Building Services

BOA-Systronic. Systematic savings on energy and costs.

In recent years the professional demands placed upon consultants have increased

significantly: system operators now call for innovative concepts capable of meeting

increasing cost pressure.

Fluid Future®is our answer. This is KSB’s comprehensive energy efficiency concept

for our customers’ complete hydraulic systems. Its aim is to optimise a plant’s overall

efficiency. To make that reality, we’ve developed five interlocking modules. Together

they enable us to identify and achieve savings right through the life cycle of your pumps

and valves:

n System analysisn Selectionn High-efficiency hydraulic componentsn High-efficiency drivesn Demand-driven operation

Further information is available at

www.ksb.com/fluidfuture

Energy: we spend all ours to save lots of yours.

Energy Efficiency2

DEmAnD-DrivEn OpErAtiOnOptimised control systems like PumpDrive continuously match pump output to system requirements.

HigH-EfficiEncy DrivESOur high-efficiency motors even exceed today’s standards.

HigH-EfficiEncy HyDrAulic cOmpOnEntS Top pump and valve performance with minimum loss – all thanks to 140 years of innovation and expertise.

SyStEm AnAlySiS Our experts analyse your system and show where you can save energy – with SES System Efficiency Services or PumpMeter.

SElEctiOnYour KSB partner or KSB EasySelect will help you find exactly the right pumps and valves.

Further information is available at

www.ksb.com/fluidfuture/boa-systronic

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Our optimised control concepts help you operate pumps and valves efficiently. We make sure that systems are

driven by demand. You save energy and increase your equipment’s availability over its entire life cycle.

The BOA-Systronic pump/valve control system makes sure that the operation of KSB’s highly efficient circulator

pumps is driven by demand as a function of the system curve. It optimises not only energy transport but also

the hydraulic conditions in HVAC circuits. The pumps involved are operated more efficiently, saving operating

costs, while heat/cold generators yield higher efficiencies.

Energy savings of up to 70 % are possible.

BOA-Systronic: how continuous system analysis saves energy and costs.

DEmAnD-DrivEn OpErAtiOn

KSB’s BOA-Systronic can access untapped hydraulic savings potential in heating, ventilation and air-conditioning systems.

In contrast to conventional solutions, the circulator pump and the control valve work hand in hand:

The pump only supplies the quantity of water which is actually needed, which results in markedly reduced operating costs.

A quick guide to BOA-Systronic:

comparison of a conventional heating circuit with a BOA-Systronic heating circuit.

Effective teamwork cuts costs.

Product Benefits4

External temperature sensor

Controller

Balancing and measurement valve: BOA-Control IMS*

BOA-S strainer

Three-way control valve

Shut-off valve: BOA-Compact/ -SuperCompact/BOAX-S/ -SF

Variable speed pump Rio-Eco/ Etaline PumpDrive

Supply sensor

ReturnSupply

External temperature sensor

Shut-off valve: BOA-Compact/ -SuperCompact/BOAX-S/ -SF

Shut-off valve: BOA-Compact/ -SuperCompact/BOAX-S/ -SF

Supply/return section

The innovative system consists of a control unit, one measurement valve and two control valves: n BOA-Control IMS (measurement valve)n BOA-CVE SuperCompact with Systrobox (control valve with control unit)n BOA-CVE SuperCompact (control valve)

The Systrobox control unit incorporates all of the requisite hydraulic know-how to optimise the interaction of pump and

control valve. All Systrobox requires to turn a heating system into a saving system is the input of an actuating signal from

a higher-level controller (e.g. DDC or PLC).

BOA -control imS:

The measurement valve measures the

volume flow rate and temperature of

the fluid.

BOA-cvE Supercompact with Systrobox:

The main valve regulates the inflow

of heating water.

BOA-cvE Supercompact:

The second valve regulates the quantity

of return water mixed with the inflow.

(shown: BOA-Systronic system DN 150)

comparison of a conventional heating circuit with a BOA-Systronic heating circuit.

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It’s worth comparing: Perfected

collaboration between circulator

pump and control valve allows the

BOA-Systronic-equipped heating

circuit to translate optimum

hydraulic savings potential into the

best possible energy efficiency.

ReturnSupply

External temperature sensor

Controller

BOA-S strainerVariable speed pump Rio-Eco/ Etaline PumpDrive

Control valveBOA-CVESuperCompact

Supply sensor

Control valveBOA-CVE SuperCompact with Systrobox

Balancing and measurement valve: BOA-Control IMS*

BOA-Systronic system

* Volume flow rate measurement with BOATRONIC measuring computer

Shut-off valve: BOA-Compact/ -SuperCompact/BOAX-S/ -SF

Shut-off valve: BOA-Compact/ -SuperCompact/BOAX-S/ -SF

Shut-off valve: BOA-Compact/ -SuperCompact/BOAX-S/ -SF

Supply/return section

Savings Potential6

Benefit from clear savings with BOA-Systronic.At KSB, everything is geared towards efficiency. The smooth interaction of BOA-Systronic and KSB

variable speed pumps makes for substantial savings.

maximise your primary energy and pump electricity savings:

On average, around 62 euros can be saved for each cubic metre of volume flow rate, and around 270 euros

per 100 kW of thermal output. In larger systems (e.g. local heating networks, etc.), additional energy and

cost savings can be achieved through the optimised operation of pumps installed in the primary circuits of

heating networks.

