Control Panel

Technical Guide
How to select the appropriate
motor control system for your pump

Pumping

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Energy represents
up to

40%

of the Total Cost

of Ownership in
pumping systems

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Control panel technical guide - Pumping

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For energy efficient

pumping systems
Whatever the usage of a pump, it is crucial for the motor control system to ensure
the continuity and reliability of the service. Moreover, the choice of the appropriate
motor control system leads to an efcient pumping system.
The Extended Product Approach (EPA) results on the EN 50598 series of standards and provides
a generic methodology to select the right motor control solution. It is important to take a holistic approach

Discover our White

Paper: Three steps for
Reducing Total Cost
of Ownership (TCO) in
Pumping Systems

of the pump, the motor and the controls, in order to optimize the pump system.

Extended product
Motor system
Motor control system
Motor starter solutions
Direct On
Line (DOL)
Starter

Star-Delta
Starter

Motor

Pump

Soft-Start
Starter

Complete drive module (CDM)

Variable Speed
Drive (VSD)

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Auxiliaries

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Follow the selection

process
4 solutions
Determine which product family suits the needs
of your pumping system

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Apply the Extended Product

Approach to pumping systems
A 3 step process to select the appropriate motor control solution for the motor of your pump

Does the application require to manage the flow rate of the pump ?
No

Yes

Constant flow

Does the application require to manage water hammer issues ?

No

ON / OFF

Direct-on-Line
(DOL) starter

Variable flow

No

Yes

ON / OFF

Start and stop

control

Adjustable
speed in real
time

Soft-Starter

Variable
Speed Drive
(VSD)

with inrush current

limitation

Star-Delta
starter

Start to build your pumping system with the appropriate motor control solution

TeSys GV
Protection

TeSys K / D / U

TeSys GV

Compact NS/NSX

Altistart

TeSys GV

Altivar

Control

p. 6 - 7
5

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p. 8

p. 9
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Direct on Line (DOL) starter

TeSys Offer
TeSys offer
is compliant with Premium Efficiency motors (IE3)

Stand alone
ON-OFF control
in constant flow
systems for:

All-in one

TeSys GV

Jockey pump
Backup pump

Motor circuit breaker from

0.75 to 75 kW

Primary pump
Circulating pump

Disconnection and
breaking
Short-Circuit protection
Overload Protection
Coordination Type 1, Type 2

Transfer pump
Flood and drainage
control systems
Boiler feed water pump
Tank filling pump

TeSys U
Complete Motor Starter
up to 15 kW

Low consumption
device
Easy to install, operate
and maintain

-50%

Let TeSys
Solink be
your drive!

CONTACTOR

POWER
CONSUMPTION

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Disconnection and breaking

Short-Circuit protection
Overload Protection
Start/Stop Control
Total coordination
Direct / Reverse
Communication ready

TeSys K

TeSys D

Mini Contactor
Direct / Reverse
from 1.5 to 5,5 kW

Contactor
Direct / Reverse
from 0.06 to 75 kW

Start/Stop Control
Compact contactor
1 NO or NC auxiliary contact

Start/Stop Control
1 NO and NC auxiliary
contact
Common accessories
and add on blocks

20

times
faster for control
circuit wiring

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Star-Delta starter
TeSys Offer
TeSys offer
is compliant with Premium Efficiency motors (IE3)

Star-Delta
ON-OFF control with
inrush current limitation
in constant flow
systems for:

TeSys GV
Motor circuit breaker from 0.75 to 75 kW

Primary pump

Circulating pump
Transfer pump
Flood and drainage
control systems

Disconnection and breaking

Short-Circuit protection
Overload Protection
Coordination Type 1, Type 2

Water tapping pump

Water lifting pump
Pumping station

Low consumption
device
Inrush current
limitation

-50%

TeSys D
Contactor from 0.06 to 75 kW

CONTACTOR

Line, Delta, Start contactors

Pre-assembled / Customer assembly

POWER
CONSUMPTION

Warning
starting torque
must be < 1/3
nominal torque

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Accessories

Time delay auxiliary contact blocks

Electrical interlock
Mechanical interlock

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Soft Starter
TeSys Offer - Altistart Offer
Altistart offer
is compliant with Premium Efficiency motors (IE3)

Soft Starter
Smooth start & stop
control in constant
flow systems for:
Primary pump
Transfer pump
Flood and drainage
systems
Water tapping pump
Water lifting pump
Well pump
Pumping station
Rainwater evacuation

TeSys GV

Compact NS / NSX

Motor circuit breaker from 0.75 to 75 kW

Motor circuit breaker from 40 to 400 kW

Disconnection and breaking

Short-Circuit protection
Overload Protection
Coordination Type1, Type 2

Disconnection and breaking

Short-Circuit protection
Overload Protection
Remote reset
Communication ready

Water hammer
reduction
Starter bypass function
Inrush current limitation
Easy to install

