In the plumbing industry, product advancements are also driven by government standards and regulations through the U.S. Department of Energy (DOE). The minimum efficiencies in fractional horsepower pumps will soon take effect in 2028 — just a few short years away. Plumbing & Mechanical Chief Editor Nicole Krawcke sat down with Becky Henderson, national sales development manager, USA Distribution — DBS, Grundfos Pumps Corp., to discuss these coming changes and how speed and motor control have really opened the door for pumps to increase performance.
Becky Henderson is the national sales development manager of USA Distribution – DBS, Grundfos Pumps Corp. Image courtesy of Grundfos
PM: What is Grundfos’ stance on the new DOE minimum efficiency standard for circulator pumps which will take effect in 2028?
BH: As governments worldwide implement stricter energy efficiency standards, companies that are already producing efficient products will have a competitive advantage on the market. Grundfos created the market for high-efficiency circulator pumps in 2005 when we released the ALPHA Pro, a wet-rotor pump with a permanent magnet rotor and built-in micro-frequency converter. Our latest residential pump innovations are currently the highest-rated energy efficiency circulators on the market, boasting best-in-class energy ratings from the Hydraulic Institute. Energy efficiency is a key aspect of our commitment to reduce the environmental impact of our products.
The technology can revolutionize the market by inspiring manufacturer developments and delivering enormous energy savings across the US. It’s raising the bar, and we look forward to full implementation in 2028.
PM: How will these efficiency improvements affect the overall performance and reliability of the pumps?
BH: The new DOE minimum efficiency standards will generally make circulator pumps more efficient. Still, the impact on overall performance and reliability will depend on how manufacturers choose to meet those standards, whether it be through design, variable speed drives, and/or more efficient motors. It’ll be important that manufacturers balance design changes with proficiency, cost and durability to improve overall circulator efficiency without significantly affecting performance or reliability. We hope efficiency improvements will inspire the residential water system market to develop features that deliver significant energy savings and drive future product development.
Efficiency improvements will redefine the circulator industry, inspiring enhanced performance, ease of use, installation, and reliability. Having the ability to control rotational speed electronically is first step in product enhancements. The electronic programming in our Grundfos ALPHA allows the pump to maintain a precise temperature range without the use of an external aquastat. Operation time is limited to prevent energy waste and meet each homeowner's unique needs. ALPHA pumps can automatically detect air in the system and prevent a dry run condition. They also have an internal battery that stores the program setting for up to eight years without power. The new pumps are designed to be a versatile and efficient solution that adapts to system demand and optimal performance.
PM: How does Grundfos plan to meet the new DOE minimum efficiency standards by 2028?
BH: As a leading manufacturer of energy-efficient residential pumps, Grundfos is proud to share that the ALPHA and MAGNA product lines exceed the DOE 2028 standard. Our timeline will offer a full range of compliant pumps for all flow ranges prior to 2028.
PM: What technological changes or innovations are you implementing to comply with these standards?
BH: Grundfos manufactures all the components in our products. From the motor windings to the computer chips, we are constantly innovating and improving the performance and reliability of our products.
Our vision is a fully integrated system approach to recirculation. We have designed our products to be applicable for any heating source and any piping material. Grundfos is always looking for new ways to improve the user experience, for the contractor and the homeowner.
For example, based on initial testing, our ALPHA-guided setup through the Grundfos GO app optimizes pump configuration, reducing energy consumption by up to 88% when replacing a non-ECM pump. The solution intelligently adapts to daily water usage habits, delivering a constant flow of hot water only when needed. For a typical household of three, this can save up to 12,000 gallons yearly and significantly reduce a home’s utility bills. You don’t have to wait for hot water, and you don’t have to waste energy for this convenience. ALPHA’s environmentally friendly solution eliminates waste, ensuring homeowners enjoy instant hot water at every tap and showerhead, optimizing comfort, efficiency, and potential financial benefits. It’s ideal for contractors who want to provide unparalleled comfort, energy efficiency, and long-term savings to homeowners.
PM: How has speed and motor control opened the door for pumps to perform many of the functions necessary for optimal performance without adding additional equipment and labor to the installation?
BH: The introduction of speed and motor control technology has enabled residential circulator pumps to perform a broader range of functions that previously required additional equipment and labor during installation. The innovation has driven the creation of the most adaptable circulator of its kind. We see results like energy savings, enhanced system efficiency for overall performance, reduced maintenance that can extend the pump’s lifespan, and enhanced diagnostics that can identify and troubleshoot issues before they lead to an error or failure.
The trick to speed control is to understand its relationship to energy consumption. When speed is reduced, it affects power consumption threefold. The affinity laws provide more precise mathematics, but a 20% reduction in speed is roughly equivalent to a 50% reduction in power.
Throttling valves and bypasses previously used to keep pumps operating at a set flow rate or avoid a dead-head situation waste a lot of energy because the pump runs at full speed. With motor control, we can match the correct motor speed to a specific flow without throttling. We can also reduce the rpm so low that the pump can stop without demand, eliminating the need to provide bypass piping. Internal programming eliminates the need for separate timers and aquastats. Speed and motor control has opened the door to many innovations that are now driving optimal pump performance.
