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Control PanelTechnical GuideHow to select the appropriate motor control system for your pump
Pumping
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Control panel technical guide - Pumping2
Energy represents
up to 40%of the Total Costof Ownership in pumping systems
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Control panel technical guide - Pumping3
Extended product
Motor system
Motor control system
For energy efficientpumping systems
Whatever the usage of a pump, it is crucial for the motor control system to ensure
the continuity and reliability of the service. Moreover, the choice of the appropriate
motor control system leads to an ef cient pumping system.
The Extended Product Approach (EPA) results on the EN 50598 series of standards and provides
a generic methodology to select the right motor control solution. It is important to take a holistic approach
of the pump, the motor and the controls, in order to optimize the pump system.
Motor starter solutions
Complete drive module (CDM)
Direct On Line (DOL)Starter
Star-DeltaStarter
Soft-StartStarter
Variable Speed Drive (VSD)
Auxiliaries
Motor Pump
Discover our White Paper: Three steps for Reducing Total Cost of Ownership (TCO) in Pumping Systems
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Control panel technical guide - Pumping4
Follow the selection process
Determine which product family suits the needs
of your pumping system
4 solutions
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Control panel technical guide - Pumping5
A 3 step process to select the appropriate motor control solution for the motor of your pump
Does the application require to manage the flow rate of the pump ?1
Start to build your pumping system with the appropriate motor control solution3
Direct-on-Line (DOL) starter
ON / OFF
Star-Delta starter
ON / OFF with inrush current limitation
Soft-Starter
Start and stop control
Variable Speed Drive
(VSD)
Adjustable speed in real
time
Constant flow Variable flow
Does the application require to manage water hammer issues ?2
Control
TeSys K / D / U Altistart Altivar
Protection
TeSys GV TeSys GV
p. 9 p. 8 p. 6 - 7
Apply the Extended ProductApproach to pumping systems
Yes
Yes
No
NoNo
TeSys GV Compact NS/NSX
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Control panel technical guide - Pumping6
Direct on Line (DOL) starterTeSys Offer
TeSys GV Motor circuit breaker from 0.75 to 75 kW
Disconnection and breaking
Short-Circuit protection Overload Protection Coordination Type 1, Type 2
TeSys KMini Contactor Direct / Reverse from 1.5 to 5,5 kW
Start/Stop Control Compact contactor 1 NO or NC auxiliary contact
TeSys DContactorDirect / Reversefrom 0.06 to 75 kW
Start/Stop Control 1 NO and NC auxiliary
contact Common accessories
and add on blocks
TeSys U Complete Motor Starter up to 15 kW
Disconnection and breaking Short-Circuit protection Overload Protection Start/Stop Control Total coordination Direct / Reverse Communication ready
ON-OFF control in constant flow systems for:
Jockey pump
Backup pump
Primary pump
Circulating pump
Transfer pump
Flood and drainage control systems
Boiler feed water pump
Tank filling pump
Low consumption device
Easy to install, operate and maintain
Stand alone All-in one
Let TeSys Solink be your drive!
is compliant with Premium Efficiency motors (IE3)
TeSys offer
-50%CONTACTOR
POWERCONSUMPTION
20 timesfaster for control circuit wiring
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Control panel technical guide - Pumping7
Star-Delta starter TeSys Offer
TeSys GV Motor circuit breaker from 0.75 to 75 kW
Disconnection and breaking Short-Circuit protection Overload Protection Coordination Type 1, Type 2
TeSys DContactor from 0.06 to 75 kW
Line, Delta, Start contactors Pre-assembled / Customer assembly
ON-OFF control with inrush current limitation in constant flow systems for:
Primary pump
Circulating pump
Transfer pump
Flood and drainage control systems
Water tapping pump
Water lifting pump
Pumping station
Low consumption device
Inrush current limitation
Star-Delta
is compliant with Premium Efficiency motors (IE3)
TeSys offer
Accessories Time delay auxiliary contact blocks
Electrical interlock
Mechanical interlock
Warningstarting torque must be < 1/3 nominal torque
-50%CONTACTOR
POWERCONSUMPTION
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Control panel technical guide - Pumping8
Soft Starter TeSys Offer - Altistart Offer
TeSys GV Motor circuit breaker from 0.75 to 75 kW
Disconnection and breaking Short-Circuit protection Overload Protection Coordination Type1, Type 2
Compact NS / NSXMotor circuit breaker from 40 to 400 kW
