INTELLIGENT VARIABLE SPEED Pumps

FILE NO: 5-1

DATE: December 2007
SUPERSEDES: 5-1
DATE: December 2004
IVS Sensorless Series
I
V
S
S
e
n
s
o
r
l
e
s
s
S
e
r
i
e
s
L
L
L
L
L
L
L
Innovative Solution for
Heating and Air
Conditioning Systems.
The IVS Sensorless pump has been designed to meet the need for
energy-efficient pumping systems in todays buildings. Traditional
pumping systems incorporating fixed speed pumps waste energy
through crude flow control via throttling valves. Lifetime Cost
Analysis shows that the capital cost of a fixed-speed pump is
typically only 5% of its lifetime cost.
Variable speed technology allows the speed of the pump to be tuned to suit system demand.
Technological advancements make variable speed pumps attractive in terms of both capital and life
time cost.
Pressure transducers / sensors are no longer required, further reducing capital and installation cost.
The IVS Sensorless pump is a new generation pump with complete integration in a compact
package.
Applications for this technology include variable volume heating and chilled water applications.
Eligible for Enhanced Capital Allowances (ECAs) as part of the UK Governments Climate Change
Programme (further details can be obtained from DEFRA at www.eca.gov.uk).
2
Primary / Secondary Chilled Water Systems
Figure 1 shows a chilled water system with constant speed primary pumps and variable speed
secondary pumps in a duty / standby arrangement. The secondary pumps in a primary/secondary
chilled water system distribute the chilled water from the primary production loop to the loads which
satisfy the cooling requirements of the building.
Adding variable speed drives to the secondary system results in increased control potential and
significant energy savings. The system now becomes a variable volume, variable speed system in
which the pumps can automatically adjust speed by utilising pressure feedback.
Referring to fig 1, the variable speed drive is programmed to maintain a pressure at the location of the
differential pressure sensor. As demand for cooling reduces, the two port valves start to close and the
differential pressure across the load increases. The drive then slows the pump to maintain the set value.
Because of the position of the sensor, the head/flow characteristic will follow a control curve (see fig 2)
between min and max flow.
In addition to saving energy, reducing the speed increases the life of the pump and motor bearings.
Reduced pressures across control valves increase valve life and reduces system noise.
The installation shown in Figure 1 has variable speed drives remote from the pumps that will occupy
valuable plant-room space and incur a level of mounting and wiring cost. Two pressure sensors are shown
suchthat should one sensor fail then the standby pump and drive will take over the duty. Again, wiring and
mounting costs are incurred and the sensors may require periodic calibration.
The use of IVS Sensorless pumps gives significant energy savings and greatly reduces capital and
installation cost in variable volume chilled water or heating systems.
Intelligent Variable Speed Pumps
3
Figure 1. - Typical Primary / Secondary Chilled Water System Incorporating Variable Speed Drives
4
Sensorless Technology
Sensorless control is an innovative concept in glanded
circulating pumps. Pump performance and characteristic
curves for ten different speeds are embedded in the memory
of the speed controller during manufacture. This data
includes power, pressure and flow across the flow range of
the pump. During operation, the power and speed of the
pump are monitored, enabling the controller to establish the
hydraulic performance and position in the pumps head-flow
characteristic.
These measurements enable the pump to continuously
identify the head and flow at any point in time, giving
accurate pressure control without the need for external
feedback signals. Patented software technology within the
controller ensures trouble-free operation in all conditions.
Incorporating the pumps hydraulic data into the controller and removing sensors results in true integration of all components and removes
the risk of sensor failure.
Available Pump Models
The IVS Sensorless control is available with the following pumps types:
4300 Split Coupled Vertical In-line 4280 Close Coupled End Suction
4302 DualArm Split Coupled Vertical In-line Twin Head 4030 Long Coupled End Suction
4380 Close Coupled Vertical In-line 4392 Close Coupled Vertical In-line Twin Head
4382 DualArm Close Coupled Vertical In-line Twin Head
L
L
Figure 2 - System Control Curve
The Sensorless Solution
In figure 3 the pumps and remote variable speed drives have now been
replaced by vertical inline IVS Sensorless pumps. The pressure sensors
are no longer required as the IVS Sensorless pump is preprogrammed
to follow a control curve (fig 3) between the head point at design duty
and the head required at minimum flow. The control curve is fully site
adjustable and gives the installer the flexibility to replicate sensor
positions at varying distances from the pump. This feature removes
the problems associated with incorrect sensor placement and allows
optimum energy savings to be realised.
