Yuki SHIMIZU
Fluid Machinery Development Department, Business Development Division, Fluid Machinery and Systems Company
This paper introduces a new water supply unit launched in December, 2019. This next generation water supply unit, equipped with a PM motor having built-in inverter, was developed based on the concept of “eDYNAMiQ*1” by fusing the advanced original technologies that have been cultivated by Ebara’s standard pump business over many years. To develop the product, we visited many scenes and thoroughly interviewed various customers to create the product concept. We incorporated their demands into the product to the maximum by realizing overwhelming downsizing (industry’s smallest class 1.5 to 3.7 kW) and lightweight, and by improving installation flexibility while maintaining conventional energy saving, maintenance, and safety features. The product can provide every customer with optimization in various installation environments.
Keywords:Water supply unit, PM Motor, Inverter, Downsizing, Light weight, Improved installation flexibility, Near Field Communication, eDYNAMiQ, Super Save Energy Pump, Water hammer
*1 “eDYNAMiQ,” stands for Eco (Ecology), Dynamic and Integrated Quality, was coined to evoke the features of our standard pump technology.
In order to reduce running costs and CO2 emissions, we offer the Save Energy Pump Series (hereinafter referred to as the SE Series), whose main concept is energy conservation. In this product lineup, the Super Save Energy Pump Series (hereinafter referred to as the SSE Series) with a PM motor and pump controller achieves the industry's highest level of energy conservation.
Model F3100NEO is the third water supply unit in the SSE Series, following the inverter-pump unit model HPE for shallow wells and the wall cabinet type direct connecting water supply unit model PNAGM.
Water supply units are the most important water supply equipment for providing stable water supplies to facilities in buildings, condominiums, factories, and so on. Therefore, it is imperative that they ensure safe drinking water supplies and provide high reliability with no water outages. In recent years, various new calls for energy savings, space saving for effective use of building space, and ease of handling to reduce installation and maintenance times, etc., have increasingly become requirements.
In developing this unit, we visited a number of work sites, talked with various customers, and conducted a survey on current requirements and a research on market demands. Based on the results of our survey and research, we created the product concept of “better use of space and easier installation.” Making the most use of “eDYNAMiQ*1Technology,” we have developed a new water supply unit, model F3100NEO (Fig. 1) with three new features: (1) a smaller size than the previous model, (2) light weight, and (3) improved installation flexibility. This paper introduces the product outline and features of model F3100NEO.
*1 “eDYNAMiQ,” stands for Eco (Ecology), Dynamic and Integrated Quality, was coined to evoke the features of our standard pump technology.
Fig. 1 F3100NEO model BN-MG
Water supply systems are mainly classified into two types: direct water supply system and receiving tank system. This unit uses the latter. In the receiving tank system, water fed from the water pipe is temporarily stored in the receiving tank and then is pressurized by the water supply pump unit.
Figure 2 shows the structure of the unit. Two pumps having a PM motor with a built-in inverter are installed on a common base of this unit. A control panel and a pressure tank are mounted on them. The pumps are connected to the pipeline manifold in the same discharge direction. This unit provides a structure that allows use of space more effectively and easier installation than the conventional model (Model F3100BN), while maintaining the features of earlier models such as, components, functions, and performance, etc.
Fig. 2 Structure of product
In regard to pump motors, we have developed a new IE5-equivalent PM motor and a new PM motor with a built-in inverter. The inverter is mounted on the anti-load side of the motor, but thanks to our unique technology, the overall length and diameter of the motor, including the inverter, are almost the same as those of the conventional model (Model F3100BN).
In addition, a general inverter is cooled by the motor-cooling fans. If the fan’s motors fail, the overheated inverter will stop the pump. Thus, periodic replacement is necessary. On the other hand, the cooling mechanism of a PM motor with built-in inverter (Fig. 3) is capable of providing a stable water supply. This is because the cooling fan at the end of the motor shaft cools the inverter and motor simultaneously, as the motor shaft rotates, thereby eliminating the risk of fan failure owing to the service life of the fan’s motors and the need for periodic replacement.
Fig. 3 Structure of PM motor with built-in inverter
Figure 4 shows the internal configuration of the control panel. By replacing the inverter, which is usually installed in the control panel, with a PM motor having a built-in inverter, the control panel can be smaller and lighter, resulting in a more compact unit. The components used in the control panel are same as those used in the conventional model (Model F3100BN), maintaining the same quality and functionality. Meanwhile, the internal layout and shape of the control panel are optimized to improve maintainability.
