KSB Know-how, Volume 2

B OA- Sy s t ro n i c

Contents
Intelligent pump and valve management saves energy . . . . . . . . . . . . . 2
1

Heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

System concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Volume flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Circulator pump heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hydraulic balancing of branch circuits . . . . . . . . . . . . . . . . . . 12

Differential pressure control elements . . . . . . . . . . . . . . . . . . . 14

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

10

Practical testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

10.1 Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10.2 Circulator selection for BOA-Systronic . . . . . . . . . . . . . . . . . . 19
10.3 Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10.4 External temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10.5 Volume flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10.6 Differential pressures of the pumps . . . . . . . . . . . . . . . . . . . . . 22
10.7 Electrical pump power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11

Payback period for BOA-Systronic . . . . . . . . . . . . . . . . . . . . . 24

11.1 Control valve investment and energy savings . . . . . . . . . . . . . . 24

11.2 Investment costs for heating circuit with Riotec pump . . . . . . 25
11.3 Investment costs for heating circuit with Rio-Eco pump . . . . . 26
11.4 Total savings comparison Riotec/Rio-Eco . . . . . . . . . . . . . . . . 26
12

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

13

Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
List of tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Intelligent pump and valve management saves energy

The new BOA - Systronic system solution improves the supply temperature control
of heating circuits. It opens up a previously unused potential for saving electrical
energy used by the circulator pump.

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Heating circuit

1
Heating circuit

Mixing or injection-type
systems produce a constant
volume flow rate through the

Every heating circuit consists of

consumer installations1. As a

several control components

result, part-load conditions

such as the circulator pump and

which account for more than

the control valve, which are

95% of the operating period

connected by pipes. The circu-

result in the circulator pump

lator pump conveys the heating

handling predominantly cold

water from the heat generator

return water most of the time.

(boiler) to the consumer instal-

In a mixing or injection-type

lations, and the control valve

system, the discharge head of

adjusts the volume flow rate

the variable-speed circulator

pumped through the consumer

pump remains constant, irre-

installations. Conventional

spective of the actual load

heating set-ups can be charac-

conditions, i.e. irrespective of

terized as follows:

external temperature. Only

external heat gains will result

THE CONTROL COMPO-

in energy savings, depending

NENTS IN CONVENTION-

on the set pump characteristic

AL HEATING SYSTEMS ARE

curve (p = constant or p =

NOT COORDINATED

variable).
If several heating circuits of

The circulator pump and

a mixing or injection-type

the control valve fitted in con-

system branch off a main feed

ventional, mixing or injec-

circuit, they must be balanced

tion-type systems operate in-

manually.

dependently, without coordination between the two components. There is no system

knowledge about the hydraulic conditions in the heating
circuit, so that some of the
hydraulic energy supplied by
the circulator pump may actually be destroyed by valves
and differential pressure control elements elsewhere in the
heating circuit.

Constant volume fl ow rate through consumer installations: results from the hydraulic confi guration of the main feed circuit (e.g. 3-way mixing
valve). Whether the system is operating under nominal load or part-load conditions, the circulator pump will always deliver the nominal
volume fl ow rate calculated for the design point. Only when external heat is acting on the consumer installations will the level of this volume
fl ow rate be adjusted by the control function of the thermostats.

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System concept

2
System concept
An analysis of this situation re-

The supply temperature is in-

main feed manifold is now

sulted in the BOA-Systronic

creased by the higher-level con-

automatically performed via the

system concept, which has the

troller. This results in hydraulic

circulator pump, which reduces

clearly defined benefit of reduc-

savings regarding both volume

commissioning costs for the

ing the running costs of the

flow rate Q and discharge

heating circuit. When the heat-

heating circuit.

head H, whose product is pro-

ing circuit of a conventional

portional to the corresponding

mixing or injection-type system

electrical power savings for the

is commissioned, the tempera-

SAVINGS POTENTIAL BY
SYSTEM CONCEPT

circulator

pump2 .

ture difference between supply

and return (temperature differ-

BOA-Systronic coordinates the

A positive side effect is that

ential) is set for the design point

operation of circulator pump

static hydraulic balancing at the

using the balancing valve, usu-

and control valve. Depending

on the control signal issued by
the higher-level heating controller the two BOA-CVE SuperCompact control valves adjust
the resulting volume flow rate
pumped through the consumer
installations. At the same time,
the appropriate discharge head
Higher-level heating
controller

setpoint is transmitted to the

variable-speed drive of the circulator pump.
BOA-Systronic transforms the
conventional, constant-flow
mixing or injection-type system
into a variable-flow system, and
adjusts the discharge head of
the circulator pump to the reduced volume flow rates via the
system control curve.
The radiator diagram illustrates
the physical fact that at identical heat output the volume
flow rates provided to the consumer installations can be reduced if the supply temperature
is increased at the same time.

Fig. 01 Hydraulics schematics of BOA-Systronic

t2

Electrical power input of circulator pump: P

= constant Q(t) H(t)dt.
electr.
t1
The constant describes the efficiency of circulator pump and frequency inverter as well as water density and acceleration due to gravity.

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System concept

ally by throttling this valve.

ic balancing of branch circuits,

The pressure drop across the

they can even be replaced by

valve may amount to several

more cost-effective balancing

tenths of bar. With BOA-Sys-

valves. Variable volume flow

tronic, this step is dispensed

rate control by BOA-Systronic

with.

has no influence on the hydraul-

As BOA-Systronic produces

ic balancing of the branch cir-

only the discharge head actually

cuits, which is performed for

required to overcome system

the design point.

resistance, flow noises are prevented, even with external heat

input, and expensive differential pressure control elements
are not required for balancing
the heating circuits. For hydraulKNOWLEDGE ABOUT
PIPING CHARACTERISTIC
OF HEATING CIRCUIT

Fig. 02 Comparison of systems

Conclusion
The savings realised by BOA - Systronic result from knowledge about the hydraulic
conditions in the heating circuit. They are completely independent from differential
pressure control of the circulator pump. With BOA - Systronic , differential pressure
control of the circulator pump is effected as before.

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Components

3
Components
The transformation into a sys-

ing on the actual load (external

and thus the hydraulic resist-

tem with variable volume flow

temperature).

ance of the heating circuit. The

presupposes that the partial

The control unit is mounted on

measuring valve remains fully

volume flows are hydraulically

the main control valve at the

open both during commission-

decoupled and that information

factory. The BOA-Control

ing and over the entire operat-

about the flow rates required in

IMS 4

valve is used here to

ing range and due to its very

the heating circuit is available.

measure the volume flow rate at

low -coefficient acts just like

For this reason, BOA-Systronic

the main feed manifold during

a piece of pipe. The measuring

comprises three valves. The two

commissioning. This measuring

computer is not included in the

BOA-CVE SuperCompact con-

signal is used to determine the

system scope of supply.

trol valves are used for adjust-

discharge head of the circulator

ing volume flow through the

pump for the design point as

consumer installations depend-

well as the system control curve

Fig. 03 BOA-Systronic components

BOA- CVE SuperCompact: Automated shut-off and control valve for HVAC applications with smart electric actuator. The valve is produced
in nominal sizes from DN20 to DN150 and nominal pressure class PN6/10/16. Thanks to its compact design, it is the smallest and lightest
valve of this pressure class manufactured in series production today, enabling the space-saving design of air-conditioning and heating centrals.
Due to its low weight, the valve is easy to install and handle. The self-calibration feature of the actuator is another benefi t, which does away
with the adjustment of limit switches.
BOA- Control IMS: The valve measures volume fl ow rates independently from valve travel positions and minimum differential pressures.
Unlike on conventional valve models, the measurement accuracy is constant across the entire valve travel. The measuring signal is read and
processed by a measuring computer. Valves of this kind are often insulated, and any identifi cation on their bodies may be diffi cult to read.
After start-up, the computer display therefore fi rst shows the nominal diameter of the connected valve. The operator can then choose via two
keys whether the current fl ow rate is to be indicated [in m 3 /h] or the temperature of the fl uid handled [in C]. Volume fl ow rates can be checked
within a matter of seconds in this way. BOA- Control IMS, which has a linear characteristic, can also be used as shut-off valve. Thanks to a
travel stop with a protective cap, the valve can be set exactly to its original position once the shut-off process has been completed.
-coeffi cient: describes the resistance a valve offers to the fl uid passing through it. The -coeffi cient depends on the valve type and design.

