Goulds/Vogel Hydrovar

What is the Hydrovar?

The HYDROVAR is the world’s first pump mounted,
micro-processor based pumping system controller.
Designed by our VOGEL division in Austria, the
HYDROVAR does much more than just change motor
speed. It truly manages your pump performance to
match a wide range of system conditions and require-
ments. By combining the HYDROVAR with our popular
Lowara SSV, Hi-Tek and C series, and our VOGEL
PMVH, LMRH and LMRZ series pumps, we have
created an extremely versatile range of pumps for use
in HVAC, water supply, irrigation, filtration, pressure
wash, boiler feed, circulation, and a wide range of
OEM applications.

How is this different?

The typical construction of a pressure set or constant operates through a control panel. On systems which
pressure system includes one or more pumps assem- require alternating duty sequencing, a microprocessor
bled together with common suction and discharge is required and on some systems, bypass lines are
headers which are then connected to a large pressure maintained by the use of metering valves. The use of
accumulator. This package set is then connected to the some of these variable speed drives also requires the
system. As the system demand increases the pumps use of special motor/controller combinations.
are switched on by some form of pressure sensor that

All components contained within one unit!

FREQUENCY
CONVERTER
BLOCKPUMPS totally enclosed IP 54

PRESSURE TRANSMITTER CONTROL by

or DIFFERENTIAL MICROPROCESSOR
PRESSURE TRANSMITTER incl. automatic switch over

2 PCS-1A
Motor Power:
from 1,1 kW up to 22,0 kW

Highlights
Fitting of oversized
motor allows
increased output in
overspeed range.

Pump duty adjusts

automatically to meet
demand, i.e. follows
the system curve.

Shut down of
pump during zero
consumption.

Energy saving up to
70% at partial load.

Top line is pump with constant speed

Example: Bottom line is pump with variable speed
Circulator having 11 kW motor power at partial load
Power consumption as per curve
Capacity in % Pump at constant speed Pump at variable speed Saving in kW Saving per 1/3 year
following system curve (2920 hours)

25% 5,8 kW 1,8 kW 4,0 kW 11.680 kWh

50% 7,6 kW 3,2 kW 4,4 kW 12.848 kWh
75% 9,2 kW 5,7 kW 3,5 kW 10.220 kWh

34,748 kWh

PCS-1A 3
Highlights
SIMPLE INSTALLATION!
1) mechanical installation 2) electrical connection 3) setting of desired parameters

Rigid Aluminum
housing totally
enclosed IP 54

Saving of investment costs

by elimination of control
panel

Sufficient cooling
of inverter by
motor fan

No need for flow

metering because of indirect
flow sensing
No need for external pressure
or differential pressure sensing

Simple design of multiple pump units (max. 4 pumps) by integral processor and
interface connection (RS 485) which allows automatic switch over in case of pumps
being out of sequence, cyclic change of lead and lag pumps, automatic start
and stop of lag pumps following the system demand, provision for connection
into central control system.

CCS

4 PCS-1A
Engineering
Control:
The built-in frequency inverter and microprocessor pro-
vides pump control based on pressure, differential pres-
sure, or low. The VOGEL pressure control version stops
the pump at zero consumption. The discharge of the
pump is being calculated via the speed indirectly and
may be programmed to compensate for varying friction
losses following a programmable system curve.
The Hydrovar variable speed pump may additionally be
controlled externally with the required speed fed in by an
external control system.
To prevent unauthorized personnel from changing
operating data, a password may be set up. The starting
and stopping of the pump as well as the setting of
control parameters is done at the keyboard and shown
at the LCD display at the drivehead (not in MINVEVAR).
The display is two lined and programmed for seven
languages. There are also three diodes to indicate pump
ready, pump running and fault.
An analogue signal to monitor speed or pressure is
provided. Communication with a central control system is
also possible via an RS 485 interface. Each HYDROVAR
drivehead contains an individual microprocessor which
controls the automatic operation of lead and lag pumps
according to demand. Cyclic change over of lead and lag
pumps, automatic start and start of the next pump to
come in case a pump gets out of order. No external
controls are necessary.
The voltage controlled frequency inverter supplies a
sinus variated pulse width modulated output voltage. It
works with controlled sinusoidal current synthesis and
dynamic overcurrent limitation. The high switching fre-
quency of 8 kHz prevents undesired noise from driving
motors. Reactions to the feeder are prevented by a filter
(according to EN 55011). Inverter cooling is enhanced by
the motor fan.
There is also a memory for inverter “fault” signals, oper-
ating hour counter and an automatic cyclic start up of the
pump as a test run.
.

