speed control
TRANSCRIPT
2
User interface
Software
Control
Sensor
Frequency converter
Standard motor
Pump
Within the Grundfos concept of speed-controlled pumps, the circula-tor is integrated with a frequency converter, a sensor and software for speed control. This sensor automatically identifies variations in flow and communicates this information to the frequency converter. This in turn regulates itself, to achieve the head needed. This interaction happens constantly thus ensuring the most energy-efficient opera-tion possible.
3
Flow > RPM
Head > RPM
Effect > RPM
=Q2
Q1
n2
n1
=n2
n1
2H2
H1
=n2
n1
3P2
P1
H (%)
Fixed systemcharacteristic
P (%)
100
100 Q (%)
Q (%)100
50
50
100
12.5
25
RPM100%
Regulating the temperature is not sufficient
By controlling a heating system or an air-conditioning sys-
tem on the basis of temperature only, a considerable amount
of energy is wasted if the flow varies. Without constant
regulation the volume of water flowing through the system
will be unnecessarily excessive.
Old circulators …and new
In systems with circulators that have no speed control the
head increases as the flow decreases, and visa versa. In
practice, this means that a lot of energy is lost in the system.
The development of speed-controlled pumps means that this
energy, formerly lost in a hydraulic system due to changes
in consumption throughout the day and the year, can now
be saved or used for other purposes. As the utilisation of
energy is subject to the law of affinity, the value of even small
differences is significant.
A comparison ...
To make a comparison with the world of motoring, a
pump without speed control is like a car being driven at
full speed with the driver reducing the speed by applying
the brakes. Taking the same analogy using speed control,
this is comparable to a driver controlling the speed of the car
by using the accelerator.
This new era of pump
technology means
electronic speed control
The law of affinity shows the clear link between RPM/Flow/Head/Effect.Decreasing the flow to RPM to 50% gives a Flow at 50%, but the Head is decreased to 25%, and the needed Effect is reduced to only 12.5%.
Speed control, new technologySpeed control, old technology
4
The basic principle
The idea behind speed-controlled pumps is to integrate
electronic control, thus ensuring each pump automatically
adapts its output to the current conditions. This ensures that
energy consumption is always maintained at its minimum,
for the given conditions. By automatically controlling its own
speed, the pump will continuously regulate the pressure
(head) so that it is optimally adapted to the speed of water
(flow). As the flow decreases, the converter will regulate the
speed of the circulator, to achieve the required head. The
pump will therefore adjust to the reduced friction in pipes,
valves and thermostats at the lower flows.
The components and their interaction
Within the Grundfos range of speed-controlled pumps the
circulator is integrated with a frequency converter, a sensor
and software for speed control. The sensor automatically
identifies the variations in the flow and communicates this
information to the frequency converter so it can regulate
accordingly, to achieve the required head. This interaction is
continuous and ensures the most energy-efficient operation.
Temperature control as well
The pump can also be temperature-regulated. This regulation
also happens automatically.
Electronic
speed control
means ...Two pumps Single pump operation (1 operation/1 standby)
Pump type Motor size Controller Control mode
Twin-head pumps with integrated speed control
UPED Series 2000 ≤1.5 kW None Proportional/constant pressure
TPED/LMDE/LPDE ≤7.5 kW DC 2000 ME(PO) All control modesSeries 1000
Standard twin-head pumps
All pumps 22-45 kW DC 2000 MF All control modes
Single head pumps with integrated speed control
UPE Series 2000 ≤1.5 kW Twin head module Proportional/constant pressure
TPE Series 2000 ≤7.5 kW PMU Proportional/constant pressure
TPE/LME/LPE/CLME/NBE/ ≤22 kW DC 2000 ME (PO) All control modesNKE Series 1000
Standard single head pumps
All pumps 22-315 kW DC 2000 MF All control modes
2-4 pumps in parallel operation (+1 standby)
Single head pumps with integrated speed control
UPE Series 2000 ≤1.5 kW PMU Proportional/constant pressure
TPE Series 2000 ≤7.5 kW PMU Proportional/constant pressure
TPE/LME/LPE/NBE/NKE ≤22 kW DC 2000 ME(PO)/MEH All control modesSeries 1000
Standard single head pumps
All pumps 22-315 kW DC 2000 MF/MFH All control modes
H
Q Flow
Reduced frequency
Set point
Pres
sure
Reduced frequencyH
Q Flow
Set point
H
Q Flow
Increased frequency
Set point
Pres
sure
Pres
sure
1. When the flow is decreasing, the controller will detect a rise in pressure.
2. The controller will send a signal to the frequency converter to decrease the output until the pressure has returned to the required level.
