EI Jan13 PDF

The Association of Electrical Equipment and Medical Imaging Manufacturers nwww.nema.orgn January 2013 n Vol. 18 No.
Contemplating the Future of Smart Manufacturing

industrial automation, controls, motors, and systems
ALSO INSIDE
n Energy Efficiency Bill Becomes Law n IEEE Promotes Efficiency through Automation n Motor Summit Sets Labeling Agenda n Electricity Metering and Smart Meter Updates n NEMA Launches Latin America Initiative
CONTENTS
FEATURES:
Setting the Stage for Smart Manufacturing.............................................................................................9 Take the Pain out of System Design and Startup with Drives Configuration Software...............................10 Innovative Robotic Palletizing System Highlights Manufacturing and Distribution Center .......................12 Recent Evolution in Industrial Manufacturing Leads to Improved Quality, Better Output .........................13 Protect Your Home and Family with Backup Power Supplied through a Transfer Switch ...........................14 Alternative Backups Sources on the Rise................................................................................................15 Three-Part Safety Portfolio Reduces Arc-Flash Risk................................................................................17 Optimize Maintenance and Energy Efficiency Monitoring Motor Operation Yields Significant Savings..........................................................................18 MIT Study Creates Electroindustry-based Method for Mapping Products to Energy Use and GHG Emission...........................................................................................................20 Applying the Law of Conservation of Energy..........................................................................................22 Fire Pump Motor ControllersAt the Heart of Life Safety .....................................................................24 1IS IEC Participation Grows...................................................................................................................25 Energy Efficiency Improvement with Permanent Magnet Motors and Variable-Frequency Drives..............26
Did you know...

Theres a great line up of speakers, including NEMAs Gene Eckhart, at CANENAs Annual General Meeting, February 27-28, 2013, in Montreal. Information and registration at www.CANENA.org
ECO BOX
NEMA electroindustry text and cover pages are printed using SFI certified Anthem paper using soy ink. SFI certified products come from North American forests managed to rigorous environmental standards. SFI standards conserve biodiversity and protect soil and water quality, as well as wildlife habitats. SFI forests are audited by independent experts to ensure proper adherence to the SFI Standard. SFI participants also plant more than 650 million trees each year to keep these forests thriving.
Publisher | Joseph Higbee Managing Editor / Editor in Chief | Pat Walsh Contributing Editors | William E. Green III Chrissy L. S. George Economic Spotlight | Timothy Gill Standards | Vince Baclawski Government Relations Update | Kyle Pitsor Art Director | Jennifer Tillmann Media Sales Team Leader | Stephanie Bunsick
electroindustry
electroindustry (ISSN 1066-2464) is published monthly by NEMA, the Association of Electrical Equipment and Medical Imaging Manufacturers, 1300 N. 17th Street, Suite 1752, Rosslyn, VA 22209; 703.841.3200. FAX: 703.841.5900. Periodicals postage paid at Rosslyn, VA, and York, PA, and additional mailing offices. POSTMASTER: Send address changes to NEMA, 1300 N. 17th Street, Suite 1752, Rosslyn, VA 22209. The opinions or views expressed in electroindustry do not necessarily reflect the positions of NEMA or any of its subdivisions. Subscribe to electroindustry at www.nema.org/subscribe2ei Contact us at comm@nema.org Follow NEMA: www.nema.org/facebook, blog.nema.org, podcast.nema.org, twitter.com/NEMAupdates, www.youtube.com/NEMAvue, www.nema.org/linkedin
CONTENTS
NOTES:
NEMA Officers........................................................................................................................................................................................3 Comments from the C-Suite..................................................................................................................................................................3 View from the Top..................................................................................................................................................................................4 Learn More..........................................................................................................................................................................................IBC
27 29
ERVI 10. ARIZONA PUBLIC / S2%) 781,421 (4% CE CO,
ELECT NERAL LAND GE / 2%) 9. PORT 2,223 (4% 82 RIC CO,
DEPARTMENTS:
Government Relations Update................................................................................................................6 IEEC Promoting Efficiency through Automation...................................................................................................................................6 Cyber Threat Looms Over 113th Congress..............................................................................................................................................6 President Signs Energy Efficiency Bill into Law.....................................................................................................................................7 NEMA Welcomes Vote to Normalize U.S.-Russia Trade Relations.........................................................................................................7 OSHA Revised Hazard Communication Standard Comes Online..........................................................................................................8 CPSC, Industry Prepare for 2013 Activities............................................................................................................................................8 Electroindustry News...........................................................................................................................27 2012 Motor Summit Convenes in Zurich............................................................................................................................................27 Medical Imaging Industrys Leadership to Protect Patients from Unnecessary Radiation................................................................28 ESFI Recognizes Electrical Safety Leaders...........................................................................................................................................29 Magnet Wire Section Elects David Reed Section Chair.......................................................................................................................29 NEMA Board Approves New Members:..............................................................................................................................................29 Innovation Incentive: How to Engage Suppliers and Drive Innovation..............................................................................................30 Code Actions/Standardization Trends....................................................................................................31 ANSI C12 Electricity Metering and Smart Meter Updates..................................................................................................................31 International Roundup........................................................................................................................32 NEMA Launches Latin America Initiative............................................................................................................................................32 Economic Spotlight.............................................................................................................................IBC
7. PPL 1,403,ELECTRIC UT 889 ILITIES (7% / CORP, 4%)
6. ALABAMA POWER CO, 1,405,947 (7% / 4%)
Top 10 Utilities by Total Smart Meters

United States
1. P 4,6 ACIFIC G 41,9 AS 52 & ELEC (23% TRIC / 14 CO, %)
GY, T ENER / 6%) ERPOIN 6 (9% 5. CENT863,28 1,
4. GEOR A PO 2,148GI ,720 WER CO, (11% / 7%
O, IC C ECTR & EL % ) GA S / 4 IEGO (7% AN D ,417 8. S 1,352
2. FLORI DA POWE 2,793, R & LIG 499 (14 HT CO, % / 8% )
t as of August 2012; includes utilities ot receive American Recovery and 2009 (ARRA) funds.
#. UTILITY, ### (XX% / XX%)

Number of Smart Meters Installed % Share Among Top 10 Utilities % Share Among All U.S. Utilities
TOP TEN UTILITIES = 60% OF ALL U.S. UTILITIES
31
Source: U.S. EIA, form EIA-861 Data, 2011 (file 8)
EBCI Gauges Business Confidence .....................................................................................................................................................IBC
COMPANY DELIVERY ELECTRIC (13% / 8%) 3. ONCOR 462 2,664, LLC,
Contact us at zpryme.com and smartgridresearch.org to learn more about how Zpryme Smart Grids Practice can help you better understand and engage the Smart Grid ecosystem. 2012 Zpryme Smart Grid Insights: Intelligent Research for an Intelligent Market. All Rights Reserved.
Officers
Chairman John Selldorff President & CEO Legrand North America First Vice Chairman Christopher Curtis President & CEO Schneider Electric Second Vice Chairman Thomas S. Gross Vice Chairman & COO Eaton Corporation Treasurer Don Hendler President & CEO Leviton Manufacturing Co., Inc. Immediate Past Chairman David J. FitzGibbon Vice Chairman & CEO ILSCO Corporation President & CEO Evan R. Gaddis Secretary Clark R. Silcox
COMMENTS FROM THE C-SUITE

Like a sprinter, NEMA is quick out of the blocks this year. This phrase out of the blocks is a helpful way to view the associations approach to 2013. There is much preparation and many factors that play into quickly getting to full speed and having success down the homestretch. Here are a few that are propelling NEMA to the front. Strategic Initiatives As we begin the new year, the board is driving us forward with strategic initiatives. High performance buildings lead as one of these top priorities. Efforts to manage building ratings, develop energy-efficiency tax incentives, and promote Energy Saving Performance Contracts are already in motion. Continuing the successful strides of the past, Smart Grid again is in focus. NEMA will continue to support the Smart Grid Interoperability Panel and promote Smart Grid applications on policy and technical fronts. Safety remains the first priority. This is why NEMA is promoting a three-year code adoption cycle in states across the country. Finally, there is a growing consensus that any successful strategy to address the public debt and economic growth will include major tax reform. Now that tax reform is on the doorstep of the Capitol, NEMA is there representing the industrys interests. Tighter Integration The board has shown leadership by directing that we synchronize communications and government relations in unified messages that permeate the vital conversations of our countrys leaders. Filling Gaps The competitiveness of American electrical manufacturing comes down to an intelligent, highly trained, and skilled workforce. Brain drain, the reduction in available, qualified labor, is the focus of a study NEMA is conducting on how to best approach this industry reality. Aligning Efforts The success of NEMA is shared by the electrical side of the organization, as well as the medical imaging side, represented by the Medical Imaging Technology Alliance (MITA). Shared goals can be achieved by united endeavors. The strategic alignment of these efforts will further NEMAs influence and reach. This years sprint will see NEMA carrying the industry banner to the finish line. I hope you enjoy this issue of electroindustry focused on industrial automation, controls, motors, and systems. ei
Evan R. Gaddis President and CEO NEMA electroindustry January 2013
Views from the Top

Efficiency Has Something for Everyone
Enrique O. Santacana, President and CEO, ABB Inc. News from the energy industry recently featured accounts of a veritable bonanza going on in the oil and gas sector with even the National Intelligence Council projecting U.S. energy independence by 2030. However, even with natural gas prices as low as they currently are, it is a safe assumption they will not remain there. Global markets have a way of evening things out, and gas still only makes up around one quarter of the fuel mix in the nations power generation portfolio. The point here is that energy costs will inevitably rise, to say nothing of the impact of new environmental regulations or the risk of making our electric grid more dependent on gas pipelines. Fortunately, there is a ready solution to mitigate all of these issues. The phrase energy efficiency often conjures up images of ENERGY STAR appliances, LED lights, and other consumer-level products, but the fact is that there are far larger gains to be madeand savings to be realizedin industrial applications. For example, industrial motors account for around 25 percent of all the electricity consumed in the U.S. each year, yet most of them operate at full speed whether they need to or not. Variable speed drives allow motors to ramp up and down with demand, saving 20 to 50 percent of the energy used by the motor. Typical applications realize a full payback within two years, some in a matter of months. On the supply side, proven technologies such as high-voltage direct current (HVDC) transmission lines and FACTS (flexible ac transmission systems) are also making a difference. HVDC lines incur 25 percent lower losses than comparable ac systems, and FACTS devices allow 20 to 40 percent more power to flow on existing lines. Both of these technologies have been in commercial operation for decades, although recent advances in power electronics have significantly increased their efficiency and competitiveness. other technologies that provide a justifiable return. In addition, efficiencyboosting solutions often come with additional benefits such as enhanced reliability. Nowhere is this more apparent than in the electric grid where the aforementioned FACTS devices not only dramatically improve the throughput of existing transmission lines, but also make them less susceptible to system disturbances. As technology advances, the advent of big data and ever more powerful analytic tools promises to deliver still more gains in energy efficiency. Data centers, for example, already account for more than two percent of all electricity consumption and are becoming increasingly energy-intensive. Still, most are legacy installations with only the most basic environmental controls. Todays data center infrastructure management systems offer sophisticated monitoring and control capabilities for server operations, cooling/ventilation, and overall energy consumption that give operators the ability to optimize their operations. Efficiency is not particularly glamorous, and there is still the challenge of costs and benefits accruing to different parties. (Those who buy the high-efficiency motor/drive package might not pay the energy bill.) However, energy efficiency remains the most expedient way to reduce energy costs, environmental impact, and energy security risk all at the same time. In short, energy efficiency has something for everyone. ei
Looking ahead, energy storage technology has the potential to go a step further to unlock previously unavailable resources.
Looking ahead, energy storage technology has the potential to go a step further to unlock previously unavailable resources. One example of this is in regenerative braking, a concept now familiar to many thanks to hybrid cars. A pilot project at SEPTA, the Philadelphia-area rail system, captures energy from decelerating trains and stores it in batteries. The energy can then be used to reduce SEPTAs own energy consumption, but it also delivers highly responsive on-demand power to the local utilitya service for which SEPTA is paid. In all of these examples, its important to point out that efficiency has a business case. Drives offer a particularly compelling one, but there are many
NEMA electroindustry January 2013
Views from the Top