PCS-1A 5
Primary Applications
Any process requiring various hydraulic data
Application for the HYDROVAR systems are similar to those for the pumps they are used on. The deciding factor is a
variable demand for either pressure, or flow, or both. These conditions are normally found in applications involving
water supply and circulation.

Market Applications
Municipal Pressure booster stations
Water works supply
Building Trades Pressure boosters for high rise
Irrigation systems
HVAC Boiler feed
Heat exchangers
Chillers
Induction heating
Air filtration
Water circulation
Fans (wall mounted version)
Water Purification Reverse Osmosis systems
Filter Feed
Production of deionised and ultra pure water
Agricultural/Recreational Irrigation systems
Water supply and transfer
OEM Variable flow and pressure wash systems
Fluid circulation with variable demand
Packaged booster systems
Fountains
Waste Water & Sewage Treatment - Sewage pumps & Mixers (wall mounted version)
- Cleaning systems
Industrial Applications Formulation Systems
Spray Wash Systems
Seal Barrier Fluid Systems
Cooling Tower Systems

Product Overview
differential transducer for constant flow settings. These
What is the typical HYDROVAR System? are mounted to eliminate the need for special piping.
No separate microprocessor systems:
With the HYDROVAR, one or more pumps are connected In a multi-pump system a microprocessor is used to
to common headers as in a standard system, but that is sequence the pumps or control the VFD on pump motors.
where the similarity ends. Since the HYDROVAR is a Microprocessor system, no
No special pumps or motors: other controllers are needed.
The HYDROVAR will mount directly onto standard No separate control panels and inverters:
240/415 volt, three phase TEFC motors with class F insu- A control panel has protections such as overload, temper-
lation up to 22kW. Preselected combinations are available ature, short circuit (and others) built in. It also acts as the
with the Lowara SSV, HTS and C series range of pumps interpreter between the pumps and the pressure sensor
and the Vogel PMV, LMR and LMRZ range of pumps. and may have an inverter to change motor speed. As a
No separate pressure sensors: system the HYDROVAR acts as the control panel on the
The HYDROVAR system comes with your choice of pump. An isolated fused main supply is the only external
pressure transducer for various maximum readings or a device required.

6 PCS-1A
Product Overview continued
No bypass lines and metering valves: need for large break tanks on the suction side. In addition,
Most standard control systems are designed to control the operation of the pump at the correct speed for the
motors and do not offer much in the way of hydraulic required duty leads to a significant reduction in energy
protection. Protection from dead heading and running off consumption.
the end of the curve must be provided in the piping. With Anti-condensation Heater
the HYDROVAR, the pump will shut down at zero All units are supplied with anti-condensation heaters to
demand or low suction, or maximum flow (one pump). switch on when the units are in standby mode.
No Large Pressure Accumulators:
Without a supply tank, a constant speed pump will be What are the various configurations?
constantly turning on and off and running up and down
the curve at maximum power to satisfy system demands. The HYDROVAR control is currently available with the
In the HYDROVAR system, each pump changes its LOWARA SSV, HTS, and C series pumps together with
operating speed from zero to 3600 rpm to constantly VOGEL PMV, LMR and LMRZ pumps up to 22 kW. Each
maintain constant pressure or flow and therefore elimi- of these configurations was specifically selected to
nates the need for a large pressure accumulator. A small provide optimum performance and energy savings on a
pressure tank is required to maintain system pressure at wide range of system needs 30, 37 and 45 kW only for
zero demand, however this is less than half that required wall mounting. Each system comes with a standard three
for a constant speed system. Where local regulations phase TEFC motor selection. Specifications for the
permit, HYDROVAR pump sets can be connected directly HYDROVAR controller portions of these systems are as
onto the water supply line therefore also eliminating the follows:

