One Pump OPE 10: The true innovation is the silicone-encapsulated motor. No condensation, silent operation and maximum reliability for modern systems.

When it comes to innovations that set new quality standards, we are currently leading the way. Our entire product range can now be controlled for heating, air conditioning, solar, and geothermal systems via the integrated pump control or externally via the PWM1, PWM2, 0-10, and WLAN protocols. And we are constantly evolving!

In heating technology, everyone promises "efficiency" and "silence." The real difference, however, lies in the technical details: How is the motor protected, how is condensation prevented, how are vibrations and thermal stresses dampened? The new OPE 10 series from One Pump – electric circulator pumps with intelligent frequency converters that meet the QSG 602* standard – achieves precisely that: a motor that is completely encapsulated by injecting technical silicone . This is not merely an aesthetic measure, but an architectural modification that insulates the motor, prevents air pockets where condensation can form, stabilizes the temperature, and reduces noise directly at the source .

The rest of the machine functions flawlessly: rotating parts are immersed in clean water , a ceramic shaft and bearings ensure wear resistance and water lubrication, and an integrated inverter adjusts the pump to the system's current needs. The real difference, however, lies elsewhere: the electrical core doesn't "breathe" air . It's embedded in an elastic, thermally conductive, and dielectrically safe silicone matrix. The result? Insensitivity to condensation , lower noise levels, and superior reliability in practical applications, especially in low-temperature circuits (heat pumps, fan coil units, radiant cooling).

Injection encapsulation: What it really means

“Encapsulation” doesn’t simply mean applying resin to the winding. It means completely filling the spaces around the stator and the terminals with a silicone compound that has the following properties:

• Avoid air pockets : No micro-cavities = no internal microclimates where moisture condenses;

• Electrically insulating : high dielectric strength, better durability compared to conventional paints;

• Damping of vibrations : Silicone acts as a "viscoelastic shock absorber" and interrupts the acoustic transmission paths;

• Thermal management : The thermally conductive composition distributes local temperature peaks, thus stabilizing the temperature of the stator package and wiring.

Why silicone and not hard epoxy resin?

Many use epoxy resins : hard, rigid, and even thermally conductive. However, rigidity is a double-edged sword in modern drives, where frequent temperature cycles occur and the differing expansion rates of copper, sheet metal, insulators, and resins cause microcracks over time. The engineering silicone chosen for OPE has a lower modulus of elasticity and excellent resilience : it absorbs expansion without cracking, maintains the continuity of the encapsulation, and preserves its dielectric and moisture-proof properties in the long term.

In short: less stress , less cracking , longer lifespan .

The enemy is (humid) air. OPE 10 eliminates it.

Condensation occurs when cold parts come into contact with humid air. This is particularly likely in poorly ventilated technical rooms, in cooling circuits, or during the on/off cycles of heat pumps. If the motor has air pockets around the windings or in the terminal boxes, the moisture condenses. This results in oxidation , leakage currents , arcing, and intermittent malfunctions .

OPE's answer is brutally simple: fill everything . Silicone injection molding with degassing and process control eliminates any air pockets. There is no space for water to accumulate and no internal air circulation that could introduce moisture. By definition, the motor operates in a dry environment , since there is no air present .

Practical advantages:

• Insensitivity to condensation even with very cold return air streams;

• More stable electrical reliability throughout the entire seasonal cycle;

• Reduction of “mysterious” failures related to humidity and micro-arcs.

How it is made: The process is just as important as the material.

OPE encapsulation is not a final "bath", but a factory process with strict parameters.

1. Stator preparation : Windings, insulators and connections fixed within tolerance.

2. Controlled preheating : Silicone viscosity brought into the optimal range.

3. Degassing : Removal of dissolved air to avoid cavities and bubbles.

4. Injection into the mold : progressive filling to avoid air inclusions and ensure complete wetting of the spaces.

5. Polymerization : Thermal curing with a defined profile to develop the mechanical properties and thermal conductivity of the compound.

6. Electrical and IP tests : dielectric testing, insulation, absorption, thermal behavior.

The point is simple: without a process, there is no encapsulation , only resin. OPE relies on a dedicated industrial supply chain to ensure consistent quality, rather than one-off treatments.

Useful side effects: thermal and acoustic

Thermal management

Thermally conductive silicone creates a heat dissipation path from the winding to the housing. In practice:

• Temperature peaks at the edges of the lamination stack and at the copper/insulation contact points are distributed ;

• The junction temperature of the windings stabilizes;

• The electrical lifetime doubles with every temperature reduction of approximately 10°C (rule of thumb for the thermal aging of insulators).

Translation: longer lifespan , larger operating margin, reliability .

Vibration damping

Silicone is a viscoelastic material : it dissipates mechanical energy. In a motor, where unavoidable defects (minor imbalances, radial magnetic forces, inverter harmonics) generate vibrations, the encapsulation interrupts the transmission chain to the housing. The result: less structure-borne noise , fewer resonances, and improved acoustic comfort , especially under partial load – the real operating conditions of most systems.

The rest of the machine: overall coherence

The encapsulated motor does not operate in a vacuum (of air... yes, but not due to its design).

• Rotating parts are immersed in clean water : natural lubrication and cooling.

• Ceramic bearings and shafts : high hardness, chemical inertness, reduced wear even at low speeds where the fluid film is crucial.

