Understanding the Pump Application

Learn how the Pump Application works, so you can calibrate and manage pumps using the WellAware Field App

Last Updated: October 15th, 2021

Every WellAware Device comes preloaded with various WellAware Asset Apps based on the subscription type that was purchased. The Pump Application is one such Asset App that is included with subscriptions that include a pump monitoring and control service.

The Pump Application can be managed and configured on your WellAware Devices using the WellAware Field App.

This article explains the Pump Application and how to use it to view pump settings while on location, as well as setup and calibrate pumps controlled by WellAware devices.

Accessing the Pump Application

When you connect to a WellAware Device in the Field App, you’ll be able to view its list of Asset Apps below the device information on the Device Home Screen.

To access the Pump Application, tap the Pump Application tile on the Device Home Screen. The Pump Application can be found as the tile with a pump icon and the name “PUMP”.

 

Navigating the Pump Home Screen

After you select the Pump app, you’ll be taken to the Pump Home Screen. On the Pump Home Screen, you’ll find:

• Pump Settings
• A "Stop Pump" button
• A "Start Purge" button
• A button to calibrate the pump
• A button to update the pump setpoint
• A button to go to the Advanced Settings

Pump Settings

The Pump Settings, shown at the top of the pump home screen below the pump graphic, shows the pump mode, the maximum pump output, the current setpoint, and additional settings related to the selected Pump Mode.

Here are additional details on the Pump Settings:

Default Settings

Pump Mode: The methodology used to control the pump. Jump to Changing Pump Mode >

Max Pump Output: The maximum rate the pump can physically achieve in the configured rate units. This is determined and set through the pump calibration process.

Current Setpoint: The current pump rate setpoint in the configured rate units.

Mode-Specific Settings

Cycle Time (Timed Pumps Only): The control period of the pump, or the total on and off time. For example, a pump with a Max Pump Output of 50 GPD, a setpoint of 10 GPD (20% of max), and a Cycle Time of 60 seconds will turn on for 12 seconds (20%) and off for 48 seconds (80%). 12 seconds on + 48 seconds off = 60 seconds cycle time. Jump to Setting Cycle Time > 

Current PPM Target (Proportional Dosing Only): The target concentration which drives the Current Setpoint based on the Meter Flow Rate. For example, a pump with a Current PPM Target of 100 PPM (parts per million) with a Meter Flow Rate of 100,000 gallons per day will have a Current Setpoint of 10 gallons per day. If the Meter Flow Rate drops to 50,000 gallons per day, the Current Setpoint will update to 5 gallons per day to maintain the 100 Current PPM Target. Jump to Proportional Dosing >

Meter Flow Rate (Proportional Dosing Only): The measured flow rate from the connected meter, which informs the Current Setpoint using the Current PPM Target.

Stop Pump Button

This button immediately and temporarily stops the pump. After Stop Pump is pressed, the option becomes "Resume Pump". Use this button if you need to temporarily diagnose or service the pump, but do not want to change the Pump Setpoint.

Start Purge Button

The "Start Purge" button immediately and temporarily sets the Pump to the Max Pump Output. This is useful for fixing pumps with air in the suction line, or when a pump has lost prime. When the "Start Purge" button is tapped, it will become "Stop Purge."

Calibrate Pump

Press the Calibrate Pump button to calibrate the pump. This is done during the initial install, and also if the Current Setpoint is not delivering the desired rate output. The processes for initial calibration and recalibration are slightly different. Jump to Calibrating the Pump >

Change Setpoint

Press the Change Setpoint button to change the current pump setpoint. For standard control modes, this will allow you to update the target rate in the configured rate units. For Proportional Dosing, this will allow you to update the Current PPM Target.

Advanced Settings

The Advanced Settings give you further control over the Pump Application. In the Advanced Settings, you can change the Pump Mode, update the Proportional Dosing settings (for Proportional Dosing mode), update the cycle time (for Timed pumps), and get the tachometer reading (for VSD pumps with a tachometer).