HYDROVAR Supply Voltage Motor

Model Rated kW (Frequency 40 Hz to 60 Hz) Voltage Amps

HV 2.1 1,5 230 V, 1 phase +/- 15% 230 V, 3 phase 7A

HV 2.2 2,2 230 V, 1 phase +/- 15% 230 V, 3 phase 9A
HV 3.2 2,2 400 V, 3 phase +/- 15% 400 V, 3 phase 5A
HV 3.3 3,0 400 V, 3 phase +/- 15% 400 V, 3 phase 7A
HV 3.4 4,0 400 V, 3 phase +/- 15% 400 V, 3 phase 9A
HV 3.5 5,5 400 V, 3 phase +/- 15% 400 V, 3 phase 12 A
HV 3.7 7,5 400 V, 3 phase +/- 15% 400 V, 3 phase 15 A
HV 3.11 11.0 400 V, 3 phase +/- 15% 400 V, 3 phase 22 A
HV 3.15 15,0 400 V, 3 phase +/- 15% 400 V, 3 phase 29 A
HV 3.18 18,5 400 V, 3 phase +/- 15% 400 V, 3 phase 35 A
HV 3.22 22,0 400 V, 3 phase +/- 15% 400 V, 3 phase 42 A
HV 3.30 30,0 400 V, 3 phase +/- 15% 400 V, 3 phase 60 A
HV 3.37 37,0 400 V, 3 phase +/- 15% 400 V, 3 phase 75 A
HV 3.45 45,0 400 V, 3 phase +/- 15% 400 V, 3 phase 88 A

NOTE: A 3 phase TEFC motor must always be used with the HYDROVAR controller. The motor connects to the HYDROVAR and the
HYDROVAR connects to the power supply. For 2,2 kW and below, the HYDROVAR input requirement is single phase 230 volt.
For 2,2 kW and above the HYDROVAR input requirement is three phase 400 volt.
Att: Both options available for 2,2 kW.

The HYDROVAR controller comes with a pressure trans- the difference in pressure (up to 2 bar) on each side of
ducer, transducer connection cable and transducer the pump circulator system or orifice plate (constant flow
mounting hardware as standard. systems). This difference is converted to flow and used to
The standard pressure transducer is 316 L stainless steel adjust the pump running speed.
with a viton gasket and is designed for pressures up to 10 The HYDROVAR can work with any sensor (i.e. lever.
bar. For higher pressure applications a 25 bar transducer velocity, temperature, chem concentration, flow...) emitting
is supplied. If constant flow is selected a differential a 4-20 mA signal.
pressure transducer option is available. This measures

PCS-1A 7
Product Overview continued
Motor mounted HYDROVAR units

15 - 22 kW 4 - 11,0 kW 1,5 - 3,0 kW

Low-cost HYDROVAR MINIVAR

The MINIVAR control-design is similar to the HYDROVAR
but smaller and less expensive.
The sizes are for 0,75 / 1,1 kW (later 1,5 / 2,2 kW)
motors.
Standard controls for the unit are two push buttons and
one LED indicator.
A separate programming module is available and
necessary to program the unit.
Sequence-control for max. 4 pumps is possible also with
the MINIVAR.

8 PCS-1A
Product Overview continued
HYDROVAR for mounting on the wall (Industrial HYDROVAR)
Hydrovar wall mounting version Hydrovar split size 18,5 and 22 kW
1,5 - 3,0 kW 4,0 - 11,0 kW 15 - 45 kW

Applications:

1. HYDROVAR wall mounting version with

clearwater submersible pump
This HYDROVAR design variant allows the device to be
used to control submersible pumps for drinking water and
sewage. The length of the shielded cable to the motor
should not exceed 20 m. For cable lengths up to 150 m,
and additional electrical device is necessary, which are
optionally available, the maximum speed must also be
reduced. All control functions are identical to those of a
normal HYDROVAR control device.

