the pump curve, the controller inherently protects against end-of-curve, cavitation, deadheading, and other damaging conditions by avoiding them altogether.

Instinctive Tuning

A sophisticated tuning feature automatically calculates the optimal closed-loop pressure gains by identifying the pressure and flow characteristics of the system. This eliminates the trial and error associated with tuning traditional systems and ensures stable performance without troublesome pressure overshoot or hunting.

Programmed Alternation

The starting order of the auxiliary pumps may be alternated based upon the number of times each has been started. This distributes pump and motor wear evenly to maximize reliability and prolong the life of the system.

Smooth Filling

A smooth-fill function ensures that lines fill evenly to prevent cavitation and water hammer with systems that drain.

System Priming

For systems requiring a jockey or priming pump, a priming sequence can be initiated whenever the master pump starts or goes off-line.

Low-Flow Optimizer

Systems that have widely varying demand can waste energy and place undue wear on pumping equipment. The controller monitors the system, with or without a flow transducer, for minimum-flow conditions. If low flow is detected, pressure is boosted by a preset amount and all pumps are switched off to conserve energy and eliminate unnecessary cycling.

NPSH Monitor

The control continuously monitors suction pressure and automatically adjusts to ensure that the pump operates with adequate net positive suction head (NPSH) over its entire flow range. This prevents cavitation that can damage the pumping system.

Pump Status Monitor

The drive is equipped with a backlit liquid crystal display that continuously shows pump pressure, flow, speed, current, and power as well as the running and fault status of each pump in the system.

Fault Tolerant

The program is capable of automatically recovering from many types of fault conditions to ensure continuous operation in unattended installations. If a nuisance fault or power interruption occurs, the system will, depending upon user-selectable settings, attempt to clear the fault and restart automatically.

Communications

Several industry-standard serial protocols are available for communicating with a building automation system (BAS) or other supervisory controller, including Modbus RTU, ANSI, N2, LonWorks, and BACnet. A SCADA interface is optionally available for remote operation.

Inputs & Outputs

The following inputs and outputs are provided for interfacing the pump controller with the pumping system:
 

Inputs Analog Inputs Outputs
manual start pressure feedback pump 1 running
manual enable suction feedback pump 2 running
auto enable flow feedback pump 3 running
external no fault manual speed potentiometer pump 4 running
setpoint 2 enable   pump 5 running
jockey pump OK   pump 6 running
fault reset   pump 7 running
pump 1 flow OK   pump 8 running
pump 2 flow OK   jockey pump running
pump 3 flow OK   pump 1 fault
pump 4 flow OK   pump 2 fault
pump 5 flow OK   pump 3 fault
pump 6 flow OK   pump 4 fault
pump 7 flow OK   pump 5 fault
pump 8 flow OK   pump 6 fault
pump 2 disable   pump 71 fault
pump 3 disable   pump 8 fault
pump 4 disable    
pump 5 disable    
pump 6 disable    
pump 7 disable    
pump 8 disable