Pump Controllers and Float Switch Price in Kenya

Pump controllers are the heart of modern water supply systems in Kenya, including urban water needs to remote agricultural water requirements. With the energy costs increasingly becoming a big concern, pump controllers are becoming vital to ensure optimal, efficient and safe use of water pumps.

In this blog, we will discuss the different types of pump controllers, float switches, uses, prices and considerations for purchase and installation.

What are Pump Controllers

Think of a pump controller a smart device that guards your water pump. Without controllers, water pumps would run continuously on power resulting to energy wastage, wear & tear and damage in case of dry runs.

The Cost of Pump Controllers in Kenya

The price of pump controllers in Kenya varies widely depending on the type, brand, features, and power handling capabilities. Here’s a general overview:

• Basic Pressure Switches/Flow Sensing Controllers: These are the most affordable, typically ranging from KES 3,000 to KES 10,000.
• Float Switches: Sold at Prices from KES 1,000 to KES 5,000, depending on cable length and material.
• Low Variable Speed Controllers (Inverters): For smaller pumps (e.g., up to 1.5 kW or 2 HP), from KES 15,000 to KES 40,000.
• Mid-Range to High-End Variable Speed Controllers and Intelligent Systems: Prices can range from KES 40,000 to KES 200,000+ for industrial-grade units, multi-pump control panels, or controllers with advanced features like remote monitoring, complex programming, and higher power ratings. Specialized borehole pump controllers can also fall into this higher price bracket (e.g., KES 17,000 for a 0.75-4kW 3-phase intelligent controller).

Why are Pump Controllers Essential?

A pump controller automates the pump’s operation, turning it on and off based on specific parameters like water pressure, flow, or liquid levels. This automation brings a multitude of benefits:

• Energy Efficiency: By running the pump only when needed, controllers significantly reduce electricity consumption, translating into lower utility bills.
• Extended Pump Lifespan: Preventing dry running, frequent cycling, and excessive pressure protects the pump’s motor and components, extending its operational life and reducing maintenance costs.
• Consistent Water Supply: Controllers ensure a steady and reliable water pressure, enhancing user convenience in homes and optimizing processes in industries and agriculture.
• Protection against Damage: Features like dry-run protection, overload protection, and surge protection safeguard the pump from various damaging conditions.
• Automation and Convenience: Eliminating the need for manual pump operation, freeing up time and labour.

Types of Pump Controllers

Pressure Switch Controllers

• How they work: These are among the simplest and most common. They use a pressure switch that senses changes in water pressure within the system. When the pressure drops below a set point (indicating water demand), the switch closes, turning on the pump. When the pressure rises above another set point (indicating demand has been met), the switch opens, turning off the pump.
• Applications: Ideal for domestic water supply, booster pumps, and small-scale irrigation where maintaining a relatively constant pressure is key.
• Limitations: Can lead to frequent on/off cycling if there are small leaks in the system or fluctuating demand, which can stress the pump.

Flow Sensing Pump Controllers (Electronic Pressure-Flow Regulators)

• How they work: These controllers combine pressure sensing with flow detection. They start the pump when a drop in pressure and the presence of flow is detected (e.g., a tap is opened). They stop the pump when the flow ceases (e.g., the tap is closed), often with a built-in delay. Most also incorporate dry-run protection.
• Applications: Popular for residential water supply, garden irrigation, and light commercial use, offering smoother operation than basic pressure switches.
• Advantages: Reduce pump cycling, provide dry-run protection, and are generally more robust than simple pressure switches.

Level Controllers (Float Switches)

• How they work: These controllers use float switches to detect liquid levels in tanks, reservoirs, or sumps. A float switch contains a mercury or mechanical switch that changes state (opens or closes) as the water level rises or falls, triggering the pump.
• Applications: Commonly used for filling overhead tanks, emptying sumps (e.g., sewage or drainage pumps), and managing water levels in boreholes.
• Variations: Single float switches for on/off operation at a specific level, or multiple float switches for controlling pump operation between high and low levels.