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Altistart 01

Altistart 22

Soft starter for small and simple

pumping systems from 0.37 to 15 kW

Soft starter for standard pumping

systems from 4 to 400 kW

Reduce voltage start

Ramp-up time <5s
Start per hour 1 to 100
IP 20

Start & Stop smooth control

Ramp-up time <30s
Start per hour 1 to 6
Integrated by-pass
Type 1 coordination
IP 20 up to 45 kW
Embedded Modbus

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Variable Speed Drive (VSD)

TeSys Offer Altivar Offer
Altivar offer
is compliant with Premium Efficiency motors (IE3)

Altivar
Fine control in variable
flow systems for:
Secondary pump

TeSys GV

Boosters

Motor circuit breaker from 0.75 to 75 kW

Progressive cavity
pump systems

Water distribution
systems

Disconnection and breaking

Short-Circuit protection
Overload Protection
Coordination Type1, Type 2

Water treatment plant

Lifting station
Water intake station
HVAC & R
Water storage station

Operation at the Best

Efficiency Point (BEP)
of the pump
Energy efficiency
management
Water hammer
reduction
Speed threshold
against cavitation

Assess your energy

savings by the use of
VSD rather than a
throttling device to
control your pumping
system.
9

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Altivar 12

Altivar 312

Altivar 212

VSD for small pumping

systems from 0.18 to 4 kW

VSD for simple pumping

systems from 0.18 to 15 kW

VSD dedicated
to HVAC machines
from 0.75 to 75 kW

8 pre-selected speeds
Modbus communication
SoMove software
Compactness
IP 20

16 pre-selected speeds
Energy management
Modbus CANopen
SoMove software
IP 21

Fine control of the motor's

speed
Energy management
Modbus, BACnet, LonWorks
PC_Soft software
IP 21 or 55

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Accessories
Sensors

p. 11

Enclosures

p. 12

Surge protection devices

p. 13

The Extended Product

Approach (EPA) into
practice
p.14-15

10

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Sensors
Control and protect your
pumping installations
Sensors are crucial in order to ensure safety and a total control of pumping systems
A full range of pressure and level sensors dedicated to pumping environment are available in order to measure and optimize the energy
performance of the installation

2
3

OsiSense XM
Electromechanical
sensors for pressure
control
Ref.: DIA4ED2150201EN

OsiSense XMLK
Pressure sensors
for pump applications

OsiSense
XX230A

OsiSense
XMP

OsiSense
XMLK

OsiSense
ZMLP

Ultrasonic level
sensors

Pressure switch
for power circuit

Pressure sensors

Switch with digital

display

Level control up
to 2 m
1 or 2 level
adjustable
PNP/NPN
IEC Compliant,
IP 65

Pressure range:
6, 12, 25 bars
2 or 3 phases
disconnection
Fresh water, sea
water (070C)
IEC Compliant, IP 65

Pressure range:
6, 10, 16 bars
Analog output
4-20 mA or 0-10 V
Compatible with
Altivar offer
Fresh water
(080C)
IEC Compliant, IP 65

Analog input
4-20mA
Logic output PNP
or NPN
Analog output
4-20 mA
Compatible with
Altivar offer
IEC Compliant, IP 65

Ref.: 9012CT1001
11

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Enclosures
Protect the electrical
equipment of your pump
An appropriate enclosure is required in order to increase your electrical equipments'
lifetime and ensure the continuity of the service of your pumping system.
Protect the electrical equipments of your pumping installation with the appropriate enclosure

Indoor
How to reduce damage
to components through
effective thermal
management
Ref.: CPTG001_EN

Outdoor

Spacial

Thalassa

Multi purpose metallic

enclosures

Multi purpose insulating

enclosures

Steel & Stainless Steel

IP 55 or IP 66
Wall mouting or Modular
and Compact Floor standing

Polyester
Floor standing IP 43 to 55
Wall mounting IP 66

Universal Enclosures
Catalogue

Thermal management systems

Ref.: UE13MK04EN

Climasys
Heating, cooling & control thermal solutions

Choose your enclosure

and your accessories
online
12

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Clymasys CV - Ventilation
Clymasys CA - Airing
Clymasys CE - Air-Air Exchangers
Clymasys CU - Cooling units
Clymasys CR - Resistance heaters
or heating units
Clymasys CC - Thermostats,
hygrostats, hygrotherm control

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Surge protection devices (SPDs)

Make sure that your pumping
equipments are protected
The pump and its control equipments are subject to surge risks coming from lightning and switching.
Remote and well pumps have a high occurrence probability. Hence, it is essential to consider pumping installation requirements, safety
and continuity of the service.
Voltage

Lightning surge
thousands of Volts

Switching surge
hundreds of Volts

230 V

Time

How to prevent
machine malfunction
and electronic damage
due to voltage surge.