We have also developed the product based on our concept and incorporating suggestions and requests from our customers for improvements (optimal wiring hole position, larger wiring hole, etc.).
Fig. 4 Internal configuration of control panel
This product is equipped with a PM motor having a built-in inverter, resulting in the distance between the pumps being reduced from 500 mm to 250 mm, compared with the conventional model (Model F3100BN-ME). As a result, the footprint of the unit’s base is reduced by about 32% (Fig. 5) compared with the previous model (Model F3100BN-ME), achieving the industry's smallest unit. In addition, the width and height of the unit are less than those of the conventional model (Model F3100BN-ME) for space saving and easy installation, resulting in use of building space more effectively.
Fig. 5 Industry's smallest footprint
Water supply units are often installed in very small spaces or when the carry-in passage is narrow. Under these circumstances, some units had to be disassembled to be brought in; the results of the survey revealed that the need for weight reduction of each component was very high. Therefore, reviewing every detail of the components to make them more compact, we have successfully reduced the weight of all conventional models (Model F3100BN-ME) by 15 to 44 kg.
Installation environments vary depending on the site, and both ease of installation and ease of maintenance are requested. In the case of the conventional model (Model F3100BN), there were cases where customized specifications were used to meet such needs. This product, however, is designed to meet such site variations with standard specifications as much as possible.
The conventional model (Model F3100BN) has only one discharge direction, but this product allows the user to choose the leftward or rightward direction, by simply swapping the discharge companion flange for the blank flange at the site (Fig. 6), for effective piping layout. This system was used in the past in the conventional unit quantity control models, and was well received. Thus, we have adopted it in this unit as well.
Fig. 6 Selectable discharge direction
In some sites, the control panel’s display of the installed unit was difficult to see during repair, depending on the layout of the existing equipment, thereby resulting in poor maintainability. In the case of the conventional model (Model F3100BN), to deal with this problem, the orientation of the control panel was reversed by 180 degrees. This product allows the user to select one of the three orientations as standard without any additional parts (Fig. 7). Even if the installation environment is severe, the orientation of the control panel can be changed easily, so that it is suitable for maintenance.
Fig. 7 Orientations of control panel
For installation in harsh environments such as, under the receiving tank or in small pump rooms, the control panel can be installed separately or hung on a wall as an optimal option (Fig. 8). The control panel can be installed in a desired position that is easy to see and operate, using a standing support for fixing the control panel and cables for the motor and sensors that can be extended up to 8 m. As a result, the burden of management and daily inspection can be reduced.
Fig. 8 Separate installation of control panel
By using an IE5-equivalent PM motor, the optimal operation control technology for water supply unit cultivated over many years, and our unique E-mode operation function, the annual power consumption has been reduced by approximately 19%, compared with the conventional model (Model F3100BN-MD), thus contributing to energy savings.
Demonstration model:
50 mm diameter, 3.7 kW nominal output, single alternate operation type
Calculation conditions:
113 houses receiving water
The water supply pattern of the houses was estimated by the calculation formula of the Center for Better Living (CBL).
The E mode operation function automatically switches between the “minimum pressure variable control” and the “new low flow rate stop control”, contributing to energy savings while monitoring the operating status. In addition to the conventional estimated constant end-pressure control, these types of control are expected to enhance energy saving performance. There is no need for complicated settings. Just pressing the E button (Fig.9) on the operation panel enables this function.
Fig. 9 Control panel
This product inherits the following standard functions from the previous model (Model F3100BN) .
If a water supply unit stops for a long time due to a reduction in inflow pressure caused by, for example, power failure, water outage, etc., air may enter into the feed water pipe. When the cause stopping the unit is resolved and the unit restarts, while the air is still inside the water supply pipe, there is a risk of water hammer occurring inside it. Water hammer can exert a large force on feed water pipes and connection devices, which in the worst cases may be damaged and lead to water leakage. Every one of our water supply units with inverter has the “control function for speed of rising pressure in power recovery (patented)” as standard. This function reduces generation of water hammer by slowing down the speed of rising pressure when restarting a unit that has been stopped for a long time due to the aforementioned reasons. This is a particularly effective function when continuing to use an existing water supply pipe for many years, which has been increasing in recent years (Fig. 10).
Fig. 10 Control function for speed of rising pressure in power recovery
Water supply units are one of the most important lifelines. This product also has an emergency backup function as a standard, which has been available since the previous model (Model F3100BN). Even if one of the pumps or inverters fails, it will be automatically switched to another pump or inverter in order to continue operation. In case the pump unit cannot be operated due to a failure of the main board, a water outage can be avoided temporarily by using the control panel to operate the unit manually.