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Control

4
Control
BOA-Systronic is a control sys-

supply temperature measured,

tem which is installed down-

the higher-level controller gen-

stream of the heating systems

erates the control error signal,

control unit. It does not replace

which is the input of the (PI or

the higher-level controller.

PID) control algorithm. This

control algorithm generates a

HIGHER-LEVEL CONTROL-

signal, which in conventional

LER IS RETAINED

mixing / injection-type systems

is then transmitted to the control

Supply temperature control

valve.

remains the task of the higher-

This output control signal from

level controller. Input signals

the higher-level controller is the

for this controller are, among

input for BOA-Systronic, i.e. it

others, the external tempera-

is transmitted to the Systrobox

ture measured and the supply

control unit. With the help of

temperature measured in the

the system control curves deter-

heating circuit. With the help of

mined during commissioning,

the heating curve stored in the

Systrobox translates the control

higher-level control unit, the

signal into two separate control

setpoint for the supply tempera-

signals for the two BOA-CVE

ture of the heating circuit is

SuperCompact control valves

generated on the basis of the

and into a discharge head set-

external temperature measured.

point for the circulator pump.

Based on this setpoint and the

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Volume flow rates

5
Volume flow rates

type systems. As a result, pre-

water, whereas the control valve

dominantly cold return water

in the mixing line adjusts the

is pumped through the heating

volume of cold return water to

Thermal output of the heating

circuit under part-load

be mixed in. The additional op-

circuit is calculated for the

conditions.

timizing effect of external heat

design point as the product of

The volume flow rate through

load compensation by the ther-

volume flow rate Q and temper-

the heating circuit is only re-

mostatic valves remains un-

ature differential T.

duced by the regulating func-

affected.

tion of the thermostatic valves

The radiator diagram illustrates

(external heat load compensa-

that volume flow rate can be re-

tion).

duced while thermal output at

Pth = 1.163 Q T

Conventional systems

the consumer installations stays

BOA-Systronic

the same, if the supply tempera-

figuration, conventional mixing

The innovative control concept

ture is increased accordingly.

of BOA-Systronic regulates

Two methods can be used,

provide the consumer installa-

thermal output by variation of

which can be realized by mak-

tions only with a constant vol-

the temperature differential and

ing use of a standard function

ume flow rate, irrespective of

the volume flow rate, consider-

offered by the heating control-

the heating controllers signal.

ably reducing the water volume

ler.

The volume flow in the supply

to be pumped through the heat-

line is coupled with the volume

ing circuit. This is possible

flow of the cold return water

because the two BOA-CVE

Parallel shift of heating

curve

pumped through the mixing

SuperCompact control valves

The controllers heating curve is

line (Fig. 04).

decouple the volume of heating

shifted parallel by a fixed

water coming from the supply

amount towards higher supply

line from the volume of cold re-

temperatures. The controller

turn water pumped through the

adds the fixed amount T to the

So thermal output of the heating

mixing line.

supply temperature setpoint

circuit can only be regulated via

The main control valve installed

(parallel shift of the heating

the temperature differential in

in the supply or return line regu-

curve). Due to the increased

conventional mixing / injection-

lates the volume of heating

temperature differential, the

or injection-type

systems 6

can

Qtotal =Q1supply+Q2mixing

Q 1 supply

Q total

(hot)

Volume flow rate Q [%]

Owing to their hydraulic con-

Q total

100

Q 2 mixing

80
60
40
20

Q 1 supply

Q 2 mixing (cold)

20

40

60

80

100

Controller signal [%]

Fig. 04 Volume flow rates of 3-way valve

6

3-way configuration: In a 3-way mixing valve, the fl uids to be mixed enter the valve via two input ports and the sum of their fl ow exits
through a single output port. The ratio between the fl ow rates through both inlet ports is determined by the stem position. The sum of the
throttling cross-sections on both inlet ports is constant over the entire valve travel. The valve therefore provides a constant volume fl ow at its
outlet port, independent of stem position.

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Volume flow rates

nominal volume flow rate is

In principle, this new design

design point of the circulator

reduced by 25% in all cases,

point can also be achieved with

pump remain unchanged. In

resulting in a new design point

a conventional hydraulic con-

this case, the investment costs

for the circulator pump (Fig. 05)

figuration. However, BOA-

for the circulator pump and the

Systronic offers a number of

other valves cannot be reduced.

INCREASED SUPPLY TEM-

benefits.

PERATURE BY PARALLEL

The consultant can size the

SHIFT OR SLOPE MODIFI-

consumer installations of the

CATION OF HEATING

heating circuit as usual

CURVE

The consultant can use the

benefits offered by BOA-

Thanks to the new design

Systronic without changing

point, investment costs for the

his planning

circulator pump and the valves

The consultant saves

in the heating circuit can be

planning work and thus time

reduced considerably.

and costs

Normally, a circulator
rating can be selected

Slope modification of heating curve

Benefit: Substantially reduced

The controller s heating curve

investment costs for the circu-

is shifted towards higher supply

lator pump

temperatures only if the system

pump with a lower output

The nominal diameter of

is running under part-load conditions. Depending on the value

be chosen one nominal diam-

of the control signal, the control-

eter smaller.

ler internally adds an amount

Benefit: Reduced investment

T to the supply temperature

costs for piping, shut-off

setpoint (slope modification of

valves and strainers, including

heating curve). The nominal

insulation.

volume flow rate and thus the

Q 1 supply
(hot)

Q total
+

Q 2 mixing
(cold)

Volume flow rate Q [%]

the heating circuit can usually

100
80

Q total
60
40
20

Q 2 mixing

Q 1 supply

0
0

20

40

60

80

100

Controller signal [%]

Fig. 05 Reduced volume flow rates of BOA-Systronic

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Circulator pump heads

6
Circulator pump heads

Control IMS valve measures the

cuit, the pressure losses in the

volume flow rate in the heating

consumer installations, balanc-

circuit and thus determines the

ing valves, differential pressure

Owing to the hydraulic config-

required nominal discharge head

control elements, strainers as

uration of conventional mixing

of the circulator at the design

well as thermostatic and shut-

or injection-type systems, the

point. The values obtained are

off valves.

circulator pump head cannot be

then used to determine the

The volume flow rate and dis-

matched to the system control

system constant of the heating

charge head are shown in nor-

curve. The circulator pump can

circuit. As a result, the hydraul-

malized representation here.

only react to reduced volume

ic resistance of the heating

The circulator pump of a mix-

flow rates resulting from the

circuit is known, and the control

ing or injection-type system can

control function of the thermo-

unit knows the circulator head

only respond to reduced volume

static valves at the consumer in-

required for the individual load

flow rates (external heat gain)

stallations. Depending on the

conditions.

with a constant discharge head,

pump curve selected, the dis-

thus saving a certain amount of

charge head either remains

The H/Q diagram on page 11

constant (p = constant) or is

shows an example of the possi-

reduced accordingly (p =

ble discharge heads of a differ-

NEW DESIGN POINT FOR

variable).

ential pressure controlled

THE PUMP

energy.

pump. The diagram shows the

BOA-SYSTRONIC CON-

H/Q data of a pump controlled

With BOA-Systronic, parallel

TROLS THE PUMP AS A

independently of throughflow

shift of the heating curve results

FUNCTION OF THE SYSTEM

(p = constant) and offers a

in the new nominal volume

CURVE OF THE HEATING

comparison between a conven-

flow rate

CIRCUIT

tional system and a system

equipped with BOA-Systronic.

