Solar Southwest Florida

Variable speed pool pumps are all the rage. Fantastic energy savings an whisper quiet operation are the two most cited reasons for interest in the product. Comparing variable speed pumps is important because there are a wide range of prices and installation service levels available. All will save you money, but the features and capabilities vary widely. Selecting the right pump for your pool is critical.

While not a solar product, per se, variable speed pool pumps compliment solar pool heaters and become an integral part of a solar pool heating system. It’s critical to understand the comparisons to ensure a variable speed pump will work with your solar pool heater (or heat pump or gas heater for that matter).

Variable speed pumps should not be confused with 2-speed pumps, which have far more limited features and far lower cost savings. My recommendation is to forget about 2-speed pumps and go for the variable speed pump. That’s a discussion for another day…

Here are the most popular variable speed pumps we are seeing on the market in Southwest Florida.

• Pentair IntelliFlo VS
• Hayward EcoStar
• Hayward Max-Flo VS
• Jandy ePump 1.5 and 2.0
• Waterways VSA

Pentair IntelliFlo VS

This is my favorite of the bunch. I have this pump, and have loved it from the day I installed it. It is whisper quiet at low speeds, energy efficient at all speeds, and has excellent connectivity for Pentair automation products. The Pentair IntelliFlo is a 3 HP motor coupled with a variable speed drive with fully programmable speeds and schedules. It has four speed buttons and eight programs. It communicates with Pentair automation products like the SunTouch, SolarTouch, EasyTouch, or IntelliTouch via an RS-485 digital interface. If connecting the pump to non-Pentair automation, it requires an Intellicom II digital interface. However, certain versions of the popular Aqualink system with newer firmware can natively control the Intellicom as long as you have a PDA remote (I should mention that this is not supported by Pentair). When controlling the IntelliFlo with a Pentair automation (excluding the SolarTouch or Intellicom II) or Aqualink PDA, the controller will take over control of the pump and all schedules and speeds are controlled externally. One disadvantage of external control is that the IntelliFlo no longer displays the operating speed or energy use on the integrated display. Fortunately you can get this information through the automation product, but it’s not as convenient when standing over the pump. With the SolarTouch controller and Intellicom II, the pump retains all of the scheduling, speed, and display functionality, and the SolarTouch simply overrides the currently selected speed when solar heating is active. The IntelliFlo also comes in a SVRS (suction vacuum release system) version to comply with the Virginia Graeme Baker Act and Florida Building Code for some pools.

Hayward EcoStar

The EcoStar is also a capable variable speed pump. It features a 2.5 HP motor with an onboard drive/controller with similar features to the IntelliFlo pump. There are four speed buttons and eight schedules. The Ecostar connects to automation products a little differently, with an analog interface. When connected to automation, the pump is capable of eight different speeds based on the analog input to the pump. In all cases the onboard controls are overridden and the external controller takes over. Unlike the Pentair pump, the Ecostar continues to display the pump running speed and energy use on the pump display when externally controlled. There are advantages and disadvantages to analog control. You gain flexibility because just about any automation product on the market can send the pump speed commands (even the basic GL-235 solar controller can change the pump speed). Unfortunately, the number of speeds is often limited by the number of available relays offered and available in the automation system. However, we can add additional speeds for pool service personnel or other needs with simple toggle switches. The Ecostar also comes in an SVRS model if needed. One nice feature is being able to mount the display remotely on a wall, or turn it to face any of four directions on the pump.

Hayward Max-Flo VS

The Max-Flo VS is a 1.5 HP pump, which Hayward claims to be “right sized” for most residential pools. Unfortunately, the speed setting on the pump would typically be higher to achieve the same flow rate. Do you want your pump motor running at a higher speed, making more noise and possibly not lasting as long? To me, this defeats the purpose of a variable speed pump. Nonetheless, the Max-Flo VS could be a good option for some people with smaller pools and no heaters and limited features. I do not recommend it because it has absolutely no external automation controls. If you have existing automation or plan to add it later, this pump is not for you. Speeds and schedules are handled only through the onboard control, which has a digital readout for programming, convenience, and monitoring.

Jandy ePump 1.5 and 2.0

The ePump 1.5 and 2.0 are named for their horsepower ratings. The Jandy products integrate well with Jandy automation (Aqualink), but can also operate independently. However, you need the Jandy ePump controller for independent operation, which adds substantially to the cost. In addition, you need the ePump contoller when using external automation, even though the functionality of the ePump controller is lost. The external automation is accomplished with analog controls, similar to the Ecostar, and speeds controllable through automation may be limited. I do not recommend these pumps due to the cost and lower horsepower rating compared to the Pentair and Hayward options. The ePump controller can be mounted remotely from the pump like the Ecostar’s display module.

