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ECO FLOW
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Partner Training Program
Eco-Flow-CVariable Frequency Drive for Commercial Pool and Spa Pumps
1
Product Training
2
Eco-Flow-CWhat is a Variable Frequency Drive
Pool Pump motors are supplied with Power comprising an AC (Alternating Current)The supply frequency in North America is 60 Hz (Cycles per second)
60 Cycles per second means that the motor will run at its nameplate speed
One Cycle
The motor’s speed is directly proportional to the frequency supplied
120 cycles per second = 2 x nameplate speed 30 cycles per second = 1/2 x nameplate speed
3
Eco-Flow-CHow does a Variable Frequency Drive work?
Sine Wave Power (AC) 60 Hz
VariableFrequency
Drive
Pulsed Width Modulated output(Variable Frequency)
Supply Voltage
4
Electrical Components of a VFD
DC bus choke
Diodes or SCR’s
Capacitor IGBT’s
5
Eco-Flow-CBenefits of reducing the pump’s speed
The electrical energy consumed by a Centrifugal Pump has a significant relationship to the speed at which it runs.
A small reduction in speed has a huge impact on the energy consumed
Example: Reducing the pump’s speed by just 25% will reduce the energy by 58%
This is the result of the ‘Affinity Laws’
How to calculate the amount of reduced energy:
Take the ‘new’ speed at which the pump could be run, and convert it to a decimal value, i.e., a new speed of 75% of the full speed = 0.75
Cube this speed: 0.75 x 0.75 x 0.75 = 0.42
Energy at 75% speed is therefore 42% of full speed energy
Power demanded by the Pump
Speed %
6
Why reduce the pump’s speed?
• Many pumps are over-sized for the pool to which they are installed
• Running at too high of a flow rate consumes more chemicals, prevents the filter from operating at its optimum performance and reduces equipment life
• State Health Departments mandate pool turnover time
• Some States are considering going to an 8 hour turnover during unoccupied pool times
• Discharge valves are often used to reduce the flow to achieve the required turnover
• Throttling back a discharge valve has minimal effect on reducing electrical energy
• As already seen, reducing the pump’s speed will significantly reduce the energy used
7
Flow Control Options
Operating $
Throttling Discharge Valve
Controlling Pump Speed
Operating $
8
Flow Control Valve
Reduce the pump’s speed usinga Variable Frequency Drive
How much can the pump’s speed be reduced?Step 1 – If there is an existing flow control valve, slowly adjust it to the fully open position
Step 2 – Now make a note of the flow meter reading with a clean filter condition, e.g., 750 GPM
Step 3 – Determine the capacity of the pool, e.g., 225,000 gallons
Step 4 – Divide the pool’s capacity by 360 (min.) to determine the required GPM for a 6 hour turnover, e.g., 225,000 ÷ 360 = 625 GPM
Step 5 – Determine what the required flow rate would be as a decimal of the actual, i.e., 625 ÷ 750 = 0.83
Conclusion: The pump’s speed could be run at 0.83 (83%) of its current speed to achieve the required turnover.
9
Eco-Flow-C How much can be saved?
Example:
Pool Capacity: 160,000 gallonsUtility cost: $0.16 per kilowatt hour (kWh)Pump size: 15 HPRequired turnover per hour: 26,666 (160,000 / 6)Required system flow rate to achieve State mandated turnover: 444 GPM (26,666 / 60)Actual system flow rate with discharge valve wide open: 580 GPMCalculated speed to meet required turnover: 77% (444 / 580) x 100Reduced energy: 0.77 x 0.77 x 0.77 = 0.46 or 46% of the full speed energy (a 54% saving)
Note: Using the discharge valve to reduce the flow would have resulted in a 13% saving
Annual Energy cost without VFD: $17,420
Annual Energy cost using discharge valve to throttle flow rate: $15,172
Annual Energy cost using Eco-Flow-C: $ 7,972
Minimum annual savings: $ 7,201
Typical Return On Investment: Less than 1 year
Note: Utility kWh costs are determined by taking the total utility bill and dividing it by the number of kWh used in the billing period. This method will ensure that all costs including transmission, surcharges and taxes are included.
10
Eco-Flow-CSnapshot
• Variable Frequency Drive for Commercial Pool & Water Feature Pumps
• Available for controlling 1 to 50 HP (standard), up to 600 HP (optional)
• Models for single phase input / 3-phase output
• Indoor and outdoor models
• Array of customized features
• Constant Flow feature
• Integrated Controller in NEMA 1 and 3R models
• Delivery typically 2 to 3 weeks
• 15 month warranty from ship date
11
Eco-Flow-CEnclosure Configurations
NEMA 0
• Stand alone VFD
• No options available
• Designed for installing in ‘clean / dry’
room
• Least likely of all configurations
12
Eco-Flow-CEnclosure Configurations
NEMA 1 (without options)
• VFD installed in a NEMA 1 Panel
• Includes Controller as standard
• Designed for installing in ‘clean / dry’
room
Controller VFD
Intake Filter
Exhaust Vents
13
Eco-Flow-CEnclosure Configurations
NEMA 3R (without options)
• VFD installed in a NEMA 3R Panel
• Includes Controller as standard
• Designed for installing outside
Controller VFD
Intake Filter
Exhaust Vents / Rain Hoods
Drip Shield
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Eco-Flow-CEnclosure Options
Circuit Breaker
An existing Electrical Disconnect is not situated within line of site of the VFD panel
Circuit Breaker
Required when:
Through the Door Handle OperatorIncluding Lockout facility
Note: Circuit Breaker includes a mechanical lock that prevents the Panel door from being opened when power is turned on
Wiring not shown
15
Eco-Flow-CEnclosure Options
Bypass
The customer would prefer to have a back-up method of running the pump should the VFD fail.