As a special accessory, we offer a remote monitoring device with an alarm buzzer, which has been favored since the conventional model (Model F3100BN), to monitor the operation status of the water supply unit (also shown on the control panel) at a remote location, such as the monitoring room. No power supply is required because power is supplied from the water supply unit, and the maximum wiring length is 500 m.
The NFC function, which has been available since August 2017 and has been well received by customers, is also included as a standard function in this model as well as the previous model. NFC is an abbreviation for Near field communication and is a technology defined by ISO/IEC 18092. This technology allows devices to communicate with each other by simply putting them close together. It is widely used as an easy communication method, for example, in “Suica*2” and “Osaifu-Keitai*3.”
The use of NFC is possible by simply installing a dedicated application, “Fresher LINK,” from Google Play into an NFC-compliant Android*4 smartphone and by starting the application (Fig. 11). Water supply units are operated by a variety of people, including owners, facility builders, administrators, and maintenance workers. Considering this situation, we chose not to create a dedicated terminal, but instead, we created “Fresher LINK” so that everyone operating the pump unit could access NFC by simply installing the application free of cost into a commercial smartphone.
*2 “Suica” is a trademark of East Japan Railway Company.
*3 “Osaifu-Keitai” is a trademark of NTT Docomo Inc.
*4 “Android” and “Google Play” are trademarks of Google LLC.
Fig. 11 How to use NFC
This function can display the following:
Equipment information (model name, product number)
Operating conditions (shut-down, pressure, frequency, current, temperature)
Failure information (failure records)
Settings
Cumulative operating time
Cumulative number of starts
Elapsed time from alarm occurrence
The operator can grasp the operation status, quickly and easily through the easy-to-understand display on the smartphone screen, allowing for more efficient management and inspection. In addition, in an emergency like a device failure, even those who are inexperienced in equipment operation can accurately and smoothly transmit and deploy the unit information or failure information displayed on the smartphone to the parties concerned, which is useful for early recovery. Note that “Cumulative operating time,” “Cumulative number of starts,” and “Elapsed time from alarm occurrence” are new items that were added after the application was upgraded to implement customer’s feedback (Fig. 12).
Fig. 12 Newly added items
This application can be used as an information-sharing tool. For example, the application can not only scan information and simply display it on smartphones, but can also send it as attached files in emails and can send data upon making inquiries to Ebara (Fig. 13).
Fig. 13 How to handle data with NFC
The application can convert scanned data into a text file and attach it to an email. With this function, users can use this electronic-data in various ways, such as:
Drawing up inspection reports
Operation records management
Sharing information with persons concerned
In the case of device failure or other problem, the operation information of the water supply unit, scanned with a smartphone can be uploaded through the application to customer service to solve the problem immediately. Even if it is difficult to explain the alert or the operation status over the phone, this function can make the explanation much easier to understand with accuracy. Based on the sent data, we can solve the problem quickly and accurately depending on the unit condition to provide customers with a peace of mind.
With regard to water supply units, we have been making energy-saving proposals to reduce operation costs by increasing the efficiency of pumps and motors and introducing optimized operation control, in order to meet the needs of our customers. We have also been improving our products for day-to-day tasks, for example with various backup functions that provide our customers with peace of mind and safety, even in the event of a device failure, and the NFC function for easy maintenance. In the recent market for water supply units, the demand for renewal accounts for about 70% of sales, and customers require a shortening of water outage times using the existing environment to the greatest extent possible. Therefore, it was difficult to renew the model due to the necessity of changing fitting dimensions between pipes. By visiting many sites and listening to the real voices of our customers, we created the new concept “better use of space and easier installation,” and successfully developed a product that reflects those voices more seriously than ever before.
We will continue to respond to the needs of our customers and help them achieve optimal water supply systems, and will provide products based on the concept of our standard pump technology brand, “eDYNAMiQ*1,” in order to deliver “Saiteki-Kai*5” to various applications and sites.
*1 “eDYNAMiQ,” stands for Eco (Ecology), Dynamic and Integrated Quality, was coined to evoke the features of our standard pump technology.
*5 “Saiteki-Kai”was coined to express optimal solution and comfort.
1) “Energy-saving New Model F3100 Packaged Pump System with Top Runner Motors,” Ebara Engineering Review No.245 (2014-10)
2) “New Booster Pump Unit with NFC Device,” Ebara Engineering Review No.256 (2018-10)
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