Disconnection and breaking Short-Circuit protection Overload Protection Remote reset Communication ready
Altistart 01Soft starter for small and simple pumping systems from 0.37 to 15 kW
Reduce voltage start Ramp-up time
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Control panel technical guide - Pumping9
Variable Speed Drive (VSD) TeSys Offer Altivar Offer
Fine control in variable flow systems for:
Secondary pump
Boosters
Progressive cavity pump systems
Water distribution systems
Water treatment plant
Lifting station
Water intake station
HVAC & R
Water storage station
Operation at the Best Efficiency Point (BEP) of the pump
Energy efficiency management
Water hammer reduction
Speed threshold against cavitation
Altivar
is compliant with Premium Efficiency motors (IE3)
Altivar offer
Altivar 12VSD for small pumping systems from 0.18 to 4 kW
8 pre-selected speeds Modbus communication SoMove software Compactness IP 20
Altivar 312VSD for simple pumping systems from 0.18 to 15 kW
16 pre-selected speeds Energy management Modbus CANopen SoMove software IP 21
Altivar 212VSD dedicated to HVAC machines from 0.75 to 75 kW
Fine control of the motor's speed
Energy management Modbus, BACnet, LonWorks PC_Soft software IP 21 or 55
TeSys GV Motor circuit breaker from 0.75 to 75 kW
Disconnection and breaking Short-Circuit protection Overload Protection Coordination Type1, Type 2
Assess your energy savings by the use of VSD rather than a throttling device to control your pumping system.
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Control panel technical guide - Pumping10
Accessories Sensors p. 11 Enclosures p. 12 Surge protection devices p. 13
The Extended Product Approach (EPA) into practice p.14-15
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Control panel technical guide - Pumping11
SensorsControl and protect your pumping installationsSensors are crucial in order to ensure safety and a total control of pumping systems
A full range of pressure and level sensors dedicated to pumping environment are available in order to measure and optimize the energy
performance of the installation
1
2
3
4
1 2 3 4
OsiSense XX230AUltrasonic level sensors
Level control up to 2 m
1 or 2 level adjustable
PNP/NPN IEC Compliant,
IP 65
OsiSense XMPPressure switch for power circuit
Pressure range: 6, 12, 25 bars
2 or 3 phases disconnection
Fresh water, sea water (070C)
IEC Compliant, IP 65
OsiSense XMLKPressure sensors
Pressure range: 6, 10, 16 bars
Analog output 4-20 mA or 0-10 V
Compatible with Altivar offer
Fresh water (080C)
IEC Compliant, IP 65
OsiSense ZMLPSwitch with digital display
Analog input 4-20mA
Logic output PNP or NPN
Analog output 4-20 mA
Compatible with Altivar offer
IEC Compliant, IP 65
OsiSense XMLK Pressure sensors for pump applicationsRef.: 9012CT1001
OsiSense XM Electromechanical sensors for pressure controlRef.: DIA4ED2150201EN
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Control panel technical guide - Pumping12
Enclosures Protect the electrical equipment of your pump
An appropriate enclosure is required in order to increase your electrical equipments'
lifetime and ensure the continuity of the service of your pumping system.
Protect the electrical equipments of your pumping installation with the appropriate enclosure
Indoor Outdoor
SpacialMulti purpose metallic enclosures
Steel & Stainless Steel IP 55 or IP 66 Wall mouting or Modular
and Compact Floor standing
ThalassaMulti purpose insulating enclosures
Polyester Floor standing IP 43 to 55 Wall mounting IP 66
Thermal management systems
Clymasys CV - Ventilation Clymasys CA - Airing Clymasys CE - Air-Air Exchangers Clymasys CU - Cooling units Clymasys CR - Resistance heaters
or heating units Clymasys CC - Thermostats,
hygrostats, hygrotherm control
ClimasysHeating, cooling & control thermal solutions
Choose your enclosure and your accessories online
Universal Enclosures CatalogueRef.: UE13MK04EN
How to reduce damage to components through effective thermal managementRef.: CPTG001_EN
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Control panel technical guide - Pumping13
Surge protection devices (SPDs)Make sure that your pumping equipments are protectedThe pump and its control equipments are subject to surge risks coming from lightning and switching.
Remote and well pumps have a high occurrence probability. Hence, it is essential to consider pumping installation requirements, safety
and continuity of the service.
Voltage
Time
230 V
Switching surge
hundreds of Volts
Lightning surge
thousands of Volts
Equipotential bondingEnsure that the motor and the pump are correctly grounded at the same protective earth conductor that the installation.