Forecasting Fewer Catastrophic Outages
Robert Gilligan, President and CEO, GE Industrial Solutions Theres a huge storm coming. Not necessarily today or tomorrow, but its coming. Whether its a disaster like Hurricane Sandy, an earthquake, snow, flood, or forest fire, we must be better prepared for the power outages these events can bring. Besides causing overwhelming loss of life and property, Sandy refocused our attention on the critical importance of electrical powersomething we invariably take for granted. Power outages are not merely inconveniences. Theyre dangerous threats to a society that increasingly depends on electricity for its survival. The breadth and intensity of Sandy and its crippling effect on the nations largest metropolitan area has challenged us to rise to a new level of power preparedness. We need to become more creative and pedantic about how we ensure a reliable power supply for the diverse needs of commercial, institutional, and industrial users. These users must maintain the ability to serve customers. The urgency and cost/benefit profile of preparedness strategies among these diverse groups are quite different. Matching the right power plan and backup equipment with each segment requires a full range of solutions: from advanced, leadingedge technologies to simpler, more economical approaches. Most Urgent For critical operations, like hospitals, data centers, and law enforcement facilities, losing power for even a few seconds can be immensely damaging. These facilities demand 100 percent reliability. As part of a comprehensive preparedness plan, it makes sense for critical locations to invest in a proven system that ensures operations remain running when the grid goes down. Battery-based UPS (uninterruptible power supply) systems are the gold standard for reliable performance. A UPS systems always-accessible power is an instant-on bridge that keeps lights on and critical electrical loads running until an alternate source, like on-site generators, takes over. However, because UPS systems are always on, inefficient units can be expensive to operate. As with any battery-based system, efficiency wanes over time and systems need to be upgraded or replaced. Fortunately, UPS systems have made great efficiency gains. Some, like GEs patented eBoost with 99 percent efficiency, even carry ENERGY STAR certification. The improvements are so dramatic that energy savings with new equipment may entirely offset upgrade costs. The key is finding the most reliable product type for each unique operation and then researching the most efficient choice. This enables smart planners to offset backup power supply costs with efficiency gains. Least Urgent Matching emergency power sophistication and costs with real energy needs is an important exercise for everyone. For example, homes, small retail stores, or restaurants wont suffer irreparable harm if power is lost for a few hours or even a day. Power is important to these consumers but not critically urgent. These facilities dont need to invest in an expensive, always-on, backup power system like a UPS. These energy consumers can look for reliable solutions that are more affordable and practical, like manual generators. Backup Power Tweens Between mission-critical applications and generator users, we find essential facilities, like emergency medical walk-in clinics, gas stations, and supermarkets the backup power tweens. These applications require scalable solutions that balance needs, cost, timing, and sophistication. New quick-connect power system design ideas, like GEs GenTower, enable economical preparedness for important, but not critical, operations. This backup energy hub is wired and ready to connect to high capacity, truck-mounted generators to fully power operations. Fleets of generator trucks can be dispatched after the threat of damage has passed or ahead of anticipated outages. Facilities can then operate their main power system without modifications to the building or its electrical system. After a simple connection, its business as usual, powering important facilities and services until grid power returns and it works without expensive capital investment or system maintenance. GE understands and is committed to leading the future of electrification with advanced technologiesfrom everyday grid operation and microgrids to renewable energy and standby power. We work to protect and control the distribution of electricity throughout our customers facilities and help ensure the reliability of their electrical infrastructure. Energy-Recovery Forecast: Good Energy technologies are improving every day, even as severe weather conditions become more frequent. The good news is that we can stay ahead of the curve and deploy reliable, scalable, and efficient solutions that keep the power on so when one of Sandys siblings come calling, well have the energy to be safe, productive, and comfortable. Thats a forecast we can all be happy with. ei
Government Relations Update

IEEC Promoting Efficiency through Automation
Growing the opportunity for automation to play a larger role in industrial energy efficiency projects is the goal of the Industrial Energy Efficiency Coalition (IEEC), a two-year old organization administered by NEMA. Founding members ABB, Eaton Corporation, GE, Rockwell Automation, Schneider Electric, and Siemens are promoting policies that give proper attention to the efficiency gains that automation can contribute to any manufacturing facility or other industrial process. Energy-intensive manufacturers, such as glass, paper, steel, and chemical producers, have long been aware of the cost of inefficient energy use and have made major investments in sensors, controls, and automation to reduce their energy costs. The challenge for IEEC is to drive industrial efficiency into the next tier of manufacturing facilities (some 150,000 facilities), where energy is a smaller portion of the cost of production. While investments in energy efficiency in these facilities would provide a very good ROI, they can often fall back in terms of prioritization of capital expenditures. Even if facility managers recognize the value of automation for energy efficiency and reduced production costs, they sometime face headwinds at the corporate level where other priorities, such as new product development, must be weighed. Many of these other priorities might be more compelling than energy efficiency for one reason or another, especially because the first step in an industrial efficiency project is an energy audit, which by itself provides no return on investment. But few projects deliver the sort of guaranteed value to the bottom line that reducing energy costs through automation can promise. IEEC has become a well-known group in Washington, D.C., and is currently having an impact on Congressional energy-efficiency policies and Department of Energy programs. IEEC is exploring ways to: increase its ranks among other industrial vendors and suppliers, expand its influence before policymakers, and improve visibility to and leadership among its customers. Learn more at www. industrialenergyefficiencycoalition.com
ei
Jim Creevy, Director of Government Relations | jim.creevy@nema.org
Cyber Threat Looms Over 113th Congress

Washington disagrees on most everything these days. One exception lies in the massive risk to our safety and economy posed by cybersecurity vulnerabilities. What to do about it, however, remains a source of dispute. Cybersecurity policies may impact NEMA manufacturers as providers of technology that may be part of designated critical infrastructure, such as industrial automation and control equipment, power equipment, or medical imaging devices. Policies influencing the operation of these or other systems may have impacts on the manufacturers of system components. Multiple congressional proposals as well as an internal White House draft executive order frame the debate. With the failure of Congress to enact legislation in 2012, there is a need for a fresh start. Key issues are keeping the two sides, which are largely divided along partisan lines, apart. First, because of the sheer enormity of IT networks in modern society, a workable policy must establish some boundaries. While the interconnected parts of any network are ultimately vulnerable, we must balance the cost of protecting the asset along with the national security, economic, and health/safety impacts from a cyber-event affecting that asset. The question of how to define critical infrastructure remains unanswered. In the draft executive order and in the Lieberman-Collins approach (S 3414), the Department of Homeland Security, in consultation with other agencies, identifies critical infrastructure as that in which a cybersecurity incident could reasonably result in a debilitating impact on national security, national economic security, or national public health or safety. Getting even this aspect of the policy right is no small feat. The larger debate is the proper and most effective role for government. One approach would establish a process for developing voluntary standards appropriate for each industry. The executive order would go further by starting with a voluntary program but later encouraging agencies to propose regulations compelling critical infrastructure owners and operators to implement certain cybersecurity practices. Critics contend that either approach is likely to be burdensome, slow to respond to rapidly-evolving cyber threats, and to not adequately recognize the investments in cybersecurity that industry is already making.
The electrical sectors role in new cyber policy is complicated by the fact that the Federal Energy Regulatory Committee, through the North American Reliability Corporation, already regulates the bulk power system through Order 706, Mandatory Reliability Standards for Critical Infrastructure Protection.
Liability protection for entities that take positive action against the cyber threat is, in concept, a carrot with which all agree. However, major differences remain as to what precisely an entity must do to earn that protection, from sharing cybersecurity threat information with the federal government to getting third-party verification that the entity
is complying with federally-approved voluntary best practices. The cyber threat is only growing larger making the need for a consensus approach by industry and the U.S. government even more urgent. ei Jim Creevy, Director of Government Relations | jim.creevy@nema.org
President Signs Energy Efficiency Bill into Law

On December 18, President Obama signed into law a handful of NEMAendorsed energy efficiency provisions. The American Energy Manufacturing Technical Corrections Act (HR 6582) is the legislative vehicle for provisions promoting advanced metering in the federal government; a greater focus at the Department of Energy (DOE) on deployment of existing manufacturing technologies; improved energy efficiency within federal facilities; and a study on barriers to industrial deployment of electric motors, demand response, and combined heat and power technologies. NEMA and like-minded members of Congress worked toward enacting energy efficiency legislation throughout the 112th Congress. Senators Jeanne Shaheen (D-NH), Rob Portman (R-OH), Jeff Bingaman (D-NM), and Lisa Murkowski (R-AK), and Representatives Charlie Bass (R-NH), Jim Matheson (D-UT), and Ed Whitfield (R-KY) were influential in keeping the discussion of energy efficiency front and center. Often credited as something everyone can agree on, energy efficiency proposals were still met with significant headwinds and the ultimate outcome remained unclear until the very end of the Congress. Numerous proposals were in play throughout the legislative session, and HR 6582 is evidence that energy efficiency is an issue that can find bipartisan and bicameral agreement. This provides a great deal of hope that further efficiency measures can be successful in 2013 and beyond. Indeed, NEMA is already engaging key offices on strategies for developing and gathering support for new energy efficiency legislation in the coming 113th Congress. Specifically, HR 6582 requires the DOE to develop and issue an annual bestpractices report on advanced metering of energy use in federal facilities; establish collaborative research and development partnerships with other programs to support the use of innovative manufacturing processes and to support applied research, development, demonstration, and commercialization of new technologies and processes to improve industrial efficiency; and conduct a study, in conjunction with the industrial sector, of the barriers to deployment of industrial efficiency technologies. The bill also compels certain federal facilities to use a web-based tracking system to publish energy and water consumption data on an individual facility basis and ensures certain technical corrections to lighting efficiency and electric motor provisions in the Energy Independence and Security Act of 2007. ei Jim Creevy, Director of Government Relations | jim.creevy@nema.org
NEMA Welcomes Vote to Normalize U.S.-Russia Trade Relations

Recent bipartisan approval to grant permanent normal trade relations status to Russia clears the way for U.S. businesses to access benefits associated with the worlds ninth largest economys entry into the rules-based international trading system. Significant potential for growth in U.S. electroindustry exports to Russia is obvious, given the size of the markets, infrastructure needs, the permanent lowering of trade barriers, and greater transparency of regulation and protection of intellectual property rights required under World Trade Organization disciplines. Read more at www.nema.org/RussiaTrade-Relations-Vote. ei Craig Updyke, Manager of Trade and Commercial Affairs | cra_updyke@nema.org
Government Relations Update

OSHA Revised Hazard Communication Standard Comes Online
All U.S. employers that use hazardous chemicals in their workplaces have until December 1, 2013, to train employees on new label and Safety Data Sheet (SDS) formats required under the U.S. Occupational Safety and Health Administrations (OSHA) revised Hazard Communication Standard (HCS). OSHA issued the revised HCS in March 2012 to harmonize the classification and communication of workplace hazards with the U.N. Globally Harmonized System for Classification and Labeling of Chemicals. The new HCS standardizes labels and SDS formats used to warn users of chemicals of their physical properties and dangers. While implementation of the revised HCS is staged over a number of years, the rule impacts chemical manufacturers and importers, chemical distributors, and end users differently. Any NEMA members that produce Safety Data Sheets will be required to use a new 16-point standardized format and evaluate the hazards reported therein. All members that use chemicals must continue to warn employees of appropriate measures to protect from risks and train them on the appropriate handling of chemicals. For more information on the changes to the HCS and the various implementation deadlines, please visit www.osha.gov/dsg/ hazcom/index.html. Additional resources on the revised HCS are available on the NEMA Intelligence Portal. ei
CPSC, Industry Prepare for 2013 Activities

