Controls, Automation & Monitoring FAQs

All of T-T's control panels and systems undergo a rigorous inspection and test process in accordance with our ISO9001 QA procedures before they are shipped. This process involves over sixty key checks and full electrical testing under load conditions, after which the product is certified and test documentation stored; test result documentation is available to customers on request.

T-T's control systems can be operated with several different starting methods:

• Direct On-Line (DOL) - a relatively inexpensive starting method where the motor is connected directly to the power supply, designed for easy installation and use. They are suitable for use smaller motors or those with a large electrical supply available as it needs a higher starting current. High torque capability allows for quickly starting a motor.
• Star-Delta - an alternative to DOL, the motor is connected in a star configuration during the starting phase and then switched to a delta configuration once it has reached a certain speed; reducing the starting current by around a third compared to DOL. Star-Delta is ideal for larger motors but needs additional components in the control panel, so it is usually more expensive than DOL.
• Soft Starting - similar to Star-Delta in that it offers a reduction in starting current being drawn, but with the advantage of controlling the current restriction as it is done electronically via thyristors (for precise adjustment of the starting torque).
• Variable Speed Drive (VSD) - VSD provides full control of speed, torque and energy efficiendies, as well as optimising performance based on the application's current demand and transmitting a wide range of information from the motor to other peripheral devices. Variable Speed Drives can be costly to install as a capital cost.
• Auto-Transformer Starting - a method that uses an auto-transformer to reduce the starting current of electric motors and gradually increases the voltage during startup to prevent high currents and voltage dips. This method is ideal for large motors or when there are limitations on the electrical supply capacity. However, it may provide a lower starting torque compared to other starting methods.

Control panels are electrical devices that allow users to interact with and manage the operations of all kinds of machinery and processes, such as:
• Hand/off/auto selector switches to choose between different operating modes.
• Start/Stop buttons
• Reset button
• Interactive gauges for level control, conveyor speed, mixing processes, etc..

T-T Controls & Automation offers a range of control panels for different applications:

• Raincycle - a simple control solution for applications such as water harvesting, irrigation systems, outdoor taps (non-potable water), utilities (toilets, laundry and cleaning) and industrial processes.
• Libra Micro - a simple and effective control panel with a Printed Circuit Board (PCB) design that features an audible alarm and volt-free contact for remote alerts. The Libra Micro is compatible with liquid level controls such as T-T's FLO series of float switches, ideal for use in compact sump dewatering.
• Libra Midi - features a combination of PCB and compact control gear design, an intermediate motor control unit that is available in single and dual versions for use in pumping/conveyor systems, flood defenses and motor control.
• Libra Maxi - a versatile control system with a range of options to suit every application, from different starting methods to single and dual pump configurations and a multitude of system-protecting features such as a thermostatically controlled heater and motor protection fuses for optimal performance. The Libra Maxi is ideal for use in heating & ventilation and process machinery applications.
• PumpPal & PumpPal Pro - these control units are designed for operating sump and drainage pumps, with audible alarms, LED indication and volt-free contacts for remote monitoring.

Contact our team for expert selection advice call +44 (0)1630 647200; email response@ttpumps.com; or complete an enquiry form online.

T-T recommends that regular maintenance inspections are undertaken on the system to ensure that it continues operating within it's design parameters for reliable performance.  In addition to this, remote monitoring such as Seer,can provide continual 24/7  reviews of the pump station control panel and pump 'health', with its performance ensuring any anomalies are quickly identified and reported.

A PLC (Porgrammable Logic Controller) is a small comoputer that receives operating data and sends operating instructions for automating processes.

T-T Controls, Monitoring & Automation has vast experience in PLC system design, including Human-Machine Interfaces (HMI) and Supervisory Control and Data Acquisition (SCADA) interfaces.

For more information on T-T's automation and bespoke manufacturing facilities, visit our Custom Controls, Automation & Monitoring page.