Basis for calculation (design point): - Operating hours of the circulator pump per year = 6800 h- Full-load operating hours of the condensing boiler per year = 2100 h- Fuel costs (natural gas) = 0.80 €/m³

- Price of electricity = 0.18 €/kWh- Temperature differential = 20 °K- Pump discharge heads = 5–12 m- External heat = 10 %

The savings above include the optimised operation of a circulator pump and potential savings due to the increased efficiency of a condensing boiler based on the following calculation data:

180

160

140

120

100

80

60

40

20

00 20 40 60 80 100 120

Volume flow rate (%)

Dis

char

ge

hea

d (

%)

Fixed speed pump

Constant-pressure control

Proportional-pressure control

System curve

BOA-Systronic

BOA-Systronic ensures that the pump is operated as a function of the system curve.

potential savings per circulator pump and condensing boilerNominal diameter BOA-Systronic / Flow rate / Thermal output at design point

Dn 20 25 32 40 50 65 80 100 125 150 200

m³/h 0.5 – 1.5 1.0 – 2.7 2.3 – 4.2 3.6 – 6.7 5.7 – 11 9 – 15 13 – 23 20 – 38 32 – 53 45 – 95 80 – 185

kW 10 – 35 20 – 60 50 – 90 80 – 150 130 – 250 220 – 350 300 – 530 450 – 900 700 – 1200 1000 – 2200 1900 – 4300

cO² (t)

0.1 – 0.2 0.1 – 0.2 0.2 – 0.4 0.4 – 0.6 0.6 – 0.7 0.9 1.3 – 3.2 2.8 – 4.5 rio-Eco

cO² (t)

Etaline pumpDrive 0.9 – 1.3 1.2 – 1.9 2.3 – 4.2 3.3 – 3.9 3.5 – 10 5.8 – 17 13.8 – 30

€ 50 – 90 70 – 140 120 – 220 210 – 350 300 – 480 500 – 650 700 – 1500 1400 – 2300 rio-Eco

€ Etaline pumpDrive 400 – 660 600 – 960 1000 – 1800 1500 – 2100 1800 – 4300 2900 – 7400 6100 – 13700

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Our calculation example: a refurbished heating system of a high-rise building.The example makes clear the potential savings which can be exploited with BOA-Systronic. In the case of re-

furbishment of the high-rise building’s heating system shown here, they would total around 7800 euros a year.

maximise your primary energy and pump electricity savings:

System data (design point)

Heating circuit 1 Heating circuit 2 Heating circuit 3

Nominal system diameter = DN 65 = DN 100 = DN 100

Thermal output = 400 kW = 650 kW = 850 kW

Flow rate = 17 m3/h = 28 m3/h = 36.5 m3/h

Head of the circulator pump = 8 m of water = 8 m of water = 8 m of water

Pump type = Rio-Eco 65 – 120 = Rio-Eco 80 – 120 = Rio-Eco 80 – 120

Potential energy savings of circulator pump: n Savings due to

pump replacement = € 2670 (42 %1)

n

Savings due to BOA-Systronic = € 3120 (83 %2)

Total = € 5790 (90 %1)

Annual CO2 savings = 19 tonnes

Potential savings on primary energy n Efficiency increased by 2 % = € 2000

total potential savings: total savings per year = € 7790

Annual savings of cO2 = 19 tonnes

1 Refers to the power input of variable speed circulator pumps (label B) operated without BOA-Systronic2 Refers to the power input of variable speed circulator pumps (label A) operated without BOA-Systronic

System curve

cumulative savings for energy costs, three circulator pumps + primary energy

cu

mu

lati

ve s

avin

gs

(in

th

ou

san

d e

uro

s)

190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Savings achieved by using a high-efficiency pumpAdditional circulator pump savings due to BOA-Systronic

Additional savings on primary energy due to BOA-SystronicTotal savings

Here, the use of BOA-Systronic proved extremely worthwhile.

richard von Weizsäcker School, Öhringen (germany)

The Richard von Weizsäcker School near Hohenlohe is a school building constructed

to the passive house standard and inaugurated at the end of 2010. A portion of the

building’s total required heating is covered by a heat recovery system integrated in

the ventilation system. If the outside temperature is mild, the building only requires

a small amount of additional heat. Further demands on the hydraulic system result

from the differing hydraulic characteristics and system temperatures of radiators, floor

heating and air heating circuits. The heating system has been equipped with BOA-

Systronic in order to meet these requirements. The variable-flow principle ensures

that the heating circuits are only provided with the heating water quantity actually

required.

Scope of supply: 6 Riotronic Eco/Rio-Eco pumps, 6 BOA-Systronic systems DN 20 – 32,

KSB valves

Reference Projects8

Here, the use of BOA-Systronic proved extremely worthwhile.