Speaking to the National Association of Manufacturers (NAM), Consumer Product Safety Commission (CPSC) Chair Inez Moore Tenenbaum highlighted the agencys work in 2012 and shared her expectations for 2013. She spoke briefly of CPSCs completion of several rules mandated by the Consumer Product Safety Improvement Act of 2008 (CPSIA; Public Law 110-314) and recent work on high-powered magnets, revisions to guidelines for public announcements of recalls, and CPSCs increased use of social media. CPSC will focus on three areas in 2013: import surveillance; continued implementation of and modifications to the SaferProducts.gov public database; and safety standards, including those for childrens play yards, portable gas generators, all-terrain vehicles, off-road vehicles, table saws, and upholstered furniture. Ms. Tenenbaum also expressed a desire for greater collaboration between industry and the agency in public safety campaigns. Recently, other developments have focused industrys attention on CPSC. At a Safety Academy event in September, CPSC general counsel staff announced the agency is modifying the way it interprets its authority under Section 6(b) of the Consumer Product Safety Act with respect to publication of companyidentifiable information. Rather than adhering to current policy and waiting to disclose information relating to pending agency investigations until a resolution is reached, the new policy would allow CPSC to disclose preliminary, confidential information identifying the manufacturer of a consumer product under investigation in response to inquiries or if CPSC feels disclosure would serve consumers interests. NEMA joined other members of the NAM CPSC Coalition in sending a letter to Ms. Tenenbaum expressing concerns about the proposed change. It could discourage companies from voluntarily reporting potential product defects and working cooperatively with CPSC to address them out of fear of publicity and potential reputational harm resulting from such disclosure. Industry leaders also have noted the significant impact a recent court ruling could have on how manufacturers interact with the SaferProducts.gov database. In October, the District Court for the District of Maryland published its ruling in favor of an unnamed company in its effort to stop CPSC from publishing on the database a report of harm (ROH) containing materially inaccurate information (MII). The court found that CPSCs decision to publish the ROH containing known MII was a final regulatory action and CPSC violated the Administrative Procedure Act by acting in an arbitrary and capricious manner and abusing its discretion. The court determined that the ROH did not relate to use of the companys product as required by CPSIA or CPSCs implementing regulations. The case is expected to be appealed. Going into 2013, CPSC will have three commissioners, split 21 along party lines. The two vacancies on the commission likely will not be filled until later in the year. President Obama has nominated Marietta S. Robinson to fill the seat vacated by former Commissioner Thomas Moore in 2011, but has not yet announced a nominee to take the seat of Commissioner Anne Northup, whose term expired in October 2012. Commissioner Robert Adlers term expires in October 2014. NEMA will continue to focus on CPSCs activities in the areas of product safety, electrical safety, and life safety in 2013 and advocate on the industrys behalf. ei
Sarah Owen, Government Relations Manager | sarah.owen@nema.org
Industrial Automation, Controls, Systems
Smart Manufacturing
Bruce M. Quinn, Vice President for Global Government Affairs, Rockwell Automation, and 1IS Government Affairs and Trade Committee Chair
Setting the Stage for
n the near future, the global manufacturing sector will look nothing like it does today.
Advanced manufacturing technology is rapidly transforming the global competitive landscape. The companiesand nationsthat act now to seize its promise will thrive in the 21st century. Those who are devoted to incremental change and fail to engage in smart manufacturing will rapidly fall behind. The NEMA Industrial Automation Control Products and Systems Section (1IS) endorses an initiative to define a roadmap for the implementation of advanced process manufacturing technologyor smart manufacturingin the U.S. The section represents the relay and industrial control industry with its 32,873 full- and part-time employees of manufacturing establishments within the U.S. during 2010 with total shipments of $8 billion1. The sections primary objective is to maintain and improve national, regional, and global market access for the products and services of its members. Smart manufacturing marries information, automation technology, and human ingenuity to bring about a rapid revolution in the development and application of manufacturing intelligence to every aspect of business. It will fundamentally change how products are invented, manufactured, shipped, and sold. It will improve worker safety and protect the environment by making zero emissions, zero-incident manufacturing possible. It will help keep jobs in this country by keeping manufacturers competitive in the global marketplace despite the substantially higher cost of doing business in the U.S. In the 1980s and 90s, manufacturers took steps to address those higher costs by reducing waste and improving their operations through lean manufacturing practices. Those efforts, while ongoing, are producing diminishing incremental returns and businesses cannot cut their way to prosperityinnovation is the path to growth. It is time for a new, bold strategy for U.S. competitiveness that will capitalize on smart manufacturing as a strategic asset for growth.
1
Investments in a smart manufacturing infrastructure are essential to securing Americas industrial future and economic well-being of its citizens. Smart manufacturing will increase the flexibility of our plants, reduce the use of energy, improve environmental sustainability, lower the cost of products, and enable us to develop innovative products using next-generation materials. We must act together to make that future a reality. Here are four crucial first steps: Industrial/Manufacturing Competitiveness. Investment in U.S. industry, its supply chain, and technologies will make it more efficient, sustainable, and globally competitive. Research and Development. R&D tax credits for innovative manufacturing processes and applied research on the factory floors go beyond basic science and new product research in corporate labs. Manufacturing Workforce Development. Provide the educational and training infrastructure American manufacturing needs to compete successfully in the global market. National Manufacturing Strategy. Prepare the country for the market-altering leaps in manufacturing productivity and efficiency that smart manufacturing will bring about. The section will be discussing specific policy positions and start crafting specific legislative language that might prove helpful. Our focus will be on the 113th Congress, working with the House and Senate manufacturing caucuses and others, as well as the administration to development meaningful policy in support of U.S. manufacturers. We invite your participation in our effort.
ei
As Rockwell Automations senior executive in Washington D.C., Mr. Quinn ( bmquinn@ra.rockwell.com) is responsible for government affairs, communication, and strategic business development at state, federal, and global levels.
U.S. Census Bureaus 2010 Annual Survey of Manufacturers
Take the Pain out of System Design and Startup with Drives Configuration Software
Greg Mears, Product Manager, Drives Software, Rockwell Automation
nverters, drives, variable frequency drives, motor driveswhatever you call them, engineers understand and accept their performance-enhancing, energy-saving, and motor-protection benefits.
and can become a nuisance for programmers, typically during system start-up when time can be limited. In the past, the first phone call to tech support involved troubleshooting to remedy these communication gaps. With integrated drives configuration, users can now configure both sides of the network connection at the same time with one tool, reducing the potential for errors. This capability can be especially beneficial in applications involving a large number of drives, where managing the various configurations can consume an inordinate amount of engineering time and resources.
That acceptance has led to a proliferation of drives offerings, with much of the hardware based on similar technology resulting in excellent or enhanced quality across leading brands. Engineers considering drives options may want to focus on the ease-of-use tools and features provided by the configuration software as much as the actual hardware. By examining the whole drives package, especially the configuration software, engineers can make a more informed decision that saves them time and labor during configuration, commissioning, and startup. Like all software, drives configuration software is experiencing rapid evolution making it easier to use and more powerful. The most profound advancements involve integrating the controller and drive. For networked drives, integration capabilities help lower programming, installation, and overall ownership costs by minimizing the software tools required. This helps users gain faster startups, improved accuracy, and easier drive-system maintenance.
Streamline Drives Configuration Data

To ease maintenance and improve access to information, some software saves drive configuration data as part of the controllers project file and also stores it in the controller. As a result, there is no need to store and maintain multiple filesusers only need one file for the controller and all drive configurations. In the event of a failure, replacement and restoration of the original drive configuration is a much easier process. In some cases, the controller can automatically download the configuration to a replacement drive, further reducing down-time.
say goodbye to the complicated world of drivecontroller integration.

Traditionally, adding a drive to a control system meant learning to work with a new software tool and managing separate drive configuration files. By using programming software that integrates the drives and the controller, users have less of a learning curve and can more easily manage the drive and the control system since there is only one software package to purchase and learn.
Remove Cryptic Parameter Descriptors

Individually programming parameters and tags when configuring drives can be a major challenge. Many controllers store drive information in memory as a contiguous block, where each drive parameter is represented by a physical address or number rather than a descriptive name. Typical tags might read .data3 or .data4, forcing users to constantly refer back to user manuals to interpret and document the control program. This tedious task is time-consuming and often must be repeated for each drive in a system. Engineers installing drives should look for programming software in which a device-specific data structure is created automatically. These data structures can now be represented with descriptive names rather than generic numeric-based parameters addressing schemes used in the past. The data structures also use the proper data typesinteger, real, Boolean, etc.for each parameter, so no manual data type conversion is required by the programmer. Engineers also should seek software options that provide network I/O drop-down boxes containing all the parameter
Reduce Chance of Mismatch I/O

When installing drives, a major complexity is configuring the settings to synch up between two programming environments. For example, a conflict in the I/O configuration setting can arise when the controller and drive are configured at different times with different tools. In other words, the controller expects one size of I/O while the drive is configured for a different size. This mismatch creates an I/O connection error in the program
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Rockwell Software RSLogix 5000 v20 software from Rockwell Automation delivers the high performance of an integrated control system for manufacturers and machine builders requiring a smaller control system, integrating motion capabilities on the EtherNet/IP network with the Allen-Bradley CompactLogix controller family.
The PowerFlex 755 AC Drive Add-On Profile, opened in Rockwell Software RSLogix 5000 v20 software from Rockwell Automation, illustrates drive configuration integrated in the controllers programming environment. Images courtesy of Rockwell Automation
names. This minimizes the potential for errors when defining various network I/O. Tags can then be created in the control development environment and accessed via HMI (humanmachine interface), reducing set-up and configuration time. A copy-and-paste programming feature can quickly create additional duplicate drives.
reducing drive startup and commissioning time, wizards can improve set-up accuracy by significantly reducing manual configuration with the end device. Engineers also can enjoy the benefits that device configuration software can offer to simple, hardwired, or stand-alone applications. Drives are just one of many components in a system. For these applications, device configuration software can take what once required several different software configuration tools and wrap it into a single software package with a simple catalogue of devices available at the engineers fingertips. Combining a controller with a full suite of compatible components and application development toolsapplication profile, quick starts, wiring diagrams, and pre-developed HMI screenscan provide engineers with a simplified way to implement common control tasks as part of the machine design. This dramatically improves end user experience and reduces the risk of potential engineering programming, training, and maintenance nightmares. Clearly, its not just about hardware anymore. With simplified programming software, engineers can say goodbye to the complicated world of drive-controller integration and hours of grueling tagging and coding validation. Advancements in programming software capabilities are just the start of integration and interconnectivity capabilities to come. ei Mr. Mears serves as product manager for Low Voltage Drives, Control Products & Solutions, at Rockwell Automation, and is responsible for drive configuration software, embedded logic control, safety, and integration activities with other Rockwell Automation products.
Simplify Coding
A common problem in many drives installation projects is that multiple engineers are developing different versions of the same code. With numerous code variations, installation and startup become more tedious and complex. Thats because engineers must check and verify each versionand the specific set of errors used with each codeto confirm a smooth installation. Programming software capabilities, such as user-defined add-on instruction, encapsulate drive-specific operations into a reusable module of code. This reduces the development and validation effort, and promotes consistency among projects since theres no need to constantly reinvent commonly used control algorithms. Some software packages further simplify the programming of networked drives with tag generator tools. Users no longer have to worry about I/O mapping and correlating the I/O image with device user manuals. Tag generating tools help save users a significant amount of programming time per device, depending on the complexity of the device. Startup wizards for drive commissioning are another key advancement in drives configuration software. Instead of using a linear list editor to navigate through hundreds of parameters, startup wizards provide a simple step-by-step process. Graphs, images, and descriptive text assist the user through the remaining commissioning process. Besides dramatically
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A robotic arm can pick up four 55-pound buckets at one time. Photo courtesy of ABB
Innovative Robotic Palletizing System Highlights Manufacturing and Distribution Center

Rick Tallian, Consumer Products Segment Manager, ABB Robotics, North America
unn-Edwards, a leading manufacturer and supplier of paints and painting supplies, serves professionals and consumers throughout the Southwest. Established in 1925, the company sells most of its paint through its own 109-store network. It faced a challenge in 2010 when it consolidated all manufacturing and distribution operations into a new, fully automated facility in Phoenix.
on the right. If needed, the buckets from line A can be placed on pallet B, or from B to A. The vacuum gripper is strong enough to pick up the buckets but sensitive enough not to remove the tint plugs that are attached to the top of each pail. The system is unique for several reasons including its use of a single robot, its speed and flexibility, the weight of the load that is being palletized, and the dexterity of the gripper. The biggest consideration for us was the cycle time, said Clay Fenstermaker, director of engineering at Dunn-Edwards. We first considered an overheard gantry robot system, but Systems Automated came up with a simulation that showed that the fixed position, ABB robot could deliver the rate we needed. This could well be the most sophisticated five-gallon paint bucket packaging line in the world, said Mr. Fenstermaker. The system was launched in January 2011. The Phoenix plant has been designed to accommodate future growth of the company for years to come. ei Mr. Tallian has more than 20 years experience in the development of robotic material handling and packaging systems for a wide variety of industry segments, specializing in robotic assembly, picking, packing, and palletizing applications.
In designing the palletizing system, the requirement was to palletize the five-gallon buckets of paint at a rate up to 48 buckets per minute, building two pallets every 90 seconds (36 buckets/pallet). An integral part of the automation portfolio is an innovative, high-performing robotic palletizing system, which was designed and installed by Systems Automated of Sylmar, California. The system utilizes a single ABB IRB 660 articulated arm robot and a vacuum gripper that can pick up four 55-pound buckets at a time. The current speed of incoming lines requires a speed of 44 buckets per minute, with excess cycle time capacity available when necessary. Because the system is able to achieve such high speeds, DunnEdwards is able to serve two incoming conveyors and build two pallets at a time. The ABB IRB 660 robot sits between the two conveyors and picks buckets from the left conveyor and puts them on a left pallet or from the right conveyor for placement
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Recent Evolution in Industrial Manufacturing Leads to Improved Quality, Better Output