Variable Speed Pump Controllers (Inverters/VFDs – Variable Frequency Drives)

• How they work: These are the most sophisticated and energy efficient. Instead of simply turning the pump on or off, a VFD adjusts the pump’s motor speed to precisely match the system’s demand. This is achieved by varying the frequency and voltage of the electrical power supplied to the motor.
• Applications: Widely used in large residential buildings, commercial establishments, industrial processes, and advanced irrigation systems where precise pressure control, energy savings, and reduced wear and tear are critical.
• Advantages: Significant energy savings, constant pressure delivery (even with fluctuating demand), extended pump life, reduced noise, and soft start/stop capabilities.
• Considerations: Higher initial cost compared to other types.

Smart/Intelligent Pump Controllers

• How they work: These are advanced versions of VFDs or integrated systems that often include touchscreens, data logging, remote monitoring capabilities, and more comprehensive protection features (e.g., overcurrent, undervoltage, phase loss, dry run, over-temperature). They can often be programmed for specific schedules or conditions.
• Applications: Complex industrial applications, large agricultural projects, smart homes, and building management systems.
• Advantages: Maximum control, diagnostics, predictive maintenance capabilities, and integration with broader automation systems.

Direct-On-Line (DOL) Starters and Star-Delta Starters (for larger motors):

• How they work: While not “controllers” in the same sense as the above, these are fundamental electrical control methods for starting and stopping larger AC motors, particularly in industrial pumping applications. A DOL starter applies full voltage directly to the motor, while a Star-Delta starter reduces the starting current by initially connecting the motor windings in a “star” configuration and then switching to “delta” for normal running.
• Applications: Used for high-power pumps in industrial settings, water treatment plants, and large agricultural pumps. Often integrated with other control mechanisms like level switches or pressure transducer

Where to Get Pump Controllers in Kenya

The demand for efficient water management has led to a good supply of pump controllers across Kenya. You can buy Automatic Water Pump Controllers at Aqua Hub Ltd, a top water pump and irrigation accessories supplier in Kenya.

Application of Controllers and Float Switches

Pump controllers are versatile devices with applications spanning various sectors in Kenya:

• Residential Home Water Needs: Ensuring consistent water pressure for showers, taps, and appliances, especially in homes relying on borehole pumps or booster pumps from municipal supply.
• Rental Apartments and Buildings: Managing booster pump systems to provide adequate water pressure to multiple floors.
• Agriculture and Irrigation: Automating water supply to crops, ensuring efficient use of water resources, and preventing dry running in boreholes or surface water sources.
• Industrial Uses: Regulating water flow and pressure for cooling systems, processing, cleaning, and other vital operations.
• Water Treatment Plants: Controlling pumps for filtration, purification, and distribution.
• Rainwater Harvesting Systems: Managing pumps to transfer collected rainwater for household use or irrigation.
• Sewage and Drainage Systems: Automating the emptying of sumps and preventing overflows.

How to Connect Float Switch

Start by Selecting a convenient submersible pump according to your required water needs. You can mount your float switch on the wall or install it suspended in a wall or tank. Identify a low point or height from the bottom of the water source where you want the float switch to disconnect the pump when water volume drops below it. Identify a high point as well, where you want the water pump to start automatically when water volume exceeds this level. Adjust the weight of the float switch and then wire the pump to the circuit breaker and magnetic contactor mounted on the wall. Connect the float switch cable to the circuit using a splicing kit. Lower the submersible pump and float switch to the borehole.

