Skip to content
IEMI Labs
All product designs
IndustrialDesign complete (stages 1–6, rev A), not built, not validated

LiftStation

Cellular alarm, callouts and pump health for small private lift stations

Calls the right people when a small lift station alarms, loses power or a pump fails, and shows weeks ahead which pump is slowing down, using only the floats and pump current already in the panel.

Who buys it
HOA boards and property managers, RV-park, campground and mobile-home-park owners, and small towns without SCADA, buying direct or through their pump contractor.
Why it pays
One avoided weekend emergency plus a saved pump every few years is worth about $1,500–2,500/yr per station, against $228/yr of service (est.).
Target price
$399 unit + $19/month (or $199/yr prepaid); NEMA 4X box kit +$129 (target)
First-minute wow
A phone call at 2 am that says "Lift station 1 high level, press 1 to accept", and the next morning a card saying "Pump 2 capacity down about 30%, current up 12%: likely debris".
LiftStation concept: the idea and where each part goes
The concept. The CAD design is below, under Printable CAD.

What the research found

And how this design answers it

  • Utility tenders and SCADA integrators take 12–24 months → sold direct to private owners and their pump contractors, card payment, 1-hour install, no SCADA
  • Mission ($1,195 + service) and Sensaphone Sentinel ($1,561 + $24.95/month) are proven alarms → $399 hardware plus pump health and acknowledged voice callouts
  • Wet wells are NFPA 820 classified areas → nothing goes into the wet well; it reads only the safe-side contacts of existing IS or float relays
  • Intrinsically safe level transducers cost about $1,468 plus a barrier → inflow and pump-down rate inferred from float timing and wet-well geometry
  • Li-ion backup in a hot outdoor panel is a hazard → primary lithium D-cell used only during outages, no charging
  • Remote pump control is a liability → rev A has no pump control; one relay drives only a local strobe

Use case

High level at 2 am in an RV park

Park managerOwnerPump contractor

  1. 01Trigger: the high-level float closes at 02:07 on a holiday weekend; the lag pump has failed
  2. 02Detection: the board sees the float relay contact and that pump 2 draws no current; the alarm reaches the cloud in under 15 s
  3. 03Alert: voice call to the manager, escalating to the owner and then the contractor every 5 minutes until someone presses 1
  4. 04Action: the contractor arrives with the live page open (floats, currents, estimated time to overflow) and resets the tripped pump

Outcome: Overflow and weekend emergency avoided, about $1,500 plus any regulator costs (est.)

How it works

Architecture

  1. 01

    Sense: float and IS relay dry contacts, contactor aux contacts, generator-run contact, 0.333 V CTs on each pump, 24 V supply voltage

  2. 02

    Decide (node): nRF9151 builds cycle records (fill time, pump-down time, current per pump) and raises alarms at once

  3. 03

    Send: LTE-M/NB-IoT MQTT over TLS; alarms immediately, cycle batches every 15 min, 30-day flash buffer

  4. 04

    Decide (cloud): inflow and pump-rate from float timing, pump-health rules, time-to-overflow estimate, callout escalation

  5. 05

    Tell: voice and SMS callouts with acknowledgement, station page, monthly one-page report for the board

Hardware

Real parts, buyable today

Bill of materials: about $202 per unit at qty 1 including 2 CTs, PSU and antenna (est.); IoT SIM about $2/month.

BlockPartWhy this part
Cellular + MCUNordic nRF9151 SiP (LTE-M / NB-IoT)Modem and app MCU in one part, TLS in the modem, $17–23
Pump currentMagnelab SCT-0750-050 split-core CTs + TI ADS131M04Clamp-on with no break in conductors; per-pump current signature
Inputs2× Toshiba TLP291-4 optocouplersEight isolated inputs for float relays, contactors, generator and door
BackupSaft LSH20 Li-SOCl₂ D-cellOutage reporting without charging a battery in a hot panel
PowerMean Well HDR-15-24 DIN PSU (bought, electrician-installed)Listed, finger-safe mains conversion; the board itself is 9–36 VDC

Mechanical

Printable CAD

6 parts, generated from code and checked as closed solids. Pick a part to inspect it, or download the STL files to print.

See the CAD parts render
LiftStation printable parts, rendered from the CAD
Render of the printable parts from the actual CAD. Not yet printed or photographed.

Loading the CAD…

Real CAD · drag to rotate · scroll to zoomReal CAD · swipe sideways

Open risks we are working on

  • Plain cellular alarms are a commodity at $15–25/month; pump-health insight has to be worth the switch to owners who already have a dialer
  • Float-timing inflow and pump-rate need accurate wet-well geometry; errors of ±15–30% are likely until a site is calibrated
  • nRF9151 showed zero stock and a 16-week lead time; a Quectel BG95 fallback design may be needed
  • Rural RV parks may have weak LTE-M coverage; each install needs a signal check before the contractor leaves
  • Install quality depends on the contractor correctly identifying safe-side contacts in the panel; a wrong connection is a hazardous-area mistake

Design stage only: nothing on this page is for sale. Specifications and prices are targets.