Tom Fowler, Staff Product Specialist, Motor Control Business, Schneider Electric
ndustrial manufacturing has been evolving over the last 20 years. Everyone knows about jobs that have moved offshore or the pressures to improve profits and productivity, but not everyone is aware of the new businesses and products that have developed as a result of the recent evolution in industrial manufacturing.
over an industrial communication network or even over the internet to remote locations results in minimal down time on the factory floor. New proximity and photo sensors keep track of products during the manufacturing, assembly, and packaging processes with higher scan rates for productivity improvements. They improve product quality with better output consistency. Even such basic control products as a start-stop pushbutton are available for wireless control operation or connection to an industrial communication network for simplified connection with less wiring than older conventional solutions. The programmable logic controller or PLC has also evolved in the last 20 years. Long known as the brains of an industrial automation system, they can now perform more sophisticated tasks, but with the simplicity of many of popular point and click computer systems. Products and services from the NEMA industrial automation companies have long been the backbone for the manufacturing floor, but now they are taking a lead position in the evolution of manufacturing in the world today. ei Mr. Fowler is a staff product specialist for low voltage power and control products at Schneider Electric. He has held several product management and marketing assignments during his 36-year career in the industrial control and automation industry and is past chairman of the NEMA 1IS Business Committee.
Competitive pressures have never been greater in manufacturing, and as a result a large number of companies either greatly scaled back or totally eliminated their industrial engineering and maintenance departments. While realizing short-term profit improvements, the need for this skill to keep factories running at peak efficiencies gave way to the birth of a thriving business in manufacturing plant services. A large number of manufacturing facilities now rely on outside service companies with special expertise to keep their electrical distribution, control, automation, and infrastructure running at peak efficiency levels. Industrial service companies are also providing their customers with new product solutions from NEMA member companies. Automation systems that increase productivity or products, such as NEMA Premium efficiency motors coupled with variable speed drives, reduce energy consumption, which will also help achieve LEED certification, reduce a manufacturers carbon footprint, and improve our environment. New products from NEMA industrial automation member companies are also contributing to productivity and profitability improvements on the factory floor. NEMA industrial automation products have long been known to provide the safe distribution and control of electrical power on the factory floor, but now they are adding intelligence to these basic electrical products. Products such as electrical circuit breakers and electric motor starters provide control and protection as well as provide predictive maintenance and self-diagnostic information when a problem occurs. The ability to communicate the information
The NEMA Premium program covers single-speed, polyphase, 1500 hp, 2, 4, 6, and 8 pole, squirrel cage induction motors. Learn more at www.nema.org/NEMA-Premium-Motors Contact NEMA for the current version of ANSI/NEMA MG 1.
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Protect Your Home and Family with Backup Power Supplied through a Transfer Switch
Neil A. Czarnecki, Vice President, Engineering, Reliance Controls Corporation Daniel G. Scheffer. PE, Vice President Engineering and TechnologyASCO Power Switching and Controls, Emerson Network Power
Automatic or NotMaking the Switch

Residential transfer switches fall into three general categories automatic, non-automatic ( e.g., pushbutton operated), and manual. An automatic transfer switch is one that transfers from the normal to the backup source of power upon detection of loss of power and without human intervention. Non-automatic and manual transfer switches require a human operator to do something to make the transfer occur. There are three primary kinds of manual transfer switches for residential applications. Whole house transfer switches consist of a transfer switching system installed between the utility meter and the main loadcenter, (an example would be a double-pole doublethrow safety switch) or between the main breaker and the branch circuit breakers (an example would be a transfer-rated panelboard). Subpanel transfer equipment uses a small loadcenter that contains only the branch circuits to be powered by the generator or alternate power source. A transfer switch powers this subpanel alternately from the main panel or the standby source, wired in accordance with the provisions of the NEC. Load-side transfer switches use multiple transfer switching devices connected after the branch circuit breaker, one for each circuit to be powered from the generator.
torms like the recent Hurricane Sandy left more than eight million customers without power. Many of the residential customers either
owned a standby generator or quickly acquired one to protect their homes and families. While such generators provide the opportunity to power essential appliances such as refrigerators, freezers, heating systems, pumps, water heaters and the like, the ability to do so safely requires the use of a transfer switch.
The proper application of transfer switches avoids dangerous practices such as backfeeding electrical panels or dryer outlets, which can inadvertently energize power lines and endanger electrical utility workers and neighbors; mitigates fire, shock, and appliance damage hazards in the home from makeshift wiring practices; and protects the occupants from exposure to toxic levels of carbon monoxide. Optional standby transfer switches are safety devices that are required by the National Electrical Code (NEC). Article 702.6 states, Transfer equipment shall be required for all standby systems subject to the provisions of this article and for which an electric-utility supply is either the normal or standby source. The use of transfer switches provides protection from inadvertent interconnection of the normal and alternate supplies, a condition that occurs when a standby generator is connected to residence wiring supplying power through the de-energized utility wiring to neighbors homes or to the utility transformer. Obviously, inadvertently electrifying circuits that other people believe to be dead pose significant safety hazards. Utility workers and neighbors have been electrocuted by making contact with these backward fed circuits.
Choices, Choices, Choices

There is a wide variety of selection criteria to be considered when choosing a residential transfer switch. Safety The point cannot be overstressed that the only safe means of connecting standby generator power to a residence is by using a transfer switch. Jury-rigged methods are dangerous and violate the NEC and most local building codes. Always use transfer switches to connect power to the circuits of a residence.
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Local Codes and Permits The local codes and permits at the site of installation may restrict some types of installations. Always determine local code and permit restrictions before choosing a system. Agency Certification Transfer switches will be marked for the intended use and certified to the appropriate product standard(s). Homeowners should verify that the transfer switch is suitable for the intended use by checking the product for a mark from a nationally recognized testing laboratory (UL, CSA, ETL, MET Labs, Wyle, etc.) and the words suitable for use under Article 702 of the NEC. Do-it-yourself vs. Professionally Installed It is recommended that transfer switches be professionally installed, but they can be simple enough to be installed by a capable homeowner. When in doubt, however, a professional should do the work. Before buying a transfer switch, decide whether you can or want to install it yourself. Fully Installed Automatic/ Non-Automatic vs. Portable/Manual There is no question that a fully installed automatic transfer switching system is the ultimate in convenience and ease of operation, requiring virtually no operator intervention. There is a cost for all this convenience. Automatic and permanently installed non-automatic systems are generally more expensive than manual systems, generally require professional installation, and sometimes use a larger generator that may require its own foundation and/or shelter. In contrast, manual transfer switches require significant work by the homeowner to start and connect the generator and engage the desired circuits, often during bad weather conditions. These systems are generally smaller, simpler, less expensive, and easier to install. The selection of automatic versus manual should take into consideration factors such as: In an emergency situation, can I buy the system and get it installed in time to prevent damage to my home? Is the homeowner willing and/or capable of doing the tasks required by a manual system? Are there frequent power outages, wherein the convenience of an automatic would offset the increased cost, or are outages so rare that an automatic would be a waste of money? Are there features to the home such that every power outage must be handled immediately, whether the homeowner is present or not?
Continued on page 16
Alternative Backups Sources on the Rise
hen severe weather blows into town, theres a chance that you or your neighbors may lose power. Although we cant prevent
these outages, there are ways to prepare for them. Having a backup power source is a good place to start.
One alternative backup power is the battery. Batteries a form of energy storageare available in several applications that range from charging small appliances, like a cell phone or laptop computer, to larger products, like wheelchairs, electric vehicles, or energy systems (e.g., wind, solar, or emergency lighting). Several NEMA member companies are involved in these portable energy technologies and offer products for residential and commercial use. Duracell offers the Powerpack 600, a standalone form of portable power for ac, dc, and USB-powered electronics. With its 600W capacity, it could power a portable light, cell phone, laptop, portable cooler, or small TV. You could also connect it to jumper cables to give your vehicle a little juice. For batteries strong enough to power emergency lighting, wheelchairs, telecommunications networks, and uninterruptible power sources, Panasonic offers a valve-regulated lead-acid (VRLA) rechargeable battery. Its predecessor, the classic lead-acid battery or flooded battery, is open to the atmosphere so gases escape the battery rather than being recombined back into water. With these types of batteries, water must be added back. Virtually all the gases created inside a VRLA battery are recombined back into water, so no water addition is required. This feature is why they are called maintenance-free.
Continued on page 16 NEMA electroindustry January 2013
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Whole House vs. Partial A whole house transfer switch has the distinct advantage of being able to run any of the loads in the home. Partial transfer switches, whether automatic, non-automatic, or manual, power only those critical circuits predefined by the homeowner. Thus, they require less attention, but are more restrictive in that they cannot power any loads other than the predefined critical circuits. Whole house systems usually require professional installation, as their installation generally affects the incoming utility power. Where a whole house transfer system is installed ahead of the existing service disconnect, the transfer equipment must be verified as marked suitable for use as service equipment. Partial transfer systems can sometimes be do-ityourself installations. Subpanel vs. Load Side A subpanel style transfer installation generally uses a small loadcenter that is powered by either the main loadcenter or the generator through a single transfer switch. It is a simpler system, but requires that the circuit conductors be moved from the main loadcenter into the subpanel. This can be a daunting challenge in some installations. Load-side transfer equipment is more complicated, involving a transfer switch for each individual load. However, they install after the branch circuit breaker, making installation much easier and less expensive. Separately Derived vs. Non-Separately Derived A separately derived system requires that all current-carrying conductors be switched (including the neutral). This requires the use of a three-pole (line 1, line 2, neutral) transfer equipment solution. (Ground conductors are not switched.) A non-separately derived system requires that both neutrals be solidly connected, not switched. This allows for the use of two-pole (line 1, line 2) transfer equipment. NEC allows either configuration. For additional information, see NEMA ICS 10, Part 1, Annex B1.
Backing Up Renewable Energy

Another feature of the VRLA battery is that it has a one-way valve that releases a buildup of gases in the event of abnormal or incorrect charging. Because a classic lead-acid battery does not have a valve, a buildup of gases could cause the battery to leak, blow out, or lose electrolytes. SAFT America, Inc., provides two different types of batteries: Sunica.plus nickel-cadmium (Ni-Cd) and nickel-metal hydride (Ni-Mh). The Sunica.plus Ni-Cd batteries are specifically designed for renewable energy systems such as wind, solar, or a hybrid of both. These batteries can withstand extreme temperatures and have long lifecycles. They can also be used for bigger backup power systems including telecommunication networks and signaling systems. The technology behind Ni-MH batteries is similar to Ni-Cd batteries in that bothchemistries use nickel oxyhydroxide in the positive electrode. However, Ni-MH batteries use a hydrogen absorbing alloy in place of cadmium in the negative electrode. Ni-MH batteries have a variety of uses ranging from powering personal mobility devices and small appliances to larger scale systems such as photovoltaic (PV), renewable energy, and emergency lighting. They can also be used for radio communication and tracking. Another useful application from a consumers perspective is that this technology can be used for electric and hybrid vehicles. SAFT also offers portable energy applications including a PV module, mobility module, and Smart VH module. The PV module, as you may have guessed, is well-suited for small, off-grid PV applications. The mobility module is designed for personal mobility applications including electric wheelchairs, scooters, and bikes. The Smart VH module is similar to the mobility module, but what makes it a little different is that it allows several batteries to be connected to it, giving it increased capacity. If these technologies seem a bit daunting, start small. Even an LED flashlight could help get you out of a darkened situation. ei Chrissy L. S. George, Assistant Editor/Writer | chrissy.skudera@nema.org
Stay Safe
With safety maintained as a top consideration, standby generators can be an effective means of protecting home and family from the ravages of Mother Nature. Transfer switches provide the only safe interconnection method. Be safealways use a transfer switch.
ei
Mr. Czarnecki is a member of 1IS and 5LVDE committees on transfer equipment, the NEMA primary representative to NEC Code Making Panel 13, chair of the CANENA committee on transfer switch standards, and other bodies. Mr. Scheffer is a member of NEMA 1IS, SCAC, and C&S Committee.
Find a manufacturer at www.nema.org/mfgs

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Much of the information in this article was adapted from NEMA ICS 10 Part 3 Safety Bulletin: NEMA Safety Considerations for Residential Transfer Equipment and Residential Transfer Switches, which can be downloaded at www.nema.org/Transfer-Switches.
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Three-Part Safety Portfolio Reduces Arc-Flash Risk

Incorporating motor control centers with remote monitoring, arc-resistant devices, and closed-door power-removal
Paul Krause, Development Manager for Low-Voltage MCCs, Rockwell Automation
Helping protect employees working on or near energized electrical equipment requires mitigating risks associated with high levels of incident energy, especially when the potential hazard is an uncontained arc flash of current that can reach 35,000 F. Extreme temperatures can cause clothes to ignite or even burn skin directly. Molten metal and shrapnel can explode into the air from a motor control center (MCC). Standards set forth by the National Fire Protection Association and other organizations have begun to address arcflash danger. Portions of OSHA and IEEE codes, as well as the National Electrical Code relate to standards for personal protective equipment and limits of approach focused on withstanding an arc flash. Other guidelines that take a proactive perspective include equipment design standards aimed at containing arc flash in the first place.
A robust arc-flash option provides: a pressure relief system that redirects gases through the top of the enclosure arc-containment door latches resistant to high internal blast pressures insulated power bus closing plates at the ends of each MCC lineup Using a lower horizontal bus rating (maximum 1,200 ampere bus) and smaller main disconnects reduces electrical hazard further by minimizing let-through energy within the MCC. Closed-door Technology Closed-door power removal technology allows an operator to disengage an MCC unit from the power source without opening the enclosure door. Removing the unit stabs from the power bus before opening the door to troubleshoot or perform maintenance minimizes personnel exposure to the main bus and hazardous voltage.
Improving arc resistance and adding closeddoor capabilities in Rockwell Automation CENTERLINE MCCs resulted from customer input and feedback critical to addressing the growing concern of electrical safety. Photo courtesy of Rockwell Automation
Three-Pronged Approach
The optimal approach to MCC arc-flash safety combines proactive, preventative methods with systems, designs, and features that protect employees from electrical hazards.
Remote Monitoring Extending IT infrastructure to control equipment and applications adds a risk management capability critical to avoiding arc-flash exposure. MCCs integrated with DeviceNet and EtherNet/IP (trademarks of the Open DeviceNet Vendor Association) networks enable personnel to monitor, troubleshoot, and diagnose the MCC remotely without exposure to dangerous conditions and power equipment. In addition, real-time remote data monitoring, without opening an MCC door, increases the ability to identify potential problems before a safety event occurs. Arc-Resistant Devices IEEE C37.20.7-compliant arc-resistant control devices and enclosures help protect personnel by minimizing arc initiation and increasing MCC structural containment properties.
After withdrawing and disconnecting the stabs from the power bus, an employee can open the door and remove the unit. Using a remote operation tool to disconnect and connect stabs places the operator safely outside the arc flash boundary. Premium closed-door technology uses a multipoint validation system to provide power removal confirmation, notifying the operator when the power stabs are entirely withdrawn from the vertical bus. Closeddoor power removal also helps companies put processes back online faster by reducing the need to obtain hot-work permits to service equipment.
Safety First
Rockwell Automation was the first NEMA MCC manufacturer to combine CENTERLINE ArcShield arc resistance and SecureConnect closed-door power removal technologies. Improved safetywith a focus on improved productivity and cost managementis an automatic, integral element in emerging MCC technology. ei Mr. Krause serves as engineering development manager for Low Voltage Motor Control Centers, Control Products & Solutions, at Rockwell Automation.
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Optimize Maintenance and Energy Efficiency
Monitoring Motor Operation Yields Significant Savings