3. When the flow is increasing again, the controller will detect a drop in pressure.
4. The controller will send a signal to the frequency converter to increase the output until the pressure has returned to the required level.
Flow
Constant frequency
Set point
Pres
sure
H
Q
5
A new era in pump technology
The development of speed-controlled pumps has created
nothing short of a revolution in pump technology. By being
able to automatically control its own speed, the pump will
continually regulate the pressure so that it optimally adapts
to the flow. The driving force behind this innovative process
has been the desire to achieve energy savings and an increase
in comfort levels – without compromising the pumps
lifespan or reliability.
The easy to install all-in-one solution
Grundfos speed-controlled pumps have an in-built motor,
frequency converter and the necessary application software
to make installation much simpler. As well as ensuring the
optimum adjustment of flow rates, and thereby achieve
energy savings, the installation costs and the risks of errors
are reduced as components are pre-configured, and therefore
already fully integrated.
Large capacity and parallel coupling
Offering large flow capacity and the parallel coupling
of pumps, we design solutions with external frequency
converters and control systems. Although these do not
comprise a single unit in the physical sense, they are
fully integrated as regards functionality and offer a true
all-in-one solution.
Two versions: Series 2000 and Series 1000
We offer two versions of speed-controlled pumps – each
of which covers a wide range of products. The Series 2000,
which is pre-defined to continuously regulate the pressure
according to flow, and the Series 1000, which allows for
any configuration of control method required: i.e. constant
pressure, proportional pressure, temperature control or
constant flow.
Electronic speed control
with Grundfos, allows for fully
integrated pump control
6
Grundfos electronic
speed-controlled pumps have
many possible applications
Full-line in building services
Grundfos speed-controlled pumps are equally suitable for
heating, air-conditioning and pressure-boosting systems.
All these types of systems can benefit from using a speed-
controlled regulator, which adjusts automatically.
Heating which offers significant energy savings
In the area of heating, the ultimate benefit of Grundfos
speed-controlled pumps is the ability to achieve huge
energy savings without compromising the pumps lifespan
or reliability.
Air-conditioning and custom-built pump solutions for
optimising the system
Never mind how complex an air-conditioning system is, or
how dramatic the variations in flow are during any 24-hour
period, we will have the correct pump solution to optimise
the entire system.
Pressure boosting and reliability of supply
Through continuously controlling the speed, and thereby
adjusting the flow, the use of Grundfos speed-controlled
pumps for boosting, reduces energy consumption, while
ensuring the supply is regulated throughout the day.
H(m)
2 4 6 10 20 100 200 600
6040
20
10
64
2 Q(m3/h)
H(m)
2 4 6 10 20 100 200 600
6040
20
10
64
2 Q(m3/h)
H(m)
2 4 6 10 20 100 200 600
6040
20
10
64
2 Q(m3/h)
CRE
Hydro Solo-E Hydro Multi-E Hydro 2000
TPE/LME/LPE(D) NBE/NKE
UPE(D) Series 2000MAGNA UPE Series 2000
TPE Series 2000
CLME
TPE/LME/LPE(D) NBE/NKE
TPE series 2000 CLME
7
A one-stop
pump supplier
Meeting all requirements
Grundfos offers a broad range of speed-controlled pump
solutions. Our extensive range of different pumps and
components ensure this. When coupled with a wide selection
of support tools and the expert advice available, you have a
reliable, value-for-money solution, for virtually any pump
application.