Waterways VSA

Waterway, based in California, is located where some of the highest daytime residential electricity rates cause pool pumps to be a major household cost. The Waterway VSA uses a Champion motor and an AO Smith onboard controller. Like the Max-Flo VS, the Waterways VS cannot be controlled externally, severely limiting the functionality and potential savings for pools with features or heating systems. The control module may be mounted remotely. One nice feature is being able to control external equipment like a heat pump with a relay. However, this functionality is a bit backward to me – the pump tells the heater if it is running fast enough for the heater to start. External automation systems do it right, telling the pump to increase speed when heating is required. Like the Max-Flo VS, this pump is not for you if you want to operate a solar pool heater or heat pump effectively. This is a value priced pump with a seemingly good warranty.

Conclusion

The Pentair VS and Hayward Ecostar are close competitors at the top. Both are powerful pumps with great external control options that depend on the existing or future automation system needs. The digital interface on the Pentair adds some nice capability at the cost of flexibility with non-Pentair automation. The Ecostar’s display mounting flexibility and ability to be controlled out of the box with just about any existing automation is great, although sometimes the number of speeds that can be controlled is limited. I cannot recommend the Jandy ePump due to cost and lower horsepower, but it has many of the Ecostar control features and works well with Jandy automation. The Hayward Max-Flo VS and Waterways VSA are only suitable for pool-only situations with no features or heat sources, and you will experience far less functionality and future flexibility. If you have a solar pool heater, and want optimum pool heating with external controls, forget about these last two pumps.

Beyond the Pump Itself: Installation and Programming

A word of caution about installation and programming of variable speed pumps… You may see amazingly low advertised prices for variable speed pumps through discount retailers. Unfortunately, the initial programming of variable speed pumps can be daunting for the average homeowner, and properly setting up the pump to operate for various features and heat sources is not for beginners. In fact, it’s beyond the current capabilities of many pool professionals who are just coming up to speed (pun intended). Connecting variable speed pumps to existing or new automation products just further complicates the installation and programming. But most importantly when having a variable speed pump installed, ask your installer if they are going to install a flow meter! If they don’t, they are doing you a disservice. Installing a flow meter allows the installer to calculate the minimum speed possible to get the desired turnover, an also meet the flow rate requirements for optimum operation of solar pool heaters, heat pumps, cleaners, in-floor cleaners, and other pool features. The idea is to meet the flow requirements of all features of your pool and spa, and balance that with the amazing energy savings offered by any of the above variable speed pumps.

If you see a price that is too good to be true, it is. You will be calling your pool service company (or me) to properly set up your pump. If a capable installer charges more that the competition, there is probably a very good reason. I can’t stress enough that you should not go for the cheapest variable speed pump and installer. That said, once the pump is set up and operating to your satisfaction, the system is simple, reliable, and will pay for itself in no time!

I was at a home last week on a sales call for a solar photovoltaic (electric) system. Whenever I am at someone’s home, I look around at the appliances, lighting, and construction of the home. I ask myself, “is this home efficient?” If not, I’m obligated to point out that making a home more efficient can often be more cost effective than installing solar panels. Homeowners look at me quizzically, because after all, I am there to sell solar panels, right?!

Pentair Variable Speed Pump

This particular homeowner had a 2 HP single speed swimming pool pump. The pool and pump were under one year old. I had to tell him that despite the pump being very new that he should replace it with a variable speed pump right away – before he considers installing a solar energy system.

Some people do not believe this amazing variable speed pool pump efficiency at first. Once I go through the math, it becomes pretty obvious. A 2HP pump running 8 hours per day will cost approximately $60 per month at Southwest Florida’s current electricity rates. A variable speed pump running at a low speed for a longer period of time to achieve the same turnover typically results in electrical consumption of $15 per month – a savings of $45! This would vary somewhat depending on features that you operate like a spa, water feature, pool cleaner, or other features that require a higher pump speed for some period of time, but there are always significant savings regardless of what features are operated.

How many solar panels would you need to install to get the same savings? Let me get straight to the point and tell you that a solar energy system that saves you $45 per month would cost about $12,000 before tax credits and incentives. You could replace the pump several times over the lifetime of the photovoltaic system and still come out well ahead!

There are a lot of factors involved that can shift these numbers one way or another, but it’s safe to say that when it comes to pool pumps, efficiency has a tremendous return on investment.

With new building codes in effect in Florida, I’ve been asked quite a lot about variable speed vs. variable flow pumps, especially with solar pool heating systems. The answer turns out to be a bit complex. The simple answer is that a variable speed pump will give you better trouble-free performance while still resulting in significant energy savings. The whole story is more complex.