PM: Do you foresee any significant changes in the cost of installation or maintenance due to these new standards?
BH: New technology always comes with a price, although the cost of technology appears to be normalizing as more manufacturers enter the market. We believe the labor saved in installation and callbacks will prove the value of our pumps, as labor is often the highest cost in construction.
Modern circulator pumps equipped with speed and advanced motor control technology offer significant benefits to both installers and homeowners by reducing maintenance needs and extending pump lifespan. Technological advancements aim to minimize wear and tear, while integrated diagnostics provide proactive issue identification and troubleshooting. Automated optimization of system efficiency contributes to improved overall performance. Consequently, the need for maintenance is decreased, and the pump's lifespan is extended, ultimately providing a cost-effective and reliable solution for residential heating and plumbing systems.
"Grundfos understands smart home integration is the future of domestic plumbing and HVAC. Look for future products that seamlessly integrate with other smart devices in the system to redefine the limits of a residential pump and the comfort it can provide in homes across America, " Henderson says. Images courtesy of Grundfos
PM: Are there any additional environmental benefits associated with these new circulator pumps?
BH: Energy savings aside, Grundfos is committed to sustainability and to an environmentally responsible manufacturing process. We build our pumps to last. With the new Grundfos GO commissioning tool, software upgrades are pushed to existing pumps, keeping technology current and pumps out of landfills.
There is an enormous energy cost in distributing potable drinking water. The municipal utility costs for producing and transmitting clean drinking water to US homes amounts to trillions annually. The costs continue when treating the additional sewage created when potable water is wasted. Efficient hot water recirculation saves energy for our local communities and is environmentally responsible because it is source reduction.
PM: How has feedback from various stakeholders influenced your approach to meeting these efficiency standards?
BH: The DOE mandates for efficiency were a great opportunity for Grundfos to showcase the capabilities of electronically commutated motors (ECM). The product is more energy efficient than anything in its class, but the product features also allow the contractor to be more efficient in installation. Innovative commissioning tools allow the pump to adapt to different water heating/boiler types, improving their efficiency. Homeowners using the new Grundfos Home app can proactively engage their energy and water consumption for even more significant savings. Our mission was not just to save kilowatts; it was to change the circulator from a dumb pump to a system solution.
PM: Do you anticipate any industry-wide challenges as the 2028 compliance deadline approaches?
BH: Since DOE changes to 1HP and higher a few years ago, pump manufacturers have been keenly aware of the need for better efficiencies in fractional horsepower pumps. Contractors are quickly becoming more comfortable with “smart” technologies. I think the transition will be relatively smooth in 2028, as many customers are already making the change to better products. The key is to start the conversations and education now and utilize all channels contractors and end-users engage with.
PM: How will these new circulator pumps provide value to contractors and their customer’s bottom lines?
BH: Labor is the largest cost associated with the plumbing system. We want to make the system as bulletproof as possible so the installer can finish the job quickly and correctly the first time. Our commissioning tool takes all guesswork out of the setting. The ALPHA defaults to the best efficiency regardless of the system. The pumps are simple to install and come with several features, like dry-run protection, to eliminate nuisance callbacks.
PM: How do you plan to educate contractors and engineers about the benefits and features of your new energy-efficient circulator pumps?
BH: Throughout 2024, the Grundfos residential team has traveled all over the U.S. to host Grundfos BASEMENT events in over 20 major cities. These gatherings allow installers to touch and see a range of Grundfos pumps and technologies like the Grundfos GO app, and to commission the pumps firsthand while asking questions and gathering education directly from the source. Getting insight directly from the professionals who install and maintain our pumps is invaluable. It’s been great for our team to see the installer's reaction to our products and respond to their questions in real-time.
We also rely on our network of incredibly skilled sales representatives to ensure the message is shared nationwide. Social media, YouTube, webinars with our trade publication partners, and other electronic platforms that today’s engineers and contractors use are also great ways to share content.
PM: What future innovations are you exploring to continue improving the efficiency and performance of circulator pumps beyond the 2028 standards?
BH: As a company, we are focused on the importance and value of digital integration with our circulators. Grundfos understands smart home integration is the future of domestic plumbing and HVAC. Look for future products that seamlessly integrate with other smart devices in the system to redefine the limits of a residential pump and the comfort it can provide in homes across America.
PM: How does Grundfos plan to stay ahead of potential future regulatory changes?
BH: To stay ahead of potential future regulatory changes and ensure we’re ready to comply with new requirements as they arise, we will employ a combination of strategies, including monitoring and engaging regulatory bodies, conducting our own ongoing research and development, consistent participation in industry associations, and overall scenario planning for various situations to best inform the company’s strategic planning and decision-making.
Grundfos is proud to be an industry leader in innovation and sustainability. Energy regulations are necessary, but they are not what drives us. Grundfos is committed to finding solutions to the world’s water and climate challenges and improving people's quality of life. With that mission in mind, we will be ready for whatever comes next.
