A submersible pump system includes a submersible pump assembly having one or more stages of impellers and a submersible motor assembly that drives the pump assembly. The submersible pump assembly includes a motor housing, a motor within the motor housing for driving the pump assembly and a control m
A submersible pump system includes a submersible pump assembly having one or more stages of impellers and a submersible motor assembly that drives the pump assembly. The submersible pump assembly includes a motor housing, a motor within the motor housing for driving the pump assembly and a control module mounted to the motor housing for operating the motor. The control module is electrically connected to a power line and comprises a controller and a variable frequency drive driven by the controller. The controller operates the variable frequency drive to drive the motor to maintain a constant pressure output condition from the pump assembly.
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1. A submersible pump system comprising: a pressure switch configured to measure a surface pressure of a fluid in piping proximate to a use point of the fluid in the piping;a power source having a power line extending therefrom, the power source configured to shut off power to the pump when a maximu
1. A submersible pump system comprising: a pressure switch configured to measure a surface pressure of a fluid in piping proximate to a use point of the fluid in the piping;a power source having a power line extending therefrom, the power source configured to shut off power to the pump when a maximum pressure condition is detected at the pressure switch;a submersible pump assembly having one or more stages of impellers, the pump assembly having a discharge fitting configured to be connected to the piping;a pressure sensor measuring a pressure of fluid directed through the discharge fitting into the piping, the pressure sensor being positioned above the discharge fitting in proximity to the submersible pump assembly and remote from the pressure switch, the pressure at the pressure sensor being greater than the surface pressure; anda submersible motor assembly driving the pump assembly, the motor assembly having a motor housing, a motor within the motor housing for driving the pump assembly and a control module for operating the motor, the control module being electrically connected to the power line, the control module being electrically connected to the pressure sensor by a sensor cable entirely submerged with the submersible pump assembly and submersible motor assembly, the control module comprising a controller and a variable frequency drive driven by the controller based on pressure data from both the pressure switch and the pressure sensor;wherein the controller is calibrated by measuring the pressure sensed by the pressure sensor at a time when the power source is shut off when the maximum pressure condition is detected by the pressure switch; andwherein the controller operates the variable frequency drive to drive the motor to maintain a constant pressure output condition from the pump assembly at a pressure that is a fraction of the measured pressure sensed at the time when the power source is shut off when the maximum pressure condition is detected by the pressure switch. 2. The submersible pump system of claim 1, wherein the controller is programmed with an offset pressure, the controller operates the variable frequency drive to drive the motor at a setpoint pressure that is equal to the pressure sensed by the pressure sensor at the time when the power source is shut off when the maximum pressure condition is detected by the pressure switch less the offset pressure. 3. The submersible pump system of claim 1, wherein the control module is submersible with the motor and the motor housing. 4. The submersible pump system of claim 1, wherein the control module is housed within the motor housing. 5. The submersible pump system of claim 1, wherein the pressure sensor is submersible and positioned above the pump assembly. 6. The submersible pump system of claim 1, wherein the controller is configured to turn on, turn off, speed up or slow down the motor based on the pressure sensed by the pressure sensor to maintain the constant pressure output condition. 7. The submersible pump system of claim 1, wherein the controller controls a power supply to the motor. 8. The submersible pump system of claim 1, wherein the motor comprises a permanent magnet motor. 9. The submersible pump system of claim 1, further comprising a communication module spatially separated from the control module, the communication module configured to be electrically connected to the power line, the communication module configured to transmit data to the control module via the power line, the controller configured to receive the data transmitted via the power line. 10. The submersible pump system of claim 9, wherein the communication module comprises a remote control and a receiver communicating with the remote control, the receiver being configured to be electrically connected to the power line to transmit data received from the remote control to the control module via the power line. 11. A method of operating a submersible pump system comprising: providing a pressure switch and a power supply at a surface, the pressure switch measuring a pressure of fluid in piping, wherein the pressure switch is operably coupled to the power supply to shut off the power supply when a pressure switch maximum pressure is detected;providing a pressure sensor, a pump assembly and a motor assembly submerged in a bore-hole or storage tank, the motor assembly having a motor and a control module for operating the motor, the control module being electrically connected to the power supply by a power line, the control module being electrically connected to the pressure sensor by a sensor cable, the control module having a controller and a variable frequency drive driven by the controller based on pressure data from the pressure sensor;operating the motor at increasing speed to increase a pressure provided by the pump assembly until the pressure switch shuts off the power supply to the pump;establishing a maximum pressure value sensed by the pressure sensor at a time when the power supply is shut off by the pressure switch when the pressure switch maximum pressure is detected;determining a setpoint pressure by subtracting an offset pressure from the maximum pressure value sensed by the pressure sensor; andoperating the motor to provide a constant pressure output condition from the pump assembly at the setpoint pressure. 