Calibrating the Pump

During the initial install, the Pump Application must be calibrated to record the Max Pump Output. Once the Max Pump Output is configured, the WellAware Connect will control the pump to hit the Current Setpoint based on the configured Max Output.

Initial Calibration

The initial calibration process is a 7-step wizard to allow you to calibrate your chemical pumps using a sight glass. The process includes an initial calibration step, and then a "fine tuning" step if necessary. Follow the steps in the wizard to calibrate the pump.

Recalibration

The recalibration process involves a subset of steps in the calibration wizard and can be used to fine-tune a pump whose calibration is slightly off or has drifted over time.

Changing the Pump Mode

The WellAware Connect configured with the Pump Application offers the ability to control several types of pumps with varying control methodologies. Changing the Pump Mode will allow you to select the appropriate type of pump and control methodology for your specific pump and purchased WellAware application.

These are the possible pump modes:

• Setpoint - Variable Speed Pump: For chemical pumps that use a variable speed motor and can be modulated with a 0-5V input signal
• Setpoint - Timed: For chemical pumps that use a standard on/off cycle to change rates. This is the most common pump mode.
• Proportional Dosing: For connecting chemical pumps to an external 4-20 mA signal, such as that from a flow meter, to update setpoints in real-time to maintain a constant PPM. Jump to Proportional Dosing >
• Closed-Loop - Variable Speed Pump: For variable speed drive pumps that supply a digital pulse output from a tachometer, enabling constant motor-speed control.

Setting the Cycle Time

For Timed Pumps, the Cycle Time determines the total time the pump cycles between On and Off periods to hit the target setpoint. The Cycle Time operates on the principle of a "duty cycle", where the pump is turned on for a percentage of the cycle time to hit a target setpoint.

For example, a pump with a Max Pump Output of 100 GPD and a Current Setpoint of 30 GPD will target a duty cycle of 30%, or an "On Time" that is 30% of the total Cycle Time. For a Cycle Time of 30 seconds, that would equal an On Time of 9 seconds (30% of 30 seconds), and an Off Time of 21 seconds.

Cycle Time = On Time + Off Time

Cycle Time = 9 seconds On + 21 seconds Off

Cycle Time = 30 seconds

Changing the Current Setpoint

To change the target setpoint of the pump, tap "Change Setpoint" from the Pump Home Screen. For basic control modes, you will be able to quickly update the current target setpoint in the configured rate units (e.g. gallons per day).

For Proportional Dosing, you will be taken to the Proportional Dosing settings, where you can update the Current PPM Target.

Proportional Dosing

Proportional Dosing is a special mode enabled when you have purchased the On-Demand Chemical subscription with your WellAware Connect Pump Controller.

In Proportional Dosing mode, the WellAware Connect monitors an external meter in real-time, updating the Current Setpoint after each cycle to hit a target concentration (Current PPM Target).

In most cases, the external meter is connected using a 4 - 20 mA output from the existing meter.

Setting the Pump into Proportional Dosing Mode

To set the pump into Proportional Dosing mode, go to the Pump Home Screen, select Advanced Settings > Change Pump Mode > Proportional Dosing.

Configuring Proportional Dosing

When the Pump Mode is set to Proportional Dosing, you can configure the Proportional Dosing settings by going to the Pump Home Screen, and selecting Advanced Settings > Configure Proportional Dosing.

These are the Proportional Dosing settings:

PPM: The target concentration, in parts per million (PPM), for chemical dosage

Low Flow: The low range of the meter output. For a 4 - 20 mA output, this corresponds to the flow rate at 4 mA. For most applications, this will be 0.

High Flow: The high range of the meter output. For a 4 - 20 mA output, this corresponds to the flow rate at 20 mA. This may or may not be equal to the maximum meter measuring range. It is configured on the meter itself.

Failsafe Flow: This is an assumed flow rate in the event the WellAware device loses a connection to the external flow meter. It is wise to select a reasonable average rate.