Automatic Water Level Cotroller

The automatic water level controller is designed to maintain the water level in tanks or reservoirs by automatically switching the water pump on and off based on the water level. This device helps in preventing overflow or dry running of the pump.

Components

1. 555 Timer IC (1no)
2. BC547 NPN Transistor (2no)
3. 1k 0.25-watt Resistors (2no)
4. 22k 0.25-watt Resistors (3no)
5. 180k 0.25-watt Resistor (1no)
6. 1M 0.25-watt Resistors (2no)
7. LED 1.5V 5-mm (1no) 1N4007
8. Diode (D1) (1no) 100nF (104)
9. Capacitor (C1) (1no) 12V
10. SPDT Relay (Contact Rating 30A) (1no)
11. Connectors & IC base (4 pin)
12. Slide switch (1P2T) (1no)P
13. 13 A Plug Top
14. 13 A Socket
15. 2 Core Wire
16. Enclosure box

The pump will automatically start for the following conditions

1. Overhead tank water level comes below the "ON" level.
2. The underground water level above UL1 level.
3. Manual switch S1 should be in ON position.

The pump will automatically stop for the following conditions

1. Overhead tank water level touches the "OFF" level.
2. Underground water level comes below UL1 level.

The COM wire should be always under the water level both in the overhead and underground tank.

The pump will stop automatically if the water level comes belowUL1 level in the underground tank.

And the pump will start automatically if the water level touches the UL1 level in the underground tank.

Input Voltage: 230V

Operating Voltage of Circuit: 12V

Relay:30 A

Output Power: 1 HP =746W

Operating Temperature: 0°C to 50°C

Water Level Sensors:

1. Place water level sensors in both the overhead tank and underground tank.
2. Connect the COM terminal of each set of sensors to the ground.
3. The ON and OFF sensor lines from the overhead tank will control the upper and lower water level limits.
4. The UL1 sensor in the underground tank ensures there is sufficient water available for pumping.

555 Timer and Related Circuitry:

1. Connect the 555 Timer IC in an astable configuration.
2. Resistors (22kΩ, 1MΩ, etc.) are used to set the timer's timing cycles.
3. A capacitor (104 or 0.1µF) is used for stable operation.
4. Use the first BC547 transistor to handle the 555 Timer's output signal to control the relay.

Relay Control Circuit:

1. Use a second BC547 transistor to act as a switch for the 12V relay.
2. The relay connects and disconnects the 220V AC power supply for the water pump.
3. The diode (1N4007) is placed across the relay coil to protect against voltage spikes (flyback protection).
4. An LED is connected with a 1kΩ resistor to indicate the relay's operation state.

Power Supply:

1. A 12V DC supply is used to power the entire circuit.
2. The 220V AC supply is connected to the relay's common (COM) and normally open (NO) contacts to control the pump.

Working Principle:

1. When the water level in the overhead tank falls below the ON level sensor, the circuit activates the relay, turning on the pump to fill the tank.
2. When the water reaches the OFF sensor, the circuit deactivates the relay, turning the pump off.
3. The UL1 sensor in the underground tank ensures the pump only operates if there is sufficient water available.

Assembly Tips:

1. Carefully solder all connections.
2. Ensure proper insulation to avoid short circuits.
3. Test the circuit with a 12V power source before connecting it to the 220V AC line to ensure correct functionality.

This setup automatically manages water levels and pump operation, ensuring efficient water management.

Electrical Safety:

1. Always turn off power before installing or servicing the controller.
2. Use only the specified power supply voltage.(230V/50HZ)

Water Safety:

1. Install the water level sensors correctly to prevent accidental water spillage.
2. Ensure that the water tank is properly sealed to avoid leakage or overflow.

Installation Precautions:

1. Do not install the controller in areas exposed to direct water spray.
2. Check for any faulty wiring before use to avoid short circuits or electrical hazards

Description of the Components:

1. Water Level Sensors: These sensors detect the water level inside the tank.
2. Controller Unit: The main unit that processes the sensor data and controls the pump.
3. Pump Relay: The relay switches the pump on/off depending on the water level.
4. Display LED: Displays water level in several steps.

Unboxing the Device

Carefully remove the components from the box. Check for any visible damage to the controller or sensors during shipping.

Tools Required

1. Screwdriver
2. Wire cutter/stripper
3. Electrical tape (if necessary)
4. Drill (for mounting Enclosure)

Step-by-Step Installation Guide

1. Mount the Controller: Place the controller unit in a dry, safe location near the water tank.
2. Install the Water Level Control Wires: Place the wires at the desired high and low points inside the tank.
3. Connect the Pump in Socket: Connect the pump and ensure proper electrical connections.
4. Power Supply: Connect the controller to a stable power source, following the voltage specifications.(230V/50HZ)
5. Final Check: Double-check all connections and ensure the installation is secure.

Basic Operation: The controller automatically detects the water levels and controls the pump accordingly. The pump will turn on when the water level falls below the low threshold and turn off when it reaches the high threshold.

Indicators

1. Red LED: Pump is on and water is being filled.
2. Red LED: Water level is either too high or too low (20%-40%)
3. Green LED: Water level is high (Up to 40%)

Cleaning and Maintaining: Periodically clean the sensors to ensure accurate readings. Avoid using abrasive materials; use a soft cloth or sponge.

Checking the Electrical Connections:  Inspect the wiring for any wear and tear. Ensure the connections are firm and free from corrosion.

Replacing the Fuse (if applicable): If the system stops working, check the fuse. Replace with the same type and rating of fuse if necessary

Common Problems and Solutions

1. Pump doesn’t turn on: Check the water level settings. Ensure the power supply is connected and functional.
2. Pump runs continuously: Verify that the water level sensors are correctly positioned and not malfunctioning.