The main problem with any remote monitoring system is predicting failure or the circumstances that can lead to failure. Very often, it is not the product that is a fault, but the operating circumstances.

A good example is a sewage pumping station, designed to pump domestic effluents while adhering to Design Construction Guidelines. These pumping station requirements are set out by water companies that are to eventually become adopted in line with the Sewers for Adoption process.

Unfortunately, household wipes are becoming a major problem to many sites where the wipes accumulate and enter the pumping station in a surge. The pumping station has difficulty dealing with the accumulation and this can result in total failure during the maintenance to handover period. The handover period can take months to years before being handed over to the water company for adoption; during that period of maintenance, the builder/developer has the full responsibility of keeping the pumping station fully operational and maintained.

As builders and developers are not focused on maintaining the pumping station, they look for specialised companies and systems that will assist in keeping a pumping system fully operational.

The Seer Monitoring system provides complete monitoring of a system and can give advance warning of potential problems. 

With technology advancing at pace gathering speed, and the Internet of Things (IoT) allowing all things to be connected remotely, what benefits can be achieved by all this data captured, packaged to the cloud and then remotely accessed?

Looking at the uses of remote monitoring via the cloud in respect to pumping stations, the first benefit is the data or, in basic terms, an insight into building up a picture of the operation. With many variables consistently recorded, such as incoming voltage, pump running durations, operating current and wet will infill rate, there is the ability to track all activity in real-time, and then plot this as history.

IDENTIFYING ‘BEHAVIOUR’ AND ESTABLISHING PUMP MONITORING RULES

Once a picture is established in terms of normal operation for the asset - such as peak demand trending early morning and evening usage rates - and the appropriate pump operating cycles for this period, you can begin to assign ‘rules’ in how the data is to be managed when exceptions to this normal behaviour occur.

For example, a pump station generally will see a consistent infill rate during peak demand periods of 6am to 9am and empty the sump to a normal stop level in approximately 4 minutes when called to operate. However, on any given day, the 4-minute run time becomes longer and longer despite the inflow to the station remaining constant - we can use our previous data to identify the root cause of the issue.  or example, a stuck non-return valve could mean that all liquid being pumped is simply being re-circulated into the sump via the standby pump and pipework leg.

Creating rules from the data will provide early warning notifications to be generated by such events as above and alert responders.

Before this technology to monitor, record and report data in such a manner, system failures and prolonged run periods would have gone undetected, resulting in excessive wear, high running costs and potential environmental damage.

Remote monitoring of pumping stations can provide several cost-saving benefits over traditional site visits. Some of the specific ways in which remote monitoring can help to reduce costs include:

• Labour attendance efficiency - Any changes in normal pump operations are detected and reported, meaning that staff deployed to respond to such breakdowns know what the issue is before arrival and therefore are equipped with an understanding of the failure and any respective spare parts that are required. Diagnoses prior to site attendance reduces labour time, the number of visits required, and consequently, the productivity of reactive maintenance staff is increased.
• Reduced travel costs - With remote monitoring, it is not necessary for operators to physically visit the pumping station to collect data or perform inspections. This can help to reduce the cost of travel, including expenses such as fuel, vehicle maintenance, and accommodation.
• Increased efficiency - Remote monitoring allows for continuous monitoring of pumping stations, which can help to identify problems as they arise and allow for timely intervention. This could help to reduce downtime and increase the overall efficiency of the pumping station, leading to cost savings.
• Reduced labour costs - Remote monitoring can help reduce the amount of labour required to monitor and maintain pumping stations. This can lead to cost savings through reduced labour costs and increased productivity.
• Enhanced safety - Remote monitoring can help to reduce the need for operators to work in potentially hazardous environments, such as at pumping stations that handle dangerous fluids. This can help to improve safety and reduce the risk of accidents, leading to cost savings through reduced insurance premiums and other related expenses.
• Life expectancy - The equipment's life expectancy is extended as trends from the data map a decrease in performance, and areas of concern can be addressed, such as wearing parts. Effective proactive maintenance in this manner ultimately extends the longevity of the equipment in service.