Kevin Trimmer, Product Manager, Eaton Corporation.
small percentage of motors and motor loads in the U.S. are equipped with traditional condition-based monitoring systems, which are usually reserved for the most critical and expensive equipment. That leaves the majority of motors without monitoring systemsand a tremendous potential to save energy and reduce downtime due to unexpected conditions that are caused by a lack of data. Today, advanced relays provide a costeffective way to monitor parameters that can help organizations improve the energy efficiency of their systems.
Condition monitoring systems (CMSs) consist of hardwired vibration sensors, pressure transducers, and resistance temperature detectors connected to a data acquisition system. Qualified personnel then analyze the data from sensor outputs and take appropriate action. The lack of adoption stems from the costs, time, and complexity associated with conventional condition-based monitoring systems. Advanced motor overload and monitoring relays can help fill the gap. They monitor parameters to gain more precise and real-time perspective of performance. Although relays do not monitor the exact same parameters as a conditioning monitoring system, they provide critical information that can reduce costs, save energy, and improve maintenance.
Advanced relays help Sheboygan Regional Wastewater Facility identify and resolve situations before they lead to energy inefficiencies or downtime. Photos courtesy of Eaton Corporation
conventional wiring approach would not be cost-effective on these smaller motors, so the potential energy savings and optimized preventative maintenance would be negated. Yet, without critical power data, the resulting unscheduled downtime and inefficient operation of equipment translates into: reduced throughput environmental fines energy waste higher maintenance costs increased capital expenditure reduced profitability Today, solid-state motor overload and monitoring relays can provide real-time line, load and motor protection, and control. In addition to monitoring electric motor health, the technology provides line conditioning for improved motor reliability and reduced maintenance downtime. These electronic relays help reduce installation and infrastructure costs by up to 84 percent compared with conventionally wired systems. Further, all motors need a relay anyway. Users can configure the system locally or with a variety of standard industrial communication protocols, allowing for integration into supervisory control and data acquisition (SCADA), programmable logic control, and distributed control systems. Motor protection relays equipped with fieldbus protocols enable maintenance and operations teams to monitor key failure indicators on motors in real time. As
Monitoring All Systems Optimizes Uptime

Electric motor-driven systems used in industrial processes consume an estimated 23 percent of electricity in the U.S. Conventional field-wired sensors and CMSs have helped to dramatically reduce energy use by large motorsthose more than 200 hpthrough advanced monitoring and diagnostic systems that help facilitate maintenance and improve system uptime. There are a high percentage of critical loads at low horsepower where condition monitoring is not being utilized. Deploying similar monitoring systems on smaller motors, however, could reduce motor energy use by another 18 percent. The
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system performance problems are addressed, energy waste is avoided resulting in savings and improving system reliability simultaneously. Advanced relay control circuits and registers allow the data to initiate action locally or at system level. Instantaneous power consumption and motor efficiency monitoring enables real time optimization of energy usage required for the motor load condition. The technology is easily retrofitted and provides flexibility and expandability to accommodate plant complexity. With real-time, continuous information, maintenance teams can find potential issues before they cause downtime or waste energy. Instead of performing spot checks, personnel can detect variations from a centralized location. This speed of information helps personnel be proactive to avoid downtime. Solution The installation of the new motor protection relays (equipped with fieldbus communications) provided the plant with real-time monitoring of its motors and pumps at remote lift stations.
Advanced relays provide a cost-effective way to monitor parameters that can help organizations improve the energy efficiency of their systems, while reducing downtime
Previously, the extra power draw would have gone on for an extended time without being detected, leading to large energy losses and extra mechanical and electrical stress on the pump and motor. Using the data from motor overload and monitoring relays, a service technician was immediately dispatched. He removed a foreign object that was wrapped around the impeller, which had resulted in a decrease in the power draw back to the normal level. Results The advanced relays provide added monitoring and are helping Sheboygan identify and resolve situations before they lead to energy inefficiencies or downtime. With the ability to monitor motors and pumps in hard-to-access areas, Sheboygan now can trend real-time motor and pump conditions that could have gone unnoticed for days or weeks when using traditional bi-metal protection and flow meters. Additionally, a full suite of protection is provided, including a low power feature that protects pumps against starved or dead-headed conditions. ei Mr. Trimmer is the product manager for advanced motor protection with Eaton Corporation. His experience includes sales, marketing, and application experience in the electrical industry.
Real-World Example
Sheybogyan Regional Wastewater Treatment Facility serves 68,000 people in Sheboygan, Wisconsin. Average daily flow is about 11 million gallons, and if there is a rain event or substantial snowmelt, peak flow can reach 64 million gallons. It is essential that all pumps operate effectively to ensure that increased flow levels can be managed properly and adverse sewer problems avoided. Problem At its Indiana lift station, Sheboygan had three 75 hp motors with a full load current of 96 amperes. It was using three bi-metallic overload relays to protect the motors and flow meters on the output of the pump to ensure proper flow from the pumps. Flow data was communicated to its headquarters and logged in a SCADA system. However, they had no means of monitoring anything else related to the motor or pump. After retrofitting advanced overload and monitoring relays in place of the bi-metallic overload relays, the maintenance supervisor later noticed one of the three motors was drawing more power (75kW), while the other two were drawing only 50kW. Yet, all three flow meters for each pump reported the same flow reading. This increase, if left undetected, is equivalent to an additional $10,900 in annual energy costs, assuming a 50-percent duty cycle.
An advanced overload relays user interface combines protection, operation and monitoring values into a single display.
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MIT Study Creates Electroindustry-based Method for Mapping Products to Energy Use and GHG Emission
Robert Boteler, Government Relations, Nidec Motor Corporation
EMAs Motor and Generator Section (1MG) recently participated in a Massachusetts Institute of
Use, 99.778%
Materials, 0.115%
Technology (MIT) research project designed to increase NEMA members understanding of and ability to influence the environmental impact of their products, specifically with regard to energy and greenhouse gas (GHG) emissions.
Manufacturing, 0.094%
Characterizing the carbon footprint of a product generally requires a comprehensive lifecycle analysis that considers the environmental impacts of a product from raw material extraction and transportation to manufacturing (or service provision), distribution, consumer use, and end-of-life disposal. MIT has developed a streamlined approach, which focuses on the identification of the principal drivers of carbon impact within a product and the characterization of the effect of changes in those factors. The project leveraged existing data and input from NEMA member firms to create an electroindustry-based method for mapping product characteristics to potential energy use and GHG emissions. One valuable benefit of this effort is insight into the risks and opportunities for carbon mitigation within the industry.
Transport, 0.007% Assembly, 0.00025% End--of--Life, 0.006%
Figure 1. Overall lifecycle impact, expressed as global warming potential, of a typical 25 hp NEMA Premium electric motor, operated for 5,000 hours/year over 20-year lifetime powered by an average U.S. electricity grid mix. This is based on a general purpose, 6-pole, cast iron, premium efficiency, and total fan-cooled enclosure.
The study shows that, under typical use conditions for motors 1 hp and larger, the use phase dominates other lifecycle stages in terms of energy consumption, and the associated GHG emissions related to energy consumption are variable depending on dominant energy sources in the region in which the item is used (e.g., GHG emissions in a coal-dominated energy grid would be higher than in a hydroelectric-dominated energy grid). When a motor is fully employed during its entire service lifetime (5,000 hours/year for 20 years), the use stage makes up more than 99.8 percent of the impact in terms of lifecycle energy. If a motor is used at the same intensity for just one year, the use stage impact remains highly dominant, making up 98.6 percent of the lifecycle energy impact. However, there may be exceptions for motors that are not frequently in use. For motors that are used for 50 hours or less during their lifetime, the impact of materials and manufacturing stages is greater than that of the use stage. Under most use scenarios powered by the average U.S. electricity grid mix, the materials and manufacturing combined are responsible for less than 0.5 percent of total lifecycle carbon emissions, where the manufacturing burden is a bit lower than the materials burden. The MIT study evaluated three sample polyphase categories. NEMA members provided specific information detailing
Measuring Efficiency
The project also represents the initial phase of a broader exploration into this important issue. The methodology is scalable and expected to be applicable to a wide variety of NEMA products and divisions. Motors were selected as an initial test product because of their impactelectric motors are responsible for 40 percent of global electricity usage, most significantly from driving pumps, fans, compressors, and many other mechanical traction equipment. The International Energy Agency (IEA) estimates seven percent of global electricity demand could be saved through the use of higher energy efficiency motors (IEA, 2006). To date, limited research has been reported on the carbon footprint quantification and methodology development for these products specifically.
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the materials used as well as the manufacturing processes used for the production of each selected motor. The total masses of several types of motor products were obtained through the extensive review of product catalogues from 12 motor companies. Researchers at MIT used several statistical tools, including Monte Carlo simulation, to identify the top GHG contributors and their impact given the uncertainty in background data and contextual conditions. The total mass for a cast iron ac motor product (general purpose, three-phase NEMA ac motor) is closely related to frame size. There is a relationship between horsepower and frame size, as shown in Figure 2. The MIT study found variation in the data due to the number of poles, enclosure type, and efficiency class, as well as individual manufacturer differences. While there are differences in the mass fraction and materials for each component across a set of motor attributes, the study assumed that motors ranging from 1 hp to 100 hp have largely the same set of components, as well as the same mass fraction of these components. As a result, this analysis was used to quantify the GHG emissions in materials and manufacturing phases for an undefined motor between 1 hp and 100 hp, shown as a function of frame size. the application, design, and selection of motor-driven systems as a leading method of reducing GHG in the industrial and commercial market segments. NEMA is proud to have taken part in this important study that will help members and non-members better understand and evaluate their products GWP. 1MG introduced NEMA Premium high performance motor standards in 2001 as a clear way for end users and original equipment manufacturers to quickly identify polyphase motors having efficiency levels at or above nominal energy efficiency levels contained in ANSI/NEMA MG 1-2011 Motors and Generators, Table 12-12 or 12-131. The Motors and Generators Section continues to support motor-driven solutions that include the expansion of regulations that broaden motor types and categories covered by efficiency standards while maintaining performance and assuring interchangeability and retrofit capability for motor users in the U.S. ei Mr. Boteler received NEMAs Kite and Key award in 2007 for his work advancing efficient motors. He has spent more than 25 years promoting and developing motor efficiency programs including the NEMA Premium motors program and the electrical motors section of the Energy Independence and Security Act.
Motor-Driven Solutions
The determination that greater than 1 hp electric motors likely have more than 99.8 percent of global warming potential (GWP) in the use stage confirms the need to improve and manage
Contact NEMA for the current version of ANSI/NEMA MG 1.
Figure 2. There is a fixed relationship between horsepower and frame size. For an ac motor with given horsepower, frame size is variable, ranging from 2 poles, 4 poles, 6 poles, and 8 poles. Operated for 5,000 hours/year over a 20-year lifetime with an average US electricity grid mix.
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Applying the Law of Conservation of Energy

