GRUNDFOS

iSOLUTIONS

GRUNDFOS iSOLUTIONS
WE BRING MORE
THAN PUMPS…

JSX 2016 1
LCC (Life Cycle Costs)

Energy Consumption:
85%

Maintenence:10%

Investments: 5%

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Why speed control
4

Why speed control

An example: (constant pressure)
• A fixed speed water supply pump has a Hnom = 3 bar at Qnom
• The flow has to be controlled by a throttle valve
• By reduced flow the pressure will increase to more than 5 bar

H
System
Pressure at Fixed speed
pump solution = 5 bar
Fixed
Excess speed
pressure
Required pressure = 3 bar

Reduced Nominal
Q
flow flow Qnom
Why speed control
By changing speed of the pump
the performance can be changed
and energy can be saved.

As an example the speed halved :

2900 rpm  1450 rpm

n   1450 
Qx  Qn   x   12   6 [m3/h]
 n
n  2900 
2
n 
2
 1450 
H x  H n   x   40     10 [m]
 n
n  2900 
3
n 
3
 1450 
Px  Pn   x   11    1,37 [kW]
 n
n  2900 

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 Why speed control
Set point
An example: (constant pressure)
• A speed controlled pump automatically adapt
PI
the pump performance to the actual need. Controller
• The flow is reduced by lowering the speed of the pump
• The pressure is constant 3 bar
Freq.
conv.
H
System
Pressure at Fixed speed
pump solution = 5 bar
M
Fixed
Excess speed
pressure
Pressure at Variable speed Required pressure = 3 bar
pump solution = 3 bar

Variable speed

Reduced Nominal
Q
flow flow Qnom
Why speed control

An example
If the pump is a CRE 5-8:

By reduced flow
the power consumption is
reduced with 43%!

1.34 kW

Reduced 0.75 kW
with 43%
0.43 kW
Grundfos motors achieve highest energy
efficiency rating worldwide
CR15-4 w/MG Motor
Dutypoint: Q = 20 m3/h, H = 60 m

Energy consumption
10774 kWh/Year

Running time: 9 hours@365 days

CRE15-4 w/MGE Model G
Dutypoint: Q = 20 m3/h, H = 60 m

Energy consumption
8484 kWh/Year

Running time: 9 hours@365 days

CRE15-4 w/MGE Model J
Dutypoint: Q = 20 m3/h, H = 60 m

Energy consumption
7662 kWh/Year

Running time: 9 hours@365 days

Comparison of energy savings

Yearly energy consumption Index

Index

100

79
71

CR15-4 w/MG Motor CRE15-4 w/MGE Model G CRE w/MGE Model J

IE5 vs IE3 = … ?

9%
GRUNDFOS
iSOLUTIONS Which products are in the iSOLUTIONS range?
• Intelligent pumps – like e.g. Magna3 and MGE with built-in control features
• Intelligent controllers – e.g. the CU 352 and CU 362 with multi pump functions and much
more…
• Communication modules/units for communication to overall systems, like PLC’s and
SCADA systems
• A wide range of sensors to provide the measurements in the process and enabling us to
optimize the application, e.g. power, flow, specific energy etc.
• Intelligent motor protection and drives – for surveillance and optimization of
pumps/speed.

Pumps Controls

Communication units Sensors Monitoring/Drive units

JSX 2016 14
GRUNDFOS
iSOLUTIONS

Data example with 2 digital outputs

Alarm!
I am
stopped

JSX 2016 16
Communication
GRUNDFOS
iSOLUTIONS

Example with Grundfos bus

systems
Sensor I am
Load
Started Speed is warning running
percentAlarm!
145 times 72 % Flow is
Overloa
Specific energy 15 m3/h Controlled
d
from bus
Frequency Water is
55 C Not at
Head is
DC link power limit
8m
voltage Max flow
Power consumption Remote flow is
40 W 18 m3/H
Time is
14:27:43 Control mode Running for
Energy cons. Prop. pressSetpoint is 12762 hours Not at
23433 kWh 8m power limit
231 V

JSX 2016 18
External setpoint function

• Setpoint can be set here. The setpoint can be influence by other

parameters.