Overall, remote monitoring can help reduce the cost of maintaining and operating pumping stations while also improving efficiency and safety.

By frequently reviewing a pumping station's operating data, decisions can be made such as to ‘hold’ effluent in the chamber and instead allow pumping during periods of lower energy costs and when septicity is not a risk. Start and stop levels can also be adjusted to maximise storage potential in the wet well chamber prior to any ‘hold off’ period being entered.

All the above benefits offer more than just financial, labour resource and environmental benefits - above all it is peace of mind that equipment which is typically installed below ground and forgotten about is actually being monitored 24 hours a day, 7 days per week, 365 days per year.

• Sewage Pumping Stations
• Potable Water Supply
• Water Treatment Plants
• Sewage Treatment Plants
• Flood Warning for River and Culverts
• Effluent Distribution and Control
• Industrial Processes
• Food processing

Seer is available for rent for up to a 4 year period which is an economic choice for many sites which will be adopted by water companies. After 4 years the SEER unit becomes your property and you only have to pay the annual charge for monitoring and subscription to the cloud.

We offer standard monitoring portfolios for pumping systems and beyond. Bespoke monitoring offers plenty of choices and to get the best from any system there is a need to establish what you want monitored and useful that will be in protecting your system to ensure reliability and efficiency.

For expert advice with selecting the ideal pump monitoring guide for your application, call our team on +44 (0)1630 647200, email response@ttpumps.com or fill in our online enquiry form.

A pump monitoring unit is a device used to monitor and control pumps in a system. It typically includes sensors that measure various parameters such as flow rate, pressure, temperature, and power consumption, as well as control inputs that allow the operator to adjust the operation of the pump.

The unit may also include alarms and other features that alert the operator to potential problems or malfunctions in the pump system.

Some pump monitoring units are designed for specific types of pumps, such as water or oil pumps, while others are more general-purpose and can be used with various pump types.

The Seer range of monitoring equipment from T-T uses sensors to collect data about the performance and operation of a machine or system. The collected data is then analysed to identify patterns or trends indicating a problem or potential failure. Seer Monitoring is ideally suited to domestic, industrial and commercial settings. It can be used to monitor a wide range of equipment, including pumps, motors, engines, and other mechanical or electrical systems.

Seer monitoring systems improve efficiency, reduce downtime, and prevent costly equipment failures using data collected to optimise the performance of the equipment and to identify and troubleshoot problems before they lead to failures.

T-T has a range of monitoring devices available that are suitable for a range of applications:

• Alert/Alert Pro - detects the open and closed state of a volt-free switch (such as a float or pressure switch), giving an alarm on a closed circuit and resetting on an open circuit. Suitable applications include high/low-level alarm, high/low-pressure alarm, high/low temperature alarm and as an intruder alarm. The Alert Pro provides the same monitoring functions as the Alert, except with the addition of volt-free relay contact for remote monitoring capabilities.
• See the table below for information about T-T's Seer Monitoring Units:

 The monitoring system you choose will depend on the number and type of statuses you want to monitor, whether you require data logging, if you want to receive alerts remotely and the kind of connectivity your system will run on.

Identifying the detailed data you wish to capture and review will help you to choose a system, this can include incoming power supply, motor current, motor trip conditions and warning alarms such as high-level events.  

With any system that is fitted with Seer Monitoring and includes remote monitoring by T-T Controls we will contact you in the event of an issue to explain the details, discuss any remote intervention options and advise on whether on-site engineer attendance is required.

For any sites not monitored by T-T Controls please call us on +44 (0)1630 647200 and explain the issue, we can then try to solve the issue remotely and advise if breakdown service is needed.

If you have a Pump Maintenance Package/Service Agreement please provide us with the reference number and postcode for your site, this way we can identify your site and assist you faster.

