Design Commissioning Tips

1
Taco Variable Speed Drives Design/Commissioning Tips
Design/Commissioning
Tips for Variable Speed
Pumping Systems
2
Differential Pressure
Transmitters
The main goal of the secondary chilled water system is to
distribute the correct amount of water to satisfy the load.
It must first accurately monitor the system for changes
in load dynamics.
Secondly, it must respond to these load changes
with the correct amount of flow.
Typically a differential pressure sensor is the device
chosen for feedback in a building management system.
Differential Pressure Transmitter Types

Photo
Mfg.
Name
Model No.
Accuracy
Differential
Pressure
Pressure
Range
Burst
Pressure
Output
Taco
DPS629
+/- 0.5% FS
0-25psid
50 psid
250 psi
4-20 mA | 0-10 VDC
Taco
DPS3100
+/- 0.075% FS
1-100psi
-14.5 to 2000 psi
10000 psi
4-20 mA | 0-10 VDC
3
Transmitter Installation
NOTES:
Material of construction as required by application.
DP Transmitter may be wall mounted or pipe stand mounted.
Orientation of DP XMTR and pipes has no effect on performance.
Gauges can be rotated for best viewing.
DP XMTR Isolation Valve
High Gauge
DP XMTR
Low Gauge
DP XMTR Isolation Valve
Supply
Upstream
(High Side)
Manifold
Block Valve
Return
Downstream
(Low Side)
Manifold
Block Valve
Tag: AHU-________ HW
Tag: AHU-________ CW
It is critical that the design engineer

tell the installing contractor WHERE in
the system they would like the sensors
installed. This is most easily done with
a small schedule indicating which
terminal unit the engineer wants.
4
Transmitter Quantity
Quantity:
Three sensors can provide a very
accurate picture of system demand.
One for the longest run

(Student dorm or remote part of East Campus)
(New basketball arena in Central Campus)
(Administrative office located in remote part of West Campus)

One for the dominant load

One for another zone
For buildings with a very asymmetric layout,

other sensors may be added to monitor
each zone.

TIP: Provide three way valves or bypass

at remote points of the system.
5
Determining Differential
Pressure Setpoint
The sensor must keep enough pressure differential across
the supply and return to push the design capacity flow
through the coil and control valve.
3 psi (7) PD
DP
10 PD
Setpoint = Sum of coil pressure drop + control valve

pressure drop at design conditions (17)
6
Sensor Placement
Whether the Dp sensor is located at the pump discharge or the end of
the pipe loop with the highest head does not affect the ability of the
pumps to move the design flow. However, it dramatically affects the
amount of energy consumed by the pumps.
A P sensor located near the pump discharge will save very little energy.
The setpoint must be equal to the pressure drop through all the coils,
control valves and connecting piping downstream of the sensor at
design flow. This value is only slightly less than the pumps design
head. The shaded area represents the energy savings compared to
constant speed pumps.
Pressure
TERMINAL
UNIT
DIFF. PRESSURE
TRANSMITTER
CONTROL
VALVE
BYPASS
W/VALVE
Area of Power
Reduction
Setpoint
100%
Motor
Speed
Curves
PRIMARY
Speed
Sensor Location 80 setpoint (Across Pump)
7
A P sensor located at the furthest most significant load will save

the most energy. Its setpoint must be equal to the pressure drop
through the single coil, control valve and connecting piping
downstream of the sensor at design flow. This will be about 17 like
our example on the previous page. Again the shaded area is how
much energy can be saved compared to constant speed pumps.
TERMINAL
UNIT
Pressure
Area of Power
Reduction
CONTROL
VALVE
BYPASS
W/VALVE
PRIMARY
PUMP
DIFF. PRESSURE
TRANSMITTER
Setpoint
25%
Speed
Sensor Location with 17 setpoint (Across Load)
8
Minimum Allowable
VFD Speed
A good rule of thumb for 1750 RPM applications is that the minimum
allowable VFD speed should be no less than 15Hz (25% max speed).
The primary reasons are:
1. Protect the seal from premature failure
A minimum speed is required to overcome
the spring compression forces between the
stationary and rotating elements. Additionally,
it must overcome the difference in pressure
between the system fluid and atmosphere.
There are speeds at which the seal spring (or large differential pressure)
forces the two seal faces closed and forces out all of the fluid necessary
for lubricating and cooling. Operating in this condition is equivalent to
running the seal dry.
A good rule of thumb for 1750 RPM applications is that the minimum
allowable VFD speed should be no less than 15 Hz. Preferably 20 Hz.
The equivalent rule of thumb for 1150 RPM minimum VFD speed is 25Hz.
Process Fluid acts as
lubricant between faces
Pump Housing
Gland
Process Fluid
Primary Ring
Mating Ring
Invisible Leakage: Fluid evaporates upon reaching the atmosphere
9
2. Below 15hz (25% max speed) is unlikely

