FUSION Controller

The FUSIONTM is Sirius' DC/Solar solution to pump control. It brings an advanced level of sophistication to the control world. In addition to being certified for operation in hazardous areas it also has significant capability in terms of communication.

The controller has been designed to work with most pump and brushed motor combinations. Anywhere that you desire to

  1. have ultimate control of your injection rates,
  2. communicate through SCADA, or
  3. want to simplify calibration the FUSIONTM will solve your problems.

The patented FUSIONTM provides duty cycle injection control and variable speed to enhance injection on time along with batch production, providing the most flexibility, ease of operation, and ground breaking turn down ratios never before available in metering pumps.


FUSIONTM tightly integrates variable speed rate with injection control to deliver combined advantages such as;

  • Multi-point injection where the speed is adjusted for each point to maximize injection time and optimize accuracy even when point to point rates vary significantly.
  • This level of integration also allows complete control of the pump which eliminates the need for an additional recirculation loop thus reducing system complexity and maintenance.
  • Keeping the customer's maintenance needs in mind has also driven us to use variable speed and injection cycle integration to deliver a unique closed loop injection process that can be expanded across multipoint applications without the need for multiple, complex, flow measurements.
FUSION controller chemical injection pump

To the left, is an application where the FUSIONTM was used to upgrade a site to conform to safety and electrical codes. The FUSIONTM, replaced a common general purpose (not rated for hazardous environments) timer. To conform, hazardous rated electrical connectors and solar panels were used to replace the general purpose equipment originally supplied. The FUSIONTM, operates a chemical injection pump providing better control, communication, and safety.

The FUSIONTM Intelligent Calibration is an in-situ test; thus, accounting for intake head, viscosity, and injection pressure. The FUSIONTM learns what the operator is trying to achieve during calibration and performs the necessary calibration calculations so the operator does not have to. Visual Rate Feedback eliminates the guess work with setting rates.

DC AC controllers

For those customers who use both DC and AC power supplies we have made it even easier. The FUSIONTM controller operates on both power supplies making it seamless for operators. In addition pumps can be moved around the field providing additional versatility to the system.

Fusion Controller Voltage Compensation

Patented VOLTAGE Compensation: One thing many times overlooked on DC (Solar) injection or metering applications is the effect of variable voltage on the performance of the chemical pump. A DC motor has a linear relationship with applied voltage. A chemical injection pump that is coupled to a DC motor utilizes a positive displacement pump whose injection rate is proportional to pump rpm or strokes per minute.

Variation in voltage can be 30% or more. Because the rpm of a DC motor is also linked proportionally to this change in voltage, a corresponding variation in chemical delivery can be expected. An example of the cyclic day to night voltage variation of a solar charged battery is illustrated in the plot to the right. Variation in the chemical rate could be 30% or more due to change in voltage.

By monitoring the voltage on the battery or DC motor, adjustments can be made to either the "ON" time of the chemical pump, or to the average rpm of the chemical pump in order to consistently deliver a calibrated rate to the process. If the battery voltage during the setup or calibration of the pump is monitored and recorded internally in the pump controller, any subsequent voltage variations can be used to automatically compensate and adjust the injection rate.

Some of the net short term and long term effects of chemical injection rate variability:

  • Over injection of chemical causing increase in operational costs.
  • Under injection of chemical causing production downtime, or increased corrosion, or risk of leaks.

A properly voltage compensated DC injection system will provide more consistent and predictable rates with chemical treatments and result in lower operational costs with less downtime risk.

To read more on Sirius' Voltage Compensation see Autonomous Local Control or Technical Bulletins 1 in the Publications section.

Solar battery diagram


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