T-T monitoring systems can be provided with or without monitoring by T-T Controls, with joint notification options available. With monitoring by T-T you can rest assured that we are receiving site data 24/7, 365 that is used to predict, prevent and resolve any problems as they develop.

T-T has some 40 plus years of designing and manufacturing control systems; from the early days, there has always been a demand reporting system failure that was normally an alarm light/beacon or audible alarm being the mainstay.

Over the years, we have evolved our monitoring systems as technology advances and our experience grew with pumping systems and industrial processes. Initial advances beyond a simple indicator light or audible alarm employed the telephone via PSTN lines, then mobile GSM reporting via SMS text messaging and now cloud technology with the Internet of Things products and services.

Alert - our entry-level unit, providing an audible and visual indication of an alarm condition,  typically level, is available in both mains power and conjunctive battery backup. Variations such as the Pro unit are available for replication of the alarm warning via a volt-free contact to other connected devices such as BMS (building management systems).

Alarm Tel - uses the Public Service Telephone Service (PSTN) phone line connectivity to provide recipients with notification of the alarm condition via a telemetry dial-out unit speech recorded message unit.  Capable of monitoring 3 user-defined alarm conditions, plus mains failure built-in as standard, the Alarm Tel offers reliable communication with no possibility of lack of network coverage or loss of GSM signal. Onboard battery backup provides coverage to report the alarm condition, even in the event of mains failure.

Seer - is the most advanced system in our range and uses cloud-based IoT servers to host and relay data captured via our Seer range of monitoring units.  Three units are offered, entry-level Seer Micro ideal for retrofitting into existing control panels or offering conversion from GSM-based alarm units.  SEER Junior is the next model in the range, supplied as a standalone weatherproof unit with data capture on an enhanced number of variables.  Finally, the SEER Advanced is the flagship model of the range, with the ability to monitor peripheral data inputs such a voltage per phase, along with other performance-related variables such as motor current draw, flow, combined with the facility to monitor the presence of digital signals such as level inputs, limit switches, etc., and display/relay this critical information worldwide in real-time 365 days per year.

Float switch level control brings many advantages to fluid handling applications, such as:

• Automatic control – float switches are ideal for pump and motor automation, starting and stopping operations when liquid levels reach pre-set high or low points.
• Increased safety – by negating the need for manual operation, float switches stop pumps from becoming damaged due to low-level dry running as well as preventing a tank or wet well overflow.
• Remote monitoring – when paired with a suitable monitoring system, some float switches allow for remote monitoring of wet well levels.
• Energy efficient – float switches optimise energy consumption by preventing pump dry running and also reduce potential emergency repair costs and environmental fines due to overflows.

Float switches are devices that detect liquid levels in a tank and control external components accordingly. This could be starting/stopping a pump or valve to prevent a wet well from overflowing or a pump from running dry, or powering an alarm that alerts you to high or low fluid levels.

All of T-T's Flo Series of float switches have an internal microswitch and rolling ball operator - as wet well levels raise the float the micro switch is activated, creating a closed circuit and signaling that fluid levels have reached a predetermined point. When well levels lower the float, the circuit is opened and the electrical signal that was powering the high-level alert stops.

Read our article How Does a Float Switch Work? in our Knowledge Hub for more information.

There are many level control devices available, such as float switches, conductivity rpobes and tuning forks, each with their own variety of options. Choosing the best level control solution for your application can be confusing or even daunting, but T-T Controls is here to help.

Read our How-To Guide in the T-T Knowledge Hub, How-to: Selecting Liquid Level Control Solutions, for an overview of available level control devices and their intended applications.

For further advice, call our team on +44 (0)1630 647200; email response@ttpumps.com; or complete an enquiry form online.