to move water out of the mechanical room
According to the pump affinity laws, flow
is proportional to speed and head is
proportional to speed squared. When you
run a pump at speed or 15hz, you can
only generate 1/16 of the pumps head.
i.e. 1/4 2 = 1/16
1/16th of the head is unlikely to even move
the water out of the mechanical room.
Energy reduction at 1/4 speed = 1/4 3 or 1/64 of design HP.
This is the realistic lower end of turn-down.
3. Specialty Pump Exceptions
Some pumps such as vertical turbines require water
to lubricate journals and bearings. Particularly vertical
turbine pumps. The minimum speed must be set to move
water up the height of the column and overcome any static
head loss. There are times that this will be above the hz.
10
Establishing Minimum
System Flow
The overall hydronic system and each of its major
branches need a minimum amount of flow.
It is recommended to use a bypass with balancing valve or a three way
valve at the end of each major zone for the following reasons:
Prevents thermal stagnation.
Impeller
Increases the life of the pump
at full

by preventing dead-head or
speed
no-flow condition.
Rule of thumb: Ensure there is

Impeller at
at least 1/4 GPM per design HP
1/4 speed
to protect the pump at min speed.
Note: More flow will be required if you are trying to protect against dead head on a full speed situation.
11
Design tips for

flow meters
Use a Flow Meter for:
Accurate Staging
End of Curve Protection
Shut Off Protection
Best Efficiency Control
12
Pump staging with flow

Here we show 2 pump parallel operation.
Note the pumps are selected to allow the single pump
curve to intersect the system curve.
If the system flow increases beyond the single pump
intersection point(a), the system will see a drop below
the system setpoint and initiate the lag pump start.
Design System Head Curve
HEAD
Design Point
One Pump
Two Pump
A
Control DP
Lag Pump Reject Zone
GPM
13
Liquid Flow Sensor

Installation Detail
NOTES:
Refer to instruction manual for mechanical installation details.
Orientation (Horizontally preferred).
Locate for use in full pipe (Make sure to eliminate air).
A Upstream 10 pipe dia. length of straight rin pipe
with no restrictions, enlargements, valves, couplings
Fair (Unacceptable if air is present)
or other intrusions.
B Upstream 5 pipe dia. length of straight rin pipe
with no restrictions, enlargements, valves, couplings
or other intrusions.
Best
Flow Sensor (Supplied)
Hot Tap (Supplied)
2 NPT Coupling
(By Field)
Nipple (Supplied)
Flow
Fair (Unacceptable if fluid contains sediment)
14
Common Problems
Most systems are set up
with the following problems:
Incorrect pressure
sensor installation
Incorrect pressure
sensor setpoint
Air not bled out of sensor
Control loops detuned to
handle all situations
15
Differential Temperature
Delta-T lends itself to even more cost effective variable speed pumping.
The issues associate with placement and of Delta-T sensors is replaced
with ease and simplicity of thermistors.
As the Delta-T falls below setpoint, the pumps would slow down.
As the Delta-T rises above setpoint, the pumps speed up.
Remember that BTUH = GPM x T x 500
Temperature Sensor
TRP1 Series Sensor is a thermistor type 10K Ohms (Type III) sensor.
The TRP1 Series is a stainless steel bullet probe which is 1/4 in
diameter and 1 long with a 24 wire leads.
Output: 10K Ohm @ 77F.
Taco Catalog #300-28

Supersedes: 08/30/12
16
Effective Date: 10/11/12

Printed in USA
Taco, Inc.,1160 Cranston Street, Cranston, RI 02920 / (401) 942-8000 / Fax (401) 942-2360
Taco (Canada) Ltd. 8450 Lawson Road, Unit #3, Milton, Ontario L9T 0J8 / (905) 564-9422 / Fax (905) 564-9436
www.taco-hvac.com

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1

Taco Variable Speed Drives Design/Commissioning Tips

Differential Pressure Transmitter Types

4-20 mA | 0-10 VDC

-14.5 to 2000 psi

4-20 mA | 0-10 VDC

It is critical that the design engineer

(Student dorm or remote part of East Campus)

(New basketball arena in Central Campus)

(Administrative office located in remote part of West Campus)

For buildings with a very asymmetric layout,

Setpoint = Sum of coil pressure drop + control valve

Sensor Location 80 setpoint (Across Pump)

A P sensor located at the furthest most significant load will save

Sensor Location with 17 setpoint (Across Load)

Invisible Leakage: Fluid evaporates upon reaching the atmosphere

2. Below 15hz (25% max speed) is unlikely

Rule of thumb: Ensure there is

Design tips for

Pump staging with flow

Design System Head Curve

Lag Pump Reject Zone

Liquid Flow Sensor

Fair (Unacceptable if fluid contains sediment)

Taco Catalog #300-28

Effective Date: 10/11/12

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