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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 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 efficient pumping system. Discover our White
Paper: Three steps for
Reducing Total Cost
The Extended Product Approach (EPA) results on the EN 50598 series of standards and provides of Ownership (TCO) in
Pumping Systems
a generic methodology to select the right motor control solution. It is important to take a holistic approach
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
Auxiliaries
Drive (VSD)

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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

1
Does the application require to manage the flow rate of the pump ?

No Yes

Constant flow Variable flow

2
Does the application require to manage water hammer issues ?

No No Yes

ON / OFF Adjustable
Start and stop
ON / OFF with inrush current speed in real
limitation control
time
Variable
Direct-on-Line Star-Delta Soft-Starter Speed Drive
(DOL) starter starter (VSD)

3
Start to build your pumping system with the appropriate motor control solution

TeSys GV TeSys GV TeSys GV

Compact NS/NSX
Protection

TeSys K / D / U Altistart Altivar

Control

p. 6 - 7 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 All-in one

ON-OFF control
in constant flow
systems for:
• Jockey pump TeSys GV
• Backup pump
Motor circuit breaker from
• Primary pump 0.75 to 75 kW
• Circulating pump
• Disconnection and
• Transfer pump breaking
• Flood and drainage • Short-Circuit protection
control systems • Overload Protection
• Boiler feed water pump • Coordination Type 1, Type 2
• Tank filling pump

TeSys U
Complete Motor Starter
up to 15 kW
• Disconnection and breaking
• Low consumption • Short-Circuit protection
device • Overload Protection
• Start/Stop Control
• Easy to install, operate • Total coordination
and maintain • Direct / Reverse
• Communication ready

-50%
CONTACTOR
Let TeSys
Solink be
POWER your drive!
CONSUMPTION

TeSys K TeSys D
Mini Contactor Contactor
Direct / Reverse Direct / Reverse
from 1.5 to 5,5 kW from 0.06 to 75 kW

20
• Start/Stop Control • Start/Stop Control
• Compact contactor • 1 NO and NC auxiliary
• 1 NO or NC auxiliary contact contact times
• Common accessories faster for control
and add on blocks 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 TeSys GV
systems for:
Motor circuit breaker from 0.75 to 75 kW
• Primary pump
• Disconnection and breaking
• Circulating pump • Short-Circuit protection
• Transfer pump • Overload Protection
• Flood and drainage • Coordination Type 1, Type 2
control systems
• Water tapping pump
• Water lifting pump
• Pumping station

• Low consumption
device
• Inrush current
limitation

-50%
CONTACTOR
TeSys D
Contactor from 0.06 to 75 kW
• Line, Delta, Start contactors
POWER • Pre-assembled / Customer assembly
CONSUMPTION

Warning Accessories
starting torque • Time delay auxiliary contact blocks
must be < 1/3 • Electrical interlock
nominal torque • 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 TeSys GV Compact NS / NSX
• Well pump
Motor circuit breaker from 0.75 to 75 kW Motor circuit breaker from 40 to 400 kW
• Pumping station
• Disconnection and breaking • Disconnection and breaking
• Rainwater evacuation
• Short-Circuit protection • Short-Circuit protection
• Overload Protection • Overload Protection
• Coordination Type1, Type 2 • Remote reset
• Communication ready

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

Altistart 01 Altistart 22
Soft starter for small and simple Soft starter for standard pumping
pumping systems from 0.37 to 15 kW systems from 4 to 400 kW

• Reduce voltage start • Start & Stop smooth control

• Ramp-up time <5s • Ramp-up time <30s
• Start per hour 1 to 100 • Start per hour 1 to 6
• IP 20 • 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 • Disconnection and breaking
pump systems • Short-Circuit protection
• Water distribution • Overload Protection
systems • 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

Altivar 12 Altivar 312 Altivar 212

VSD for small pumping VSD for simple pumping VSD dedicated
systems from 0.18 to 4 kW systems from 0.18 to 15 kW to HVAC machines
from 0.75 to 75 kW
• 8 pre-selected speeds • 16 pre-selected speeds
• Modbus communication • Energy management • Fine control of the motor's
Assess your energy • SoMove software • Modbus CANopen speed
savings by the use of • Compactness • SoMove software • Energy management
VSD rather than a • IP 20 • IP 21 • Modbus, BACnet, LonWorks
throttling device to • PC_Soft software
control your pumping • IP 21 or 55
system.