L
150-200
Series 4380 Starline IVS Sensorless
Close Coupled Vertical In-Line Centrifuga
150-200 @198 mm
0 10 20 30 40 50 60 70 80
0
20
40
60
80
100
120
140
Flow (lps)
Head
(kpa)
Water, sg= 1.00
82
81
81
77
77
71
71
62
51
1394 rpm
1280 rpm
1160 rpm
1040 rpm
930 rpm
1450 rpm
1394 rpm
807 rpm
756 rpm
580 rpm
1
2
3
4
5
6
7
13/01/2005, 14:42:50, Wayne Rose, AHBP, 01612232223, Fax: 01612209660
6.4b
Control (QPC)
5
Figure 3. - Primary / Secondary Chilled Water System Incorporating IVS Sensorless Pumps
Product Features
Fast and easy installation - no pressure sensors required
Supplied with customers pre-sets
Compact space-saving design - as compact as a standard pump
BMS compatible - analogue / digital I/O and RS485
Interchangeable with standard pumps
Multiple control modes
Bypass frequency selection to eliminate system vibration problems
Programmable motor pre-heat function to prevent condensation problems
Built in RFI filter to give EMC Directive compliance
Built in DC link chokes to reduce mains borne harmonics
Product Options
IP56 and IP66 Enclosure ratings
Quick connection key pad and cable for programming and monitoring - one required per site
L
L
6
Adjusting the head at minimum flow is effectively the
same as controlling pressure at different points in the
system (different sensor locations) but infinitely simpler.
The optional programming key pad can be used to
change these set-points and also the alternative modes
of control. Turning the quadratic curve fit off results in a
straight line between the maximum and minimum head
points (see figure 4) known as Proportional Pressure
Control.
Sensorless Control Modes
The default mode of operation for IVS Sensorless pumps is to follow a system control curve similar to
that shown in figure 2. This mode of control is also known as Quadratic Pressure Control as the
control curve is a quadratic curve between two operating points Hmax and Hmin. Hmax is the design
duty head of the pump and Hmin is the head at minimum flow which is set to a default of 40% of Hmax.
L
Figure 4 - Proportional Pressure Control
150-200
Series 4380 Starline IVS Sensorless
Close Coupled Vertical In-Line Centrifuga
150-200 @198 mm
0 10 20 30 40 50 60 70 80
0
20
40
60
80
100
120
140
Flow (lps)
Head
(kpa)
Water, sg= 1.00
82
81
81
77
77
71
71
62
51
1394 rpm
1300 rpm
1200 rpm
1100 rpm
1000 rpm
1450 rpm
1394 rpm
901 rpm
756 rpm
580 rpm
1
2
3
4
5
6
7
13/01/2005, 14:44:05, Wayne Rose, AHBP, 01612232223, Fax: 01612209660
6.4b
Control (PPC)
It is quite common to see pressure sensors located directly
across the variable speed pump. This is usually done to avoid
the cost of remotely installing the sensor but reduces the
opportunity for energy saving as the set-point pressure for
the variable speed drive is the constant design head of the
pump (figure 5). Constant Pressure Control is available on
IVS Sensorless pumps and is used where the pressure loss,
before individual loads or zones, is minimal.
Figure 5 - Constant Pressure Control
150-200
Series 4380 Starline IVS Sensorless
Close Coupled Vertical In-Line Centrifuga
150-200 @198 mm
0 10 20 30 40 50 60 70 80
0
20
40
60
80
100
120
140
Flow (lps)
Head
(kpa)
Water, sg= 1.00
82
81
81
77
77
71
71
62
51
1394 rpm
1330 rpm
1270 rpm
1450 rpm
1394 rpm
1205 rpm
1195 rpm
580 rpm
Control (CPC)
7
Constant Curve Control
Where the Building Management System is to be used to
control the speed of the pump (using a 0 - 10V signal) then
sensorless control can be switched off by inserting a link
between two terminals.
