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CN-122014584-A - Intelligent control system and control method for sewage pump

CN122014584ACN 122014584 ACN122014584 ACN 122014584ACN-122014584-A

Abstract

The invention discloses an intelligent control system and a control method of a sewage pump, wherein the system comprises a main control board, an HMI control panel, a motor protection unit, a dual-mode liquid level detection unit and a fault prompting unit; the HMI control panel comprises a wireless communication module and a key module which are arranged independently of the main control panel, the main control panel is manually controlled through the key module and remotely controlled through the wireless communication module, the motor protection unit collects key electric parameters of a motor in the sewage pump in real time, the dual-mode liquid level detection unit collects first liquid level signals according to a main detection mode and also collects second liquid level signals according to a standby detection mode, the main control panel judges whether faults occur according to the key electric parameters, the first liquid level signals or the second liquid level signals, and the fault prompt module sends fault prompt signals when judging that the faults occur. The intelligent sewage pump control system realizes comprehensive intelligent and automatic control of the sewage pump, has compact design, controllable cost and comprehensive functions, and supports multi-mode remote monitoring.

Inventors

  • ZHOU RONG
  • ZHENG GUOFAN
  • WANG XIANCHAO
  • LI HONG

Assignees

  • 苏州路之遥科技股份有限公司

Dates

Publication Date
20260512
Application Date
20260211

Claims (20)