PCS-1A 9
Product Overview continued
2. Many pumps in process must have Explosion area Non-explosion area
Split version

explosion proof drives.

That’s why HYDROVAR units are available in a
Wall-mounting
wall-mounting version up to 11 kW and in a split version version
up to 45 kW. These units can be combined with
explosion-proof motors but they are mounted outside
of the explosion area and not on the motor.

30-45 kW
later 15-22 kW
Explosion-proofed
motor

3. Hydrovar wall mounting units for sewage

submersible pump
That’s why HYDROVAR units are available in a
wall-mounting version up to 11 kW and in a split version
up to 45 kW. These units can be combined with
explosion-proof motors but they are mounted outside
of the explosion area and not on the motor.

Saving cost for building, saving energy

Cost saving by reduction of

reservoir volume

Saving pump energy

up to 50%

10 PCS-1A
Product Overview continued
What does the HYDROVAR do?
The basic function of the HYDROVAR is to control the pump to meet your system demands in one of three ways.

It performs these functions by: • Shut off a single pump at maximum flow or
automatically turn on the next pump in a multiple
1. Measuring the system pressure or flow via a series.
transducer mounted on the pump discharge. • Protect the pump and motor from over voltage, under
2. Calculating the motor speed to maintain the correct voltage, overload, and earth fault.
flow or pressure. • Vary the time of pump speed acceleration and
3. Sending out a signal to the pump motor start, increase deceleration.
speed, decrease speed or stop. • Compensate for higher friction losses at high flow rates.
4. In the case of multiple pump installations the • Send out a signal for remote monitoring of pressure
HYDROVAR will vary the order of the lead pump and and frequency.
turn on the lag pumps automatically in the case of
• Conduct an automatic test run of the pump at set times.
duty/assist sets.
• Keep track of the amount of time the pump(s) has run.
In addition to the basic functions, the HYDROVAR can
do things only the most advanced computerized control • Display all functions in an LCD window in English and
systems can do, such as: choice of languages. (English, German, Spanish,
Portuguese, French, Italian, Dutch)
• Shut off the pump(s) at zero demand.
Or: communicate with another HYDROVAR,
• Shut off the pumps ar zero suction. computer, or other controller via an RS 485
interface.

HYDROVAR Single Pump Operation and Control

The HYDROVAR controller can be used with both single
pump and multiple pump systems. With a single pump,
the following controls are possible.
1. Constant discharge pressure over the flow range
of the pump.
In this method, the desired discharge pressure is set
(in bar) by the operator. The HYDROVAR varies pump
speed as demand increases or decreases to keep the
pressure constant.
In order to set the HYDROVAR for this application, the
pump should be selected so that the maximum pres-
sure and flow required by the system is on or below
the full speed (usually 2950 rpm) performance curve of
the pump. A single pump should not be selected if it
cannot meet the maximum system requirements.
Constant Pressure Control

PCS-1A 11
HYDROVAR Single Pump Operation and Control, con’d
2. Compensation for system losses (following sys-
tem curve).
The operator can increase the discharge pressure of
the pump as the flow increases to compensate for the
added friction losses in the system. This allows the
pump to “follow the system curve.” To do this, the
operator enters the percentage increase in discharge
pressure required at the maximum speed at which this
increased pressure will start.
The pump should be selected so that the maximum
flow is on or below the 2950 curve. An alternative
method is to use a differential pressure transducer on
a circulator suction and discharge. The HYDROVAR
will automatically compensate the friction losses
depending on the increasing flow and speed.

Compensation for System Losses

3. Maintaining a constant flow.

This method allows the operator to set a required flow
in either circulator or process applications. The actual
flow value can be measured either by means of a flow
sensor (4-20 mA; analog) or by using an orifice plate in
combination with a differential pressure transducer
(4-20mA; quadratic function). Correct settings must be
made while programming the unit.
As demand changes the HYDROVAR increases
pressure to maintain flow. The pump should be
selected so that the flow required is near to the
maximum efficiency point of the pump and the
maximum pressure required is within the scope of
the pump performance at full speed.

