GRUNDFOS iPUMP

SMART SENSORS
INCREASE UPTIME
Well on the way to a unique Industry 4.0
pump monitoring solution

CONFIDENTIAL
GRUNDFOS iPUMP
One smart sensor
keeps an eye on everything
Imagine if one single sensor on your pump could
tell you everything you needed to know about
the operating status of that pump, so you could
avoid breakdowns, increase uptime, and plan
your maintenance to suit system needs.
At Grundfos, we have been imagining this, too,
and now we have turned the idea into reality: We
have developed the iPump concept – a prototype
for a new smart monitoring solution. Grundfos
CR pumps can now be retrofitted with a sensor
that gives you all the details you need, when you
need them.
With iPump, Industry 4.0 concepts such as the
Internet of Things and cloud computing are at
your service. Our smart sensors can communicate
using a local display, your SCADA system, or a
cloud-based solution. You are always up to date
WATER TREATMENT BUILDINGS
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GRUNDFOS iPUMP
The iPump concept in brief
on system status, and if something goes wrong, • Includes sensors, accessories, and communication devices
you will immediately know what has happened, • Easily installed on new pumps or retrofitted on existing ones
and what you can do to get your system back in • Fits all sizes of Grundfos CR pumps
operation. • Monitoring with local display, SCADA integration or cloud solution
Imagine if you could avoid costly downtime.
With Grundfos iPump, you are well on your way. Benefits
We need your help
iPump sensors register everything there is to
Increased system uptime
know about your pumps, but there is one thing
they cannot tell us: What do you think of iPump?
What value does it add? What benefits do you Improved service and maintenance planning
see in your daily operations? And how does
the concept support you as you prepare for an
increasingly digital future with Industry 4.0? Your
input will help us develop an even better concept
that helps you increase uptime and lower operat-
ing costs.
PROCESS INDUSTRY BOILER SYSTEMS WATER INTAKE TEMPERATURE CONTROL WASTEWATER INDUSTRIAL WASHING
AND TRANSPORT AND CLEANING
GRUNDFOS iPUMP
APPLICATION EXAMPLES
How can our iPump sensors be used to gather data,
and how does that add value? Here are four examples.
Dry-running detection in industry applications
Prolonged dry-running will damage any pump and result in
costly downtime. This will disrupt your system and must be
avoided. Our 6th Sense dry-running sensors raise an alarm
when dry-running is detected, stopping the pump immedi-
ately and allowing just-in-time repair.
Components used
• 6th Sense dry-running sensor
Benefits
• Increased uptime
• No need to replace existing pump
Predictive maintenance in wind turbines
Wind farms are often located in remote areas, and accurate mainte-
nance planning of the cooling system for electronics and turbine oil
is essential. Our Shaft Seal Leak Detector (SSLD) monitors the leak
flow from the shaft seal on the cooling pump and issues a warning
if the seal leaks too much. Additionally, our 6th Sense multi sensor
monitors the pump bearings to predict faults.
Components used
• SSLD
• 6th Sense multi sensor
Benefits
• Increased uptime
• Accurate planning of maintenance visits
• Service technicians always bring the right spare parts
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GRUNDFOS iPUMP
Communication options that suit your installation
iPump installations can be set up with a local display unit,
integrated with your SCADA system, or configured as a
cloud solution with online data storage. Select a commu-
nication unit that suits your needs; for more information,
see page 10.
Fault detection in water distribution
When a booster pump malfunctions, the cause is often not known until the service personnel
arrives onsite. Our 6th Sense multi sensor can monitor pump operation and warn of any abnormali-
ties and raise the alarm when needed. Additionally, our iPlug differential pressure sensor measures
the differential pressure, estimating the current pump flow rate.
Components used
• 6th Sense multi sensor
• iPlug
Benefits
• Immediate information about faults
• Timely information about service and maintenance needs
• Service technicians always bring the right spare parts
System status of water transport
iPump can be used to monitor the operation of your water transport system and inform, warn and
alarm you when needed. Our 6th Sense multi sensor collects information about worn pumps, valve
failures, dry-running or cavitation. Along with our iPlug differential pressure sensor, it monitors
overall system conditions, for example informing you when pipes begin to clog up.
Components used
• 6th Sense multi sensor
• iPlug
Benefits
• Increased uptime
• Timely service planning
• Warning at abnormal or changed system operation
GRUNDFOS iPUMP
What can we detect with
the iPump concept?
Our iPump sensors can detect all important parameters
and potential issues related to pump operation.
TEMPERATURE
The temperature of the pumped liquid is often important to achieve optimal
operation. Our 6th Sense multi sensor monitors the liquid temperature.
ROTATION SPEED
In some applications, knowing the pump rotation speed can be a useful indicator
of system status. Our 6th Sense multi sensor uses algorithms to calculate pump
rotation speed based on vibration measurements.
PRESSURE
Based on accurate differential pressure measurements, it is possible to calculate
the system inlet and outlet pressure. Our iPlug pressure sensor does this while also
measuring liquid temperature. The pressure measurement allows you to estimate
system flow using the pump curves.
DRY-RUNNING
If a pump runs dry, its bearings and mechanical shaft seal may be damaged, result-
ing in pump breakdown. Our 6th Sense dry-running sensor detects dry-running in
any liquid type using ultrasound.
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GRUNDFOS iPUMP
BEARING FAULTS
Damaged bearings will often result in machine damage and production disrup-
tions. Our 6th Sense multi sensor monitors and analyses pump vibrations, detect-
ing faults in any type of bearing.
MISALIGNMENT
When the mass of the rotating parts of a pump is unevenly distributed, the result
is pump misalignment which increases the load on the pump and motor bearings
and may damage the pump. Our 6th Sense multi sensor uses vibration measure-
ments and algorithms to detect misalignment.
WATER HAMMER
Water hammer due to poorly designed piping may overload the mechanical parts
of the pump. The root causes of water hammer may be difficult to find, but our 6th
Sense multi sensor can detect water hammer using vibration measurements and
algorithms.
SHAFT SEAL LEAKAGE
Minor leakages from mechanical shaft seals are normal, and contribute lubrication
to the pump. A damaged seal, however, will leak more than necessary, and dam-
ages may result in major lubricant leakages. Our Shaft Seal Leak Detector (SSLD)
continuously monitors the amount of leaked fluid from the mechanical shaft seal.
CAVITATION
Cavitation (collapsing vapour cavities in the pumped liquid) can cause significant
damage to the impeller or pump housing. Our 6th Sense multi sensor monitors pump
vibrations using spectral analysis, detecting air in the liquid and even early signs of
cavitation, which is not possible with traditional NPSH measurement techniques.
GRUNDFOS iPUMP
iPUMP SENSORS
6th Sense multi sensor
Pump failure detection
• Bearing fault
• Dry-running
• Imbalance
• Cavitation
• Water hammer
Monitoring
• Liquid temperature
• Rotation speed
• Operation time
6th Sense dry-running sensor
Pump failure detection
• Dry-running in all pumped liquids
Shaft Seal Leak Detector (SSLD)
• Continuous detection of actual
leakage from mechanical shaft seal
• Adjustable warnings and alarms at
different leakage levels
• Collection or easy disposal of leak-
ing fluid
iPlug differential pressure sensor
• Continuous measurement of
differential pressure and outlet
pressure
• Calculation of inlet pressure
• Allows estimation of flow rates
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GRUNDFOS iPUMP
iPUMP ACCESSORIES
SSLD leak collection box
Technical data
• Accelerometer
• Ultrasonic sensor
• PT100 sensor element Mounted on the side of the pump. The box collects
• ½” screw connection
leaking fluid from shaft seal, preventing glycol
• Temperature range: 0-120° C
• Pressure range: 0-25 bar deposits on pump and surroundings
• Material: 1.4401 stainless steel
Technical data
• Ultrasonic sensor
• ½” screw connection
• Temperature range: 0-120° C
• Pressure range: 0-25 bar OPTIMAL SENSOR POSITION
• Material: 1.4401 stainless steel
Bearing NDE 6TH SENSE
Technical data
• For pumps with mechanical shaft seals
• Consists of an iPump shaft seal and a
sensor Bearing DE
• Optical sensor element
• Temperature range: 0-90° C
Dry-running protection
• Leakage range: 1-200 ml/h
• Sensor material: silicone rubber
RPM
Imbalance
Temperature
Technical data Cavitation
• ½” screw connection. For large pumps,
an iPlug with capillary tube is required. Water hammer
• Pressure range: 0-20 bar
• Material: 1.4401 stainless steel
GRUNDFOS iPUMP GRUNDFOS iPUMP

