A small domestic pump often switches itself, with a float switch or pressure controller built in. Once you have a larger pump, three phase power, two pumps, or a pit that must never overflow, the switching moves into a control panel. The panel starts and stops the pumps from floats or pressure switches, protects the motors, alternates between pumps, and raises an alarm when something goes wrong.
The live panels in the Pump Control Panels range are HydroSTART controllers from Maxijet.
What a HydroSTART panel does
Per the listings, HydroSTART controllers automate and protect pumps in domestic, agricultural and light industrial systems, guarding against dry running, overload and pressure swings. They accept up to 5 float switches for level control or up to 3 pressure switches for pressure control, with adjustable overload, undercurrent and zero-current sensing. Dual pump models alternate duty between pumps, and there's a high level alarm with a stormwater or sewage mode. They use an inner door construction.
DOL or soft starter
- Direct-on-line (DOL) connects the motor straight to full voltage. It's simple and reliable, and suits most small and medium pumps. The catch is the starting current: a motor draws several times its running current for a moment as it starts.
- Soft starter ramps the voltage up over a few seconds, so the motor starts gently. That cuts the starting current, reduces the mechanical shock on the pump and pipework, and helps prevent water hammer when a large pump starts.
Choose a soft starter for larger three phase pumps, for sites on a generator or a weak supply where a big starting current causes problems, and for long rising mains where a hard start causes hammer.
Single or dual pump
A dual pump panel runs two pumps with duty alternation, sharing the running hours between them and bringing the second pump in if the first fails or can't keep up. Most commercial and multi-unit sewage stations are designed with two pumps for this reason. A single pump panel suits a single pump in a domestic or light duty station.
The live range
| Controller | Pumps | Supply | Range | From |
|---|---|---|---|---|
| Single pump DOL (FPC-82141/82143) | 1 | 1 or 3 phase | 0.1–16A or 12–18A | $2,443.05 |
| Dual pump DOL (FPC-82241/82243) | 2 | 1 or 3 phase | 0.1–16A or 12–18A | $2,602.55 |
| Dual pump soft starter (FPC-82243-S) | 2 | 3 phase | 1.5kW to 37kW | $5,644.05 |
| Dual pump hot water controller with time clock and BMS (FPC-82241-HWC/TC/BMS) | 2 | 1 phase | 0.1–16A | $2,800.55 |
The hot water version is for hot water circulation systems, alternating two circulators on a time clock with a building management system output.
Sizing it
- Use the motor's full load current. The DOL panels are selected by current range (0.1–16A or 12–18A), so read the full load amps off the motor nameplate and choose the range that covers it.
- Soft starters by kW. The soft starter panel is sold by motor kW, from 1.5kW to 37kW. Choose the size that matches the motor.
- Count the floats. A typical dual pump sewage station uses floats for off, duty pump on, standby pump on and high level alarm. Check your design against the 5-float limit. See our float switch guide.
- Remote alarm. If nobody will see the panel's alarm, add a remote alarm or strobe.
Many other Maxijet controller and accessory listings in this collection (GSM/SMS senders, rain to mains controllers, tank level indicators, undersink controllers) aren't orderable online at the moment; contact PSA if you need one. All panels must be installed and connected by a licensed electrician. The HydroSTART range is available to order on backorder; contact PSA to confirm lead time.
Frequently Asked Questions
What's the difference between a DOL and soft starter pump controller?
A DOL controller starts the motor at full voltage, which is simple but draws a large starting current. A soft starter ramps the voltage up, reducing starting current, mechanical shock and water hammer.
When do I need a dual pump controller?
When the station has two pumps for duty/standby. A dual controller alternates the pumps and brings the second one in if the first fails or can't keep up.
How do I size a pump control panel?
DOL panels are chosen by the motor's full load current (0.1–16A or 12–18A). The HydroSTART soft starter panel is chosen by motor kW, from 1.5kW to 37kW.
How many float switches can a HydroSTART controller take?
Up to 5 float switches for level control, or up to 3 pressure switches for pressure control.