At first glance, the features of a Variable Flow pump like the Pentair Intelliflo VF seem perfectly suited for a solar pool heating system. The pump would operate at a constant flow rate that is optimal for solar pool heating, adjusting the pump speed as necessary to meet changing pressures from water features or dirty filters. An automatic controller could further optimize performance by adjusting flow rates depending on the heating source and features being used. Unfortunately, there are two problems with this approach:

1. Variable Flow pumps are designed to shut off when there is a significant flow rate change. In some cases the enabling or disabling of a solar pool heating system will result in a fault that shuts the pump off.
2. Variable Flow pumps on the market do no meet the Safety Vacuum Release System (SVRS) requirements for the Virginia Graeme Baker Act and incorporated in the Florida Building Code 2010 that went into effect March 15, 2012.

The best solution is to install a variable speed pump like the Pentair Intelliflo VS. This pump varies in speed, which loosely translates into varying flow rates. Because in any given configuration a pool circulation system has a relatively stable pressure, we can set up a variable speed pump to act essentially like a variable flow pump. We “dial in” speeds for pool heating, features, and cleaners with a flow meter at the time of installation. Optimal flow rates are selected to optimize the performance of heaters and pool features with energy savings. Flow rates decrease when filters become clogged, but this is easily remedied by proper maintenance practices.

However, we need to again consider the Virginia Graeme Baker Act and SVRS systems. If your pool does not meet certain guidelines for safety, a SVRS system is now required when replacing a pool pump or pump motor. Fortunately, variable speed pumps come in SVRS models like the Pentair Intelliflo VS+SVRS. The downside is that nuisance tripping of the SVRS system can still occur with the solar pool heating system, particularly at low flow rates. In our experience, the corrective measure is to run the speed at slightly higher speeds than otherwise required to not trigger the SVRS. Unfortunately, you will not be able to take full advantage of the energy savings of the variable speed pump, but the savings will still be spectacular. The best capability is the ability to run the pump at optimal speeds based on heating source and pool features with an automatic controller. We can successfully integrate a variable speed pump, SVRS, and solar pool heating this way.

To recap, the ideal energy saving pool pump for solar pool heating systems is a variable speed pump without SVRS if your pool plumbing allows it, or a VS+SVRS pump if you must upgrade due to new codes. A Variable Flow pump may work, particularly at higher flow rates, but it is not advised with solar pool heating systems. If you don’t know whether a SVRS is required on your pool, your friendly Fafco Solar representative can tell you!

Fafco Solar Video on Pentair Variable Speed Pump

Fafco Solar just released a short promotional video on the Pentair Variable Speed pool pump.

The variable speed pump is a perfect match for solar pool heating systems, especially when an automatic controller is used. Without a controller the pump can be scheduled to run at optimum solar circulation speed when solar energy is most likely to be available. Adding a controller adds the capability of changing the pump speed based on the availability and demand for solar heating.

With or without solar energy, the variable speed pump will pay for itself with energy savings. You can cut pumping costs up to 90% with this great technology while getting a far quieter and longer lasting pool pump.

Solar pool heaters work better with variable speed pumps because the optimum flow rate can be achieved to maximize solar performance. A single speed pump is typically fine to use with solar pool heating, but if you want maximum pool heating, a variable speed pump can both save you a tremendous amount of money and provide the proper flow rate.

Typical efficiency vs. flow curve for solar pool heating panels (FAFCO Sunsaver shown).

Most solar pool heating panel manufacturers recommend a flow rate of 4 gallons per minute per panel. If you have seven panels, you need a flow rate of 28 gallons per minute. Anything less and the efficiency drops off quite rapidly. Anything more and you are wasting money on  your pumping costs, pumping water at a rate higher than required for solar pool heating to be efficient.

When we have a solar pool heater installed, we insist that every job gets a flow meter installed (at least temporarily).  The pump can be programmed to operate at the proper speed when solar pool heating is likely to be required. With an automatic controller, the pump can be set to go to optimum speed whenever solar pool heating is required, but reduce the speed when heating is not active.

There are lots of other variable speed pump resources on my Solar Southwest Florida blog. I have also assembled some Pentair variable speed pump marketing videos below. Enjoy!

http://www.youtube.com/watch?v=mcZfjpk_eeA

The best way to control a solar pool heat system is with an automatic controller. If you do not have one, you are missing out on great convenience, and not maximizing your solar pool heating investment. Most people who do not have a controller just leave their solar pool heating system all the time. That means any time the pump is running, water is flowing through the solar panels.