1
2Type 1 iPRF1 12,5rLightning rod on the top of building
Type 2 iPRD General case: No lightning rod on the top of the buiding
SPD Device
Compliant solution for 230/400 V installation in any case where the short circuit current (Isc) is up to 50 kA;SPDs must be protected by an external short circuit protection (MCCB or MCB)
How to prevent machine malfunction and electronic damage due to voltage surge.Ref.: CPTG002_EN
Surge arrestors for commercial and industrial buildings Selection guide.Ref.: A9DP96EN
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Control panel technical guide - Pumping14
The Extended Product Approach into practice
2 EP configurations at test
D.O.L starter + valve
Thermal magnetic motor circuit breaker TeSys GV2ME Contactor TeSys D IE3 Premium Efficiency Motor (30 kW) Centrifugal Pump Throttling device : proportional/linear valve
VSD motor control
Thermal magnetic motor circuit breaker TeSys GV2P Variable Speed Drive ATV 212 IE2 High Efficiency Motor (30 kW) Centrifugal Pump
Details for the D.O.L starter + valveThe use of a throttling valve to control
the ow rate leads to signifi cant energy
loss in the system.
There is no energy consumption during
the stand-by phase and very few loss during
operation.
100% ow(valve 100% open)
50% ow (valve 50% open)
0% ow (standby)
Energy loss Pump + valve [kW] 5.4 9.4 0Energy loss Motor [kW] 2 1.5 0Energy loss Contactor [kW] 0.03 0.03 0Total Loss [kW] 7.43 10.93 0
Motor rated power [kW] : 30
Details for the VSD motor controlThe use of the VSD to control the ow rate
allows to operate the pump at its Best
Effi ciency Point.
The VSD causes additional energy loss during
both operation and stand-by phases.
100% ow(100% speed, 100% load)
50% ow(50% speed, 25% load)
0% ow (standby)
Energy loss Pump [kW] 5.4 0.8 0Energy loss Motor [kW] 2.9 0.75 0Energy loss VSD [kW] 1.5 0.6 0,05Total Loss [kW] 9.8 2.15 0,05
Motor rated power [kW] : 30
Example of Extended Product (EP) best selection depending on the duty profile of the pump system
Related energy loss at different operating points
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Control panel technical guide - Pumping15
2 examples of duty profiles
The choice of the most energy-efficient motor control solution depends on the duty profile and shall result from a comparative system-level analysis
The duty profile describes the various power levels required by the pumping application, including standby, and the duration
of time during which the machine is operated at these levels.
Constant flow
Time fraction100%
80%
60%
40%
20%
0%100%
Full load
50%
Half load
0%
Standby
Operating at maximum load most of the time
Load level [%] Time fraction [%]100% 85%50% 5%0% 10%
Variable flow
Time fraction100%
80%
60%
40%
20%
0%100%
Full load
50%
Half load
0%
Standby
System sized for the maximum loadOperating at half load most of the time
Load level [%] Time fraction [%]100% 20%50% 70%0% 10%
Assess the Weighted Loss (WL) according to the EN 50598 methodology:
Energy loss associated to each duty profile
WL [kW] = Time fraction [%] x Total loss [kW] + Time fraction [%] x Total loss [kW] + Time fraction [%] x Total loss [kW]
Full load Half load Stand-by
Savings of 5.67kW
Weighted Loss [kW]D.O.L. starter + valve 9.14VSD motor control 3.47
VSD motor controlRecommended EP:
Variable flow
The Extended Product Approach into practice (continued)
Savings of 1.58kW
D.O.L. starter + valveRecommended EP:
Constant flowWeighted Loss [kW]
D.O.L. starter + valve 6.86VSD motor control 8.44
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07-2015
35, rue Joseph MonierCS 30323F- 92506 Rueil Malmaison CedexFrance
RCS Nanterre 954 503 439Capital social 896 313 776 www.schneider-electric.com
Printed on ecological paper.
As standards, specifi cations and designs change from time to time, please ask for confi rmation ofthe information given in this publication.
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Publishing: Schneider Electric Industries SASPhotos: Schneider ElectricPrinting:
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CPTG010_EN
Quickly build your automation solution with ready-to-use, tested, validated and documented architectures
Let TeSys be your drive
Modicon M241 logic controllersRef.: DIA3ED2140107EN
Modicon M251logic controllersRef.: DIA3ED2140108EN
To discover the TeSys range, connect on: www.schneider-electric.com/tesys
Tesys - Motor control and protection components 2015/2016Ref.: MKTED210011EN
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