One-stop pump supplier
Working in partnership with Grundfos means you can
reduce the number of pump suppliers required, to just one
- Grundfos. A supplier who will assume the responsibility for
ensuring the correct components are selected and combined
to offer the best possible solution. This is both in terms of
reliability and from a value for money perspective.
Easy to select speed-controlled pumps
To provide straightforward and reliable answers to pump
selection questions, we have developed a collection of
support tools. For example, the electronic tool, WinCAPS.
With WinCAPS what may have previously appeared to be
a complex decision, has now become a comparatively simple
process.
Life Cycle Cost analysis
In addition, Life Cycle Cost (LCC) analysis is an important
equation within the selection of speed-controlled pumps.
The LCC creates a unique standard of reference and provides
the answers to questions about the cost savings that can
be made by choosing a given speed-controlled solution.
This method calculates the cost of a complete pump system,
from a ‘cradle to grave’ scenario and incorporates all costs
including the cost of the initial technology, installation,
ongoing maintenance as well as the all important area
of energy consumption.
Life Cycle Cost – 10 years of operation
System 1
System 2
Euro
70,000
60,000
50,000
40,000
30,000
20,000
10,000
0
System 1: Selected pump: UPS 40-120, 400 W (20 pumps).System 2: Selected pump: MAGNA 40-120, 440 W (20 pumps).
Depending on the energy price, there is a very short payback time on the extra cost of a speed-controlled pump system. Given a cost of 0.1 euro per kWh, the payback time in the example is between two and three years. Based on calculation principles from Hydraulic Institute and Europump.
Initial costs Energy costs Maintenance costs
Products
UPE Series 2000
TPE Series 2000
Series 1000
Hydro systems
System Pressureboosting
Air-conitioningsystems
Heatingsystems
8
∆p
TPE three phasedTPE single-phasedMAGNA
Pumps with integrated sensors Pre-setting for circulation, constant and proportional pressure
9
Pre-configured to adapt to the flow
The Series 2000 pumps are pre-configured to regulate the
pressure continually in accordance with flow. To achieve this,
the pump has an inbuilt sensor that automatically identifies
the variations in flow and communicates this information to
the frequency converter so that it can adjust, to achieve the
required head.
Ready to install
Being pre-configured, Series 2000 pumps eliminate the need
for any initial programming, thus making the installation
process extremely easy and straightforward.
All Series 2000 pumps benefit from the ability of being
speed-controlled which means they:
• utilise the energy by adapting to the heat fluctuations
in each specific building
• adjust to match the climatic variations throughout the
year
• ensure optimum performance throughout the day
• minimise the noise of the circulators by reducing the
load on the valves.
Large capacity
With Grundfos speed-controlled pumps, you also get a
reliable connection of pumps in situations where more than
one pump is required.
The Grundfos Series 2000
means speed-controlled pumps which
are preset and ready to operate
0 2000 4000 6000 8000Hours0
20
40
60
80
100
Flow in %
0 2000 4000 6000 8000Hours0
20
40
60
80
100
Flow in %
Yearly calculation profileYearly load profile
10
Constant flow
Temperature control
Proportional pressureProportional pressure
Constant flow
Temperature control
∆p p t Q
Pump without pre-mounted sensorR-100
The Series 1000
pumps offers free
choice of settings
Free choice of settings
The circulators of the Series 1000 pumps have options for
selecting any configuration and control method required:
i.e. constant pressure, proportional pressure, temperature
control or constant flow. The configuration can be defined
to suit any specific operating conditions and can equally be
amended to allow for ongoing changes.
Extra potential
The Series 1000 pumps incorporate all the benefits of the
Series 2000 as well as offering the potential for even more
sensitive regulation. Which solution offers the best value for
money can be calculated in each individual situation on the
basis of, for example, Life Cycle Cost analysis.
Large capacity
The Grundfos concept of speed-controlled pumps also means
reliable connection of pumps in situations where more than
one pump is required.