Constant Flow Control

4. Actuator Mode.
In actuator mode the pump speed can be varied via an
external source using a 4-20 mA signal. In this case
the built in controller is taken out of circuit.

5. Protection from low/no suction or run out.

If the required value (pressure or flow) cannot be
achieved within a predefined period of time, the
controller will switch off automatically. When the auto
reset function is set on the controller it will attempt to
restart five times but will switch off completely after five
unsuccessful attempts.

Actuator Mode

12 PCS-1A
HYDROVAR Single Pump Control

6. Operator custom controls. 7. Operator indicators and display

The HYDROVAR has several operator controls which The following displays are found on the HYDROVAR, the-
may be selected for both single and multiple; pump unit can also be monitored remotely through the RS 485
applications depending on working conditions and interface (not on the MINIVAR).
individual preference. Please refer to the operating • Indicator lamps show power on, run and fault, which
manual for specific program options. indicate the basic status of the unit.
• The HYDROVAR has language options available that • The display shows a pressure reading, which shows
can be preset. the current pressure being read by the transducer.
• Except for the basic settings the HYDROVAR is • The jog mode shows the current pressure and frequen-
password protected which means that the program cy in Hertz, the operator can modify the speed by using
can only be changed by authorized personnel. The the up/down button as a test. The HYDROVAR reverts
factory installed password number is 0066. back to its programmed settings once this display is
• The Hydrovar can be set to operate at any frequency changed.
up to 60 Hz. In order not to overload the motor the unit If the pump stops, the HYDROVAR will record and
should not be set at frequencies higher than the display the last three error messages. This mode is
normal rating of the motor being used. used for trouble shooting.
• Units available can be programmed to show bar, psi, • The numbers of hours of both the pump and
m3/h, gpm or percentage. HYDROVAR are logged. These settings can be reset.
• The display contrast can be altered to operator
preference.
• Testing of the HYDROVAR can be done manually or
programmed to operate automatically at set times.
• All the program settings can be locked or re-set to
default factory settings.

PCS-1A 13
HYDROVAR Multiple Pump Operation and Control
Up to four HYDROVAR controlled pumps can operate
together to form a system. No other control panels are
necessary.
In a multi-pump system, the RS-485 interface is used as
a controller. The microprocessors monitor the activity in
each HYDROVAR to adjust overall system performance.
HYDROVAR controllers must be of the same size
and type.

HYDROVAR Multi-Pump System

Constant Pressure Systems
Constant pressure is maintained by the HYDROVAR in a
multipump system in the same manner as a single pump
system. The HYDROVAR can use up to four pumps to
maintain constant pressure. However, as the first pump
reaches maximum speed, increased demand will cause
the pressure to drop as the pump runs down its curve. In
a single pump system, the pump would shut down at run
out. On a multipump system, the pressure drip causes
the second pump to come online.

Multi-Pump Constant Pressure System Curve

Set Up
In a multiple pump system the HYDROVAR units are
wired together through the microprocessor interface. The
operator sets each HYDROVAR to multi-controller mode
and assigns each pump an address (Adr. 1, Adr. 2, etc.).
The operator enters the required system pressure and
the pressure drop allowed before the next pump starts.
Automatic Lead/lag
The HYDROVAR will automatically change the sequence
the pumps use to turn on or off in order to provide even
wear. The operator can adjust how often this sequence
change is made.
System Loss Compensation with Multi-Pump
Following a system Curve on Multi-Pump systems HYDROVAR System
To compensate for increased friction losses the overall
pressure setting can be automatically up-graded every the pressure required by the system is automatically
time an additional pump is started. increased by the amount entered. To determine the added
Set Up pressure, the operator must deduct the pressure drip at
which the next pump starts.
While programming the units the operator must set a
pressure drip to allow an additional pump to come on line. Operator Controls and Indicators
However, the operator also needs to enter the amount of Controls and indicators for the multi-pump system are the
pressure increase needed for each new pump based on same as those covered under the single pump controls
system losses at higher flows. As each new pump starts, and indicators.

