Basics of Variable-Speed Pumps for Pools

How to properly work with the EcoStar variable-speed pump

To ensure the correct installation and programming of the EcoStar Variable Speed Pump, it’s critical to read the owner’s and installation guides. The EcoStar should be installed in accordance with all federal, state and local codes and regulations.

Installation

Before removing the existing pump (if one is already installed), take readings from pressure (discharge) and vacuum (suction) sides of the pump to help with the installation of the EcoStar. These readings can be taken from the two drain plugs: one in the suction part of the basket and the other in the area of the impeller or pressure side. After removing the old pump, follow the wiring requirements in the EcoStar installation guide. In most cases, the existing breaker will not need to be removed and replaced; the EcoStar only needs a 15-amp breaker.
Note: if being installed on a Hayward/Goldline control, the high voltage to the pump should come directly from the breaker and not the filter pump relay. If you’re using a third-party control, the high voltage to the pump should come from the filter pump relay.

Maximizing Flow

Now that the EcoStar is installed, thread in the pressure and vacuum gauges, and ramp up the speed of the EcoStar manually until the readings from the original pump are matched as closely as possible. This gives us a base line or maximum flow setting for the EcoStar. (In other words, we are closely matching the flow of the old pump.) From this reading, a sound assessment can be made when programming the circulation time and other pool functions, such as the cleaner, spa and water features.

Another way to determine the maximum flow rate is to ramp up the speed of the pump until it cavitates. (Cavitation occurs when the suction side cannot provide enough water for the discharge.) Reducing the speed until the cavitation stops gives us the maximum setting. Getting the minimum setting is a little tricky. It important to provide enough water to fill the filter while operating other elements, such as a salt cell. Make sure your minimum speed fills the filter with water (which will be dripping out of the air relief), and that other items required during circulation are operating properly.

Pump Affinity Law

Let’s touch briefly on the Pump Affinity Law. In essence, when you cut the speed of a pump in half (from any speed) you will flow half the water at a quarter of the head pressure along with an eighth of the electrical usage. Note that when you apply the law again, the savings continue. Having the ability to set the right speed has benefits other than energy savings.

1. Each piece of pool or spa equipment that has a recommended flow rate to operate can be set for a specific speed and time.2. Running the water slower through the filter will typically capture smaller particles.
3. Better distribution of chemicals occurs since you are running for a longer period of time.
4. Reducing the flow of water helps to reduce the wear and tear on equipment.
5. Last but not least, low-speed operation yields quiet pump operation.

Promoting energy-efficient options

With energy costs on the rise, many pool owners seek products that are more energy efficient and can save them money. In some cases, state governments have imposed regulations in an effort to conserve energy. California’s Title 20, for instance, regulates the operation of inground filter pumps and pump motors by requiring lower speeds, which leads to less energy consumption.

Most pool pump motors operate at 240 volts and generate 3,450 rpm when running at full speed (based on standard U.S. electricity, which is 60hz). A variable-speed pump motor offers an operating range of 172 rpm to 3,450 rpm. Where a regular pump operates on standard single-phase power, a variable-speed pump comes equipped with a converter box to alter the current to three-phase power. This gives the variable-speed pump the ability to reduce the power in 5 percent increments, allowing the pump to be programmed for multiple tasks — drawing just enough energy to complete each one.

Programming

Let’s address programming the EcoStar standalone model. When you start to program the EcoStar you will instantly notice that it is like programming a Hayward/Goldline control. Fortunately, there’s no learning curve required for understanding a new method of programming.

The EcoStar comes with all you need to control the time settings and speeds you are looking for in a variable-speed pump. It has eight timer/speed settings that can be set for circulation, cleaner, heater, spa, and water feature-operation, along with other features you may need for flow control. In line with setting the lowest speed possible for filtration, refer to the illustration. It shows that shows a typical pool setting to help with programming your EcoStar. To help with timer/speed settings 1-8, 8 is the least dominant with dominance increasing to 1. As an example, setting the circulation to be timer/speed setting 8, and all the other functions 1-7 will override the circulation setting for cleaner, heater, spa or water feature operation as needed. The control panel on the EcoStar can be positioned four different ways along with remote placement up to 500 feet away.

Installation info

Once you’ve selected the proper replacement pump, it’s time to install it. Check out the old installation because the pump may not have been placed in the most efficient and/or safe location. Here are a few more tips, offered by the Association of Pool & Spa Professionals’ Basic Pool and Spa Technology, Third Edition textbook:

• Place the pump and motor in the driest location possible, and be sure there’s plenty of room for free circulation of fresh air.
• Install the pump on a firm, level foundation to keep vibrations to a minimum. Then secure the pump to the base, if necessary.
• Arrange the pipe into and out of the pump to meet connections freely and squarely. Do not strain or torque the pipe to line it up with the pump.
• Place the pump as close to the source as possible. Run piping directly and use as few fittings and elbows as possible.
• Air in the system can hamper pump and filter operations. To prevent that from happening, make sure the suction line joints are airtight.

Control

Controlling the EcoStar through a Hayward/Goldline controller is accomplished through a two-wire connection between the two. High-voltage wiring for this connection is between the breaker and pump. Do not run the high voltage from the filter pump relay. With a simple set-up in both the pump and control, the Hayward/Goldline control will take over and provide the same functionality as does the standalone.

The EcoStar pump can also communicate with third-party controllers. Please refer to the installation and technical guide for more information and instruction. As stated earlier, the high-voltage wiring to an EcoStar pump from a third-party control would need to come from the filter pump relay for proper operation.

Prioritizing the timers

The EcoStar’s built-in programming allows you to set up to eight timers. Timer 1 overrides timer 2, which overrides timer 3, etc. Therefore, follow these two basic steps:

1.Think of timer 8 as the background environment, and set timer 8 to the lowest speed that will ensure one full turnover of the pool/spa’s hydraulic system every 24 hours (900 rpm in our example avove).
2.Tasks needing high-speed operation can then be assigned higher priority timers. In our example, the cleaner needs 3 hours at 3000 rpm, and the solar heater is given a 2-hour window at 3100 rpm.

Note: task durations and rpm’s depend on system-specific factors, and therefore must be customized for each system. *Maximum daily cycle is 23 hours, 45 minutes (if the on and off time is set the same, that specific timer is turned off).

Author: Scott Petty is the product manager for pumps and above-ground equipment for Hayward Pool Products in Elizabeth, N.J.