  1. 1. The intelligent control system for the sewage pump is characterized by comprising a main control board, an HMI control panel, a motor protection unit, a dual-mode liquid level detection unit and a fault prompting unit; The HMI control panel comprises a wireless communication module and a key module which are arranged independently of the main control board, wherein the wireless communication module is in communication connection with the main control board, and the key module is electrically connected with the main control board; the main control board is used for receiving a user instruction through the key module in the HMI control panel to manually control the sewage pump, and is also used for wirelessly communicating with a remote terminal through the wireless communication module to receive a remote instruction of the remote terminal so as to remotely control the sewage pump; The motor protection unit is used for collecting key electric parameters of a motor configured in the sewage pump in real time when the main control board controls the sewage pump, and transmitting the collected key electric parameters to the main control board in real time; The dual-mode liquid level detection unit is provided with a main detection mode and a standby detection mode, and is used for collecting a first liquid level signal of the sewage pump according to the main detection mode and transmitting the first liquid level signal to the main control board when the main control board controls the sewage pump, and is also used for collecting a second liquid level signal of the sewage pump according to the standby detection mode and transmitting the second liquid level signal to the main control board when the main control board controls the sewage pump, wherein the first liquid level signal and the second liquid level signal are different; The main control board is also used for receiving the key electrical parameters transmitted by the motor protection unit, judging whether the sewage pump has a motor fault according to the key electrical parameters, receiving the first liquid level signal or the second liquid level signal transmitted by the dual-mode liquid level detection unit, and judging whether the sewage pump has a liquid level fault according to the first liquid level signal or the second liquid level signal; The fault prompting module is used for sending out a fault prompting signal when the main control board judges that the sewage pump has motor faults and/or liquid level faults.
  2. 2. The intelligent control system of a sewage pump according to claim 1, wherein a motor in the sewage pump is provided with a motor power supply loop, and the key electrical parameters comprise a motor phase current signal and a motor phase voltage signal in the motor power supply loop; the motor protection unit comprises a phase current detection circuit and a phase voltage detection circuit, wherein the input end of the phase current detection circuit and the input end of the phase voltage detection circuit are electrically connected with the motor power supply loop, and the output end of the phase current detection circuit and the output end of the phase voltage detection circuit are electrically connected with the input end of the main control board; the phase current detection circuit is used for collecting the motor phase current signals in the motor power supply loop and transmitting the motor phase current signals to the main control board; The phase voltage detection circuit is used for collecting the motor phase voltage signals in the motor power supply loop and transmitting the motor phase voltage signals to the main control board.
  3. 3. The intelligent control system of a sewage pump according to claim 2, wherein the phase current detection circuit comprises a current transformer U11, a first operational amplifier U12A, a first diode bridge rectifier, a first electrolytic capacitor C30, a first capacitor C7, a first resistor R5, a second resistor R6, a third resistor R7, a fourth resistor R37, a fifth resistor R38, and a sixth resistor R103; The primary side of the current transformer U11 is electrically connected with one phase line of a motor power supply loop, the secondary side of the current transformer U11 is electrically connected with the input end of a first diode bridge rectifier, the negative electrode of the output end of the first diode bridge rectifier is grounded, the positive electrode of the output end of the first diode bridge rectifier is electrically connected with the positive input pin of a first operational amplifier U12A through a first resistor R5, the positive electrode of a first electrolytic capacitor C30 and the first end of a sixth resistor R103 are both connected to a common connection end between the positive electrode of the output end of the first diode bridge rectifier and the first resistor R5, the negative electrode of the first electrolytic capacitor C30 and the second end of the sixth resistor R103 are both grounded, the first end of a fourth resistor R37 is connected to a common connection end between the first resistor R5 and the positive input pin of a first operational amplifier U12A, the second end of the fourth resistor R37 is grounded, the power pin of the first operational amplifier U12A is electrically connected with the circuit power supply end through a first resistor R5, the first end of the first operational amplifier U12A is connected with the first input pin 7 of the first operational amplifier U12A through the negative electrode of the first resistor R7, and the first end of the first resistor R7 is connected between the first end of the first resistor C7 and the first end of the first operational amplifier U12A.
  4. 4. The intelligent control system of a sewage pump according to claim 2, wherein the phase voltage detection circuit comprises a transformer U23, a second operational amplifier U14A, a second diode bridge rectifier, a second electrolytic capacitor C31, a second capacitor C5, a third capacitor C6, a seventh resistor R1, an eighth resistor R2, a ninth resistor R3, a tenth resistor R4, an eleventh resistor R34, a twelfth resistor R36, and a thirteenth resistor R99; the first end of the primary side of the transformer U13 is electrically connected with one phase line of a motor power supply loop through a thirteenth resistor R33, the second end of the primary side of the transformer U13 is electrically connected with a reference point of the motor power supply loop, the secondary side of the transformer U13 is electrically connected with the input end of a second diode bridge rectifier, the negative electrode of the output end of the second diode bridge rectifier is grounded, the positive electrode of the output end of the second diode bridge rectifier is