14 PCS-1A
HYDROVAR Regulation Mode “NORMAL”

Applications of the HYDROVAR with the regulation mode “NORMAL”

(if the actual value drops, the output frequency will be increased)

This regulation mode will be used to control on:

• Constant system pressure behind the pump
• Constant diff. pressure
• Constant flow
• Constant level in an open or closed tank or boiler
behind the pump

PCS-1A 15
HYDROVAR Regulation Mode “INVERS”

Applications of the HYDROVAR with regulation mode “INVERS”

(The output frequency will be decreased if the actual value drops)

This regulation mode will be used to control on: The environment should also be free of excess amounts
• Constant incoming pressure of dust, acids, corrosive gases, salts etc.
• Constant level on a tank which is mounted before the An interference filter is included in the HYDROVAR to
HYDROVAR pump prevent interference with other electronic devices.
An LCD display on the control panel supplies all
Environment information and programming help.
Pressure sensitive switches are included for on, off,
Ambient temperature requirements for the HYDROVAR increase, decrease and select. Display lights indicate
are 5°C - 40°C, the same range as most TEFC motors. power on to the HYDROVAR, pump running and fault.
Temperature limits may be extended to 52°C by using the Operating temperatures for the pressure transducer
next size of HYDROVAR controller upon request. are -25°C to 80°C. The upper limit may be extended to
Humidity requirements for the HYDROVAR cannot 120°C by using the extended mounting hardware on the
exceed more than 50% at 40°C and no more than 90% SSV station.
at 20°C. The unit should be protected from the weather
and condensation.

16 PCS-1A
External Control and Monitoring
RS-485 Interface

The HYDROVAR controller can be cable connected to

another microprocessor based control system using the
RS-485 data bus located on the main terminal board
under the cover. This allows the HYDROVAR to either All of the HYDROVAR controls, displays, and
send status information on the pumps and system to an diagnostics can be accessed through the RS-485
external data network or actually be controlled from a interface using the code structure provided in the
remote location. The protocol for the HYDROVAR is 9600 instruction manual. In the future VOGEL is planning to
baud with an 8 bit structure using 7 data bits. 1 stop bit offer specific software which will allow customers to easily
and a parity bit set an even parity. If the external device use this feature. Currently, a customer wishing to use this
uses a V 24 interface, an interface inverter for feature will need to modify existing system software to
RS-232/RS-484 may be necessary. use the access codes for the HYDROVAR.

Pump Sizing and Selection

Constant Pressure
To select a variable speed pump for constant pressure, two
primary pieces of information are needed: the pressure
required and the maximum flow rate of the system.
When this information is known, check the range curves of
the variable speed pumps being considered and select the
one that covers the pressure rating up to the maximum
flow rate. This point should be to the right of the pump BEP
and within 10% of the best efficiency.
To keep the power requirement down, the pump selected Selection of pressure controlled pumps
should meet the maximum pressure and flow point at or
near the maximum pump speed curve.
In a multi-pump arrangement, the pumps may be selected
to provide only part of the total flow needed. This will
provide a built-in backup for most of the flow range and also
balance pump wear with the use of more than one pump.
NPSH should also be calculated based on the maximum
flow and pressure rating point. This is a worst-case condition
because lower speed performance will require less NPSH.

Constant Flow
In a constant flow application a single pump, which has the
flow range needed is typically selected as shown in the
opposite graphs.
Selection of flow controlled pump

