schneider - cptg010 en (print)

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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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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Follow the selection process

Determine which product family suits the needs

of your pumping system

4 solutions

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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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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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Star-Delta starter TeSys Offer


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


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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Soft Starter TeSys Offer - Altistart Offer


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


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


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


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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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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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)


OsiSense ZMLPSwitch with digital display

Analog input 4-20mA

Logic output PNP or NPN

Analog output 4-20 mA

Compatible with Altivar offer


OsiSense XMLK Pressure sensors for pump applicationsRef.: 9012CT1001

OsiSense XM Electromechanical sensors for pressure controlRef.: DIA4ED2150201EN

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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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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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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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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:

Make the most of your energywww.schneider-electric.com

Schneider Electric Industries SAS

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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