Each of T-T's Flo Series of float switches is designed to work best in different mediums:

• FLO107 - non-mercury float switch, designed for use in potable water applications, WRAS-approved materials.
• FLO101 - ATEX Approved float switch made to be used in Zone 0 applications (explosive atmosphere and hazardous gas environments).
• FLO106 - non-mercury, heavy-duty float switch ideal for use in diesel and fuel oil applications
• FLO103 - a non-mercury, polypropylene and economic float switch for general use.
• FLO102 - a non-mercury, polypropylene float switch for general use and heavy-duty applications.

Counterweights add stability to float switches in turbulent environments and serve as the pivot point for the switch. This allows for a wider range of control over liquid levels by increasing the difference or span between the switch positions.

There are various additional products available to make your float switch installation easier and your final level control solution more reliable.

There are cable/float mounted counterweights for all applications, along with our TTC Ready Level range which is made up of a suspension chain, upper chain hook, heavy duty weight, D shackle and carribeaner for secure mounting in turbulent level control environments. 

Both a float valve and a float switch detect liquid levels and control a system accordingly. A float valve is a mechanical device that regulates liquid flow based on liquid-level detection. A float switch, on the other hand, is an electrical sensor that detects liquid levels and triggers changes in other electrical components, such as activating a pump.

It is not usually recommended to bypass a float switch because its purpose is to detect liquid levels and control the system accordingly to protect the equipment/surrounding environment, such as preventing a pump from dry-running or a wet well from overflowing.

Glass Reinforced Plastic is a combination of glass fibres and plastic, offering a high strength to weight ratio, corrosion resistance and great durability.

We provide a variety of cabinet options with different finishes and colour choices, including smooth, textured, and brick effect finishes in GRP, available in a range of RAL or BS4800 colours.

Kiosks and enclosures available for next-day dispatch include:

• Single and double door floor standing cabinets, in mild steel or GRP, standard dark green colour.
• Wall-mounted, glass-reinforced polyester cabinets in various sizes, with glazed and plain door options.

View Kiosks and Enclosures for the latest stock information, and look for items with the green van symbol for same-day dispatch (on orders placed by 3pm).

Our experienced engineers can offer advice on the kiosk size you require based on the equipment being housed, taking into account the minimum space requirements needed for electricity board cut-out meters.

We can provide expert advice on the most suitable housing materials for your specific requirements, taking into consideration factors such as protection from dampness, humidity, corrosion, vandalism, and compliance with food safety regulations.

Call +44 (0)1630 647200; email response@ttpumps.com; or complete an enquiry form here for help from a member of the team.

Yes – most of our cabinets come with marine ply back boards, which can be extended to side walls and light pads if the cabinets are for specific equipment mounting.

Yes – our most popular locks are triangle-type cam locks for mild steel and cylinder night-latches for GRP.

We can also offer cabinets with specific locking type systems, such as hasp and staple, Abloy locks and keyed alike lock barrels.

Variable Speed Drives (VSDs) are compact units that control pump operations in order to maintain a constant predetermined phsyical property - such as system pressure, flow rate or temperature.

This is achieved through adjusting the frequency and voltage of the electrical input that the pump receives, increasing/decreasing the speed at which it operates in order to manage predetermined variables.

Pumps operated by VSDs will run at the speed needed to meet a system's real-time demands and keep variables (speed, pressure, temperature) within their pre-set range.

This reduces energy use and expenditure as well as equipment wear and tear, both extending the life of the system and reducing the need for maintenance.

Find more details on the benefits of using a VASCO Variable Speed Drive.

VSD's are suitable for almost any motor, however these must be correctly selected based on the application's voltage and current.  Other factors include cable lengths and supply protection from harmonic distortion which may occur, a full range of ancillary protective devices are available for this.

VSDs are typically paired with a single motor to safeguard against failure and maintain system functionality. However, by incorporating additional starting methods like Direct-on-Line, it is feasible to use one VSD with multiple motors, leading to cost savings for the system.