Q new = 0.75 Q old

BOA-Systronic, by means of the

two control valves, adjusts the

The design point is represented

and, by application of the affin-

volume flow rate as a function

by the intersection of the system

ity law, yields the associated

of external temperature and

curve of the heating circuit with

discharge head of the circulator

measures the system curve of

the characteristic curve of the

pump:

the heating circuit during com-

circulator pump.

(see equation below)

missioning. As a result, the circulators discharge head can be

matched to the volume flow

H new = H old

Q new
Q old

= 100%

75%
100%

) H

old

= 0.56 H old

rate to be pumped. This is done

by means of the system control

The system curve describes the

The valve authority of the main

curve (Fig. 6). The system

resistance the volume flow has

control valve must then be add-

control curve is automatically

to overcome, and corresponds

ed to this value. It describes the

determined by measuring the

to the discharge head required

pressure drop at the control

volume flow rate during

of the circulator pump. It de-

valve, in relation to the differ-

commissioning; it is limited by

pends on the length and nom-

ential pressure to be produced

the minimum discharge head of

inal diameter of the supply and

by the pump (overall pressure

the circulator pump. The BOA-

return lines in the heating cir-

drop in the system). With BOA-

10

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Circulator pump heads

Systronic, valve authority is

the BOA-Systronic controlled

pump curve set, the discharge

constant over the entire operat-

circulator pump moves along

head either remains constant

ing range. This correlation is

the system control curve. As

(p=constant) or decreases with

reflected in the system control

external temperature rises, the

decreasing volume flow rate

curve and explains why the sys-

operating point moves towards

(p=variable). All the familiar

tem control curve runs parallel

lower volume flow rates and

features of the variable-speed

to the system curve, at a slightly

lower discharge heads.

pump and the thermostatic

higher level (Fig. 6)

valves are retained.

ALL FEATURES OF THE

In our example, a new design

VARIABLE SPEED PUMP

point is established for the cir-

ARE RETAINED

culator pump: the nominal volume flow rate is reduced by

The diagram also illustrates the

25%, and the nominal dis-

effect the control function of

charge head of the circulator

the thermostatic valves has on

pump is reduced accordingly.

various operating points (exter-

As a result, a circulator pump

nal heat load). Under the influ-

with a lower performance rat-

ence of external heat load, the

ing can be selected.

operating point also moves

along the characteristic curve of

Depending on the external tem-

the differential pressure con-

perature, the operating point of

trolled pump. Depending on the

P el 1

Discharge head H [%]

P el2

constant Q1 H1
constant Q2 H2

Q1 H1
Q2 H2

180

Chara
o f f ixedc t e r i s t i c c u r v e
speed p
ump

160

Operating point, conventional

with external heat load
P el 11 = 84%

Design point, conventional

without external heat load
Pel 1 = 100%

140

120

External
heat effect

Characteristic curve of
variable speed pump p = constant

100

Design point BOA-Systronic

with external heat load
P el 21 = 35%

80

External
heat effect

Characteristic curve of
variable speed pump p = constant

60

Operating point BOA-Systronic

part-load, with external heat load
P el 31 = 11%

40

External
heat effect

Characteristic curve of
variable speed pump
20

System control curve

Syst

urv
em c

BO

st
-Sy

ron

Design point BOA-Systronic

without external heat load
P el 2 = 45%

ic

Operating point BOA-Systronic

part-load, without external heat load
P el 3 = 16%

0
0

10

20

30

40

50

60

70

80

90

100

110

120

Volume flow rate Q [%]

Fig. 06 Circulator pump heads (example)

11

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Hydraulic balancing of branch circuits

7
Hydraulic balancing of
branch circuits
BOA-Systronic operates the
heating circuit with variable
volume flow rates. The question
therefore arises whether the
branch circuits are hydraulically
balanced for these variable
operating points.
The branch circuits are hydraulically balanced for the design
point (nominal load). This ensures adequate heat supply to
the consumer installations in the
individual branch circuits. In
the following, the nominal load
case is indexed N, whereas the

Fig. 07 Heating circuit with branch circuits

part-load case is indexed T.

At the design point (nominal

mains unchanged. The pressure

The following is to show that

load), the differential pressure

drop at the valve then only de-

variable volume flow control by

at the balancing valve of the

pends on the volume flow rate

BOA-Systronic has no influence

branch circuit drops as follows:

(Q).

on branch circuit balancing.

Differential pressure at
The volume flow rates in branch
by means of balancing valves

nominal load:
QN
1
1
pN = w 2 =
2
2
A

BV1, BV2 and BV3. What is

Equation 1

circuits 1, 2 and 3 are adjusted

( )

of interest is the ratio of the

pressure drops at the balancing

where is the water density, is

The opening cross-section (A)

valves at nominal load

the valves zeta coefficient, w is

and the zeta coefficient () of

the flow velocity of the water, A

the valve remain unchanged.

(e.g.

pN2
pN1

) and

part load (e.g.

pT2
pT1

is the flow cross-section at the

throttling point, and Q N is the
).

volume flow rate at design point.

1
1 2

= constant = c
2
A

()

Equation 2

Hydraulic balancing of the

Differential pressure at the bal-

branch circuit is performed for

ancing valve therefore only

the design point (nominal load).

depends on a factor (c) which

After that, the throttling pos-

describes the valve and the vol-

ition of the balancing valve re-

ume flow rate (Q):

12

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Hydraulic balancing of branch circuits

Differential pressure at
nominal load:
pN = c Q 2 N

Differential pressure BV1

Equation 3

Equation 6

pT1 = F2 p N1

Under part-load conditions, the

differential pressure at the bal-

Differential pressure BV2

ancing valve (BV) is reduced as

pT2 = F2 p N2

follows:

Equation 7
Differential pressure at
parl load:
pT = c (FQ N ) 2
Equation 4
where factor F describes the

Differential pressure BV3

pT3 = F2 p N3
Equation 8

part-load level (0-100)%.

Inserting equation 3 in equation

Therefore, the ratios of these

4 yields

differential pressures are as

follows:

pT = F2 p N
Equation 5
resulting in the following differ-

pT2
pT1

pN2
pN1

Equation 9

ential pressures at nominal and

part-load for branch circuits 1,
2 and 3:

Conclusion
The same law governing differential pressures in
the branch circuits can be established for part load
conditions as for nominal load conditions. It is
therefore ensured that the branch circuits are actually
supplied with the necessary volume flow rate for the
thermal output required.