In the event of a VFD failure, the Selector Switch would be moved from the VFD to the Across the Line position
Bypass Contactors
Required when:
Motor OverloadBypass / VFD Selector Switch
A B C
VFD
A
B
C
Wiring not shown
16
Eco-Flow-CEnclosure Options
Lightning Arrestor
The VFD panel is installed in a geographical vicinity that has an incidence of Lightning Strikes.
In the event of a Lightning Strike, the Lightning Arrestor will absorb the high electrical energy that would otherwise destroy the VFD and its Controller.
Required when:
Lightning Arrestor
Wiring not shown
17
Eco-Flow-CEnclosure Options
Line Reactor
VFD’s can transmit Harmonic distortion onto the supply lines. These Harmonics could cause interference to equipment supplied from the same electrical source.
A Line Reactor should be included if the VFD panel is to be installed on the same supply to which sensitive electronic equipment is installed, i.e.,
• Computers
• Radio Equipment
• Electronic Chemical Dosing systems, i.e., PH or ORD systems
Required when:
Line Reactor
Wiring not shown
18
Eco-Flow-CEnclosure Options
Load Reactor
When the VFD panel is to be installed:
• To a non VFD rated Motor
• More than 300 cable feet from the Motor or,
• To 480V supply voltage
Required when:
Load Reactor
Wiring not shown
19
Speed Control
20
Method A – Fixed Speed Control
Integrated Controller is used to setthe pump’s speed for specific times of the day.Up to 2 preset speeds plus a ‘Backwash’ speed can be programmed.
Note: The pump’s speed must never be adjustedto be lower than that required to meet statutoryturnover requirements, i.e., a 6-hour turnover inmost States.
Eco-Flow-C
Supply Voltage
Flow MeterTo Pool
From Pool21
Method A – Fixed Speed Control(2 programmable speeds)
% Pump Speed
Time
0800 1200 1600 2000 0000 0400
50
70
40
30
20
10
60
80
90
100
22
Method A – Fixed Speed Control(2 programmable speeds)
% Pump Speed
Time
0800 1200 1600 2000 0000 0400
50
70
40
30
20
10
60
80
90
100
23
Backwash Control
24
Manual Backwash
% Pump Speed
Time0800 1200 1600 2000 0000 0400
50
70
40
30
20
10
60
80
90
100Backwash Speed = 100%Backwash Duration = 5 min
25
Automatic Backwash
Automatic Backwash SystemContact closes during backwashVFD accelerates to Backwash speed
26
Method B – Automatic Flow Control (Pressure Sensor)
To Pool
From Pool
Flow Meter
Supply Voltage
Pressure Sensor
Eco-Flow-C
4-20mA signal proportional to pressure
As the filter gets dirty:Discharge Pressure drops & Eco-Flow-C automaticallyincreases the pump’s speed to maintaina constant flow
Note:The pump’s speed must never be adjusted to be belowthat required to meet a States mandated turnoverRequirements, i.e., a 6-hour turnover in most States
27
Method B – Automatic Flow Control (Flow Sensor)
To Pool
From Pool
Flow Meter
Supply Voltage
Flow Sensor
Eco-Flow-C
4-20mA signal proportional to flow
As the filter gets dirty:Discharge Flow drops & Eco-Flow-C automaticallyincreases the pump’s speed to maintaina constant flow
Note:The pump’s speed must never be adjusted to be belowthat required to meet a States mandated turnoverRequirements, i.e., a 6-hour turnover in most States
28
Methods B & C - Maintaining Constant Flow (Auto Flow Control)
% Pump Speed
Time0800 1200 1600 2000 0000 0400
50
70
40
30
20
10
60
80
90
100
Pump Speed increases as filter becomes dirty and filter discharge pressure or flow decreases
29
Methods B &C - Maintaining Constant Flow (Auto Flow Control)
% Pump Speed
Time0800 1200 1600 2000 0000 0400
50
70
40
30
20
10
60
80
90
100
Pump Speed increases as filter becomes dirty and filter discharge pressure or flow decreases
30
Maintaining Constant Flow during the dayand
Fixed (low) Speed at night
% Pump Speed
Time0800 1200 1600 2000 0000 0400
50
70
40
30
20
10
60
80
90
100
Automatic Flow Control
Fixed Speed Control
31
Pressure
Pump Speed
Constant Flow
Maintaining Constant Flow (Auto Flow Control)
To Pool
From Pool
FILTER
32
Control Summary
Method Speed Control Method Timed Start / Stop
Manual Backwash
Automatic Backwash
A Fixed Speed • • •
B Constant Flow – with Pressure Sensor • • •
C Constant Flow – with Flow Sensor • • •
D Constant Flow with Timed Fixed Speed • • •
33
Channels to Market
34
Channel to Market
End User
H2flow Controls
Channel Partner
H2flow Representative
35
Channel Partner Requirements
Review Handout
36