Ken Fonstad, HVAC Application Engineering Manager, ABB
hen input and output current measurements are made on a modern variable frequency drive (VFD), the current at the output of the VFD may exceed the input current to the VFD. This seems to violate the law of conservation of energy. Are the measurements and/or the reporting actually correct? If so, how can this happen?
Because this is an ac circuit, it is useful to look at the ac waves.
Voltage (V)
800 600 400 200 0 -200 -400 -600 -800
In order to understand what these measurements show, lets look at an example in detail and consider the way in which an ac induction motor draws current. Example The rms (root mean square) voltage and current below was reported on a start-up report for a VFD: input 22A at 476V; output 28A at 480V.
Voltage Boost
One question raised by this data dealt with the slight increase in rms output voltage compared to the applied input voltage. While this could be the result of a test meter that doesnt properly measure the voltage of pulse-width modulation (PWM), the meters measurement is most likely accurate. To understand this slight boost, it helps to know how a PWM VFD operates. The incoming ac voltage is rectified to produce a dc bus voltage, which is then inverted back to a controlled ac output voltage by the VFDs output stage. It is possible to provide a slight boost in the rms voltage supplied to the motor in each of these stages of the drive. On the other hand, the current drawn by the motor is significantly higher than the current drawn by the VFD. This is generally the greater cause of confusion. It appears that the VFD is making current from nothing. What is happening? First, the VFD does not really control the current drawn by the motor. It simply provides voltage to the motor and the motor draws the current that it needs. The amount of current that the motor draws depends on the load applied to the motor, the design of the motor, and the frequency and voltage of the ac that the motor receives. Example of Resistive Load To understand the relationship between voltage, current, and power, start with a simple example. Assume that 3-phase, 480Vrms ac voltage is applied to a 3-phase bank of resistors and the current drawn by each leg is 28Arms. The total power delivered to the bank of resistors can be calculated as: P=(3 ) V I where: V = 480V = 0.48kV; I = 28A; P = 23.3kW
Current (A)
50 40 30 20 10 0 -10 -20 -30 -40 -50 50
This is a resistive load; voltage and current are in phase with each other, i.e., voltage and current rise and fall at the same time and pass through zero at the same time. To calculate the power delivered to the bank of resistors, simply calculate the instantaneous 3-phase power at each point of the curves by using the same formula as above.
Power (kW)
50 45 40 35 30 25 20 15 10 5 0
When the voltage is positive the current is positive, and when the voltage is negative the current is negative; thus, the product of the two is always positive. The horizontal line shows the average power, which is the same 23.3kW that was calculated above.
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Example of Motor Load The above example is straight forward when the load on an ac circuit is a bank of resistors. However, when a motor is the load, things change. The problem is the coils in the motor. The coils have an electrical property called inductive reactance that tends to shift the phase of the current so that it lags behind the applied voltage. The data for this example was measured for a motor that was at about 60 percent of full load. The phase shift angle between the voltage and the current would likely be around 45. Voltage, current, and power graphs for the motor would look like this: kW. Apparent power is important even though it isnt the same as real power. For example, the rating of a transformer is based on the total current that passes through its windings, both the current supplied from the power source and the current that is recirculated by the load. Because of this, transformers are sized in kVA. One way to calculate real power is by calculating the average of the instantaneous power. The heavy horizontal line in the power graph shows this. The value of the average power is 16.5kW. The concept of power factor is often used in such calculations. It is the ratio of real power to apparent power. Since real power cant be greater than the apparent power, power factor is always less than or equal to 1. In the example above, the power factor is 0.707. Power Factor = (Real Power)/(Apparent Power) Power Factor = 16.5kW/23.3kVA=0.707
Current (A)
50 40 30 20 10 0 -10 -20 -30 -40 -50 50
Voltage (V)
800
Voltage (V)
800 600 400 200 0

800 600 400 200 0
600 400 200 0 -200 -400 -600 -800
Voltage (V)
-200 -400 -600 -800

Current (A)
-200 -400 -600 -800
Many meters measure apparent and real power. They must measure voltage and current at the same time. It is possible to calculate real power if apparent power and power factor are known. Real Power=Power Factor Apparent Power
50 40 30 20 10 0 -10 -20 -30 -40 -50 50
Current (A)
50 45 40 35 30 25 20 15 10 5 0
Power (kW)
50 40 30 20 10 0
Power (kW)
In the example above, the power factor of the lightly loaded motor was 0.707. The real power that the motor was drawing was: Real Power into the motor = 0.707 3 480 V 28 A = 16.5kW How does this compare to input power drawn by the VFD? The power factor of the input of a modern VFD is generally highin this case, around 0.955. A similar calculation for input power gives: Real Power into the drive = 0.955 3 476 V 22 A =17.3kW A comparison of apparent power drawn by the drive (18.1kVA) and apparent power drawn by the motor (23.3kVA) make it appear that the law of conservation of energy is being broken and the VFD is acting like a perpetual motion machine. The real power supplied to the drive was 17.3kW and the real power drawn by the motor was 16.5kW. Utilities often charge a power factor penalty to customers whose buildings have a low power factor because the extra current required to serve a building with a low power factor requires the utility to invest in larger distribution transformers and power lines. Because VFDs generally have a high power factor, they help buildings meet utility power factor requirements without the need to add power factor correction equipment. ei A teacher, Mr. Fonstad has also served as chair of the Engineering Committee of the Variable Frequency Drives Product Section of the Air Conditioning and Refrigeration Institute.
In each of the highlighted regions, the polarities of the voltage -10 -20 the current are opposite. The power in these regions is and -30 negative. Negative power means that this current isnt delivering -40 energy from the VFD to the motor. Instead, it is delivering -50 50 energy back to the VFD. This reactive or recirculating current is measured by the ammeter between the VFD and the motor. A power calculation using (kW) the ammeter reading will be Power too high.
50 45 40 35 30 25 20 15 10 5 0
50
45 Using the data above and (3 ) V I gives the following values: 40 input 22A at 476V and output 28A at 480V. 35
(3) V I= (3) 22 A 0.476kV=18.1kVA 25 (3) 15 V I= (3) 28 A 0.480kV=23.3kVA It looks like the drive is delivering more power than it is 5 drawing from the power line! 0
10 20
30
Apparently Its Power

In ac circuits, this is called apparent power, because it only appears to be power. Apparent power is measured in kVA to distinguish it from active or real power, which is measured in
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Fire Pump Motor Controllers At the Heart of Life Safety

William Buckson, NEMA Program Manager
hen it comes to Industrial Control Section products, perhaps none can be deemed more important or necessary to life safety than the fire pump motor controller. Forgotten or possibly relegated by some as the proverbial redheaded step child of motor controllers, not one building constructed higher than what municipal water pressure can provide whether it be for commercial, high rise residential, industrial, healthcare, or educational purposescan be legally occupied without one.
fire pump controls primarily based on technical data provided by NEMA 1IS SC10. Because the fire pump controller is required to be activated in emergencies when the usual power supply may become interrupted and or unavailable, transfer switcheswhether integral to the controller or provided upstreamare another 1IS product and component in the life safety system made up of the controller, motor, pump, and sprinkler arrangement. In fact, the inclusion and allowance of upstream transfer switches being located within the pump room in the 2013 edition of NFPA 20 are a result of a collaborative effort between the NEMA 1IS SC10 and 1IS SC 16 (transfer switch equipment) members.
Sprinkler systems in such buildings require these controllers to operate the motors that drive the pumps which in turn provide the required water pressure necessary to extinguish a fire in the event of an emergency. NEMAs 1IS Technical Subcommittee 10 (SC10), which comprises 99.9 percent of North American manufacturers of fire pump motor controllers, is charged with the responsibility for the technical oversight of these products, and is proactively engaged in UL, CSA, FM, CANENA, IEC, and most notably in NPFA 20 Standard for the Installation of Stationary Pumps for Fire Protection technical activities, where the heart and regulatory pulse of fire controller safety resides. This critical piece of equipment is typically isolated within its own protected environment in what is termed the pump room.
The Workings of the Fire Pump Room

The 2013 edition of NFPA 20 is the 30th revision since its origination in 1896. NEMA is expertly represented on the NFPA 20 panel by SC10 Chairman Richard Schneider, Joslyn Clark Controls, and SC10 Vice Chairman Bill Stelter, Master Control Systems. SC10 members pride themselves in the development of drafting numerous proposals as extract material for inclusion and reference into NFPA 70 National Electrical Code (NEC), under Article 695 Fire Pumps. Similar to other types of motor controllers, fire pump controller designs have evolved over the years as the result of advances in technology as well as the upgrading of many building code requirements. For example, sprinkler system pressure is typically sensed by transducers rather than environmentally unfriendly pressure switches that contain mercury. Furthermore, NFPA 20 recognizes variable speed electric as well as variable speed diesel
Harmonization Efforts
SC10 member companies were rewarded in 2006 for their technical harmonization efforts with the publication of the first tri-national fire pump controller standard (UL 218) developed under CANENA. Chairman Douglas Stephens, ASCO, is currently leading members in the development of the first revision of that standard, which will encompass the latest NFPA 20 edition changes. From an international perspective, SC10 members were instrumental in developing one of the few successful adoptions of a U.S.-based standard for international use, namely the IEC 62091, which when published in 2006, relied heavily on NFPA 20 philosophies. When the IEC 62091 re-surfaces for its maintenance cycle sometime during 2016, SC10 members and their expertise will again be central in its review and enhanced revision.
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product will provide an acceptable performance level deemed necessary in minimizing the potential for property loss that might be incurred in the event of a fire. There is no question that NEMA 1IS SC10 member products, though perhaps not considered as sexy as some, are instrumental components in the fire safety system confidence we have all come to expect from our sprinklered buildings not only here, but across the globe. Mr. Buckson ( bil_buckson@nema.org ) is the technical program manager for NEMAs Motor, Industrial Control, and Fuse Sections. In addition to working as a CSA project manager for lighting products, he was also an electronic technician with the U.S. Navy and spent 33 years with Hubbell Inc. in Wiring Device and Lighting Industries, as a testing, certification, and standards engineer.
Images courtesy of Firetrol Products
A unique and additional component of fire pump controller discipline is its mandatory compliance to factory global (FM) requirements if installed in premises insured by an FM-affiliated insurance carrier. FM 1331/1323 certifies that a compliant
1IS IEC Participation Grows