13

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Differential pressure control elements

8
Differential pressure
control elements

circulator pump is immediately

higher excess discharge head at

reduced by the differential pres-

the thermostatic valve (p 2 ), as

sure control valve in many cases!

does the fixed speed pump

By way of example, the H/Q

(p1).

If external heat is acting on a

diagram in fig. 08 compares the

room sunlight, for instance

influence of external heat gain

the thermostatic valves will re-

on the operating behaviour of a

duce the volume flows passing

fixed speed circulator pump, a

through the radiators in this

differential pressure controlled

room. If volume flow rates are

circulator pump of a mixing or

reduced, the circulator pump of

injection-type system, and a

a conventional heating system

differential pressure controlled

will either be operated with a

pump controlled by BOA-Sys-

constant or variable discharge

tronic. The diagram shows that

head, depending on the set

the BOA-Systronic controlled

pump curve. The reduced vol-

pump generates only little ex-

ume flow rate will result in a

cess differential pressure, which

reduced pressure drop in the

drops at the thermostatic valve.

piping. The excess differential

pressure produced by the circu-

NO DIFFERENTIAL

lator pump can only drop at the

PRESSURE CONTROL

thermostatic valve, which caus-

ELEMENTS REQUIRED

es considerable flow noise or

whistling. Differential pressure

This differential pressure results

control elements are often used

from the hydraulic resistance of

to prevent this. Their function

the heating circuit and the dis-

limits the increase in differen-

charge head of the circulator

tial pressure across the thermo-

pump controlled by BOA-

static valve, thus preventing

Systronic. The differential

flow noise. In conventional sys-

pressure controlled pump of a

tems, therefore, part of the dis-

mixing or injection-type system,

charge head provided by the

by contrast, produces a much

Conclusion
BOA -Systronic provides the circulator pump with the discharge head required for
the actual load conditions. No excess discharge heads are produced under part load
conditions, nor flow noises at the consumers. Expensive differential pressure control
elements for balancing the heating circuits can be dispensed with. For hydraulic balancing
of branch circuits, they can even be replaced by lower priced balancing valves.

14

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Commissioning

9
Commissioning

this procedure has been com-

termines the circulators discharge

pleted, the system knows the

head required for the design

circulators discharge head for

If parallel shift of the heating

point. To do so, the circulator

the design point and the system

curve is planned, BOA-Systronic

pump is started up with its

constant of the heating circuit,

will always reduce the volume

minimum discharge head. A

and thus its system curve.

flow rate for the design point by

corresponding volume flow rate

Therefore, the correlation be-

25 %, based on the volume flow

is produced in the heating cir-

tween discharge head and vol-

rate the system designer has cal-

cuit, which is measured by the

ume flow rate for the heating

culated for a conventional mixing

BOA-Control IMS valve at the

circuit is known.

or injection-type system.

main feed manifold. The

BOA-Systronic has to be config-

BOATRONIC M- 420 measur-

BOA-SYSTRONIC AUTO-

ured prior to commissioning.

ing computer converts this

MATICALLY DETERMINES

This is done by entering the value

measured value into an analog

THE OPTIMUM PUMP HEAD

of the volume flow rate deter-

(4-20)mA current signal and

mined for a conventional mixing

transmits it to the Systrobox

With the data stored for the

or injection-type system into the

control unit, where it is com-

volume flow rate at part load

commissioning software, together

pared against the value for the

conditions, BOA-Systronic then

with the nominal system diam-

(new) nominal volume flow

generates the system control

eter of BOA-Systronic (param-

rate. The circulators discharge

curve as well as the two valve

eterization). The nominal diam-

head is increased step by step,

control curves.

eter of the BOA-Control IMS

until the difference between set-

measurement valve corresponds

point and measured value falls

to this nominal system diameter.

below a certain limit. When

Discharge head H [%]

BOA-Systronic automatically de-

180
Operating point, conventional,
variable speed pump
with external heat load

Operating point, conventional,

fixed speed pump
with external heat load

160

H1

140

External
heat effect

Design point, conventional

without external heat load

120

100

H2
p1

80

p2

60

Operating point
BOA-Systronic
variable speed pump
with external heat load

External
heat effect

40

External
heat effect

Operating point
BOA-Systronic
variable speed pump
without external heat load

H3 p
3

BO

y
A-S

str

oni

Sy

tem

cu

rve

Hydraulic
resistance
of heating circuit

20

0
0

10

20

30

40

Q part-load 60

70

Q NS 80

90

QN

110

120

Volume flow rate Q [%]

Fig. 08 Excess circulator pump heads (example)

Q
Q

N Sys
Q
T

Design point of heating circuit with 3-way valve

p1 Differential pressure at thermostatic valve (fi xed speed pump)

Design point of heating circuit with BOA-Systronic

p2 Differential pressure at thermostatic valve

Part load condition (example)

060206_knowhow05_e_IS 15

(variable speed pump p=const.)

p3 Differential pressure at thermostatic valve (BOA-Systronic)

15

06.02.2006, 12:49:59 Uhr

10

Practical testing

10
Practical testing
10.1

Plant

BOA-Systronic has been in use

in the office building of DeTeImmobilien in Heidelberg, Germany, since 2001. The heating
water is produced in a twoboiler system with a thermal
output of approx. 2 MW. Each
boiler is equipped with a
2-stage burner. The main feed
manifold is connected directly

Fig. 09 Two-boiler system

to the boilers (without hydraulic separator) and feeds 4 heat-

sections, any disturbances in

CONTROLLER TRANSMITS

ing circuits plus several other

room temperature (external

CONTROL SIGNAL TO BOA-

hot water circuits. Four heating

heat gain) are re-adjusted by

SYSTRONIC

controllers control supply tem-

means of the radiators thermo-

perature in the four building

static valves. Both circulator

The main control valve is

sections. The controllers are

pumps are differential pressure

supplied in nominal system

fitted in a separate control

controlled (p = constant).

diameter DN50 (Fig. 15). Fitted

cabinet in the plant room.

Table 01 demonstrates the

with an EA-C40 actuator, it is

benefits of BOA-Systronic by

installed in the supply line of the

FOUR HEATING CIRCUITS

comparing the performance

heating circuit. The designation

HEAT THE BUILDING

data of the two heating circuits.

EA-C40 means that this actuator has an actuation force of

BOA-Systronic supplies heat to

the West wing of the building.
The East wing is equipped with
a conventional mixing system.
Both building sections require
the same heat output. The
Stat. Heizung West heating
controller transmits its control
signal (for the control valve) to
the control unit of BOA-Systronic, where it is converted
into the load-dependent discharge head setpoint for the circulator pump and two separate
control signals for the two control valves. In both building

Fig. 10 Return manifold

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10

Practical testing

4,000 N. The photo shows the

al-position feedback (2-10)VDC.

terminal box for cable connec-

When combined with BOA-Sys-

tion and the black handwheel

tronic, it is configured with a

for emergency operation in the

linear valve characteristic and

event of a power failure. The

fed by an analog (2-10) VDC

smart actuator makes it pos-

voltage signal.

sible to select either a linear or

an equal-percentage valve

EA-C40 FOR NOMINAL

characteristic. Configuration is

SYSTEM DIAMETERS FROM

performed exclusively by means

DN 65

of the parameterization software.