12
0 3 6 9 12 15 18 21 24 Hours0
20
40
60
80
100
Flow in %On/Off
P
Hydro Solo24-hour load profile
Hydro Multi-E
13
The ultimate challenge – a reliable supply
The Grundfos CRE pumps and Hydro pump systems for
pressure boosting are based on exactly the same principles
as all Grundfos speed-controlled pumps: By continuously
adapting to achieve the optimal flow, the energy used is
maximised and the reliability of supply remains constant
throughout the day. So even allowing for huge variations in
consumption, a high level of comfort and maximum energy-
efficient operation is guaranteed.
Superior precision and corrosion resistance
Every Grundfos speed-controlled pump is primarily produced
from high-grade stainless steel, which allows for extremely
high degrees of precision in pump design as well as offering
superior corrosion resistance.
Minimising noise
At the same time, the valve load is reduced and therefore
noise is minimised.
The Grundfos System Guide – booster edition
The Grundfos System Guide has a specific section devoted to
Pressure Boosting. If you require more technical information
on boosting, you can request a Grundfos System Guide – or
the electronic selection tool WinCAPS.
The CRE series offers
pressure boosting in conjunction
with improved supply reliability
P
On/Off
Constant discharge pressureHydro Multi-E
System type
Pressure boosting– system with break tank
gt ith b k t
Pressure boosting– system with direct connection to water mains
Zone divided watersupply
Product type
Gru
nd
fos CR
E
Hyd
ro Solo
Hyd
ro 200
0
Hyd
ro Mu
lti-E
14
Communications and comfort
Direct communication between building management
systems and individual system components is vital in
ensuring the reliability of supply as well as other aspects of
user comfort.
Network communication
A network communications option is integrated into each
Grundfos speed-controlled pump. This option can be used
with analogue or digital communications, and it gives access
to modules compatible with LONbus and the Grundfos
GENIbus.
BUS communication
By using BUS communication, the Grundfos speed-controlled
pumps can communicate with all kinds of building manage-
ment systems. From a central PC you can assess the pump
performance and monitor system conditions. This means
that the performance of each circulator can be optimised to
system requirements and pump activity can be coordinated
with other building systems.
Series 2000 pumps (in zones)Per pump:
Fault indication (digital)Operation indication (digital)
Set point (analouge)Start/stop (digital)
All pumps and MAGNAPer pump:
All available data from the pumpField bus:GENIbus
LONworks
All pumps (excl. Series 2000)System:
Fault indication (digital)Operation indication (digital)
Ou
tpu
t Equ
ipm
ent B
asic pu
mp
s
Grundfos electronic
speed-controlled pumps mean advanced
control and safe building management
PCU PMUControl2000
G 10
16
With the Grundfos concept
of speed-control, you can achieve
the reliable integration of pumps
It is essential for Grundfos to offer reliable, integrated pump
solutions to match any flow capacity and system characteris-
tics required. When there is a demand for solutions with more
than one pump, this is provided by external control panels
– the Delta Control. For large-capacity systems we integrate
the frequency converter with the control panel.
These solutions do not form a single unit in the physical
sense, however, the components are dedicated to each other
and fully integrated functionally, providing a true all-in-one
solution.
Furthermore, when we design integrated pump solutions,
value-for-money is the ultimate goal – encompassing the
total installation costs, maintenance costs and energy
consumption.