electrically connected with a positive input pin of a second operational amplifier U14A through a seventh resistor R1, the positive electrode of a second electrolytic capacitor C31 and the first end of an eighth resistor R2 are both connected to a public connection end between the positive electrode of the output end of the second diode bridge rectifier and a seventh resistor R1, the first end of the eleventh resistor R34 is connected to a public connection end between the seventh resistor R1 and a positive input pin of a second operational amplifier U14A, the positive electrode of the eleventh resistor R34 is connected to the public connection end of the second operational amplifier U14A through a negative electrode of the third resistor R1 and a third resistor R14A, the first end of the public connection end of the eleventh resistor C34 is connected to the public connection end of the third resistor C14A through a negative electrode of the third resistor R2 and the public connection end of the third resistor R14A, the public connection end of the third resistor C6 is connected to the public end of the third resistor C5 and the public end of the third resistor C14A is connected to the public connection end of the third resistor C5.
  5. 5. The intelligent control system of a sewage pump of claim 2, wherein the key electrical parameter further comprises a temperature detection signal for characterizing a temperature of the motor; the motor protection unit further comprises a motor overheat detection circuit, and the output end of the motor overheat detection circuit is electrically connected with the input end of the main control board; The motor overheat detection circuit is used for collecting temperature detection signals on the motor and transmitting the temperature detection signals to the main control board.
  6. 6. The intelligent control system of a sewage pump according to claim 5, wherein the motor overheat detection circuit comprises a temperature sensor, a first connector J12, a first optocoupler U15, a fourth capacitor C38, a fourteenth resistor R28, a fifteenth resistor R65, a sixteenth resistor R66 and a seventeenth resistor R67, wherein the first connector J12 is provided with 2 pins; The first pin and the second pin of the first connector J12 are electrically connected with the output end of the temperature sensor, the first pin of the first connector J12 is also electrically connected with the +12V power supply end through a fifteenth resistor R65, the second pin of the first connector J12 is also electrically connected with the positive electrode of the input side of the first optocoupler U15, the first end of a fourth capacitor C38 and the first end of a sixteenth resistor R66 are both connected to a common connection end between the second pin of the first connector J12 and the positive electrode of the input side of the first optocoupler U15, the second end of the fourth capacitor C38 and the second end of a sixteenth resistor R66 are both grounded, the negative electrode of the input side of the first optocoupler U15 is grounded, the collector electrode of the output side of the first optocoupler U15 is electrically connected with the positive electrode of the +3V power supply end, the collector emitter of the output side of the first optocoupler U15 is electrically connected with the input end of the master control plate through a fourteenth resistor R28, and the first end of the seventeenth resistor R67 is connected to the common connection end of the seventeenth resistor R67 between the output side of the first optocoupler U15 and the positive electrode of the master control plate.
  7. 7. The intelligent control system of a sewage pump according to claim 2, wherein the key electrical parameters further comprise digital pulse signals correspondingly generated by power supply voltage in the motor power supply loop at zero crossing points; The motor protection unit further comprises two zero-crossing detection circuits with the same structure, wherein the input ends of the two zero-crossing detection circuits are electrically connected with different phase lines of the motor power supply loop, and the output ends of the two zero-crossing detection circuits are electrically connected with the input end of the main control board; Each zero-crossing detection circuit is used for detecting a digital pulse signal correspondingly generated when the phase voltage in the corresponding phase line is at a zero crossing point, and transmitting the digital pulse signal to the main control board; The main control board is used for comparing the phase difference between the two paths of received digital pulse signals, and identifying that the motor power supply loop is a single-phase power supply or a three-phase power supply according to the phase difference.
  8. 8. The intelligent control system of a sewage pump of claim 7, wherein each of the zero crossing detection circuits comprises a second optocoupler, a first diode, an eighteenth resistor, a nineteenth resistor, a twentieth resistor, a twenty first resistor, and a twenty second resistor; In each zero-crossing detection circuit, the first end of a nineteenth resistor and the first end of a twenty-first resistor are both coupled in a phase line corresponding to a motor power supply loop, the second end of the nineteenth resistor is electrically connected with the positive electrode of the input side of a second optocoupler through the twentieth resistor and a first diode in sequence, the second end of the twenty-first resistor is electrically connected with the negative electrode of the input side of the second optocoupler through the twenty-second resistor, the collector of the output side of the second optocoupler is electrically connected with the input end of the main control board, the collector of the output side of the second optocoupler is also electrically connected with the +3.3V power supply end through an eighteenth resistor, and the emitter of the output side of the second optocoupler is grounded.
  9. 9. The intelligent control system of a sewage pump according to claim 1, wherein the first liquid level signal is in particular an analog liquid level signal and the second liquid level signal is in particular a digital liquid level signal; The dual-mode liquid level detection unit comprises an analog liquid level detection circuit and a digital liquid level detection circuit, and the analog liquid level detection circuit and the digital liquid level detection circuit are electrically connected with the input end of the main control board; The analog liquid level detection circuit is used for collecting the analog liquid level signal of the sewage pump, converting the analog liquid level signal into a liquid level voltage signal and transmitting the liquid level voltage signal to the main control board; the digital liquid level detection circuit is used for collecting digital liquid level signals of the sewage pump and transmitting the digital liquid level signals to the main control board.