Ensure that the motor and the pump are correctly grounded at the same protective earth conductor that the
installation.

Ref.: CPTG002_EN

Surge arrestors for

commercial and
industrial buildings
Selection guide.

Equipotential bonding

SPD Device

Type 1 iPRF1 12,5r

Type 2 iPRD

Lightning rod on the top of building

General case: No lightning rod on the top

of the buiding

Compliant solution for 230/400 V installation in any case where the short circuit current (Isc) is up to 50 kA;
SPDs must be protected by an external short circuit protection (MCCB or MCB)

Ref.: A9DP96EN
13

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The Extended Product

Approach into practice
Example of Extended Product (EP) best selection
depending on the duty profile of the pump system
2 EP configurations at test
D.O.L starter + valve

VSD motor control

Thermal magnetic motor circuit breaker TeSys GV2ME

Contactor TeSys D
IE3 Premium Efficiency Motor (30 kW)
Centrifugal Pump
Throttling device : proportional/linear valve

Thermal magnetic motor circuit breaker TeSys GV2P

Variable Speed Drive ATV 212
IE2 High Efficiency Motor (30 kW)
Centrifugal Pump

Related energy loss at different operating points

Details for the D.O.L starter + valve
The use of a throttling valve to control
Motor rated power [kW] : 30

the ow rate leads to significant energy

loss in the system.
There is no energy consumption during
the stand-by phase and very few loss during
operation.

Energy loss Pump + valve [kW]

Energy loss Motor [kW]
Energy loss Contactor [kW]
Total Loss [kW]

100% ow
(valve 100% open)
5.4
2
0.03
7.43

50% ow
(valve 50% open)
9.4
1.5
0.03
10.93

0% ow
(standby)
0
0
0
0

Details for the VSD motor control

Motor rated power [kW] : 30

The use of the VSD to control the ow rate

allows to operate the pump at its Best
Efficiency Point.
The VSD causes additional energy loss during
both operation and stand-by phases.
14

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Energy loss Pump [kW]

Energy loss Motor [kW]
Energy loss VSD [kW]
Total Loss [kW]

100% ow
(100% speed,
100% load)
5.4
2.9
1.5
9.8

50% ow
(50% speed,
25% load)
0.8
0.75
0.6
2.15

0% ow
(standby)
0
0
0,05
0,05

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The Extended Product Approach into practice (continued)

2 examples of duty profiles

The duty profile describes the various power levels required by the pumping application, including standby, and the duration
of time during which the machine is operated at these levels.

Variable flow

Constant flow
Operating at maximum load most of the time

System sized for the maximum load

Operating at half load most of the time

Time fraction
100%

Time fraction
100%

80%

80%

60%

60%

40%

40%

20%

20%

0%

100%

50%

0%

Full load

Half load

Standby

Load level [%]

100%
50%
0%

0%

Time fraction [%]

85%
5%
10%

100%

50%

0%

Full load

Half load

Standby

Load level [%]

100%
50%
0%

Time fraction [%]

20%
70%
10%

Energy loss associated to each duty profile

Assess the Weighted Loss (WL) according to the EN 50598 methodology:

WL [kW] = Time fraction [%] x Total loss [kW] + Time fraction [%] x Total loss [kW] + Time fraction [%] x Total loss [kW]

Half load

Full load

Constant flow

Weighted Loss [kW]

6.86
8.44

D.O.L. starter + valve

VSD motor control

Recommended EP:

Stand-by

Variable flow

Weighted Loss [kW]

9.14
3.47

D.O.L. starter + valve

VSD motor control

Recommended EP:

D.O.L. starter + valve

Savings of 1.58kW

VSD motor control

Savings of 5.67kW

The choice of the most energy-efficient motor control solution

depends on the duty profile and shall result from a comparative

system-level analysis

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Quickly build your automation solution

with ready-to-use, tested, validated and
documented architectures
Modicon M241
logic controllers

Modicon M251
logic controllers

Ref.: DIA3ED2140107EN

Ref.: DIA3ED2140108EN

Let TeSys be your drive

To discover the TeSys range, connect on:
www.schneider-electric.com/tesys

Tesys - Motor control

and protection components
2015/2016
Ref.: MKTED210011EN

www.schneider-electric.com

Schneider Electric Industries SAS

35, rue Joseph Monier
CS 30323
F- 92506 Rueil Malmaison Cedex
France

As standards, specifications and designs change

from time to time, please ask for confirmation of
the information given in this publication.

RCS Nanterre 954 503 439

Capital social 896 313 776
www.schneider-electric.com

Publishing: Schneider Electric Industries SAS

Photos: Schneider Electric
Printing:

CPTG010_EN

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Printed on ecological paper.

2015 - Schneider Electric - All rights reserved.

Make the most of your energy

07-2015

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