• Integrated frequency converter : The pump adjusts the speed to the demand, limits sudden voltage spikes, avoids overflows and reduces consumption.

• Standard Q/SG 602 : Design and production within a framework of verifiable technical requirements .

Taken together, these elements make the OPE a machine that lasts a long time : not because it uses "noble materials", but because it eliminates the typical causes of wear and tear (condensation, thermal peaks, vibrations) .

Where it really shines: Typical applications

• Heat pumps / cold water circuits : no condensation problems on the motor; quieter starts/stops thanks to damping; fewer false alarms.

• Fan coil units and chillers : operation with variable load and long operating hours at low power; here, the encapsulation dampens vibrations and the inverter reduces power consumption (kWh).

• Radiant heating : numerous zone valves, intermittent requirements; modulation prevents knocking and hissing noises, and the quiet is noticeable at night.

• In the tertiary sector and in the residential sector, acoustic comfort and reduced maintenance costs are tangible benefits for facilities and managers.

Comparison of the Swiss franc with the “traditional” approach

Many competitors counteract condensation with thicker layers of paint , seals, and junction boxes with a higher IP rating. While this helps, air remains trapped – and thus the risk of moisture condensation. Other manufacturers encapsulate the components with rigid resins : proven in the laboratory, but susceptible to temperature shocks and vibrations over time.

The OPE proposal is radical : an injected silicone encapsulation that fills everything and remains elastic throughout its entire lifespan. Not a stopgap measure, but a structural solution to the problem.

Specific advantages for planners and installers

• Insensitivity to condensation → fewer recalls after installation, especially in cold systems.

• Perceptible quiet → better conditions in the residential and service sectors; fewer complaints.

• Thermal stability → more constant electrical parameters, superior long-term stability .

• Easier commissioning → Frequency modulation helps to adjust the pump/system characteristic curve without compensation measures.

• Lower total operating costs → lower consumption and less maintenance work .

Details that make the difference

• Encapsulated wiring : The "weak points" (solder joints, connections, terminals) benefit from the absence of air and continuous insulation.

• Chemical compatibility : The selected silicone is inert to compounds typical of the plant environment; it retains its properties over time.

• Repairable maintenance ? An often overlooked topic: The goal is to avoid electrical repairs. The encapsulation is not designed to be removed: It is a fail-safe solution and not repair-friendly. In return, it offers a higher mean time between failures (MTBF) .

Silence: not slogans, but numbers that add up.

Pump noise is caused by hydraulics (turbulence, shocks) and mechanics (vibrations, magnetic forces, inverter harmonics). The silicone encapsulation works on three levels:

1. Stator vibration damping ;

2. Thermal stabilization (lower magnetic drift, therefore lower force effect);

3. Interaction with the inverter : smooth ramp-up and ramp-down, reduction of disruptive voltage spikes at partial load.

The result: less noise (dB) and – more importantly – a cleaner frequency spectrum , which means less disruptive noise. Anyone who lives or works near the utility room will notice it.

OPE in seven points

1. Motor encapsulated with injected silicone : no air, no condensation .

2. Dielectric insulation and vibration damping integrated into one solution.

3. Improved thermal management : smoothing of temperature peaks, extended insulation lifespan.

4. Rotating ceramic parts are immersed in water : reduced wear, natural lubrication and cooling.

5. Integrated inverter : Real efficiency at partial load, system protection.

6. Quiet : fewer transmitted vibrations, noticeable comfort.

7. Q/SG 602 compliance : Process quality and repeatability in manufacturing.

The photo shows an OPE10 circulation pump in a ONE PUMP climate chamber with a fluid temperature of 6°C and an outside temperature of 50°C at 93% relative humidity. These conditions can occur inside a heat pump. The test was passed after eight cycles of temperature reversal between indoor and outdoor temperatures over more than 200 hours of continuous operation. These tests are carried out on samples of the final product in addition to all laboratory tests at the factory and in European certification laboratories.

Take the air out, take the problem out.

The One Pump OPE not only prevents condensation more effectively, but eliminates it altogether by completely encapsulating the motor in technical-grade silicone . It's an elegant yet simple solution: no vacuum, no condensation . You also benefit from robust electrical insulation, vibration damping , thermal stability , and significantly quieter operation.

Today's planners and installers face low-temperature systems , non-air-conditioned technical rooms, dynamic requirements, and stricter acoustic regulations . This is the ideal environment for OPE to demonstrate its value: predictable reliability , high comfort , and lower total cost of ownership .

While others rely on layers of paint or rigid resins, One Pump has chosen the clearest path: permanent and reliable encapsulation . This is how they actively shape the future – not through unrealistic promises, but by changing architecture where it matters most.

The OPE 10 technology is currently only intended for this model and will be extended to larger models in the future.

OPE 10 will be available from all distributors from January 2026 and will also be offered as an OEM version for manufacturers.

• *QSG 602 applies to highly efficient, frequency converter-controlled circulating pumps and specifies requirements for:

  • Hydraulic performance (QH curve, power consumption, efficiency, temperature/pressure range).

  • Electrical safety and insulation (fully shielded stator, dielectric tests).

  • Reliability/noise (criteria for endurance tests and acoustic limits).

  • Labeling and quality control in production.