As an engineering company we are constantly curious and tenacious in finding a better way to make our products better or solve a problem. When we decided to develop the Perfect Pressure Pump (P3) we looked at the competitors offerings, listened to users , plumbing professionals and implemented the best solutions.
P3 incorporates our exclusive technologies. TAW never copies other companies ideas.
There is no challenge in copying an inferior product just to be another “me too”.
Creativity has always been the passion and drive in developing our products.
On-Off Controlled pumps. A cheap mans booster.
These are pumps that incorporate some type of pressure switch, bladder tank and flow switch.
Cheap yes but they have many draw backs, let’s go through some of them.
1) The pump will cycle on and off and although there are some band-aid products that lower this cycling, bottom line is the pressure will never be spot on. It will always deviate from the on and off pressures. A bladder tank is needed because without it the pressure spikes and dips could damage pipes and the pressure tank smooths out the low and high pressure deviations when the pump turns on and off.
2) The pump has two speeds, full speed or stopped. There is no variable speed in an On-Off pump. The pump cycling prematurely wears pump seals, bearings and it stresses the motors winding as the motor draws up to 7 times the full load current rating of the motor as it starts across the line at full voltage. This heats up the motor and will destroy the motor if started too frequently.
3) A bladder tank is needed and this component is high maintenance. If the pressure is not set properly, the tank will saturate or will cause the pressure switch to bounce if set too high. Bladder tanks should be checked twice a year to insure they are not leaking and still functioning. something most people never do.
4) A flow switch is a mechanical device that determines if water is moving through the pump. Without a flow switch or some other means to determine the pump is actually flowing water while running, the pump will heat up to the point that it damages the pumps seals. Flow switches are known for clogging.
If a magnetic pin wheel is incorporated, minerals and other contaminate in the water eventually stops it from working. Some of our competitors embed this device in the pump making you replace the pump to repair the problem.
5) Pressure reducing valves. Since On-Off pumps can not modulate to maintain pressure, some competitors use a pressure reducing valve, this device limits the pressure to a pre-set to prevent pipe damage and excessively high pressures. These devices also fail but when they do, it could cause a catastrophic pipe break. Reducing valves are like driving your car with one foot on the gas while modulating the cars speed with the brake. A huge waste of energy.
6) The pressure switch has mechanical contacts that eventually wear or burn out. Welded contacts could make the pump stay running till it burns out or if no pressure relief is incorporated, blow pipes.
So lets discuss TAWs technologies and why they are superior.
Variable speed pumps. The best way to go when it’s done right.
These are pumps that incorporate some sort of electronic device, typically a Variable Frequency Drive (VFD). This is the technology P3 uses. It’s superior in performance to the above On-Off pump design but more costly. VFDs can also be unreliable when they are improperly used or applied. TAW has 40 years of experience with VFDs, starting back in 1978 when the owner spent 100% of his time servicing VFDs for large companies including Toshiba, Emerson, ABB, AB, Mitsubishi, Siemens, Schneider, Eaton/ Cutler Hammer, Danfoss and dozens of others. To this day we are hired by municipalities and OEMs all over the world to consult on their VFDs. A properly designed and applied VFD should last 15-25 years. Much longer than most of our competitors 3-5 years. A properly designed VFD will incorporate the following features.
1) IP66 – meaning 100% waterproof and wash down proof. the inside and outside air do not mix. This prevents contaminants such as moisture, salt air , dust, insects and other airborne problems from entering the drive.
2) Keeping the drive cool by using proper heat sinks. A drive should be rated to 60 degrees C. Not 40 or 50. An internal fan should come on when the temperature reaches 40 or above and it should protect itself from being over heated by direct sunlight.
3) Protections including over current, over voltage, under voltage, high heat, low power, low pressure, high pressure and the like.
4) Voltage spike resistance. A good VFD will have conservatively designed power components that are rated to withstand 1200-1800 Volts. MOVs or lightening protection to protect against line surges and properly designed ground planes to prevent against electrical noise. Our VFD has all of the above, most of our competitors put together a cheap drive board and hope it lasts the 1-2 year warranty period. We torture test our drives, Our drives can withstand a direct pressure washer water stream and is 100% waterproof. We provide an aluminum sun shield if the product is to be mounted outdoors to prevent the sun from overheating the drive and our drive is 100% aluminum up to 2HP, and painted black. It is black because black spreads the internally generated heat more evenly across the drives interior surface better than any other color.