12. The method of claim 11, wherein said operating the motor comprises conducting a flow test to determine if flow is present or absent and initiating a stop pump operation when flow is absent to stop the pump assembly from pumping fluid. 13. The method of claim 12, wherein said initiating the stop pump operation comprises boosting the pressure in the pipe to a boost pressure and stopping the pump assembly when the boost pressure is reached. 14. The method of claim 12, wherein after the pump assembly is stopped, the method further comprises monitoring the pressure at the pressure sensor to determine if an under-pressure condition occurs, and when the under-pressure condition occurs, the method further comprises initiating a start pump operation. 15. A submersible pump system comprising: a power supply at a surface, the power supply having a power line extending therefrom to a submersible motor assembly;a pressure switch at a surface, the pressure switch measuring a surface pressure of a fluid in piping proximate to a use point of the fluid in the piping, the pressure switch being operably coupled to the power supply to shut off the power supply when a pressure switch maximum pressure is detected in the piping;a submersible pump assembly submerged in a bore hole or storage tank, the pump assembly having one or more stages of impellers;a pressure sensor submerged in the bore hole or storage tank, the pressure sensor measuring a pressure of fluid in the piping proximate to the pump assembly; andthe submersible motor assembly submerged in the bore hole or storage tank, the motor assembly being electrically connected to the pressure sensor by a sensor cable, the motor assembly having a motor for driving the pump assembly and a control module for operating the motor, the control module being operable in a calibration mode and in a constant pressure mode;in the calibration mode, the control module operating the motor at increasing speed to increase the pressure provided by the pump assembly until the pressure switch shuts off the power supply to the pump assembly, the control module establishing a maximum pressure value sensed by the pressure sensor at a time when the power supply is shut off by the pressure switch when the pressure switch maximum pressure is detected, the control module determining a setpoint pressure, less than the maximum pressure value, by subtracting an offset pressure from the maximum pressure value sensed by the pressure sensor;in the constant pressure mode, the control module operating the motor to provide a constant pressure output condition from the pump assembly at the setpoint pressure. 16. The submersible pump system of claim 15, wherein the control module comprises a controller and a variable frequency drive driven by the controller based on pressure data from the pressure sensor. 17. The submersible pump system of claim 16, wherein the controller operates the variable frequency drive to drive the motor to maintain a constant pressure output condition from the pump assembly at the setpoint pressure that is a fraction of the maximum pressure value sensed at the pressure sensor when the power source is shut off by the pressure switch. 18. The submersible pump system of claim 15, wherein the setpoint pressure is between approximately 50% and 99% of the maximum pressure value. 19. The submersible pump system of claim 15, wherein the setpoint pressure is between approximately 90% and 99% of the maximum pressure value. 20. The submersible pump system of claim 15, wherein the offset pressure is between approximately 1% and 10% of the maximum pressure value. 21. The submersible pump system of claim 15, wherein the control module is submersible with the motor in a motor housing. 22. The submersible pump system of claim 15, wherein the pressure sensor is positioned at a discharge fitting of the pump assembly. 23. The submersible pump system of claim 15, wherein the control module conducts flow tests to determine if flow is present or absent and initiates a stop pump operation when flow is absent to stop the pump assembly from pumping fluid. 24. The submersible pump system of claim 23, wherein the control module boosts the pressure in the pipe to a boost pressure higher than the setpoint pressure but lower than the maximum pressure value during the stop pump operation and the control module stops the pump assembly when the boost pressure is reached. 25. The submersible pump system of claim 15, wherein after the pump assembly is stopped, the control module monitors the pressure at the pressure sensor to determine if an under-pressure condition occurs, and when the under-pressure condition occurs, the control module initiates a start pump operation. 26. The submersible pump system of claim 25, wherein the control module has an under-pressure value that is less than the setpoint pressure, the control module determines that the under-pressure condition occurs when the pressure sensed by the pressure sensor is at or below the under-pressure value. 27. The submersible pump system of claim 25, wherein the control module has an under-pressure value that is less than the setpoint pressure, the control module determines that the under-pressure condition occurs when the pressure sensed by the pressure sensor is at or below the under-pressure value. 28. The submersible pump system of claim 15, wherein the control module is configured to turn on, turn off, speed up or slow down the motor based on the pressure sensed by the pressure sensor to maintain the constant pressure output condition. 29. The submersible pump system of claim 15, wherein the control module controls a power supply to the motor. 30. The submersible pump system of claim 15, wherein the motor comprises a permanent magnet motor. 31. The submersible pump system of claim 15, further comprising a communication module spatially separated from the control module, the communication module configured to be electrically connected to the power line, the communication module configured to transmit data to the control module via the power line, the controller configured to receive the data transmitted via the power line. 32. The submersible pump system of claim 31, wherein the communication module comprises a remote control and a receiver communicating with the remote control, the receiver being configured to be electrically connected to the power line to transmit data received from the remote control to the control module via the power line.
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