Maintenance Tips for Long-Term Performance

• Inspect Electrical Connections: Periodically check for loose wiring, corrosion, or signs of overheating at the terminals.
• Clean Sensors: Dust, dirt, or mineral buildup can affect sensor accuracy. Clean pressure switches and flow sensors regularly, especially in areas with hard water.
• Check Pressure Settings: For pressure-based controllers, ensure the cut-in and cut-off pressures are set appropriately for your system.
• Monitor for Leaks: Persistent pump cycling can indicate leaks in the plumbing system. Repairing leaks will reduce pump workload and energy consumption.
• Protect from Elements: Ensure controllers, especially electronic ones, are protected from direct sunlight, rain, and excessive humidity. Use weatherproof enclosures if installed outdoors.
• Observe Pump Behavior: Pay attention to how often the pump starts and stops. Frequent cycling or continuous running when it shouldn’t indicate an issue with the controller or the system.
• Consult the Manual: Always refer to the manufacturer’s manual for specific maintenance guidelines and troubleshooting steps.
• Professional Servicing: For complex variable speed drives or industrial control panels, consider professional inspection and servicing periodically.

Recommended Pump Controllers for Different Pumps

Choosing the right controller largely depends on the pump type and its application:

• For Small Domestic Pumps (e.g., 0.5 HP to 1.5 HP surface pumps for household supply):
  • Recommendation: Electronic pressure-flow regulators (automatic pump control units). They are affordable, offer dry-run protection, and are generally easy to install.
  • Examples: Pedrollo Easysmall, Ingco Automatic Pump Control
• For Submersible Borehole Pumps (especially in residential and small-scale agriculture):
  • Recommendation: Intelligent borehole pump controllers or variable speed drives. These are crucial for protecting the pump from dry running, fluctuating water levels, and ensuring optimal output.
  • Examples: Specialized intelligent pump controllers from Dayliff, CRI Fluid Systems, or other borehole equipment suppliers. VFDs are excellent for maximizing efficiency and lifespan, especially for deeper wells.
• For Large Agricultural or Industrial Pumps (e.g., 5 HP and above):
  • Recommendation: Variable Speed Drives (VFDs) or comprehensive control panels integrated with level switches, pressure transducers, and motor protection relays.
  • Examples: custom-built control panels from industrial automation specialists.
• For Sump Pumps or Tank Filling/Emptying Applications:
  • Recommendation: Float switches are the primary control method here, often combined with a basic contactor or relay for motor control.
  • Examples: Various types of float switches with appropriate cable lengths.

Critical Considerations When Buying a Pump Controller

Before making a purchase, ask yourself these vital questions:

1. Pump Specifications:
   • Power (kW/HP): Ensure the controller’s power rating matches or exceeds your pump’s power.
   • Voltage (Single Phase/Three Phase): This is crucial. A single-phase pump needs a single-phase controller, and a three-phase pump needs a three-phase controller.
   • Current (Amps): The controller’s maximum current rating should be compatible with your pump.
2. Application Needs:
   • What is the primary function? (e.g., constant pressure, tank filling, drainage, irrigation scheduling).
   • How critical is energy efficiency? If energy savings are a top priority, a VFD is the best choice.
   • What level of automation is required? Basic on/off, or advanced programming?
3. Protection Features:
   • Dry-run protection: Essential for any pump.
   • Overload protection: Guards against motor burnout.
   • Over/Under Voltage Protection: Protects against power fluctuations common in some areas.
   • Short Circuit Protection: A basic safety feature.
4. Environment:
   • Indoor or Outdoor Installation: If outdoors, ensure the controller has an appropriate IP rating (Ingress Protection) for dust and water resistance.
   • Operating Temperature Range: Kenya’s climate is generally warm; ensure the controller can withstand ambient temperatures.
5. Ease of Installation and Use:
   • Some controllers are plug-and-play, while others require professional electrical installation.
   • Consider if you need a display (LEDs or LCD) for status monitoring and error codes.
6. Brand Reputation and Warranty:
   • Choose reputable brands known for quality and reliability.
   • A good warranty provides peace of mind.
7. Budget:
   • While cost is a factor, weigh the initial investment against long-term benefits like energy savings and extended pump life.