The mixing valve is always selected two nominal diameters

smaller than the nominal system diameter and replaces the
swing check valve in the mixing
Fig. 11 Control cabinet

Parameter

line (Fig. 16).

East wing
(3-way configuration)

West wing
(BOA-Systronic)

Unit

300.00

300.00

kW

Temperature differential

20.00

27.00

Volume flow rate (max.)

13.00

9.75

m/h

8.00

4.50

Circulator pump

Riotec 65 -100

Riotec 50 -100

Differential pressure control

p = constant

p = constant

DN65

DN50

No

+3.5

Thermal output

Discharge head (max.)

Nom. diameter of main heating circuit

Parallel shift of heating curve

Table 01: Performance data of

main feed circuits

2 ACTUATOR TYPES FOR

DIFFERENT NOMINAL
SYSTEM DIAMETERS
The actuator can either be
supplied with 24 VAC/DC or
230 VAC/DC. As standard, it is
capable of processing 230/24
VAC 3-point control signals as
well as analog (0/4-20) mA current or (0/2-10) VDC voltage

Fig. 12 Heating controllers for

Fig. 13 Main feed manifold,

signals and features active actu-

West and East wings

West and East wings

17

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10

Practical testing

In the event of a power failure,

dressed by an analog voltage

the valve can be actuated by

signal (2-10) VDC.

means of an Allen key.

The Systrobox is the heart of
EA-B12 FOR NOMINAL

BOA-Systronic. The control

SYSTEM DIAMETERS UP TO

unit stores the two valve control

DN50

curves for the main control

valve and the mixing valve, as

For applications other than

well as the system control curve

BOA-Systronic, this actuator

for the pump.

also offers the option of setting

a linear or equal-percentage

SYSTROBOX IS THE

valve curve.

HEART OF BOA-

A five-core cable supplies the

SYSTRONIC. IT RECEIVES

actuator with supply and con-

AND TRANSMITS ALL

trol voltage. As the terminals

SIGNALS.

Fig. 14 Main feed circuit with

are located inside the actuator,

BOA-Systronic

the cover must be removed prior

The control unit is powered by

to installation. Operating on a

24 VAC. It contains the inter-

It adjusts the volume flow rate

24 VAC/DC voltage supply,

face for powering the BOA-

in the mixing line in accordance

the actuator requires an ana-

TRONIC measuring computer

with the valve control curve

log (0/2-10)V control signal

and for receiving and process-

stored in the Systrobox. In this

and provides (2-10)VDC active

ing its measuring signal. As in-

case, it is of nominal size DN32

actual-position feedback. When

terface with the (higher-level)

and therefore equipped with ac-

combined with BOA-Systronic,

controller, it receives the con-

tuator type EA-B12, which has

it is configured with a linear

trollers control signal and

an actuating force of 1,200 N.

valve characteristic and ad-

transmits the three control sig-

Fig. 15 Main control valve

Fig. 16 Mixing valve BOA-Systronic

BOA-Systronic

18

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10

Practical testing

nals simultaneously to the

pump and the control valves.

10.2
Circulator selection
for BOA -Systronic

The control valves receive a

k heating circuit =

8
= 0.0473
132

Equation 11

separate analog (2-10)VDC

The following analysis shows

control signal each, whereas the

that the Riotec 50-100 circula-

The example is based on a tem-

integrated FTT10 transceiver

tor pump selected, which is

perature differential of T =

sends the currently required

controlled by BOA-Systronic, is

20K, and the heating curve of

discharge head as digital signal

oversized. The system curve of

the higher-level controller was

to the pump via LON bus. A

the heating circuit is calculated

shifted by 3.5K (parallel shift),

second pair of integrated LON

as the quotient of the pump

resulting in a new design point:

terminals serves to transmit the

head (H) and the square of the

the nominal volume flow rate is

LON output variables of BOA-

volume flow rate (Q):

reduced by 25%.

Systronic as well as any other

nodes of the LON bus to a
higher-level building management system.

(Equation 12: see below)

k heating circuit =

H
Q2

For selecting the circulator

Equation 10

pump operated with BOA-Systronic, the required discharge

Systrobox comes pre-assembled

The volume flow rate for the de-

head is calculated for the design

to the main control valve as

sign point of the conventionally

point, including equations 2

standard. However, it can also

equipped main feed circuit is

and 3.

be mounted on the mixing

Qnom = 13m /h. At this volume

(Equation 13: see below)

valve, as in the present case, or

flow rate, the Riotec 65-100

in the control cabinet.

pump can provide a maximum

This new design point [Q/H] =

head of approx. H=8m (see

[9.75m 3 /h / 4.5m] can be han-

pump catalogue). For this max-

dled by a Riotec 50-60 pump.

imum case, the following sys-

For the present example, invest-

tem constant is calculated for

ment costs for the circulator

the heating circuit:

pump are reduced as follows:

Q N, Systronic = 0.75 Q N,conv = 0.75 13m 3 /h = 9.75m 3 /h

Equation 12

H N,Systronic = k heating circuit Q2 N,Systronic = 0.0473 9.75m 2 = 4.5m

Equation 13
Pump

Fig. 17 Control unit of BOASystronic (Systrobox

Catalogue price 2005 []

Riotec 65 100

1,825.11

Riotec 50 60

1,223.20

Difference []
602.91

Table 02: Reduced investment costs for circulator pump

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10

Practical testing

10.3
Measurements
To verify the function of the
BOA-Systronic system, the
following quantities were
measured, among others. (Table 03)
Measurements were taken on

Heating circuit East

(3-way mixing configuration)

Heating circuit West

(BOA-Systronic)

External temperature

External temperature

Volume flow rate at main feed manifold

Volume flow rate at main feed manifold

Differential pump pressure

Differential pump pressure

Electrical power input

Electrical power input

Tab. 03: Measured quantities

545 days in the period from

2000 to 2002. The measured

measuring period 2000 to

temperature of the heating

values were recorded at two-

2002. The diagram shows an

system is [(-12C) (+16C)] =

minute intervals, resulting in

average external temperature of

28C. The temperature differ-

711 values per day (24 hours),

approx. 10C in the period

ence between the design point

from which the day mean

monitored. Depending on the

and the average temperature is

values were calculated for each

location, the heating circuits are

[(-12C) (+10C)] = 22C.

measured quantity.

selected for an external temper-

The ratio between both values

ature of approx. 12C to 15C.

is 22/28 = 0.79. This means

Regulations stipulate that the

that in the monitored period

building must be heated until

both heating circuits on average

the external temperature

only require about 21% of the

reaches approx. 16C. The tem-

thermal output they were se-

The external temperatures

perature difference between the

lected for. This theory should

measured were plotted for the

design point and the switch-off

be confirmed by a comparison

10.4
External temperature

External temperature [C]

External temperature Heidelberg test installation Average temp. 10C (approx)

35
30
25
20
15
10
5
0
-5

22. Oct 02

22. Sep 02

23. Aug 02

24. Jul 02

24. Jun 02

25. May 02

25. Apr 02

26. Mar 02

24. Feb 02

25. Jan 02

26. Dec 01

26. Nov 01

27. Oct 01

27. Sep 01

28. Aug 01

29. Jul 01

29. Jun 01

30. May 01

30. Apr 01

31. Mar 01

1. Mar 01

30. Jan 01

31. Dec 00

1. Dec 00

1. Nov 00

-10

Years
External temperature

Fig. 18 External temperatures measured at the test installation in 2000 2002

20

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10

Practical testing

of the volume flow rates meas-

required volume flow rate Qnom

heating circuit by BOA-Systronic

ured, the differential pump

for the design point is calculat-

during the utilization period is

pressures and the pump power

ed as follows:

considerably smaller than the vol-

consumption of both systems.

