Pump control

This powerful function block controls two pumps and integrates:

• Operating hours counting
• Maintenance logic
• Alarm monitoring
• Switching between manual and automatic operation

The block is developed in SCL and is also available as an FBD version for flexible integration depending on project requirements. Both versions can be used directly in the Siemens TIA Portal – ideal for applications in water and process technology.

Note: All modules serve solely as a learning and optimization basis and are not approved for live operation. Plant modules, in particular, must be reviewed and approved by qualified personnel before productive use.

After starting, all outputs are reset to defined start values ​​and the operating hours counters are initialized.

As soon as a pump is active, an hourly timer counts each full hour of operation. If the counter reaches the predefined maintenance threshold, a maintenance request is automatically triggered. A manual reset resets both counters and cancels the request.

In the event of a fault – e.g. dry running or overpressure – the system immediately switches off both pumps and puts the control system into a safe state.

In manual mode, the pumps can be activated individually via buttons. In automatic mode, control is via level signals:

• If the level is too low, the pump starts with the lower operating hours – provided no maintenance is required.
• When the upper fill level limit is reached, both pumps stop automatically.

• Programming languages: SCL and FUP (optionally available)
• IEC timer: Two TON timers for counting operating hours
• Maintenance: Configurable threshold, automatic request after a certain number of hours
• Alarm monitoring: Monitoring for dry running, overpressure, etc. via Boolean inputs
• Status output: Active pump is output as a variable (e.g. for HMI or control system)
• Priority logic: Manual control takes priority over automatic
• Structure: Modular design with reset, counting and control areas

• Simulation of pump systems in water treatment or distribution
• Heating and cooling systems
• Irrigation systems in agriculture or horticulture
• Industrial process plants and laboratory technology
• Education and training environments to illustrate control, maintenance and alarm management

Thanks to the clearly structured, modular implementation, the module can also be easily integrated into digital twins or simulation projects.

• Runs on Siemens S7-1200 and S7-1500 controllers
• Developed for TIA Portal from version V13
• Recommended from TIA Portal version V16 for full functionality
• Testable with PLCSIM without changes

• Complete .scl file including all input/output declarations, timers, counters and status variables
• Additional FUP version with the same functionality (optional)
• Commented structure and clear program layout
• Download link directly after purchase

I am happy to support you with:

• Integration into existing projects or control architectures
• Adjusting timer values, maintenance limits or alarm conditions
• Expansion with additional functions such as additional pumps, sensors or HMI connections

Contact via shop message or email is possible at any time – individual solutions are available upon request.