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Circulator pumps for heating systems cut energy costs by up to 20 per cent

KSB SE & Co. KGaA has developed a new function for its Calio and Calio S type circulator pumps series. Called Dynamic Control, the new function is an intelligent programme that helps to reduce pump input power by up to 20 percent compared with conventionally controlled pump sets.

Modern circulator pumps change their speed to match current demand. This is achieved by adjusting their flow rate and head using an algorithm to move the operating point along a programmed control curve. The minimum system curve describes the friction loss when all thermostatic valves are fully opened. As the minimum system curve is usually unknown, plant designers select a control curve for conventional systems that is clearly above the minimum system curve. However, this uses more power than necessary and can also cause disturbing noises at the radiators’ thermostatic valves.

KSB’s Dynamic Control moves the operating point down from the selected control curve until the minimum system curve is reached. Should this go below the minimum system, the algorithm re-sets the pump to its original control curve, thus ensuring sufficient supply. Safe recognition of the minimum system curve by means of a flow rate signal rules out undersupply and ensures that the building is supplied with sufficient heat. As the implementation is purely based on software, no additional costs will be incurred by further sensors or actuators. The pump automatically gathers all required information from its internal signals. As a result, the installer no longer needs to make time-consuming settings because the pump is able to determine the system curve itself. The operator benefits from lower energy costs and less noise.

Reducing energy also has a positive effect on the operator’s carbon footprint. The new function comes fully integrated in the current Calio and Calio S type series and can be installed as an update in the third generation pumps of this series.

14 April 2020

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