Pth

Qnom =

10.5
Volume flow rates

1.163 T
Equation 14

300
1.163 20

m 3 /h = 13m 3 /h.

The conventional, mixing-type

This value is confirmed by the

ume flow rate the conventional,

system must provide a thermal

measurements (Fig. 19). Irrespect-

mixing-type system provides to its

output Pth = 300 kW at the de-

ive of its degree of opening, the

heating circuit. Fig. 19 shows that

sign point. Based on a tempera-

three-way control valve of the

the measured nominal volume

ture differential T = 20K, the

conventional, mixing-type system

flow rates supplied by the conven-

always supplies the nominal vol-

tional, mixing-type system do not

ume flow rate to the heating circuit

quite reach the theoretical, calcu-

(constant-flow system). BOA-

lated values. This is due to the

Systronic, by contrast, adjusts the

control function of the thermostat-

resulting volume flow rate in the

ic valves under the influence of

main feed circuit depending on the

external heat input to the heating

opening degree of the two control

circuit. The equation

valves and thus depending on the

ing controller. As expected, the

t2
water volume flow = Q(t) dt
t1

volume flow rate supplied to the

is used to calculate the amounts

control signal issued by the heat-

Volme flow rate [m3/h]

Volume flow rates Heidelberg test installation Savings by BOA-Systronic approx. 65%
16
14
12
10
8
5
4
2

22. Oct 02

22. Sep 02

23. Aug 02

24. Jul 02

24. Jun 02

25. May 02

25. Apr 02

26. Mar 02

24. Feb 02

25. Jan 02

26. Dec 01

26. Nov 01

27. Oct 01

27. Sep 01

28. Aug 01

29. Jul 01

29. Jun 01

30. May 01

30. Apr 01

31. Mar 01

1. Mar 01

30. Jan 01

31. Dec 00

1. Dec 00

1. Nov 00

Years
3-way configuration

BOA-Systronic

Fig. 19 Volume flow rates measured at the main feed manifold in 2000 2002

21

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10

Practical testing

of water (volume flow rates)

At identical thermal output,

pumped through the two heat-

BOA-Systronic was shown to

ing circuits, respectively. The

pump only 40 % of the water

mean values of the volume flow

volume through the heating cir-

rates measured in the two heat-

cuit, compared to the conven-

ing circuits are calculated.

tionally equipped heating circuit.

Measured Quantity

Volume flow rate (Q)

Heating circuit

3-way configuration

[m /h]

Mean value

Q Systronic /Q 3 - way configuration

BOA-Systronic

Unit

Ratio

[m /h]

11.2

3.2

0.29

Table 4: Analysis of volume flow rates in 2000-2002

10.6
Differential pressures
of the pumps

With BOA-Systronic, the pump

is operated on average at only
about 66% of the nominal
discharge head at design point.

Measured Quantity

Differential pressure (H)

Heating circuit

3-way configuration

Unit

[m]

Mean value

4.4

Ratio
H Systronic /H 3 - way configuration

BOA-Systronic
[m]
2.9

0.66

Table 5: Analysis of differential pump pressures in 2000 -2002

Pump differential pressures [mbar]

Pump differential pressures Heidelberg test installation Savings by BOA-Systronic approx. 37%
800
700
600
500
400
300
200
100

22. Oct 02

22. Sep 02

23. Aug 02

24. Jul 02

24. Jun 02

25. May 02

25. Apr 02

26. Mar 02

24. Feb 02

25. Jan 02

26. Dec 01

26. Nov 01

27. Oct 01

27. Sep 01

28. Aug 01

29. Jul 01

29. Jun 01

30. May 01

30. Apr 01

31. Mar 01

1. Mar 01

30. Jan 01

31. Dec 00

1. Dec 00

22

1. Nov 00

Years
3-way configuration

BOA-Systronic

Fig. 20 Differential pressures of the circulators measured in 2000 2002

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10

Practical testing

10.7
Pump input
power
The pump input power, and

heads, the pump draws much

thus its power consumption, is

less power from the electricity

proportional to the product of

grid. BOA-Systronic was shown

the discharge head and volume

to save approx. 70% in

flow rate. As BOA-Systronic

electrical energy.

operates the pump at reduced

volume flow rates and discharge
Measured quantity

Pump input power (P)

Heating circuit

3-way configuration

Unit

PSystronic /P3 - way configuration

BOA-Systronic

[W]

Mean value

Ratio

[W]

561

184

0.33

Table 6: Savings in pump power consumption

Pump input power [W]

Pump input power Heidelberg test installation Savings by BOA-Systronic approx. 70%
900
800
700
600
500
400
300
200
100

22. Oct 02

22. Sep 02

23. Aug 02

24. Jul 02

24. Jun 02

25. May 02

25. Apr 02

26. Mar 02

24. Feb 02

25. Jan 02

26. Dec 01

26. Nov 01

27. Oct 01

27. Sep 01

28. Aug 01

29. Jul 01

29. Jun 01

30. May 01

30. Apr 01

31. Mar 01

1. Mar 01

30. Jan 01

31. Dec 00

1. Dec 00

1. Nov 00

Years
3-way configuration

BOA-Systronic

Fig. 21 Pump power input in 2000 2002

Conclusion
In our example, both heating circuits on average require only 21% of the thermal
output at design point. By comparison, BOA - Systronic consumes only about 30 % of
the electricity required by the conventional set- up ( here : 3 - way mixing system) .

23

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11

Payback period for BOA - Systronic

11
Payback period
for BOA -Systronic
11.1
Control valve investment and energy
savings

valves and the pump as well

configuration, the differences

as automatic hydraulic bal-

depending on the nominal sys-

ancing at the main feed mani-

tem diameter of the main feed

fold.

circuit (table 07).

Items (1) to (5) can also be

In the present example, a main

planned and achieved in a con-

feed circuit with a thermal out-

ventional system by increasing

put of 300 kW was equipped

the temperature differential at

with BOA-Systronic of nominal

With BOA-Systronic, the nom-

design point. Items (6) and (7),

system diameter DN50, where-

inal diameter of the heating cir-

however, can only be realized

as a nominal diameter of DN65

cuit components can be smaller

with BOA-Systronic.

was selected for the convention-

than usual. This is due to the

al set-up of identical thermal

combined effect of increased

To compare the prices of the

temperature differential (differ-

two systems, the average price

ence between supply and return

for a conventional, mixing-type

A simulation (version 1.21) was

temperature) and reduced vol-

system of nominal diameter

used to estimate the energy

ume flow rates at design point,

DN65 was determined on the

costs incurred for the glandless

so that

basis of the catalogue prices

Riotec 50-100 pump during the

1. the main feed pipe is one

given by 5 competitors. The

heating period (table 10). Com-

mixing-type configuration com-

pared to the average price of a

prises the following compo-

mixing-type system, the invest-

main feed circuit are one

nents:

ment costs for BOA-Systronic

nominal diameter smaller

3-way control valve

would be approx. 402 higher

swing check valve in the mix-

in this case. If this extra price is

nominal diameter smaller

2. the shut-off valves in the

3. the strainers in the main

feed circuit are one nominal
diameter smaller
4. a smaller circulator pump
can be chosen
5. the measurement and control valves are one nominal

output (table 08).

