Intelligent Pumps

Intelligent pump control for efficient water distribution

When vast quantities of water need to be pumped reliably, precise pump control determines energy consumption, operational reliability, and system availability. Pumping stations are part of the critical infrastructure, meaning there are high requirements in terms of availability, cybersecurity, and remote access. Operators and manufacturers are therefore faced with the task of increasing energy efficiency, integrating existing SCADA systems, and meeting regulatory requirements such as the Cyber Resilience Act (CRA).

The "Intelligent Pumps" solution set is a ready-to-use, modular automation solution for energy-efficient pump control based on ctrlX AUTOMATION. The central control system ctrlX CORE, high-performance frequency converters, ctrlX I/O modules, and open communication interfaces form an ideal combination for industrial pump automation. Security-by-design features such as encrypted communication, role-based access, and VPN connection ensure a high level of protection and maximum operational security. The result: energy savings of up to 30%, shorter project lead times, and high availability in industrial pump automation.

Benefits for intelligent pump control:

• Energy savings of up to 30% through demand-based speed control

• Rapid integration thanks to open interfaces and pre-configured logic

• High availability and cybersecurity for critical infrastructure applications

• Scalable, enabled for remote use, and ready for future requirements

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Secure automation for pumps in critical infrastructures

The "Intelligent Pumps" solution set combines selected components from the world of ctrlX AUTOMATION to create a scalable solution for pump automation in water distribution, flood protection, and industrial drainage. Central automation control is provided by the ctrlX CORE, which communicates with high-performance frequency converters and regulates the pump speed on demand based on process requirements.

Sensors for pressure, flow rate, temperature, and filling levels are connected via ctrlX I/O modules. Integration into existing SCADA systems is flexibly implemented via Modbus TCP or MQTT. The application logic is implemented with the ctrlX PLC app in structured text (IEC 61131-3) within the engineering software module ctrlX WORKS. Secure, VPN-based remote access enables diagnostics, parameterization, and troubleshooting to be carried out remotely. The modular architecture is compact and expandable.

ctrlX OS Community

Do you need further assistance? In the ctrlX OS Community you will find blog articles, GitHub applications or how to articles on intelligent pump control and many other areas of application for ctrlX AUTOMATION.

Go to ctrlX OS Community!

Hardware and software components of the solution set

ctrlX CORE – centralized automation control

The ctrlX CORE is at the heart of the solution set. It handles PLC, control, and IoT functions, runs apps such as PLC, EtherCAT Master, and Node-RED, and controls frequency converters for demand-based speed control.

ctrlX I/O – sensor integration for process signals

ctrlX I/O modules record process data such as pressure, flow rate, temperature, and fill levels. The deterministic EtherCAT connection to the ctrlX CORE ensures rapid response times and the necessary signal diversity for protection, control, and monitoring functions in pumping stations.

Various screenshots of the HMI by ctrlX AUTOMATION

ctrlX HMI – visualization and local operation

ctrlX HMI provides web-based visualization for operation, parameterization, and local diagnostics. Intuitive user interfaces speed up commissioning and servicing of pump applications. Combined with secure remote access, it supports efficient operation throughout the entire life cycle.

High-performance frequency converters – speed control up to 630 kW

High-performance frequency converters (typically 355–630 kW) regulate the pump speed in an energy-efficient manner and protect the system with integrated protection functions. The connection is made via Modbus TCP/IP or EtherCAT; third-party inverters can also be integrated, which reduces energy and operating costs sustainably.

App icon of the EtherCAT Master for ctrlX OS operating system

EtherCAT Master app – real-time communication

The EtherCAT Master app ensures deterministic real-time communication between ctrlX CORE, ctrlX I/O, and actuators. Low cycle times ensure accurate closed-loop control and reliable protection functions – both essential for high-performance pumps.

App icon of the Modbus TCP for ctrlX OS operating system

Modbus TCP app – SCADA and converter connection

Modbus TCP is the standardized interface for connecting frequency converters and existing SCADA systems. It enables simple integration into existing control systems and connection to cloud and IoT infrastructures (e.g. via MQTT).

App icon of the PLC for ctrlX OS operating system

ctrlX PLC app – application logic in structured text

The ctrlX PLC app maps automation logic, control loops, and protection thresholds in structured text (IEC 61131-3). It enables standardized programming, accelerated engineering, and easy maintenance within ctrlX WORKS.

App icon of the Node-RED for ctrlX OS operating system

Node-RED app – flexible integration and dashboards

Node-RED complements the "Intelligent Pumps" solution set with graphical logic and visualization modules. It can be used for dashboards, data pre-processing, or IoT workflows such as MQTT bridges – ideal for quick extensions and individual requirements.

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