17
Two pumps Single pump operation (1 operation/1 standby)
Pump type Motor size Controller Control mode
Twin-head pumps with integrated speed control
UPED Series 2000 ≤1.5 kW None Proportional/constant pressure
TPED/LMDE/LPDE ≤7.5 kW DC 2000 ME(PO) All control modesSeries 1000
Standard twin-head pumps
All pumps 22-45 kW DC 2000 MF All control modes
Single head pumps with integrated speed control
UPE Series 2000 ≤1.5 kW Twin head module Proportional/constant pressure
TPE Series 2000 ≤7.5 kW PMU Proportional/constant pressure
TPE/LME/LPE/CLME/NBE/ ≤22 kW DC 2000 ME (PO) All control modesNKE Series 1000
Standard single head pumps
All pumps 22-315 kW DC 2000 MF All control modes
2-4 pumps in parallel operation (+1 standby)
Single head pumps with integrated speed control
UPE Series 2000 ≤1.5 kW PMU Proportional/constant pressure
TPE Series 2000 ≤7.5 kW PMU Proportional/constant pressure
TPE/LME/LPE/NBE/NKE ≤22 kW DC 2000 ME(PO)/MEH All control modesSeries 1000
Standard single head pumps
All pumps 22-315 kW DC 2000 MF/MFH All control modes
18
Delta Control 2000 Concept
Type Function System type Maximum half-size pumps Maximum full-size pumps Control panel
Controls for pumps with integrated speed control
PMU All pumps are speed-controlled. Small to medium heating 7.5 kW No Alternation between all pumps. and air-con systems with No. of pumps: 2-4 (8) minimum flow ≥ 25% (only for Series 2000 range)
ME(PO) All pumps are speed-controlled. Medium to large heating 22 kW No Alternation between all pumps. and air-con systems with No. of pumps: 2-4 minimum flow ≥ 25%
ME All pumps are speed-controlled. Medium to large heating 22 kW Yes Alternation between all pumps. and air-con systems with No. of pumps: 2-4 minimum flow ≥ 25%
MEH Half-size pumps are speed-con- Medium to large heating 22 kW 45 kW Yes trolled. Alternation between all and air-con systems with half-size pumps. minimum flow ≤ 25% No. of pumps: 3-4
Controls for pumps with external speed control
MF One pump is speed-controlled. Larger heating and air-con 315 kW Yes Alternation between all constant- systems with minimum speed pumps. flow ≤ 25% No. of pumps: 2-4
MFH Half-size pumps are speed-con- Larger heating and air-con 160 kW 315 kW Yes trolled. Alternation between systems with minimum half-size pumps. flow ≤ 25% No. of pumps: 3-4
19
Speed-controlled pumps mean Grundfos reliability
Just as reliability is a hallmark of the Grundfos constant-
speed pumps, so it is within our speed-controlled pumps.
Millions of our pump solutions around the world tell the
same story of pumps operating perfectly 24 hours day in, day
out, year after year.
Our pumps, in context
Each single pump is vital to ensuring the entire flow in a
system. We do however understand, that the quality of
the pump can only be assessed in its proper context. The
value of a pump, speed-controlled or not, is derived from its
interaction with the rest of the system. This calls for support
through, for example, system knowledge.
Flow Thinking is our working philosophy
Flow Thinking is our working philosophy because it means
taking a holistic approach and ensuring we create solutions,
which take the entire pumping solution into account. It also
demonstrates that partnership is the best possible working
relationship. For us, support is the essence of partnership.
Dedicated to knowledge and innovation
Ever since its foundation, Grundfos has been dedicated
to ensuring reliable products built to a superior quality
– through the relentless pursuit of knowledge and innova-
tion. We invest about EUR 50 million in research a year,
and we award the Grundfos Prize to encourage and promote
research.
Electronic tools to help with selection
Our one-on-one consultancy has been complimented with
electronic support tools. For example, dimensioning, pump
selection and cost calculations have all been made easier
through utilising either WinCAPS or WebCAPS. WinCAPS
is our efficient electronic tool that contains all the
important calculation programmes that you may find
helpful. A short version, WebCAPS, is available on the
Internet at www.grundfos.com.
The Grundfos System Guide – versions for heating,
cooling or pressure boosting
This hard-copy guide provides an overview of heating
systems, cooling systems and pressure-boosting systems.
It gives technical information about the different solutions
– and the respective circulators required.
A green company
For Grundfos, it is imperative that innovation should also
take into account the protection of the world’s resources.
Whenever a speed-controlled pump is chosen to replace
one with no regulation, it represents a small, but important
contribution, in reducing overall energy consumption.
Grundfos reliability
means knowledge,
partnership and support
This hard-copy guide provides an overview of heating systems. It gives technical information about the different solutions – and the respective circulators required.
WinCAPS is our efficient electronic tool, which includes important calculation programmes, for example, it incorporates models which can be used for calculating Life Cycle Cost analysis. A short version, WebCAPS, is available on the Internet at www.grundfos.com