ing line

deducted from the electricity

balancing valve

savings realized per heating

The gross price of BOA-Sys-

period, investment in BOA-

tronic, by contrast, is somewhat

Systronic will pay back after

higher than the average price of

roughly one year.

a conventional mixing-type

diameter smaller
6. differential pressure controllers for balancing the heat-

Nominal
system diameter

ing circuits are not required

DN25 to DN50

7. commissioning costs are re-

DN65 to DN80

duced thanks to automatic

initialization of the control

Average extra price compared to

3-way mixing configuration in [%]
11 %
4%

DN100 to DN150

13 %

Tab. 07: Average extra prices for BOA-Systronic

Heating circuit

Unit

Value

Average gross price of 3-way mixing configuration, DN65 (prices of 2005)

1,673

Gross price of BOA-Systronic, DN50 (prices of 2005)

1,858

Gross price of LON module for Riotec pump, pre -initialized

217

Difference

+402

Tab. 08: Extra price for BOA-Systronic with Riotec pump (example: DN50)

24

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11

Payback period for BOA - Systronic

Heating circuit

Unit

Value

Difference

Average gross price of 3-way mixing configuration, DN65 (prices of 2005)

1,673

Gross price of BOA-Systronic, DN50 (prices of 2005)

1,858

Gross price of LON -module forRio - Eco pump, non-initialized

187

+372

Table 09: Extra price for BOA-Systronic with Rio-Eco pump (example: DN 50)

Cost factor

Unit

Value

Average price of electricity

/kWh

Difference

0.11

Average operating hours per heating period

6,800

Average efficiency of Riotec circulator pump

35

Average pump power consumption/heating period; conv., mixing-type system DN65

kWh

5,000

Average pump power consumption/heating period; BOA-Systronic DN50

kWh

1,200

Average price of electricity/heating period; conv., mixing-type system DN65

548

Average price of electricity/heating period; BOA-Systronic DN50

131

-3,800

- 417

Table 10: Energy costs in fi rst year (example: DN 50)

11.2
Investment costs for
heating circuit with
Riotec pump

If the extra price for BOA-

present hourly rates (2005), this

Systronic is deducted from the

results in an additional 45

reduced investment costs

saved.

( 1,059 402), the investment

costs for the main feed circuit

Investment in BOA-Systronic

By utilizing all saving potentials

will be reduced to 657 in this

would, therefore, pay back im-

offered by BOA-Systronic, the

case. In addition, automated

mediately, and the investment

investment costs of the present

commissioning further reduces

and commissioning costs for

heating circuit can be reduced

the commissioning costs per

the heating circuit would be re-

by 1,059.

heating circuit by one hour. At

duced substantially.

Cost factor

Unit

Difference

(1)

Smaller nominal diameter of main feed pipe

-75

(2)

3 shut- off valves of smaller DN in main feed circuit

-123

(3)

1 strainer (standard mesh) of smaller DN in main feed circuit

-29

(4)

1 Riotec 50 - 60 circulator pump instead of Riotec 65 -100

- 602

Measurement and control valves one DN smaller (BOA-Systronic)

see above

-230

-1,059

(5)

(6) No differential pressure controller required (1 no. per heating circuit, 1.5 -inch)
Sum total of factors (1) to (6)

Tab. 11: Reduced investment costs for heating circuit with Riotec pump, example (prices 2005)

25

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11

Payback period for BOA - Systronic

11.3
Investment costs for
heating circuit with
Rio - Eco pump

If the extra price for BOA-Sys-

Investment in BOA-Systronic

tronic is deducted from the re-

would, therefore, pay back im-

duced investment costs ( 933

mediately, and the investment

372), the investment costs for

and commissioning costs for

the main feed circuit are re-

the heating circuit would be

By utilizing all saving potentials

duced to 561 in this case. In

reduced substantially.

offered by BOA-Systronic, the

addition, automated commis-

investment costs of the present

sioning reduces the commis-

heating circuit can be reduced

sioning costs per heating circuit

by 933.

by one hour. At present hourly

(Table 12)

rates (2005), this saves an additional 45.

Cost factor

Unit

Difference

(1)

Smaller nominal diameter of main feed pipe

-75

(2)

3 shut- off valves of smaller DN in main feed circuit

-123

(3)

1 strainer (standard mesh) of smaller DN in main feed circuit

-29

(4)

1 Rio - Eco 40 - 80 circulator pump instead of Riotec 65 -100

- 476

(5)

Measurement and control valves one DN smaller (BOA-Systronic)

see above

-230

-933

(6) No differential pressure controller required (1 no. per heating circuit, 1.5 -inch)
Sum total of factors (1) to (6)

Table 12: Reduced investment costs for heating circuit with Rio-Eco pump, example (prices 2005)

11.4
Total savings compari son Riotec / Rio - Eco
In the present example, the
Rio-Eco pump could be expected to pay back after approximately three years, compared to
the Riotec pump.

26

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11

Payback period for BOA - Systronic

Reduced investment costs for heating circuit (1) (6) []

Extra price for BOA-Systronic []

-1,119

-34

-1,503

-933

372

Year 02

-455

-1,608

-48

Year 03

-455

-2,111

Year 04

-493

Year 05

Interest on savings (3% ) []

Savings plus interest []

Price of electricity [ / kWh]

Pump operating hours [h]

-45

- 456

-1,062

-32

-1,094

0,11

6,800

-1,656

- 498

-1,592

- 48

-1,640

0.12

6,800

-63

-2,174

- 498

-2,138

- 64

-2,202

0.12

6,800

-2,667

-80

-2,747

-539

-2,741

- 82

-2,283

0.13

6,800

-493

-3,240

-97

-3,337

-539

-3,362

-101

-3,463

0.13

6,800

Year 06

-531

-3,868

-116

-3,984

-581

- 4,044

-121

- 4,165

0.14

6,800

Year 07

-531

-4,515

-135

-4,651

-581

- 4,746

-142

- 4,889

0.14

6,800

Year 08

-569

-5,220

-157

-5,376

- 622

-5,511

-165

-5,676

0.15

6,800

Year 09

-569

-5,945

-178

-6,124

- 622

- 6,298

-189

- 6,487

0.15

6,800

Year 10

-607

-6,731

-202

-6,933

- 664

-7,151

-215

-7,365

0.16

6,800

Year 11

-607

-7,540

-226

-7,766

- 664

- 8,029

-241

- 8,270

0.16

6,800

Year 12

-645

-8,411

-252

-8,663

-705

- 8,975

-269

-9,244

0.17

6,800

Year 13

-645

-9,308

-279

-9,588

-705

-9,949

-298

-10,248

0.17

6,800

Year 14

-682

-10,270

-308

-10,578

-747

-10,995

-330

-11,325

0.18

6,800

Year 15

-682

-11,260

-338

-11,597

-747

-12,072

-362

-12,434

0.18

6,800

Year 16

-720

-12,317

-370

-12,687

-788

-13,222

-397

-13,619

0.19

6,800

Year 17

-720

-13,407

-402

-13,809

-788

-14,407

- 432

-14,839

0.19

6,800

Year 18

-758

-14,567

-437

-15,004

- 830

-15,669

- 470

-16,139

0.20

6,800

Year 19

-758

-15,762

-473

-16,235

- 830

-16,969

-509

-17,478

0.20

6,800

Year 20

-758

-16,993

-510

-17,503

- 830

-18,308

-549

-18,857

0.20

6,800

Reduced operating costs []