5) In addition to reliability, the VFD furnishes P3 unsurpassed performance. We can prove this with our predictive PID and no flow algorithms. Without going into too much detail we will attempt to educate you on PID and why our technology is vastly superior. PID stands for Proportional, Integral, Derivative although most of our competitors do not know how to design the D part so they only use the P and I part. The P looks at the set point pressure and the actual pressure coming in from a pressure transducer and outputs the error signal. The higher the error the more compensation is output to the drive to get have the pump get to set point as fast as possible. This has its problems, most competitors wait until the pump gets to set point before adjusting the P output, this causes a high pressure “ring”. The integral reduces this ring but also effects the performance of how fast you get to set point and finally the derivative is gain that is applied to a fast rate change, more D allows the PID to maintain the set point more accurately but can cause oscillation if not designed properly. Most of our competitors fall into the latter since unlike TAW, they are not VFD experts and just slap on a drive that has “so-so” PID built into it. They totally ignore the important “D” component.
Our PID is exclusively TAWs IP. We do not wait to get to set-point, we predict what speed the pump needs to be at to maintain pressure before the over shoot/undershoot ring occurs. Our response is more like a square wave with response time typically in the 1-2 second range. Once there , no demand change will effect the pressure assuming the supply can keep up. This brings us to another exclusive TAW feature, Anti-cavitation.
6) Anti-cavitation occurs when the water supply can not keep up with demand, this starves the pump and turns the water into a vacuum on the suction side of the pump. When this vacuum reaches the discharge side of the pump it quickly is turns back into a liquid causing a “popcorn maker” sound. Cavitation is very destructive to a pump, over time cavitation will destroy the impeller. TAW automatically detects this cavitation and adjusts the pressure to the point that the cavitation stops. Once the demand decreases to the point the supply can keep up, the pressure is then returned, preventing damage or nuisance trip offs.
7) Another problem is running a pump with no flow. This will heat up the pump and damage it within hours. TAW has incorporated several new methods to solve this problem without using an external flow meter. Our no flow algorithm is not only accurate, but recently we improved it further to be reliable from 0-50 PSI inlet pressure down to 0.3 GPM. Something that has never before been able to be accomplished by any pump without some type of flow monitor.
8) Upgrade-able, since we designed our software, we have 100% control over its enhancements. Unlike competitors that simply “slap” on someones generic drive, we are constantly improving ours. And these improvements are based on listening to customers in the field. When an improvement suggestion is incorporated, an EEPROM is sent out free of charge to our family of customers to upgrade their products to the latest product enhancements.
9) Ease of use. Keep it simple! Our motto. We have one pressure pot, you turn it up to the pressure desired and you are done. Most of our competitors have complicated keypads, programming that can fail, parameters that get lost, keypads that fade and fail and it’s just over engineered and complicated. No need. Set the pressure pot and walk away, it’s that simple.
10) Lastly we want to discuss serviceability. Let’s be honest, everything eventually fails. We give P3 a three year warranty simply due to one component that will eventually fail. The pump seal. Pump seals are like brakes on your car, eventually it will need replacing, how often depends on how much the pump runs, a pump seal has a typical 3- 5 years service life. But the big difference is to replace our seal takes about 20 minutes and a $10.00 seal replacement kit. Most of our competitors simply tell you to purchase a new pump. Our check valve is also totally serviceable. You can take it out and take it apart and clean it, replace the seal if need be and put it back in service. Most of our competitors have their check inside a sealed plastic pump. Again, throw it away and buy a new one every 1-5 years. Same goes for our transducer and our VFD for that matter, no reason to replace the entire pump.
How long will our pump last? we estimate 15-20 years and anthing needing replacing is available without throwing away the entire pump.
So if you made it through this white paper you may have a better understanding of why our pump out performs all the competition.
At TAW our Passion, knowledge and experience shows. It’s what makes us who we are.
Thank you for your valuable time.
All the best,
Inventor of Perfect Pressure Pump