here is a significant commitment by the Industrial Automation Control Products and Systems Section (1IS) to actively participate in relevant parts of the International Electrotechnical Commission (IEC).
In IEC SC65B Measurement and Control Devices, staff and 1IS SC22 members have a strong presence developing requirements specifically for programmable controllers. Recent efforts by China, however, have forced the development of a new document under TC65 Industrial-Process Measurement, Control and Automation, as part of the 61010 series Safety requirements for electrical equipment for measurement, control and laboratory use. The section also supports work in TC44 Safety of Machinery; TC109 Low Voltage Insulation Coordination; TC70 Degrees of Protection Provided by Enclosures; SC17A and SC17C High Voltage Switchgear and Controlgear and their assemblies, respectively; and TC77 Electromagnetic Compatibility, particularly for its impact on functional safety. Through 1IS SC7, the section has strong involvement in SC22G Adjustable Speed Drives. The U.S. is secretariat for the committee and NEMA members are active working group members.
While NEMA has been well represented in relevant IEC SC17B Low Voltage Switchgear and Controlgear activities, more members are needed in IEC TC64 Electrical Installations of Buildings activities. Participation can affect installation requirements for member equipment. Members are urged to join USNC TAGs and review draft documents to ensure that U.S. concerns are addressed and U.S. products are not subjected to market access restrictions. There is continuing evidence that LVDC circuits will support an expanding number of applications, particularly the output of renewable energy resources and data centers, where there seems to be a focus on 390V dc systems. This seems to be an opportunity for new products, especially for control functions in dc circuits. Another significant activity for 1IS membership is the IEEE effort to create documents harmonized for North America to counter the European bias of IEC 61000-3-2 and 61000-3-12. ei Ken Gettman, Director of International Standards | ken.gettman@nema.org
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Energy Efficiency Improvement with Permanent Magnet Motors and Variable-Frequency Drives
Jun Kang, PhD, Manager of R&D and Applications Engineering, Yaskawa America Inc.
bout two-thirds of electricity is consumed by electric motors used in industrial facilities. According to the U.S. Department of Energy, motor systems are responsible for 63 percent of all electricity consumed by U.S. industry and the electric bill represents more than 97 percent of total motor operating costs.
In the induction motor, slip frequency (i.e., the frequency difference between stator rotating flux and mechanical rotating speed) induces current in the rotor windings. The interaction between rotating magnetic field and induced rotor current produces a driving force, but the rotor current causes copper loss (calculated as I2R) that decreases motor efficiency. Permanent magnet (PM) motors are more efficient than induction motors because there is no I2R loss in the rotor, and motor current is lower than in the induction motor. PM motors have many other advantages that include compact size, light weight, and high torque. A position feedback sensor has been one of the main obstacles that reduces the widespread use of PM motor for general-purpose applications. However, lowcost high-performance CPUs and establishment of the speedsensorless control theory in variable-frequency drives (VFDs) enables the introduction of reasonably-priced, highly efficient, variable frequency PM control drives. Figure 1 shows the energy saving effect of PM motors in HVAC application. One hundred VFDs are driving 3.7kW fan motors for ventilation for 24/7, 365 days a year at 75 percent speed. When induction motors are used, annual power consumption is about 1,810MWH while PM motors consume 1,670MWH.
Speed-sensorless control theory in variable-frequency drives has led to reasonably-priced, highly efficient, variable frequency PM control drives.
Permanent magnet motors are more efficient than induction motors. Photos courtesy of Yaskawa America Inc.
Saved energy is 140MWH and annual reduction in CO2 is approximately 58.8 tons. It corresponds to the CO2 absorption of 4,200 50-year-old cedar trees. Utility cost saving is about $16,800, assuming 12 cents per kWH. ei Dr. Kang is oversees technology innovation for power electronics and drive business at Yaskawa America Inc.
Figure 1. Efficiency of induction and PM motors controlled by VFD. Illustration courtesy of Yaskawa America
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Electroindustry News
2012 Motor Summit Convenes in Zurich
The 2012 Motor Summit was held in December in Zurich, Switzerland. It is held in alternating years that EEMODS (Energy Efficiency in Motor Driven Systems) is not scheduled. These are the two international conferences that bring together the motor industry. Organizer Conrad U. Brunner reported that 180 participants from 23 countries attended. is engaged with Motor Coalition partners and the U.S. Department of Energy. Mr. Hoyt wrote and presented another paper on the evolution of the NEMA Premium program for motors with a focus on the verification testing that was incorporated in 2010. Other topics at the Motor Summit included new motor systems efficiency policy for China, experiences with PM motors, Motor Policy Guide, and extended product approach for fan and pump systems. These are just a sample of U.S., Europe, Asia, and Australia. The meeting began with Mr. Delaney and Mr. de Ruvo outlining the basis of the proposed program. Two working groups were formalized, per previous meetings and discussions: MotorsStrategy MotorsTechnical Professor Martin Dopplebauer, KIT Germany, and Professor Bernd Ponick, University Hannover Germany, agreed to co-chair MotorsTechnical. Mr. Delaney and Mr. de Ruvo will continue with MotorsStrategy. Participants representing NEMA are Mr. Boteler and Mr. Hoyt (Strategy); and Bill Finley, Siemens; and Manny Gonzalez, GE (Technical). Provisional terms of reference for the project were discussed. These included determining the Conformity Assessment System (ISO/IEC) most appropriate for GMLP. The parties agreed that ISO Type 5 was the goal. The NEMA Premium motor testing and verification detailed in Appendix G and Appendix H of the NEMA Premium license will serve as the model for the planned testing and verification protocols. The meeting also included a review of existing IEC rules, additional requirements and operational procedures, label design, and business plan. The timeline for the GMLP is an aggressive 12 to 18 months, with an introduction planned for EEMODS 2013, which will be held October 28-30 in Rio de Janiero. ei William Hoyt, Industry Director | bill.hoyt@nema.org
Rob Boteler co-authored a paper on NEMA regulatory activity. Photos by Thomas Burla
The motor industry has become increasingly international, placing greater efforts at harmonizing and accepting test methods and performance standards. Three U.S. participants made important contributions to the summit: Rob Boteler, Nidec Motor Corporation and NEMA 1MG Energy Management Committee Chairman Dan Delaney, Regal-Beloit Corporation and NEMA/IECEE1 Global Motor Labeling Program (GMLP) Co-Chair William Hoyt, NEMA Industry Director Mr. Boteler and Mr. Hoyt co-authored and presented a paper on NEMA regulatory activity in which the industry
1
William Hoyt presented a paper he wrote on the evolution of the NEMA Premium program.
papers and presentations delivered by academia, policy experts, and motor manufacturers. Next Steps on Labeling After two organizational meetings prior to Zurich, NEMA and IECEE met on the last day of the summit for the first meeting of what is now the IECEE GMLP. It formalized the structure of the working groups and established building blocks for the program. Mr. Delaney is co-chair with IECEE Executive Secretary Pierre de Ruvo. The meeting was called to order with representatives present from the
IEC System for Conformity Testing and Certification of Electrotechnical Equipment and Components
Download copies of presentations at www.motorsummit.ch

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Medical Imaging Industrys Leadership to Protect Patients from Unnecessary Radiation
The medical imaging industry has revolutionized the ability to diagnose and treat patients with technologies that have enhanced the quality of healthcare and ushered in a new era of medical diagnostics. With some modalities, these images are generated using x-rays, and through the Medical Imaging & Technology Alliance (MITA), a division of the National Electrical Manufacturers Association (NEMA), manufacturers have collaborated to develop industrywide standards to reduce patient exposure to unnecessary radiation. This year, NEMA published two control standards to enhance the safety of medical imaging technologies without compromising their quality. XR 262012 Access Controls for Computed Tomography (CT): Identification, Interlocks, and Logs requires that specific permission is assigned for selected uses beyond those needed for daily routine scanning. By limiting access to alter protocols and permitting manual locking of the user interface, unauthorized users cannot access system controls. With these new safeguards in place, only authorized users can perform or change protocols, thereby minimizing the patients risk of exposure to undue radiation. Similarly, XR 27-2012 X-ray Equipment for Interventional Procedures User Quality Control Mode helps imaging facilities conduct quality testing and monitor x-ray equipment by providing an essential set of equipment controls and quality tools. Quality control user interfaces provide controlled access for x-ray dose-related constancy testing, access to and export of imaging data, electronic documentation of dose-related parameters in exam protocols, and direct access to radiation dose structured reports. These new standards build on MITAs longstanding commitment to ensure safe and effective patient care without compromising access to the most advanced, high-quality medical technologies available. For example, XR 25-2010 CT Dose Check, published in 2010, introduced two new features that assist medical practitioners in providing better care: dose notifications and dose alerts. The initiative allows manufacturers to reduce cumulative dose and medical errors by deploying additional notifications and dose alerts, and recording dose information. With these new safeguards and standards in place, physicians are better equipped to use medical imaging technologies to diagnose disease, monitor treatment, and save lives, as evidenced by recent peer-reviewed research studies. Case Studies For instance, research conducted at the Memorial Sloan-Kettering Cancer Center and published in the Journal of the American Medical Association ( JAMA) in May 2012 indicates that low-dose computed tomography (LDCT) screening of individuals at increased risk for lung cancer results in significantly fewer lung cancer deaths (356 vs. 443 deaths; lung cancerspecific mortality, 274 vs. 309 events per 100,000 person-years for LDCT and control groups, respectively). A study published in the April 2012 issue of JAMA affirmed that advanced screening methods beyond mammography are enhancing breast cancer diagnosis for women in higher risk groups. Specifically, the use of ultrasound or MRI as an adjunct to mammography to detect cancer in women with dense breasts and other risk factors. As demonstrated by these and other recent studies, medical imaging is an increasingly critical component to early disease detection. Despite the numerous benefits provided by medical imaging technologies, medical imaging manufacturers recognize the importance of mitigating the risks posed by ionizing radiation. The industry is committed to developing new products, system innovations, and patient care initiatives that optimize radiation dose while continually improving the ability of these technologies to aid physicians to diagnose disease and stage treatment. For example, in June 2012 MITA received the U.S. Food and Drug Administrations Leveraging/Collaboration Award for developing a cooperative network aimed at reducing unnecessary medical radiation exposure to pediatric patients. MITA has also partnered with the Alliance for Radiation Safety in Pediatric Imaging and its Image Gently campaign to educate medical professionals and parents about imaging protocols that can reduce imagingrelated dose for children. MITA companies also champion and implement ALARA, the as low as reasonably achievable principle, a universal guideline of radiation dose management and optimization that is incorporated into the development of all imaging procedures and technologies. Advancement of medical imaging technologies requires technological innovation to enhance image quality as well as minimize exposure to radiation. With the introduction of new standards and ongoing radiation safety initiatives, medical imaging manufacturers are undeniably leading the charge. ei Gail M. Rodriguez, PhD, Executive Director of MITA | grodriguez@medicalimaging.org
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ESFI Recognizes Electrical Safety Leaders

The Electrical Safety Foundation International (ESFI) has announced the recipients of its two annual awards that recognize leaders in electrical safety. John M. Grau received the foundations annual Outstanding Service Award in Honor of Harold Leviton, which was formally established in 2008 as a tribute to Mr. Levitons impressive legacy and dedication to improving electrical safety. During his tenure on ESFIs Board of Directors (19962010), Mr. Grau served as treasurer, chair of the development committee, and vice chair of ESFIs endowment campaign. As a board member during the foundations infancy, he was integral in establishing the solid framework that allowed the foundation to grow steadily. Currently the CEO for the National Electrical Contractors Association (NECA), he has been raising the bar for safety standards among Schneider Electric is an industry leader in anti-counterfeiting initiatives that has kept more than 250,000 potentially hazardous counterfeit goods out of the marketplace and filed 13 civil lawsuits against 40 companies involved in the manufacture, importation, and distribution of counterfeit electrical products.
Chris Curtis accepted the SAFE award on behalf of Schneider Electric at Illuminations Weekend. Photo by Eric Sorenson
electrical contractors since he began his career at NECA in 1976 as a field associate. Schneider Electric received the 2012 Safety Award for Excellence (SAFE) for outstanding efforts in fighting counterfeit electrical products. Chris Curtis, CEO, Schneider North American, accepted the honor on behalf of Schneider during NEMAs 2012 Illuminations Weekend dinner.
In December 2011, Schneider Electric launched the first report and reward program of its kind in the electrical industry. It conducts international investigations and raids, monitors the internet to identify counterfeiters and remove their listings, sponsors international anti-counterfeiting conferences, and works with federal authorities on criminal investigations.
ei
Julie Chavanne, Communications Manager, ESFI | julie.chavanne@esfi.org
Magnet Wire Section Elects David Reed Section Chair

J. David Reed, Executive Vice President, Essex Group North America, has been elected as Section Chairperson of the Magnet Wire Section (6MW). Over the past 25 years, Mr. Reed has worked for U.S. Gypsum, Newell Rubbermaid, and Superior Essex in various engineering, operations, and executive management roles. He served as president of Anchor Hocking Glass and Little Tikes while with Newell Rubbermaid. Since 2007, Mr. Reed has served as president of Essex Group, Inc. and executive vice president of Superior Essex, Inc. He is responsible for the North American magnet wire, Essex Brownell distribution, and copper rod business segments. ei
NEMA Board Approves New Members

Full Membership Bluffton Motor Works www.blufftonmotorworks.com Motor & Generator Section (01MG) Brook Crompton North America www.brookcromptonna.com Motor & Generator Section (01MG) OttLite Technologies Inc. www.ottlite.com Lamp Section (02LL) Piramal Imaging imaging.piramalhealthcare.com Molecular Imaging Section (09MO) Spectrum Dynamics www.spectrum-dynamics.com Molecular Imaging Section (09MO) Ultrasave Lighting Ltd. www.ultrasave.ca Ballast Section (02BL) US Radiopharmaceuticals www.usradiopharm.com Molecular Imaging Section (09MO) USI Electric www.usielectric.com Signaling Protection & Communication Section (03SB) ASSOCIATE MEMBERSHIP Cobham Technical ServicesVector Field Software www.cobham.com EV Connect evconnect.com/#1 Electric Vehicle Supply Equipment/ Systems Section (05EV) HD Supply Power Solutions www.hdsupply.com/powersolutions
ei
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Innovation Incentive: How to Engage Suppliers and Drive Innovation
Today, its not simply enough to say that you are an innovative company; you must be able to continuously demonstrate your capability and capacity to innovate. The challenge is that there is not much new under the sun, and unless you are blessed (or burdened) with a significant structure and budget to support continuous research and development, driving innovation can very quickly become an uphill battle. Fortunately, all hope is not lost. Innovation in its less than pure form can be invoked if we set aside the idea of continuously investing in and testing new ideas and concepts, and shift our focus to determining how we might better utilize existing resources to drive new and innovative change. The answer to this somewhat challenging question lies outside our very door, literally. Innovation can and should be driven through supplier engagement and incentives. Several years ago, I was asked to negotiate a contract resolution between an electronic component supplier and its customer. The customer had, over a period of 12 months, requested and purchased dozens of components in an attempt to complete a ballooning and fragmented project. The plight to develop an innovative solution to a longstanding problem had resulted in several misguided investments, none of which was able to resolve the problem. The customers unwillingness to engage their supplier in developing an innovative solution resulted in unnecessary material costs and significant delays, the results of which had tarnished the buyer-supplier relationship to the point that mediation was required. But who was at fault? It was apparent that the customer had failed to consider two very basic tenants of the circumstances at hand. First, what was the root cause of the problem? Second, who might be most qualified to address the root cause(s)? The electronic component supplier had never been engaged in the problem, only used as a resource to provide material. The component supplier in turn failed to ask its customer about the reasons behind the excessive and somewhat erratic purchases, thereby missing the opportunity to engage sub-tier suppliers to determine if more innovative and less costly solutions existed. To be innovative is to offer solutions to customers that resolve issues that either do not yet exist or have not escalated to the point that resolution is deemed to be necessary. This type of innovation requires engagement at all levels of the supply chain, including sub-tier suppliers. Casemore and Compay has identified several steps to creating such innovation. Here are the top three: 1. Convey intent. Today the buyersupplier relationship is still adversarial to a large extent. Customers identify problems, outline possible solutions, and then ask suppliers for products or services that will deliver intended solutions. There is very little dialoguejust one-way communication. Intentions between buyer and supplier must be clear. Using supplier portals (e.g., Graingers Gateway) or investing in supplier conferences (e.g., Kicker Audio) are great ways to initiate dialogue with suppliers to outline your intent to collect, analyze, test, or engage in developing new solutions. If you dont communicate your intent, dont expect results. 2. Collaborate. Beyond the everyday sales transactions are opportunities to identify new choices, test options, and develop robust solutions that are both unique and innovative. Proctor and Gamble (P&G) makes a concerted effort to reach out to its supply base and collaborate on solutions. As a result, P&G has made the claim that it expects more than half of its innovation to be generated outside of R&D in 2012, making collaboration a strategic component of its innovation formula. 3. Whats in it for me? Despite collecting revenue, what would engage a supplier to invest in new opportunities? The theory behind Pavlovs dog still applies today. Suppliers must have incentive to invest time and resources in innovation. Incentives can vary depending on the complexity of the innovation and the organization, but using supplier rewards and recognition, or sharing in the profits and progress of innovative ideas are great examples of how to encourage suppliers to participate. Innovation is not something that can be achieved alone, nor is it an elusive new concept that must be first proven in R&D. The most innovative ideas are often those that evolve as a collaborative concept. Engage your suppliers to provide incentives to drive innovation and watch your competitive advantage soar. ei Shawn Casemore, Founder and President, Casemore and Company, Inc. | shawn@casemoreandco.com
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Code Actions/Standardization Trends