Savings []

-45

Reduced operating costs []

402

Reduced commissioning costs for heating circuit []

Reduced commissioning costs for heating circuit []

-417

Extra price for BOA-Systronic []

Savings plus interest []

-1,059

Interest on savings (3% ) []

Reduced investment costs for heating circuit (1) (6) []

Year 01

Rio - Eco ( =50%)

Savings []

Period

Riotec ( =35%)

Table 13: Outline of costs expected in 20 years of useful life

27

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11

Payback period for BOA - Systronic

0
-1000
-2000
-3000
-4000
-5000
-6000
-7000

Savings []

-8000
-9000
-10.000
-11.000
-12.000
-13.000
-14.000
-15.000
-16.000
-17.000
-18.000
-19.000
-20.000
-21.000
0

10

11

12

13

14

15

16

17

18

19

20

Years [a]
Riotec pump: Savings plus interest (parallel shift)
Riotec pump: Savings plus interest (slope modification)

Rio-Eco pump: Savings plus interest (parallel shift)

Rio-Eco pump: Savings plus interest (slope modification)

Fig. 22 Savings realized by Riotec and Rio-Eco pumps with slope modifi cation and parallel shift (example)

Period [a]

10

15

20

Reduced costs

Unit

Investment and commissioning

Riotec
-702

Rio - Eco
- 606

Difference
96

Pump operation

-2,313

-2,530

-217

Interest on savings (3 %)

-322

-327

-4

Total

-3,337

-3,463

-125

Annual savings

- 667

- 693

-25

Investment and commissioning

-702

- 606

96

Pump operation

-5,120

-5,600

- 480

Interest on savings (3 %)

-1,111

-1,159

- 49

Total

- 6,933

-7,365

- 433

Annual savings

- 693

-737

- 43

Investment and commissioning

-702

- 606

-96

Pump operation

- 8,381

-9,168

-787

Interest on savings (3 %)

-2,514

-2,660

-146

Total

-11,597

-12,434

- 837

Annual savings

-773

- 829

-56

Investment and commissioning

-702

- 606

-96

Pump operation

-12,095

-13,234

-1,139

Interest on savings (3 %)

- 4,706

-5,017

-311

Total

-17,503

-18,857

-1,354

Annual savings

- 875

-943

- 68

Tab. 14: Total savings

28

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12

References

12
References
Since being released for sale in
2003, BOA-Systronic has been
in operation in many heating
systems in public and industrial
buildings throughout Germany.
The photo below shows three
heating circuits equipped with
BOA-Systronic systems of
nominal diameter DN32.

Fig. 23 Heating circuits with BOA-Systronic DN32

29

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13

Conclusion

13
Conclusion

pressure control valves for bal-

tions are prevented, and flow

ancing the heating circuits are

noises at the consumer points

not required. They can be re-

are avoided.

BOA-Systronic reduces operat-

placed by balancing valves,

BOA-Systronic is gentle on the

ing costs.

which are less expensive. Even

environment.

in heating circuits already

An analysis of load profiles in

equipped with a LON-compat-

Electricity is something you

heating systems revealed that

ible variable speed pump, in-

cannot produce and store for

heating circuits operate under

vestment in BOA-Systronic will

later use, but it must be avail-

part-load conditions for more

pay back in less than two years.

able at the exact moment when

it is needed. Burning fossil fuels

than 95% of their operating

time. From this finding, it is

BOA-Systronic reduces the

produces CO2 emissions of

safe to conclude that in conven-

commissioning costs for the

roughly 0.53 kg per 1 kWh of

tional mixing or injection-type

heating circuit.

electrical energy produced.

Thanks to the drastic reduction

systems cold return water is being circulated through the heat-

The circulator pump and the

in power consumption, BOA-

ing circuit most of the time.

control valves are initialized

Systronic therefore makes a

BOA-Systronic, by contrast,

automatically. Static balancing

positive contribution to envir-

provides only the volume flow

at the main feed manifold is

onmental protection.

actually required and can thus

performed automatically by the

save an average of 70% electri-

pump. The hydraulic operation

city costs for the circulator pump

of the heating circuit is opti-

over the heating period, which

mized. The system immediately

depending on the thermal

detects any air in the piping and

output of the heating circuit

thus prevents unnecessary com-

may amount to several hun-

missioning work. Altogether,

dreds of Euros in electricity

the costs for heating circuit

savings per year.

commissioning are reduced.

BOA-Systronic reduces the in-

BOA-Systronic offers increased

vestment costs for the heating

comfort of use.

circuit.
The hydraulic operation of the
In new or replacement installa-

heating circuit is optimized

tions, the investment costs for

thanks to substantially reduced

the main feed circuit can be re-

discharge heads and volume

duced without modifying the

flow rates. Excessive discharge

original planning. Differential

heads under part-load condi-

30

060206_knowhow05_e_IS 30

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List of figures
Fig. 1

Hydraulics schematics of BOA-Systronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fig. 2

Comparison of systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fig. 3

BOA-Systronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Fig. 4

Volume flow rates of 3-way valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Fig. 5

Reduced volume flow rates of BOA-Systronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fig. 6

Circulator pump heads (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fig. 7

Heating circuit with branch circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fig. 8

Excess circulator pump heads (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fig. 9

Two-boiler system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fig. 10

Return manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fig. 11

Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fig. 12

Heating controllers for West and East wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fig. 13

Main feed manifold, West and East wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fig. 14

Main feed circuit with BOA-Systronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fig. 15

Main control valve of BOA-Systronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fig. 16

Mixing valve of BOA-Systronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fig. 17

Control unit of BOA-Systronic (Systrobox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fig. 18

External temperatures measured at the test installation in 2000 2002 . . . . . . . . . . . . . . . 20

Fig. 19

Volume flow rates measured at the main feed manifold in 2000 2002 . . . . . . . . . . . . . . . 21

Fig. 20

Differential pressure of the circulators, measured in 2000 2002 . . . . . . . . . . . . . . . . . . . . 22

Fig. 21

Pump power input in 2000 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Fig. 22

Savings realized by Riotec and Rio-Eco pumps with slope modification and parallel shift . . 29

Fig. 23

Heating circuits with BOA-Systronic DN32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

List of tables
Table 1

Performance data of main feed circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Table 2

Reduced investment costs for circulator pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Table 3

Measured quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Table 4

Analysis of volume flow rates in 2000 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table 5

Analysis of differential pump pressures in 2000 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table 6

Savings in pump power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table 7

Average extra prices for BOA-Systronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Table 8

Extra price for BOA-Systronic with Riotec pump (example: DN50) . . . . . . . . . . . . . . . . . . 24

Table 9

Extra price for BOA-Systronic with Rio-Eco pump (example: DN 50) . . . . . . . . . . . . . . . . 25

Table 10 Energy costs in first year (example: DN50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Table 11 Reduced investment costs for heating circuit with Riotec pump, example (prices 2005) . . . 25
Table 12 Reduced investment costs for heating circuit with Rio-Eco pump, example (prices 2005) . . 26
Table 13 Outline of costs expected in 20 years of useful life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table 14 Total savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

31

060206_knowhow05_e_IS 31

06.02.2006, 12:50:32 Uhr

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