iPUMP COMMUNICATION DEVICES

iPump local display unit (LDU)
TELL US HOW OUR
SENSORS ARE DOING
Quick overview of pump status onsite
• Collects and processes data from iPump sensors
• Clear colour-coded display of alarms and status messages in touch
display
• Relay output can be used to stop the pump in specific failure situations

Technical data
• 24 V AC power supply
• 6 M12 terminals: 5 inputs for power supply and sensors, 1 relay output
• Touch display with 2 levels: user level and service level We value your feedback!
• IP55
• Size (L × W × H): 148 × 132 × 60 mm
With our iPump concept, you can get all important details
iPump remote terminal unit (RTU) about pump operation from just one sensor, and act on that
knowledge to avoid breakdowns, increase uptime, and plan
IN DUSTRY 4.0 Industry 4.0 surveillance options through SCADA connectivity your maintenance to suit system needs. The concept is still in
• Collects and processes data from iPump sensors
• Data and alarms are transmitted to your SCADA system
development, and we need your help to make it a success.
• Relay output can be used to stop the pump in specific failure situations

Technical data Our sensors tell us how your pumps are doing. We hope that
• 24 V AC power supply
• 6 M12 terminals: 5 inputs for power supply and sensors, 1 relay output you will tell us how our sensors are doing. Tell us what you like,
• SCADA connection: RS485 or if there is anything that we can improve to turn our iPump
• IP55
• Size (L × W × H): 148 × 132 × 60 mm concept into a solution that adds value for your operation.

iPump cloudgate Thank you!

IN DUSTRY 4.0 Next-generation cloud data storage and analytics

• Collects and analyses data from iPump sensors
• Data are transmitted to secure Grundfos cloud storage
• Predictive information from data analytics
• Browser access to graphical presentation, information, and alarms

Technical data
• 24 V AC power supply
• 6 M12 terminals: 5 inputs for power supply and sensors, 1 relay output
• Antennas: GSM, GPS, and Wi-Fi
• IP55
• Size (L × W × H): 148 × 132 × 60 mm

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 0917/BUSINESS DEVELOPMENT/12710-BrandBox
Grundfos is developing the unique iPump concept.
It relies on smart sensors, accessories, and communi-
cation devices to give you detailed system knowledge
that helps you avoid breakdowns, increase uptime,
and plan your maintenance.

iPump solutions contribute to improved operations

in applications such as the following:

owned by Grundfos Holding A/S or Grundfos A/S, Denmark. All rights reserved worldwide.
• Water treatment

The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks
• Buildings
• Process industry
• Boiler systems
• Water intake and transport
• Temperature control
• Wastewater
• Industrial washing and cleaning

GRUNDFOS Holding A/S

Poul Due Jensens Vej 7
DK-8850 Bjerringbro
Tel: +45 87 50 14 00
www.grundfos.com