Setpoint

x % External setpoint influence

Resulting setpoint

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Settings – External setpoint influence
• Six different influence functions are available. The influence table can have up to 8 points

Linear with MIN/STOP Inverse function

Linear function

Inverse with MIN/STOP Influence table Influence table with STOP at MIN/MAX
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External setpoint influence - Example
Setpoint influence H

100%

STOP Ext. input

0% Q
0% 70% 100%

- 50 ºC

The setpoint of the pump running

proportional pressure is influenced
-10 ºC by the outdoor temperature
4 20
20 ºC
mA

50 ºC

Temp [ºC] 21
External setpoint influence

Benefits!
• Avoiding external controller for doing the wanted function
• Improve functionality by influencing the setpoint
• Energy saving due to improved control of controlled parameter

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Settings – Predefined setpoint

• The function of the predefined setpoint function

Predefined setpoint

Digital input 4 Setpoint 7

Digital input 3 7 Setpoint 6 “1” “2” “4”

6 DI 2 DI 3 DI 4 Value Setpoint
0 0 0 0 Normal/STOP
Digital input 2 5 Setpoint 5 1 0 0 1 SP1
0 1 0 2 SP2
4 Setpoint 4 1 1 0 3 SP3
Actual setpoint 0 0 1 4 SP4
3
Setpoint 3 1 0 1 5 SP5
2 0 1 1 6 SP6
Setpoint 2 1 1 1 7 SP7
1
0 Setpoint 1

Normal setpoint

STOP

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Predefined setpoint – Application
example
Benefits!
• In wash and cleaning applications different tasks like “Foam dispensing”, “Flushing” and
“High pressure jets” requires different pressure from the cleaning pump.
By means of a switch the operator can change the setpoint of the constant pressure pump.

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Settings – Limit exceed function 1 and 2
• Can monitor one of the Analog inputs, Pt100/1000 inputs or some selected internal values
such as Speed or Motor load. By Limit exceeded actions like Warning or Alarm + Stop can be
selected.

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Limit exceed function?
Benefits!
• Cost saving - No need for a PLC to do this function
• Can supervise parameters which can cause damage to the pump or system and give a
warning or stop the pump if needed
• Can be used for making control of one of the relays or digital outputs

Application example
Pump running Constant differential
pressure. If a Pump differential pressure
are going below “Limit 1”, a Warning will
be generated.

Limit 1
Risk of
cavitation

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Examples of Limit exceed function
A client wants to integrate a CRE 5-5 pump into a filtration system in order to achieve a constant
volume flow of 6 m3/h. The filter resistance may lead to 15–40m pressure drop.

The pump takes water form a feed balance tank.

The temperature should not exceed 25°C. By a lasting exceeding of the temperature (> 10s), an alarm
light should be activated.

Feed balance
tank
VFS 0,6–12
0.5–3.5V
Filter unit delta p = 15–40m

Q const.: 6 m3/h at 15–40m

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28
Examples

Operating
range

70 100
Transfer medium = water
Medium temperature = 20°C
Density = 998.2 kg/m3

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 30
m3/h
Electrical plug-
connection
PIN number
Example
Temperature
signal
Flow Pipeline
signal
 AUTOMATIC CLEANING FILTER

Requirments:
- 30 bar on membrane inlet.
- Max. Flow 25 m3/h throw membrane.

Booster Event| EMEA 31

 TYPE OF GRUNDFOS PUMP CRNE
FUNCJONALITY + COMUNICATION External Setpoint Influence on
duty point.
Flow metter will reduce the
Const. Pressure,
pressure when flow achieve
regulation via AI1
max flow throw membranę –
AI2

The pump 1 send a

signal via AO1 to pump
2 via AI2 signal about
the actual speed

AI1 activated by differentia

pressure sensor -> start and
When pump no. 3 has
stop pump no. 3 thanks to
been started by Limit
Limit Exceed Function
Exceed Function will
activate 3 DI in order to:
STOP pump 1 and 2,
Start Dosing Pump +
Open Concertrate Valve

Booster Event| EMEA 32

Grundfos E-pump

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