ANSI C12 Electricity Metering and Smart Meter Updates
ANSI C12 is the accredited standards committee that develops and maintains standards for electricity metering. As secretariat, NEMA administers the C12 main committee and various subcommittees and working groups that champion the work of C12 projects. ANSI C12 SC1 C12 SC1 subcommittee is primarily focused on revision of ANSI C12.1 and ANSI C12.10 standards. ANSI C12.1 American National Standard for Electric MetersCode for Electricity Metering establishes acceptable performance criteria for new types of ac watthour meters, demand meters, demand registers, pulse devices, and auxiliary devices. ANSI C12.10 American National Standard for Physical Aspects of Watthour MetersSafety Standard was revised and published in June 2011. C12 SC1 met in October in conjunction with Edison Electric Institute Transmission and Distribution meetings. A service switch document is in final review and will be balloted soon. Subcommittee members are discussing several safety tests. The work on inservice performance is also in the review process. The subcommittee is looking at the effects of harmonic frequencies and is making several changes to what will become the new version of C12.1, expected in 2013. ANSI C12 SC15 C12 Subcommittee 15 covers meter sockets and test blocks. Some of the standards in review to be balloted for reaffirmation or revision are: ANSI C12.7-1993 (R2005) Requirements for Watthour Meter Sockets ANSI C12.9-1993 (R2005) Test Switches for Transformer-Rated Meters
Charticle courtesy of Zpryme Smart Grid Insights
ANSI C12.11-2006 (R2007) Instrument Transformers for Revenue Metering, 10 kV BIL through 350 kV BIL (0.6 kV NSV through 69 kV NSV) C12 SC15 also reviews and provides input to the development and maintenance of ANSI/UL 414 Standard for Meter Sockets. ANSI C12 SC17 C12 Subcommittee 17 and working groups 1, 2, 3, and 4 met in October to address development, revisions, and other technical issues regarding data communication electricity metering protocols. Standards under the purview of C12 SC17 are: ANSI C12.18 Protocol Specification for ANSI Type 2 Optical Port ANSI C12.19 Utility Industry End Device Data Tables
NEMA Smart Meter Package

contains all parts of ANSI C12 and NEMA SG-AMI 1 Purchase the Smart Meter Package or learn more at www.nema.org/Smart-Meter-Package
ANSI C12.21 Protocol Specification for Telephone Modem Communication ANSI C12.22 Protocol Specification for Interfacing to Data Communication Networks ANSI C12.23 (Draft) AMR Device Compliance Test Standards For more information on ANSI C12 or to participate on the committee to develop these standards, contact paul.orr@nema. org, 703-841-3227. ei Paul Orr, Program Manager | paul.orr@nema.org
31
International Roundup
NEMA Launches Latin America Initiative
Building on the very successful Promotion of U.S. Electrical Product Exports to Central America, Dominican Republic, and the Andean Region, a four-year program funded in part by the Department of Commerce Market Development Cooperator Program, NEMA launched a new initiative funded entirely by its sections. The new program focuses on the Latin American countries having free trade agreements with the U.S.Chile, Colombia, Costa Rica, Dominican Republic, El Salvador, Guatemala, Honduras, Nicaragua, Panama, and Peru. NEMA staff developed strong working relationships with the key organizations in each country responsible for codes and standards that impact members products. Moving beyond these successes, the program has the following objectives: formal adoption of electrical installation codes that are based on the National Electrical Code in all the target countries formal adoption of product standards harmonized with those used in North America by all the target countries formal adoption of energy codes and green building standards that are consistent with the latest versions available in the U.S. increased awareness and understanding by the governments and electrical communities in the target countries about the need for conformity assessment and inspection to ensure safe electrical installations heightened awareness about the proliferation of counterfeit products by the electrical community and local customs officials proactive encouragement of energy efficiency regulations that are consistent with North American requirements
A very specific list of activities has been defined for the program, including regular meetings between NEMA staff and key officials in each of the target countries, to discuss and advance all the subjects included in the list of objectives. Organizations slated for meetings include standards development organizations; conformity assessment authorities; government officials, particularly commerce and energy; customs officials to discuss intellectual property rights, counterfeit products, and action plans; leading electrical distributors; member company representatives in each country; and U.S. embassy officials. In addition to regular networking and intelligence-gathering meetings, NEMA will organize and conduct technical seminars/workshops on specific product systems to address electrical distribution and utilization issues such as overcurrent protection, bonding and grounding, etc. This differs from previous workshops conducted on more general topics electrical installation code; product standards; and testing, certification, and inspection. The new program will focus particularly on the products from the sections providing funding. Plans include three or four such workshops in different countries each year, resulting in at least one such workshop in all of the countries by the end of the three-year project. Latin America continues to be a region that attracts electrical product manufacturers from the European Union and more recently from China. These global competitors look upon the region as a growth market and strive to either displace U.S. technology or to eliminate any codes and standards, allowing for low-cost and unsafe products to proliferate in the market. ei Gene Eckhart, Senior Director for International Operations | gene.eckhart@nema.org
32
Learn
More
The Medical Imaging & Technology Alliance (MITA), a division of NEMA, is the leading organization and collective voice of medical imaging equipment, radiation therapy and radiopharmaceutical manufacturers, innovators, and product developers. MITA standards enhance the safety of medical imaging without compromising quality. XR 25 allows manufacturers to reduce cumulative dose and medical errors by deploying notifications and dose alerts. XR 26 safeguards protocols and system controls. XR 27 helps imaging facilities conduct quality testing and monitor equipment. More at www.www.medicalimaging.org
February
Lights up on lighting systems. Energy savings from lighting can no longer be achieved simply by using an appliance/ component approach. It can be achieved, however, when lamps, ballasts, drivers, luminaires, and controls work together in a systems approach. Next months issue of ei explores lighting controls, LEDs, and other new technologies; updates from the Department of Energy and enlighten America; and the second annual members Product Showcase.
Coming in
NEMAs Industrial Automation Division includes Industrial Automation Control Products and Systems Section (1IS) as well as motors and generators, arc welding, carbon/manufactured graphite, and power electronics. For a list of 1IS standards, visit www.nema.org/ Industrial-Automation-Standards The NEMA Premium program covers single-speed, polyphase, 1500 hp, 2, 4, 6, and 8 pole, squirrel cage induction motors. Contact NEMA for the current version of ANSI/NEMA MG1. www.nema.org/ NEMA-Premium-Motors
Stock art Credits:

Cover, 1 & 9 iStockphoto.com/mennovandijk
13 iStockphoto.com/Kativ 13 iStockphoto.com/fotomy
13 iStockphoto.com/IPGalanternikD.U. 13 iStockphoto.com/Lenorlux
14 iStockphoto.com/geopaul 32 Maximus256/Shutterstock.com
Economic Spotlight
EBCI Gauges Business Confidence
The Electroindustry Business Confidence Index (EBCI) indices gauge the business confidence of the electroindustry in Asia, Europe, North America, and Latin America. The most recent EBCI for current North American conditions can be found at www.nema.org/Dec12-EBCI. Shipments of Industrial Control Equipment Weaken NEMAs Primary Industrial Controls Index decreased 1.6 percent on a quarterto-quarter basis during the third quarter of 2012. The index stands 1.2 percent below its year-ago level but 45 percent above the cyclical trough observed in mid-2009. More at www.nema.org/ ShipmentsOfIndustrialControl Motors Shipments Fall Sharply Demand for motors declined for first time this year during the 2012Q3. This backslide follows on the heels of a 5.4 percent gain posted in the second quarter and a 5.9 percent gain recorded in the first quarter of this year. More at www.nema.org/MotorShipmentsFall Lighting Equipment Demand Dwindles NEMAs Lighting Systems Index declined in the third quarter of 2012 after a positive performance in the first half of 2012, falling 3.3 percent on a quarterto-quarter basis. On a year-over-year (y/y) basis, the index decreased by 1.1 percent. Lighting equipment demand has struggled to gain traction since the recovery began and remains well below the levels observed during the previous economic expansion. More at www. nema.org/LightingEquipmentDwindles HID Lamp Shipment Indexes Continue to Decline Indexes for high intensity discharge (HID) lamp shipments declined for the second consecutive quarter in 2012Q3. More at www.nema.org/ LampShipmentsDecline T12 Fluorescent Lamp Index Tumbles The T12 lamp shipment index tumbled to 37.5 a decline of nearly 40 percent on a y/y basis during Q3the first quarter following the implementation of the new efficiency standards for general service fluorescent lamps. More at www.nema.org/ FluorescentLampTumbles ei
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The Association of Electrical Equipment and Medical Imaging Manufacturers nwww.nema.orgn January 2013 n Vol. 18 No.

Contemplating the Future of Smart Manufacturing

Did you know...

7. PPL 1,403,ELECTRIC UT 889 ILITIES (7% / CORP, 4%)

6. ALABAMA POWER CO, 1,405,947 (7% / 4%)

Top 10 Utilities by Total Smart Meters

1. P 4,6 ACIFIC G 41,9 AS 52 & ELEC (23% TRIC / 14 CO, %)

GY, T ENER / 6%) ERPOIN 6 (9% 5. CENT863,28 1,

4. GEOR A PO 2,148GI ,720 WER CO, (11% / 7%

O, IC C ECTR & EL % ) GA S / 4 IEGO (7% AN D ,417 8. S 1,352

2. FLORI DA POWE 2,793, R & LIG 499 (14 HT CO, % / 8% )

#. UTILITY, ### (XX% / XX%)

TOP TEN UTILITIES = 60% OF ALL U.S. UTILITIES

EBCI Gauges Business Confidence .....................................................................................................................................................IBC

COMPANY DELIVERY ELECTRIC (13% / 8%) 3. ONCOR 462 2,664, LLC,

COMMENTS FROM THE C-SUITE

Evan R. Gaddis President and CEO NEMA electroindustry January 2013

Views from the Top

NEMA electroindustry January 2013

Views from the Top

Government Relations Update

Jim Creevy, Director of Government Relations | jim.creevy@nema.org

Cyber Threat Looms Over 113th Congress

NEMA electroindustry January 2013

President Signs Energy Efficiency Bill into Law

NEMA Welcomes Vote to Normalize U.S.-Russia Trade Relations

NEMA electroindustry January 2013

Government Relations Update

CPSC, Industry Prepare for 2013 Activities

Sarah Owen, Government Relations Manager | sarah.owen@nema.org

NEMA electroindustry January 2013

Industrial Automation, Controls, Systems

Setting the Stage for

U.S. Census Bureaus 2010 Annual Survey of Manufacturers

NEMA electroindustry January 2013

Streamline Drives Configuration Data

say goodbye to the complicated world of drivecontroller integration.

Remove Cryptic Parameter Descriptors

Reduce Chance of Mismatch I/O

NEMA electroindustry January 2013

Industrial Automation, Controls, Systems

Innovative Robotic Palletizing System Highlights Manufacturing and Distribution Center

NEMA electroindustry January 2013

Industrial Automation, Controls, Systems

Recent Evolution in Industrial Manufacturing Leads to Improved Quality, Better Output

NEMA electroindustry January 2013

Automatic or NotMaking the Switch

Choices, Choices, Choices

NEMA electroindustry January 2013

Industrial Automation, Controls, Systems

Alternative Backups Sources on the Rise

Continued on page 16 NEMA electroindustry January 2013

Backing Up Renewable Energy

Find a manufacturer at www.nema.org/mfgs

NEMA electroindustry January 2013

Industrial Automation, Controls, Systems

Three-Part Safety Portfolio Reduces Arc-Flash Risk

NEMA electroindustry January 2013

Optimize Maintenance and Energy Efficiency

Monitoring Motor Operation Yields Significant Savings

Monitoring All Systems Optimizes Uptime

NEMA electroindustry January 2013

Industrial Automation, Controls, Systems