Testing a pump underload detector before it controls a motor
A running pump may draw less current when it loses load, but a low current reading alone cannot confirm a dry pump, so the detector should report suspected underload with supporting context. Measurements should begin only after the motor is confirmed running and the startup window has passed, and mismatches between run commands and contactor feedback should be logged. Missing, stale, or invalid current data should be treated as a sensor fault rather than as zero current. The alert should use its own persistence timer and reset when readings return to normal, while latched alarms, motor-stop logic, and protection hardware remain independent of the telemetry. Validation should involve replaying simulated traces, comparing results against normal operation at several operating points, and logging timestamps, RMS current, motor state, thresholds, and fault reasons.
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