Intelligent Pump Variable Frequency Drives What are the Differences

1. Intelligent Pump Variable Frequency Drives What are the Differences? Scott Mathews � Yaskawa Electric America

2. Pumps = Largest Energy Consumed Pumps therefore represent the largest single use of motive power in industry and commerce as shown in the breakdown of energy usage by motor driven equipment: Pumps-31% Fans- 23% Air Compressors- 8% Other Compressors � 14% Conveyors � 8% Others 16%

3. AC Motor

4. AC Motor

5. AC Drive Basics

6. AC Drive Basics

7. Variable Speed Pumps

8. What is a Basic VFD? Ability to control motor speed by changing the output voltage and frequency. Basic motor protection: Overload Ground Fault Output phase loss User programs drive by parameters, not specific to any application. Drive Keypad uses generic language for alarms and faults.

9. Intelligence to the Pump System Controls Beyond using basic VFDs, adding intelligence to the pump control solutions provides additional benefits which include: The intelligence could monitor pump operating parameters and conditions�such as vibration, leak detection, increased pressure, current draw and temperatures, and� predictive maintenance. Enhanced pump protection, resulting in longer life, increased operational efficiency and high reliability. Reduce downtime

10. Intelligent Pump Drives Provide Flexibility! Maintain Constant Pressure Maintain Constant Flow Match Variable System Process Demands

11. Improves Pump Efficiency

12. Helps Reduces Cost! Pressure Tanks are eliminated by the built-in PI control maintaining the pressure eliminating or reducing the size of the pressure tank necessary to maintain system pressure. Bypass valves are eliminated by the iQpump being able to slow the pump down and thus eliminating the bypass valve to reduce pressure Jockey pumps are eliminated by the iQpump being able to reduce speed and sequence in extra pumps The extra sensors (for application protection not PI feedback) are eliminated by the extra protection of the special IQPump software (Pressure, No-Flow, etc.)Pressure Tanks are eliminated by the built-in PI control maintaining the pressure eliminating or reducing the size of the pressure tank necessary to maintain system pressure. Bypass valves are eliminated by the iQpump being able to slow the pump down and thus eliminating the bypass valve to reduce pressure Jockey pumps are eliminated by the iQpump being able to reduce speed and sequence in extra pumps The extra sensors (for application protection not PI feedback) are eliminated by the extra protection of the special IQPump software (Pressure, No-Flow, etc.)

13. Pump Specific Operator Keypad

14. Easy to Configure for Different Applications

15. Key Pump Features Features Include: 4 Programmable internal automatic set points in Engineering Units PSI, GPM, Feet, etc. Allows for different setpoints that can be changed when booster system is used for both building water and irrigation. Pump Start Levels (PSI, GPM, etc.) and Start Time to ensure smooth transitions Flexibility to start the pump at different feedback levels with an integrated timer to eliminate cycling.

16. Programming Features Standard Features Include: Sleep / No Flow Protection Protects and shuts down the pump at low speeds or in a no flow condition. Sleep Boost Intended for use with a pressure tank, will boost the set pressure xx PSI over the Auto Setpoint prior to going to sleep, therefore, extending the pump's sleep time, reduce cycling, and saving energy.

17. Programming Features Standard Features Include: Power Loss - Automatic System Restart Programmable timer allows to automatically restart the system in Auto Mode for faults relating to brown outs, loss of AC power, and power spikes Requirement for unmanned locations when only keypad control is used. No Flow / Dead Head Detection Detects changes in motor RPM relative to sudden changes in pressure or flow; protecting against broken pipe, excessive well drawdown or run-dry conditions.

18. Programming Features Standard Features Include: Transducer Feedback Loss Protection Monitors the feedback device current levels to determine if the transducer has failed. Low and High Level Transducer Feedback setpoints with time delay settings. Monitors the system feedback device (PSI, GPM, Feet, etc.) to provide a warning, alarm or fault based on programmed level. Faults can be independently configured to provide for an auto restart.

19. Programming Features Standard Features Include: Dry Run Protection: Monitors motor current and speed based on programmable loss of prime setting. System will automatically restart allowing for well recovery time. Thrust Bearing Control (Submersibles) Achieve Minimum Pump Speed (Hz) in preset time to protect motor thrust bearing lubrication. Pipe Pre-Charging (Line Fill) Slow Pipe Filling to eliminate Water Hammer

20. Programming Features Standard Features Include: Flow Meter Data Logging: A flow meter feedback signal can be connected to read and accumulate total flow for system reporting to authorities. System can be configured to detect �No Flow� and �Sleep� on low demand.

21. Programming Features Standard Features Include: Impeller Anti-Jam Automatic Control: Provides a method for the user to detect high current and attempt to expel corrosion or solids which is keeping the pump impeller from operating efficiently. Perform a quick reversal to try and dislodge jam over a programmable cycle count. If unable to clear jam, �Anti-Jam Fault� on keypad.

22. Summary Key Pump Protection Protects Against Dry Running/Low Suction Closed Discharge Value Blocked Impeller Cavitations Conditions Over Cycling No Flow Protection Loss of Prime Transducer Loss Under Pressure �Broken Pipe� Protection Over Torque

23. Management of multi-pump systems to measure and optimize operating cycle 

24. Multiplex Keypad Status Display

25. Typical System Applications Booster Pump Systems Commercial & Residential Irrigation Submersible Wells Fluid Storage Tanks Water Treatment Systems Metering Pumps Spray Wash Systems Water Display Shows Geothermal Systems Single Phase Input Converter for remote installations

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