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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

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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

4
2
3

1 2 3 4

OsiSense XM
Electromechanical
sensors for pressure
control
Ref.: DIA4ED2150201EN

OsiSense OsiSense OsiSense OsiSense

XX230A XMP XMLK ZMLP
Ultrasonic level Pressure switch Pressure sensors Switch with digital
sensors for power circuit display
• Pressure range:
• Level control up • Pressure range: 6, 10, 16 bars • Analog input
to 2 m 6, 12, 25 bars • Analog output 4-20mA
• 1 or 2 level • 2 or 3 phases 4-20 mA or 0-10 V • Logic output PNP
adjustable disconnection • Compatible with or NPN
• PNP/NPN • Fresh water, sea Altivar offer • Analog output
• IEC Compliant, water (0…70°C) • Fresh water 4-20 mA
OsiSense XMLK IP 65 • IEC Compliant, IP 65 (0…80°C) • Compatible with
Pressure sensors • IEC Compliant, IP 65 Altivar offer
for pump applications • IEC Compliant, IP 65
Ref.: 9012CT1001

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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 Outdoor

How to reduce damage

Spacial Thalassa
to components through Multi purpose metallic Multi purpose insulating
effective thermal
enclosures enclosures
management
Ref.: CPTG001_EN • Steel & Stainless Steel • Polyester
• IP 55 or IP 66 • Floor standing IP 43 to 55
• Wall mouting or Modular • Wall mounting IP 66
and Compact Floor standing

Universal Enclosures
Catalogue
Ref.: UE13MK04EN Thermal management systems
Climasys
Heating, cooling & control thermal solutions

• 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,
Choose your enclosure hygrostats, hygrotherm control
and your accessories
online

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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
1
due to voltage surge. Equipotential bonding
Ensure that the motor and the pump are correctly grounded at the same protective earth conductor that the
Ref.: CPTG002_EN installation.

2 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

Surge arrestors for

commercial and
industrial buildings Compliant solution for 230/400 V installation in any case where the short circuit current (Isc) is up to 50 kA;
– Selection guide. SPDs must be protected by an external short circuit protection (MCCB or MCB)
Ref.: A9DP96EN

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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 • Thermal magnetic motor circuit breaker TeSys GV2P
• Contactor TeSys D • Variable Speed Drive ATV 212
• IE3 Premium Efficiency Motor (30 kW) • IE2 High Efficiency Motor (30 kW)
• Centrifugal Pump • Centrifugal Pump
• Throttling device : proportional/linear valve

Related energy loss at different operating points

Details for the D.O.L starter + valve
The use of a throttling valve to control
the flow rate leads to significant energy Motor rated power [kW] : 30
loss in the system. 100% flow 50% flow 0% flow
(valve 100% open) (valve 50% open) (standby)
Energy loss – Pump + valve [kW] 5.4 9.4 0
There is no energy consumption during
Energy loss – Motor [kW] 2 1.5 0
the stand-by phase and very few loss during Energy loss – Contactor [kW] 0.03 0.03 0
operation. Total Loss [kW] 7.43 10.93 0

Details for the VSD motor control

Motor rated power [kW] : 30
The use of the VSD to control the flow rate 100% flow 50% flow
0% flow
allows to operate the pump at its Best (100% speed, (50% speed,
(standby)
100% load) 25% load)
Efficiency Point. Energy loss – Pump [kW] 5.4 0.8 0
Energy loss – Motor [kW] 2.9 0.75 0
The VSD causes additional energy loss during Energy loss – VSD [kW] 1.5 0.6 0,05
both operation and stand-by phases. Total Loss [kW] 9.8 2.15 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.

Constant flow Variable 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 Time fraction
100% 100%
80% 80%
60% 60%
40% 40%
20% 20%
0% 0%
100% 50% 0% 100% 50% 0%

Full load Half load Standby Full load Half load Standby

Load level [%] Time fraction [%] Load level [%] Time fraction [%]
100% 85% 100% 20%
50% 5% 50% 70%
0% 10% 0% 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]

Full load Half load Stand-by

Constant flow Variable flow

Weighted Loss [kW] Weighted Loss [kW]
D.O.L. starter + valve 6.86 D.O.L. starter + valve 9.14
VSD motor control 8.44 VSD motor control 3.47

Recommended EP: Recommended EP:

D.O.L. starter + valve VSD motor control

Savings of 1.58kW 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 Modicon M251
logic controllers logic controllers
Ref.: DIA3ED2140107EN Ref.: DIA3ED2140108EN

Let TeSys be your drive

To discover the TeSys range, connect on: Tesys - Motor control
www.schneider-electric.com/tesys and protection components
2015/2016
Ref.: MKTED210011EN

Make the most of your energy

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CPTG010_EN 07-2015

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