The pump speed will now vary according to the BMS
reference signal. A potentiometer can be used to vary the
speed reference signal allowing manual speed control of IVS
Sensorless pumps in primary or secondary systems.
L
Figure 6 - Constant Curve Control
150-200
Series 4380 Starline IVS Sensorless
Close Coupled Vertical In-Line Centrifuga
150-200 @198 mm
0 10 20 30 40 50 60 70 80
0
20
40
60
80
100
120
140
Flow (lps)
Head
(kpa)
Water, sg= 1.00
82
81
81
77
77
71
71
62
51
1394 rpm
1280 rpm
1160 rpm
1040 rpm
930 rpm
1450 rpm
1394 rpm
807 rpm
756 rpm
580 rpm
13/01/2005, 14:49:48, Wayne Rose, AHBP, 01612232223, Fax: 01612209660
6.4b
System
Duty Standby Operation
Duty standby operation requires additional controls or changeover logic in the Building Management System.
Please contact Armstrong for connection details.
L
Typical Specification
Provide Armstrong Series ______IVS Sensorless pump to Armstrong Series _____pump typical specification with motor and control
specification as per the following:
The driving motor shall be of squirrel cage induction type incorporating an integrated (in standard terminal box position) variable frequency
drive (VFD), vertical solid shaft with IP55 enclosure and shall be of physical dimensions such that the pump size envelope is no larger
than the fixed speed equivalent.
The integrated VFD shall be of the VVC-PWM type providing near unity displacement power factor (cos F) without the need for external
power factor correction capacitors at all loads and speeds. The VFD shall incorporate DC link chokes for the reduction of mains borne
harmonic currents to aid in compliance with the Electricity Councils Engineering Recommendation G5/4 Stage 2 and to reduce the DC
link ripple current thereby increasing the DC link capacitors lifetime. The product shall be CE marked showing compliance with both the
EMC Directive 89/336/EEC and the Low Voltage Directive 72/23/EEC. RFI filters will be fitted as standard to ensure the VFD meets
the emission and immunity requirements of EN61800-3.
VFD and motor protection shall include: motor phase to phase fault, motor phase to earth fault, loss of supply phase, over voltage, under
voltage, motor over temperature, inverter overload, over current.
Sensorless control software shall be embedded in the integrated VFD to provide automatic speed control in variable volume systems
without the need for pump mounted (internal/external) or remote differential pressure sensor. The default operating mode under
sensorless control shall be quadratic pressure control whereby head reduction with reducing flow will be according to a quadratic
control curve, the head at minimum flow being 40% of the design duty head. Control mode setting and minimum / maximum head
setpoints shall be user adjustable via an optional programming interface.
The VFD shall have the following additional features: sensorless override for BMS / manual pump control or closed loop PID control,
programmable skip frequencies and adjustable switching frequency for noise / vibration control, auto alarm reset, motor pre-heat
function, four programmable digital inputs, two analogue inputs, one programmable analogue/digital output, one volt-free contact and one
RS485 port for serial communications to building management systems.
Environmental Ratings
Temperature: 0 - 40C
Max Relative Humidity: 93% +2%, -3%
L
L
Our policy is one of continuous improvement and we reserve
the right to alter our dimensions and specifications without notice
For Armstrong locations worldwide, please visit www.armstrongpumps.com
Armstrong Holden Brooke Pullen Ltd
Wenlock Way
Manchester
United Kingdom, M12 5JL
T: +44 (0)161 223 2223
F: +44 (0)161 220 9660
E: salesuk@armlink.com
Sales & Service Office
21-23 Ormside Way
Holmethorpe Industrial Estate
Redhill, Surrey, RH1 2NT
T: +44 (0)173 737 8100
F: +44 (0)173 737 8140
E: salesuk@armlink.com
S. A. Armstrong Limited
23 Bertrand Avenue
Toronto, Ontario
Canada, M1L 2P3
T: (416) 755-2291
F: (416) 759-9101
E: info@armlink.com