WEg Bindingweg, Hanover (germany)

The central heating and drinking water supply/hot water generation plant for this large

building complex situated on Hanover’s Bindingweg is designed to supply a total of 366

residential properties with heat and water. The arrangement, consisting of a smart

BOA-Systronic system in conjunction with a number of other valves from the BOA series,

our variable speed Etaline and the variable speed Rio pumps, makes for highly efficient

operation. BOA-Systronic is used for three secondary heating circuits, which are matched

to the flow-controlled oil burner (primary side). The system keeps the main supply/return

section from supplying more than the volume of hot water actually needed. This has

resulted in impressive energy savings.

Scope of supply:

2 variable speed Etaline pumps

3 variable speed Rio pumps

BOA-Systronic (system) DN 65 – 100

Otto Hahn grammar School, Karlsruhe (germany)

The uneven distribution of heat throughout the Otto Hahn Grammar School in Karlsruhe,

Germany, necessitated hydraulic optimisation of the building’s heat distribution system.

However, the heating circuits’ branch pipes are laid in inaccessible areas, meaning that

changes to the installed system could only be made in the building’s central heating

unit. In order to balance the hydraulic system in a large and complex distribution network,

a BOA-Systronic control system was installed which regulates the supply temperature

in line with demand and adjusts the pump flow rate accordingly. Since the retrospective

fitting of the control system, the heating circuits have been supplied with the heating

water quantity required in line with demand. At the same time, BOA-Systronic also ensures

a higher temperature differential and lower return temperatures, increasing the efficiency

of the existing condensing gas boiler.

Scope of supply: 4 Rio-Eco pumps, 4 BOA-Systronic systems DN 40 – 50, KSB valves

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Further Benefits10

BOA-Systronic. Offers more than just cost savings.

n Lower commissioning costs and improved reliability:

Automatic adjustment of water volumes in the main supply/return

section of the heating circuit and automatic valve calibration

n Short payback period:

In conventionally designed heating circuits, the system has been

demonstrated to pay for itself within 2 years; a second alternative

planning option can reduce the investment costs for the pump

and valves installed in the main supply/return section of the

heating circuit

n Added user comfort:

Flow rates matched to heat demand minimise flow noises

n Integration in automation systems:

BOA-Systronic can be easily integrated via BACnet, for example.

This allows operators to ascertain at which operating point the

system is running at any given time

n Lower planning costs:

Simple system selection with economic efficiency analysis;

control valve is specified automatically

n Future-oriented technology:

Quadrupled efficiency will prepare your installation for current

and future requirements such as energy saving regulations and

energy demand certification

n Compatible technology:

Well-proven components for standard control systems

n Integrated system solution:

For room heating and air-conditioning systems with static

heating surfaces, convectors and air heating/cooling registers

Investors and operators profit from: consultants profit from:

With KSB, you‘ll always have the edge:

n money and time saved:

As systems supplier we offer competence across the board:

your one-stop, cost-effective, complete system solution

n KSB service on site

With our worldwide service network, we are always on hand

and able to deliver the right solution, no matter how complex

the requirements

With BOA-Systronic, you can clearly save money. But the innovative control system offers further advantages. Whether you are an

operator or a consultant, you can profit in many different areas.

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innovative support for consultants.Automation equipment from KSB for efficient processes:

n KSB Consultants Platform:

With our Internet tool you can find typical tenders, type series booklets, CAD files, characteristic curves, operating manuals

and a lot of other useful information. See for yourself at www.ksb.com/consultant

n KSB EasySelect:

The only selection program on the market that lets you choose both pumps and valves. KSB EasySelect is quick, clear and

simple to use. Discover the benefits of KSB EasySelect at www.ksb.com/fluidfuture/easyselect or use our Customer Portal. KSB’s

Customer Portal provides access to the KSB Web-Shop and KSB EasySelect. Simply go to www.ksb.com/customerportal

useful information online:

n KSB’s “BOA-Systronic” know-how brochure:

A compilation of technical information covering the basics of hydraulics through to the basics of control engineering

and BOA-Systronic.

n Consultants’ brochure: “KSB Building Services. Solutions from a Single Source”:

This brochure gives a comprehensive insight into some of KSB’s international building projects.

To download or order a printed version of these brochures, visit our web site at www.ksb.com/downloads

useful information in print:

In addition to the BOA-Systronic control system, KSB offers many more automation solutions designed to make your system

more efficient.

n Energy-optimised operation with PumpDrive:

The variable speed system delivers optimised, energy-efficient operation for all pump applications required in a building,

from HVAC to water supply.

n PumpMeter adds transparency:

The pump monitoring unit provides you with answers to the following questions: Is my pump’s availability assured?

Is my pump operating in an efficient and cost-saving manner? More information at www.ksb.com/fluidfuture/pumpmeter

n Perfect planning with LevelControl Basic 2.

This level-dependent pump control and monitoring unit with display provides operators with a perfectly matched combination

of pump and control unit for single-pump and dual-pump installations. The control unit is used in tank drainage and filling

applications.

KSB AktiengesellschaftJohann-Klein-Straße 967227 Frankenthal (Germany) www.ksb.com

more space for solutions.

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