Unfortunately, solar panels can also act like a radiator, giving pool heat back to the atmosphere. On very cloudy days or during rain, you may actually be cooling your pool if you solar pool heater is running. Usually this is not a huge problem, but it is definitely less than optimal.

One thing you can do is set your pump timer with ideal times to run the pump when you are most likely to get good performance from your solar panels. If your panels are mounted on the south roof, 10:00 am – 2:00 pm are the prime hours, and you pump should be run during this time. If your panels are mounted on the east roof, you will want to start you pump a bit earlier, and definitely don’t run it too late. The biggest mistake I see is when panels are mounted on a southwest or west roof, and the homeowner has the pump set to start at 8:00 am. On a cool morning with no sun hitting the panels, some cooling is highly likely. I recommend no earlier than 10:00 am for a pump start time, but the stop time depends on the time of year.

The best thing to do is observe your panels and make sure you pump is running when the sun is hitting them. Shading and time of day are important to evaluate.

Again, an automatic controller is your best option for controlling your solar pool heat, but if you aren’t willing to make that investment, take some simple steps to maximize your system’s performance!

If you have a solar pool heating system, your dealer may mention the manifold. This is just a set of valves that control the flow of water in your solar pool heating system. The function of the solar pool heat manifold is to turn you solar on or off by bypassing the solar panels when necessary. Your manifold may or may not include isolation valves to isolate the solar panels in the event that the system must be serviced.

Let’s take a look at an example manifold. The one pictured below includes two high quality Jandy brand isolation valves, a Jandy brand bypass valve, and a motorized actuator that is controlled by a pool automation system, in this case, an Aqualink system. Note that the bypass valve is also known as a diverter valve, a 3-way valve, or generically as a Jandy valve, which can be confusing.

Solar Pool Heat Manifold (Click for Larger Image)

Your solar pool heat manifold may look significantly different from this, but the concept is the same. We need to be able to control whether the water from the pool pump goes up to the solar panels, or bypasses the solar panels and returns directly to the pool. In the current configuration, the solar pool heating system is on, and water is able to flow through the panels on the roof. The red “X” is the bypass plumbing. When the bypass valve is in the other position, the solar panels are bypassed, and the water flows directly back to the pool.

The isolation valves should NEVER be closed when the bypass valve is in the solar-on position. This “dead-heads” the pump, meaning that the pump is running, but there is nowhere for the water to go.

It should be noted that the bypass valve is typically a “non-positive” valve. That means that it does not actually stop all of the water from going one way or the other. This is important so the water in the panels can drain back into the pool when the solar pool heating system is off. Draining water from the panels helps prevent freeze damage to the panels. This can be accomplished several ways, which are beyond the scope of this article, but note that it may not be readily apparent how your valve is made to be non-positive. Some systems, due to plumbing configurations, are manually draining. They must be drained manually or using a drain valve if installed.

Some common parts of the pool heating system plumbing are not shown here, like check valves that only allow water to flow in one direction. I’ll get to that concept in another article!

There are several ways to make a solar pool heat manifold, and some features may not be present in yours. If you have a question about your manifold, take a picture and email it to me at jason (at) facosolar.com and I can help you make sense of it!

One great feature of the Pentair Intelliflo Variable Speed Pump is the self-priming option. The pump is sent from the factory with this option on. However, because the pump runs at maximum power at start up, it is very loud and some people are bothered by it. If your pump is located outside a bedroom or office, you may be annoyed by the sound when the pump starts.

My pump never loses prime, so I am not concerned with the priming feature. When I clean my filter basket I may need to prime the pump again, but that is easy to accomplish by selecting one of the higher speeds manually for a moment when I first start the pump. I prefer to turn the priming feature off to avoid the noise. Here’s a video that shows you how to turn off (and on) the priming feature on the Pentair Intelliflo Variable Speed Pump.

(No Flash Player? Download here: Pentair Variable Speed Pump Priming)

With the pump off, the buttons to press to toggle priming on or off are:

Menu | Down| Down| Down| Down | Select | Select | Down | Enter

Rather than turning auto-priming off, you can also change the priming sensitivity. The pump will detect whether priming is necessary, and theoretically will not go into auto-priming mode if it detects that the pump is primed. However, I have not had good success adjusting sensitivity to reduce unwanted priming. I find it’s better to just turn off the feature.

WARNING: If you turn off the priming feature and your pump detects that it is not primed, it will go into error mode to protect the pump. This is a great feature to save your pump from damage, but it must be reset manually. I have never experienced a problem with this, but if your pump loses prime frequently, it could be a problem. Then again, if your pump loses prime frequently, you should determine the cause and fix it!