  10. 10. The intelligent control system of a sewage pump according to claim 9, wherein the analog liquid level detection circuit comprises a liquid level sensor, a second connector J7, a first common-mode inductor D28, a second common-mode inductor D29, a third operational amplifier U3B, a fifth capacitor C14, a sixth capacitor C15, a seventh capacitor C35, a twenty-third resistor R25, a twenty-fourth resistor R26, a twenty-fifth resistor R27, a twenty-sixth resistor R108, a twenty-seventh resistor R109, and a twenty-eighth resistor R110, and the second connector J7 has 2 pins; two pins of the second connector J7 are electrically connected with the liquid level sensor, the second pin of the second connector J7 is also electrically connected with the +12V power supply end through the first common mode inductor D28, and the common pin of the first common mode inductor D28 is grounded; the first pin of the second connector J7 is also electrically connected with the normal phase input pin of the third operational amplifier U3B sequentially through a second common mode inductor D29 and a twenty-third resistor R25, the common pin of the second common mode inductor D29 is grounded, the first end of a seventh capacitor C35 and the first end of a twenty-seventh resistor R109 are connected to the common connection end between the first pin of the second connector J7 and the second common mode inductor D29, the second end of the seventh capacitor C35 and the second end of the twenty-seventh resistor R109 are grounded, the first end of a fifth capacitor C14 is connected to the common connection end between the power pin of the third operational amplifier U3B and the 5V power supply end, the second end of the fifth capacitor C14 is grounded, the first end of the twenty-sixth resistor R108 is connected to the common connection end between the twenty-third resistor R25 and the normal phase pin of the third operational amplifier U3B, the first end of the twenty-sixth resistor R108 is connected to the common connection end of the output end of the third operational amplifier U3B, the twenty-sixth end of the twenty-sixth resistor C14 is connected to the common connection end of the output end of the third operational amplifier U3B through the inverting resistor R26, and the twenty-third end of the twenty-sixth resistor C14 is connected to the output end of the twenty-third operational amplifier U3B, and the twenty-third end of the twenty-third resistor C14 is connected to the common connection end of the output end of the twenty-third operational amplifier U3B, and the twenty-third end of the twenty-sixth resistor B is connected to the twenty-third end of the output end of the twenty-third resistor U3B.
  11. 11. The intelligent control system of a sewage pump according to claim 9, wherein the digital liquid level detection circuit comprises a liquid level switch, a fourth connector J8, a third optocoupler U17, a fourth optocoupler U8, an eighth capacitor C10, a ninth capacitor C40, a twenty-ninth resistor R39, a thirty-first resistor R40, a thirty-second resistor R70, a thirty-third resistor R71 and a thirty-fourth resistor R73, wherein the fourth connector J8 has 5 pins; The first pin, the second pin and the third pin of the fourth connector J8 are all electrically connected with a liquid level switch, the third pin of the fourth connector J8 is also grounded, the fourth pin of the fourth connector J8 is electrically connected with the negative electrode of the input side of the fourth optocoupler U8 through a thirty-first resistor R41, the fifth pin of the fourth connector J8 is electrically connected with the negative electrode of the input side of the third optocoupler U17 through a thirty-fourth resistor R73, the first end of the third resistor R71 is electrically connected with a +12V power supply end, the second end of the thirty-third resistor R71 and the first end of a ninth capacitor C40 are all connected to a public connection end between the fifth pin of the fourth connector J8 and the thirty-fourth resistor R73, the second end of the ninth capacitor C40 is grounded, the first end of the thirty-third resistor R40 is electrically connected with the positive electrode of the power supply end of +12V, the second end of the fourth resistor R40 and the first end of the eighth capacitor C10 are all connected between the fourth pin of the fourth connector J8 and the negative electrode of the input side of the fourth optocoupler U17, the first end of the fourth resistor C10 is also connected with the positive electrode of the fourth resistor C8, the first end of the fourth resistor C10 is connected with the positive electrode of the fourth end of the fourth resistor U8, and the fourth end of the fourth resistor C8 is also grounded, and the fourth end of the fourth resistor C10 is connected with the positive electrode of the fourth end of the fourth resistor C8 is connected to the fourth end of the fourth resistor U8, and the fourth end of the fourth resistor C17 is also connected to the fourth end of the fourth resistor U8.
  12. 12. The intelligent control system of a sewage pump according to claim 1, wherein the fault prompting unit comprises a buzzer control circuit and an external alarm control circuit; The input end of the buzzer control circuit and the input end of the external alarm control circuit are electrically connected with the output end of the main control board, and the output end of the external alarm control circuit is electrically connected with an external alarm device; the buzzer control circuit is used for receiving a first alarm instruction issued by the main control board when the main control board judges that the sewage pump has motor failure and/or liquid level failure, and sending out a buzzing signal according to the first alarm instruction; the external alarm control circuit is used for receiving a second alarm instruction issued by the main control board when the main control board judges that the sewage pump has motor failure and/or liquid level failure, and sending an alarm signal through the external alarm device according to the second alarm instruction.
