Level-based pump control in water and wastewater applications

FlexView FMA90 combined with Waterpilot FMX21 or Micropilot FMR20B enables reliable level measurement, configurable pump control and remote monitoring in a wide range of water and wastewater applications, from deep groundwater wells to pump stations, lift stations and wastewater sludge applications. The solution combines different measurement principles with integrated control functions, intuitive visualization and remote access to support stable operation, help prevent pump damage and enable balanced pump utilization.

The combination supports stable pump operation, can help prevent dry running when configured with appropriate level limits or an external level switch and reduces the need for unplanned maintenance interventions. Configurable control functions such as pump alternation and runtime tracking extend equipment lifetime and improve energy efficiency. Operators gain full process visibility through remote monitoring and visualization, even at difficult‑to‑access measurement points. The result is a future‑ready pump control solution that combines modern diagnostics, visualization and configurable pump alternation, supporting reliable operation in demanding water and wastewater applications.

Pump stations, lift stations, wastewater pits and freshwater wells often feature deep, narrow installations with limited space, such as boreholes or shafts, placing high demands on sensor robustness, overload resistance and long‑term stability. These installations are typically exposed to changing ambient conditions, including temperature variations and humidity. In deep groundwater wells, narrow geometries, deep installations and long measuring distances can limit the performance of some non-contact measurement technologies.

In wastewater applications, sludge, deposits and changing surfaces further complicate reliable level measurement. Complex hydraulic behavior, frequent pump cycling and varying inflow rates require reliable and stable level information to ensure continuous operation. When multiple pumps are installed, alternation strategies and balanced runtimes are essential to prevent uneven wear, reduce clogging risk and extend pump lifetime. At the same time, operators require remote access to monitor and adjust the process safely and efficiently, without entering confined or hard‑to‑reach areas.

A simple start to smarter control is achieved by combining stable level measurement with configurable pump control and clear visualization. Depending on the application conditions, either hydrostatic or non‑contact radar level measurement can be selected to provide a reliable input signal for pump control.

If the application involves sludge, surface buildup, foam or turbulent water surfaces, Micropilot FMR20B provides non‑contact radar level measurement. Its focused 80 GHz radar beam delivers stable level values even under challenging process conditions.

Waterpilot FMX21 provides robust hydrostatic level measurement and optional temperature measurement in wells, lift stations or wastewater pits. Its ceramic measuring cell converts the water column pressure into a stable level signal, providing a reliable basis for level-based pump switching. This makes the measurement principle particularly suitable for deep or narrow wells up to 200 m deep, where measurement performance remains stable, independent of reflections, pipe geometry or installation depth.

The measured values from either Micropilot FMR20B or Waterpilot FMX21 are transmitted to FlexView FMA90, which acts as the central control and visualization unit. FlexView FMA90 enhances the sensors and brings every insight into clear view by continuously processing incoming level values, comparing them with configured switching limits and executing configurable pump control functions.

Depending on the configuration, FlexView FMA90 automatically starts, stops or alternates pumps to maintain stable operation under varying inflow rates and hydraulic behavior. Up to eight pumps can be controlled individually or in groups. Pump operating data, including operating hours, number of starts, runtimes and downtimes, can be recorded. Alternation strategies support balanced pump utilization, while configurable flushing functions can help reduce sediment buildup and support reliable pump station operation. Pump feedback can also be integrated via digital inputs.

Relevant data, including level values, measured value curves, diagnostic information and logbook entries, can be visualized on FlexView FMA90 and accessed remotely via the integrated web server using Ethernet or the Wi‑Fi interface. Operators can monitor system status and adjust parameters from a browser-based interface without entering the pump pit. For secure integration into modern infrastructures, FlexView FMA90 was developed according to IEC 62443‑4‑1 secure product development requirements.