There are two main methods of speed/motor control:

• Fixed speed control involves running motors at a constant speed, this can be achieved through direct-on-line (DOL) or soft starters. In this method, the motor operates at a fixed speed without the ability to adjust it according to varying site demands or properties of the pump system's components.
• Variable speed control adjusts the motor speed in response to changing site demands and the characteristics of the pump system's components. VSDs adjust motor speed to match the specific requirements of the system. This allows for improved efficiency, energy savings and optimized performance.
  
  

Pressure switches can be powered mechanically or electrically, controlling pressure by monitoring pressure levels in a system and adjusting motor power accordingly.

T-T's Smart Range of pressure switches is our electrical version, offering precise control suitable for a range of pressures and capable of operating small motor loads directly, or, larger loads incorporated into a control.

Pressure control devices are useful across a range of different industries and applications, such as:

• Pressure boosting - buildings experiencing low-pressure mains delivery can install pressure control devices to improve flow to outlets such as showers, taps and household appliances.
• Pump system protection - if fluid pressure in a system is too high it can cause damage to equipment such as pumps, valves and pipes. This leads to increased maintenance needs and an increased chance of a breakdown occurring.

After a quick button press:

After holding the button for 3 seconds in order to enter setup mode:

After Holding the button for 10 seconds in order to factory reset:

Constant flashing (Set-up mode):

If you are not receiving emails from your Seer Nano monitoring unit, try the troubleshooting steps below:

• Ensure you clicked the confirm button in the confirmation email you received after set-up.
• Check your junk mail folder - if Seer Nano emails are appearing in here, check your email settings and ensure that 'noreplynano@ttpumps.com' is listed as a trusted sender (you may need to check your email provider's guidance on how to do this).
• Check your Seer Nano's WiFi connectivity by setting the device up again.

If you are still experiencing issues, call T-T and speak to our Controls & Monitoring experts at +44 (0)1630 647200.

From the home screen on the Nano Installer app, select the 'Reconfigure a Seer Nano' option and follow the step-by-step instructions.

Press and hold the button on your Seer Nano for 10 seconds, until the LED flashes green/red/green for 3 seconds. The device will then return to its factory default settings.

You will receive a notification email when the battery level is low.

No, the Seer Nano device is not waterproof.

No, Seer Nano monitoring units are not data loggers, they are an alert system. However, they are capable of reporting summary data such as monitoring unit battery level, the number of alerts the unit has experienced and the total amount of time spent in alert mode. These summaries are reported via email notification and can be configured for daily, weekly or monthly frequency.

If you need help with anything that is not already covered in these FAQs, or in other product details on this website, please contact response@ttpumps.com

Follow the troubleshooting steps below if your Seer Nano set-up is not working:

• Ensure that you have Location services enabled for the Nano Installer app. Both iOS and Android require that Location services are enabled in order to use Wi-Fi services.

Nano Installer app permissions (iOS):

Nano Installer app permissions (Android):

• Disable Mobile Data while setting up your Seer Nano.
• Your mobile device may be running services in the background that require internet connectivity. When connected to your Seer Nano via Wi-Fi your mobile device will not be able to access the internet. You may be prompted to use mobile data during the set-up process, ensure that you select 'keep trying Wi-Fi'.  
• If you are using a VPN (Virtual Private Network) on your mobile device, you may need to disable it while setting up your Seer Nano. The process required to do this may vary depending on the VPN service that you are using, although you can typically find this option in your mobile device settings. You can re-enable the VPN once your Seer Nano set-up has successfully completed.
• If you are unable to connect to a Wi-Fi network you know should be in range please ensure your router has its 2.4GHz frequency mode enabled. Some routers may require a little configuration to enable this option, but this is necessary because the Seer Nano only works on this frequency. You can search your manufacturer's website for information on how to enable the 2.4GHz option.

If you are still experiencing trouble setting up your Seer Nano monitoring unit, contact the Controls & Automation experts at T-T via telephone +44 (0)1630 647200 or email response@ttpumps.com.