  13. 13. The intelligent control system of a sewage pump according to claim 12, wherein the buzzer control circuit comprises a first relay K1, a buzzer, a fifth connector J19, a second diode D14, a third diode D15, a fourth diode D16, a thirty-fifth resistor R68 and a thirty-sixth resistor R107, wherein the fifth connector J19 has 2 pins; The coil power supply anode of the first relay K1 is electrically connected with the circuit power supply end, the coil power supply cathode of the first relay K1 is electrically connected with the output end of the main control board, the coil public end of the first relay K1 is grounded, the first normally open contact of the first relay K1 is suspended, the second normally open contact of the first relay K1 is electrically connected with the cathode input end of the buzzer through a thirty-seventh resistor R107, the anode input end of the buzzer is electrically connected with the +12V power supply end through a second diode D14, the anode of a fourth diode D16 is connected to the public connection end between the thirty-seventh resistor R107 and the cathode input end of the buzzer, the cathode of the fourth diode D16, the cathode of a third diode D15 and the first end of a thirty-fifth resistor R68 are all connected to the public connection end between the anode input end of the buzzer and the second diode D14, the anode of the third diode D15 and the second end of the thirty-fifth resistor R68 are electrically connected with the 9V power supply end, the anode of the fifth connector J19 is connected with the anode of the fifth battery, and the anode of the fifth connector J19 is further connected to the public connection end of the fifth battery, and the anode of the fifth battery is connected with the fifth terminal of the fifth battery 19, and the fifth terminal of the fifth battery is further connected to the fifth terminal of the fifth resistor J19.
  14. 14. The intelligent control system for a sewage pump according to claim 12, wherein the external alarm control circuit comprises a second relay K2 and a sixth connector J9, the sixth connector J9 having 3 pins; The coil power supply positive electrode of the second relay K2 is electrically connected with the +12V power supply end, the coil power supply negative electrode of the second relay K2 is electrically connected with the output end of the main control board, the coil public end of the second relay K2 is electrically connected with the second pin of the sixth connector J9, the first normally open contact of the second relay K2 is electrically connected with the first pin of the sixth connector J9, the second normally open contact of the second relay K2 is electrically connected with the third pin of the sixth connector J9, and the three pins of the sixth connector J9 are also electrically connected with the external alarm device.
  15. 15. The intelligent control system of a sewage pump of claim 1, wherein the HMI control panel further comprises a display module therein; The display module is in communication connection with the main control board; the display module is used for receiving a display instruction issued by the main control board when the main control board controls the sewage pump so as to display and control the sewage pump.
  16. 16. The intelligent control system of a sewage pump of claim 1, wherein the system further comprises a function expansion unit; the function expansion unit is electrically connected with the main control board; the function expansion unit is used for providing auxiliary functions for the sewage pump under the control of the main control board.
  17. 17. The intelligent control system of the sewage pump according to claim 16, wherein the motor in the sewage pump is provided with a motor power supply loop; The input end of the contactor control circuit is electrically connected with the output end of the main control board, and the output end of the contactor control circuit is electrically connected with the motor power supply loop; The contactor control circuit is used for receiving a contactor control signal issued by the main control board when the main control board judges that the sewage pump has a motor fault, cutting off the motor power supply loop according to the contactor control signal, and also used for acquiring a contactor trigger action corresponding to the motor power supply loop and cutting off the motor power supply loop according to the contactor trigger action.
  18. 18. The intelligent control system of a sewage pump according to claim 17, wherein the contactor control circuit comprises a contactor T2, a third relay K6, a first contactor wire bonding hole JP7, a second contactor wire bonding hole JP8, a first transistor Q2, a fifth diode D23, a thirty-seventh resistor R78, and a thirty-eighth resistor R81; The base electrode of the first triode Q2 is electrically connected with the output end of the main control board through a thirty-seventh resistor R78, the emitter electrode of the first triode Q2 is grounded, the first end of a thirty-eighth resistor R81 is connected to a public connecting end between the base electrode of the first triode Q2 and the thirty-seventh resistor R78, the second end of the thirty-eighth resistor R81 is grounded, the collector electrode of the first triode Q2 is electrically connected with the coil power supply cathode of a third relay K6, the coil power supply anode of the third relay K6 is electrically connected with the +12V power supply end, the anode electrode of a fifth diode D23 is connected to a public connecting end between the collector electrode of the first triode Q2 and the coil power supply cathode of the third relay K6, and the cathode electrode of the fifth diode D23 is connected to a public connecting end between the coil power supply anode of the third relay K6 and the +12V power supply end; The stationary contact of third relay K6 is connected with the phase line electricity of motor power supply circuit through contactor T2, and the normally closed movable contact of third relay K6 is connected with the first end electricity of first contactor bonding wire hole JP7, and the second end electricity of first contactor bonding wire hole JP7 is connected with the first end electricity of second contactor bonding wire hole JP8, and the second ground connection of second contactor bonding wire hole JP 8.
  19. 19. The intelligent control system of a sewage pump of claim 16, wherein the function expansion unit further comprises a serial communication interface circuit; The output end of the serial communication interface circuit is electrically connected with the input end of the main control board; The main control board is also used for carrying out serial communication with external bus equipment through the serial communication interface circuit, receiving serial instructions of the external bus equipment and carrying out medium-distance control on the sewage pump.
  20. 20. The intelligent control system of a sewage pump of claim 16, wherein the function expansion unit further comprises a memory circuit and a clock circuit; the memory circuit and the clock circuit are electrically connected with the main control board.