PCS-1A 17
System Comparison
more expensive than a standard panel.
HYDROVAR System vs Fixed Speed Systems
With the HYDROVAR, no control panel is needed. The
Since a conventional pump can only operated along its HYDROVAR contains all the functions of the most sophis-
performance curve, a constant pressure system must ticated microprocessor based VDF panels. Sequencing
always involve other components in order to regulate the and start/stop controls are communicated directly by the
supply of liquid to the “user.” These other components HYDROVAR to each pump - extra controls are not need-
can add up to much more than the cost of the pump ed for multi-pump systems. The HYDROVAR requires
alone. only a circuit breaker panel.
With the HYDROVAR system, large pressure tanks are
not required. Each unit has a soft start and gradual ramp Automatic Valves
up to eliminate premature pump wear and water hammer
and also reduce energy costs at periods of low demand. Solenoid valves or modulating/metering valves are used
A typical two pump HYDROVAR system requires no to control flow and pressure as the pumps keep running.
more than a vessel volume of 10% of the lit/min continuous duty boilers use this method. Use of these
performance of one pump. valves can create problems of water hammer and dead
heading for the pump. Bypass lines and pressure tanks
The precharge pressure of the vessel must be set to
are used to handle these types of problems.
approximately 15% less than the system pressure
requirement. The HYDROVAR eliminates the need for automatic
valves to control the pressure, flow or shut off of liquid to
the system. All these features are contained within the
Pressure Switches microprocessor controlled variable speed pump. In
addition, since there is no danger of valve water hammer
Pressure switches are normally installed at the discharge
or dead heading, bypass lines and pressure accumulators
of each pump in the system and used to turn each one
are not required.
on and off as demand changes and are connected to a
control panel to sequence the pumps. The pressure
switch is an on/off device that does not provide informa- Jockey Pump
tion on the system demand below or above the set point -
a distinct disadvantage. The standard booster system is sized for peak capacity
and is very inefficient when demand is low. For this rea-
In the HYDROVAR system, each pump is equipped with
son, a high head low flow pump is added to the system to
its own pressure transducer to measure the required
handle occasional demand during off peak periods. This
system pressure. This allows the pump to react to very
pump will run with a much lower power requirement and
slight changes in demand with the correct amount of
reduces wear on the main pumps.
pressure and flow. A pressure switch or float control may
be used on the suction side of a HYDROVAR equipped The HYDROVAR can drive the pumps at very low speeds
pump as a cut off for low/no suction. and energy consumption, eliminating the need for a jock-
ey pump. Off peak demand can be handled efficiently and
easily with the same system used for peak periods.
Control Panels
However, if main pumps become bigger a smaller pump
A typical multi-pump booster package has a control panel also driven by a HYDROVAR can be incorporated into the
that provides electrical protection and sequencing of the system to cover low demand duties in a more efficient
pumps. More sophisticated units will have a microproces- way.
sor that controls pumps and valves and interprets input
from the switches and floats. Some panels also have a
variable frequency drive inverters. Panels with micro-
processor control and or VFD control are significantly

18 PCS-1A
Hydraulic Performances

Operating range HYDROVAR 22,0 kW

Motor mounted or wall mounted.

Operating range HYDROVAR split, 45,0 kW

For mounting on the wall only.

PCS-1A 19
Features and Benefits
Feature Advantage Benefits
Variable Speed Match Pump Performance Maximizes system performance
to system demands
Reduces power consumption
One pump selection for full
performance range
Constant pressure Stepless transition for steady supply
Reduces intermittent operation
Eliminates large storage tank cost
and space
Lower mechanical load Energy savings
Higher reliability
Less system components Space savings
Single source supply
Simplified design
Microprocessor Control Pump protection No flow shutoff
Various fault protections
Eliminates bypass lines
Eliminates pressure modulation
and metering valves
System curve compensation Reduces power consumption
Meets changing demand
Multi-pump control Eliminates separate panel
Automatic sequencing
Automatic lead/lag
On-line-interface Remote monitoring and status display
Remote control
On-line transducer Pressure sensing Maintain constant pressure
Friction loss compensation
Maintain constant flow
Electronic Control Electrical protection Long service life
Soft start and stop Low starting current
Eliminates start stress No water hammer

20 PCS-1A
HYDROVAR

Multistage pumps SVH, PMVH Design VDAH (with HYDROVAR variable speed pumps)

Package booster unit VDH 2 Package booster unit VDH 3

PCS-1A 21
HYDROVAR

Single stage inline pump LMRH Cooling water circulating pumps

Heating circulators Circulating pumps for heat exchanger

22 PCS-1A
 PUMPSMART
TM

PROCESS SYSTEMS

Innovative
Pumping Solution:
- Significantly lowers life cycle cost
- Significantly increases MTBF
- Will not cavitate
- Will not run dry
- Will not run against
closed discharge valves
- Eliminates flow control valves
- Eliminates flowmeters
- Eliminates starters
- More effective process control
BECAUSE FAILURE IS NOT AN OPTION

