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The document describes Intelligent Variable Speed (IVS) Sensorless pumps designed for heating and air conditioning systems. IVS Sensorless pumps can vary their speed to match system demand, saving energy compared to traditional fixed speed pumps. They do not require pressure transducers or sensors, further reducing costs. The pumps follow embedded control curves to regulate pressure without external feedback. This allows installation in primary/secondary chilled water systems without the need for remote variable speed drives or pressure sensors. Various control modes, product features, and applications are discussed.
The document describes Intelligent Variable Speed (IVS) Sensorless pumps designed for heating and air conditioning systems. IVS Sensorless pumps can vary their speed to match system demand, saving energy compared to traditional fixed speed pumps. They do not require pressure transducers or sensors, further reducing costs. The pumps follow embedded control curves to regulate pressure without external feedback. This allows installation in primary/secondary chilled water systems without the need for remote variable speed drives or pressure sensors. Various control modes, product features, and applications are discussed.
The document describes Intelligent Variable Speed (IVS) Sensorless pumps designed for heating and air conditioning systems. IVS Sensorless pumps can vary their speed to match system demand, saving energy compared to traditional fixed speed pumps. They do not require pressure transducers or sensors, further reducing costs. The pumps follow embedded control curves to regulate pressure without external feedback. This allows installation in primary/secondary chilled water systems without the need for remote variable speed drives or pressure sensors. Various control modes, product features, and applications are discussed.
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