Description

Intelligent control system and control method for sewage pump Technical Field The invention relates to the technical field of sewage pump control, in particular to an intelligent sewage pump control system and a control method thereof. Background Along with the continuous acceleration of the urban process, the sewage treatment demands are increasingly increased, and the application scene of the sewage pump is continuously expanded. Under the background, the intelligent water service is the main stream direction of industry development, and the realization of intelligent control of a sewage pump is a necessary trend of equipment upgrading. However, the sewage pump control products in the current market have obvious limitations, and the requirements of intelligent and efficient operation and maintenance are difficult to meet. The concrete steps are as follows: (1) The traditional control product has single function, and most of traditional sewage pump control boxes only have basic start-stop, liquid level triggering and simple protection functions, and lack accurate motor state monitoring (such as overload, overheat and voltage abnormality), liquid level accurate detection and fault early warning and recording capabilities. When potential faults occur in equipment, early warning cannot be performed in advance, sudden shutdown of the water pump is often caused, maintenance is passive, and cost is high. (2) The existing intelligent product has low integration level, huge volume and high cost, and a part of the controller with advanced functions (such as networking and multi-parameter monitoring) is usually designed by intensively arranging all functional circuits on a single PCB. This design results in a large controller volume that is difficult to install in a compact sewage pump or control box that is space demanding. At the same time, complex integrated designs also increase manufacturing costs. (3) The system lacks effective networking and centralized management capability, and many products do not have a remote communication interface or only support a single communication mode and cannot be integrated into an Internet of things cloud platform. The operation and maintenance personnel must go to the site to perform equipment operation, parameter check or fault check, the operation and maintenance efficiency is low, the management cost is high, and centralized monitoring and intelligent management of a plurality of equipment are difficult to realize. Therefore, there is a need for an intelligent sewage pump control product with compact design, controllable cost, comprehensive functions and supporting multi-mode remote monitoring, so as to solve the above technical problems and assist in intelligent upgrading of sewage treatment equipment. Disclosure of Invention In view of the above, the invention provides an intelligent control system and a control method thereof for a sewage pump, which are used for solving the problems of single function, low integration level, large product volume, high cost, lack of integrated management capability and low operation and maintenance efficiency in the existing sewage control technology. The invention provides an intelligent control system of a sewage pump, which comprises a main control board, an HMI control panel, a motor protection unit, a dual-mode liquid level detection unit and a fault prompting unit, wherein the main control board is connected with the HMI control panel; The HMI control panel comprises a wireless communication module and a key module which are arranged independently of the main control board, wherein the wireless communication module is in communication connection with the main control board, and the key module is electrically connected with the main control board; the main control board is used for receiving a user instruction through the key module in the HMI control panel to manually control the sewage pump, and is also used for wirelessly communicating with a remote terminal through the wireless communication module to receive a remote instruction of the remote terminal so as to remotely control the sewage pump; The motor protection unit is used for collecting key electric parameters of a motor configured in the sewage pump in real time when the main control board controls the sewage pump, and transmitting the collected key electric parameters to the main control board in real time; The dual-mode liquid level detection unit is provided with a main detection mode and a standby detection mode, and is used for collecting a first liquid level signal of the sewage pump according to the main detection mode and transmitting the first liquid level signal to the main control board when the main control board controls the sewage pump, and is also used for collecting a second liquid level signal of the sewage pump according to the standby detection mode and transmitting the second liquid level signal to the main control board when the main control board co