24 PCS-1A
PUMPSMART
PumpSmart is a system that utilizes a standard process pump in conjunction with ITT Industries’
unique and patented PumpSmart Control System and Software.*
The software, which resides on the controller microprocessor chip, is the brains of the system,
allowing the pump to monitor and REACT to any system condition. The result is lower
lifecycle costs. Here’s How:
*Patent pending

Reduced Conventional Pumping System

Initial
Capital
1
Costs 2
3
$ 4

Control valves are

1 eliminated -
PumpSmart matches
pump performance to
PumpSmart Process System
exact system conditions.

Flowmeters
1
2 are eliminated -
PumpSmart utilizes
patented internal flow 3 2
measurement.

Starters are eliminated -

3 PumpSmart has an 4
integral starter.

Recirculation lines and

4 valves are eliminated -
PumpSmart provides
low flow protection.
PCS-1B 25
Reduced Reduced
Installation Maintenance
Costs Costs
■ Wiring and piping of valves, ■ Valve and flowmeter
$ flowmeters and recirculation
lines are eliminated.
$ ■ maintenance is eliminated.
Variable speed control runs
the pump at BEP and at
a slower RPM.
■ Reliability Factors quantify
reduced maintenance costs
and increased MTBF.

Reduced
Operating
Costs
■ Pump operation matches system
$ ■ requirements without control valves.
Energy consuming control valves,
flowmeters and recirculation lines are
eliminated.
■ Savings are calculated and displayed at
the DCS or on the PumpSmart keypad.

26 PCS-1B
ITT Industries has developed proprietary LifeCycle CostwareTM that assists our
customers in quantifying life cycle cost savings...
LIFE CYCLE COST COMPARISON
Conventional System PUMPSMART
Rating, design 2700 GPM @ 120 TDH
Rating, actual 2700 GPM @ 51 TDH
Pump Model and Size 3196XLT, 8x10-13 3196XLT, 8x10-13
RPM 1,780 1,458
Yearly hours of Operation 8,760 8,760
Actual BHP 96 61
Maximum BHP 99 74
Installed Motor Size (HP) 100 75
Equipment Life (Years) 15 15
Estimated Cost/Repair $2,500 $2,500
Initial Cost
Total Life Cycle Initial Costs $20,600 1 $19,800 2
Installation Cost
Pump & Motor Assembly $41,000 $39,000
PumpSmart 0 $4,500
Control Valve $15,600 Not Required
Flowmeter $18,000 Not Required
Starter $3,600 Not Required
Total Life Cycle Installation Costs $78,200 $43,500
Operating Costs
Yearly Energy Use (kW-hr) 43,776 26,577
Years Operating 15 15
Total Energy Use (kW-hrs) 656,639 398,652
Electricity Cost ($/kW-hr) 0.45 0.45
Total Life Cycle Operating Cost $443,231 $269,090
Maintenance Costs
Average MTBF (months) 18 36
Total No. Repairs 10 5
Total Pump Maintenance Cost $25,000 $12,500
PumpSmart Maintenance 0 1,100
Control Valve Maintenance $3,200 Not Required
Flowmeter Maintenance 2,800 Not Required
Total Life Cycle Maintenance Costs $31,000 $13,600
Life Cycle Savings
Initial Purchase $800
Installation $34,700
Operating $174,141
Maintenance $17,400
Total Savings $227,041
Present Value of Savings $112,230
PumpSmart Payback 2.6 months
1
Includes pump and motor, flow control valve, flowmeter
and starter.
2
Includes pump and motor and PumpSmart Process
System. Flow control valve, flowmeter and starter are not
required.
$227,041
Total Life Cycle
Cost Savings Initial Capital Cost

Installation Cost

Maintenance Cost

Operating Cost

PCS-1B 27