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Water Pump Dry Run Protection using Current Transformer

A water pump protection system protects a pump from dry run and bad voltages. Dry run means when no supply of water is available, and the pump is running. This badly damages the pump! Our system constantly measures the current flowing through the pump and in this way, it senses dry run and stops the pump. It also constantly measures the AC mains voltage and stops the motor if voltage is above maximum or below minimum points. In this way it provides complete protection to the pump. Here you can see the PCB of this system. In the centre is the microcontroller chip. It is a 32-bit A.R.M. processor which controls the whole unit. In the top we have an organic L.E.D. based graphical display. And here are the two relays which activates the START and STOP function of motor starter. This black thing is the buzzer. And finally in the bottom are the screw terminal for connections. This is the current transformer connector, a current transformer is called C.T. in short. And this C.T. Measures the current drawn by the pump. Here you can see the current transformer, it has a hole in the middle where we can pass the wire whose current we want to measure. And these are the output wire which we will connect to our main board. Through this hole pass one wire of the power supply line of the water pump. We have helped our client design this product from complete scratch! We have drawn the schematic of the main board using high end PC software, made footprints and symbols of various parts used in the PCB. Then from this schematic we went ahead to create the printed circuit board or P.C.B. design. In PCB layout, pins of all components are connected to each other as per the circuit diagram using tracks. Tracks are nothing but thin lines made using copper, so that the pins can be electrically connected. Advance computer design software can show in 3d how the final PCB will look like after it is manufactured. Once the design process is complete in software, we sent the files to factory for P.C.B. manufacturing process and after production we have this! See it looks exactly the same as we saw in computer simulation! In final step we solder all the components and load the software in the microcontroller, and we have the working product!