Automation and Drives

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Contents
A&D SD Standard Drives

1 (CEMEP - EU) - Background 2 3 3 EPACT Main Objectives Comparison of EPACT / CEMEP Measures EPACT/ CEMEP Motors not covered

4
5 6 7 8 9 10

Measures
Motor selection of efficiency Saving energy by optimising the system Profiting from Energy-Saving Potential Checklist for EFF2 and EFF1 motors Mechanical efficiency Siemens Motor Sources

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EU CEMEP Background
A&D SD Standard Drives

Background - Introduction of efficiency classes acc. to CEMEP - EU

After the example set by the USA with the EPACT law, the EU is now taking the initiative in co-operation with CEMEP1) to implement measures for improving the efficiency levels of electrical drives. Motive: Reduction of the emission of CO2. CEMEP prescribes efficiency classification for 2-pole and 4-pole motors in the power range from 1.1 to 90 kW. Efficiency is subdivided into three classes so that 2 characteristic curves define the three classes: "eff1" (High-efficiency motors) "eff2" (Improved-efficiency motors) "eff3" (Standard motors)
1)

CEMEP = European Committee of Manufacturers of Electrical Machines and Power Electronics; Efficiency determined as before according to EN 60034-2

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Voluntary Agreement (EU) Main motives for efficiency classification

A&D SD Standard Drives

The main objectives of the motor manufacturers are:

Increase in customer benefits by achieving savings in energy costs Market transparency for customers and users Facilitation of motor selection for the user

(Source: ZVEI brochure) : Electrical Drives: Cost savings instead of regulation

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Comparison of EPACT / CEMEP

Law/ Voluntary commitment
A&D SD Standard Drives

EPACT - USA
Status Legally prescribed minimum efficiency 2-, 4- and 6-pole 60 Hz squirrel-cage motors 1 to 200HP (0.75 to150kW) IEEE 112 B Nominal value N acc. to NEMA MG1 Rating plate with Efficiency (N) and CC032A

CEMEP - Europe
Voluntary undertaking to classify efficiency drastically reduce EFF3 motors 2- and 4-pole 50 Hz squirrelcage motors 1.1 to 90 kW Individual-loss procedure in acc. with IEC 60034-2 Tolerance in acc. with IEC 60034-1 Efficiency class on rating plate of motor N, 3/4 load and efficiency class in documentation

Motors covered Efficiency determined acc. to Efficiency ( Tol.)

Marking required

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Automation and Drives

Comparison of EPACT / CEMEP

Motors not covered
A&D SD Standard Drives

EPACT - USA
Motors <1 HP and > 200 HP Motors > 6-pole Voltages and frequencies different to

CEMEP - Europe
Motors < 1.1 kW and > 90 kW Motors > 4-pole Voltages and frequencies different to 400 and 525 V 50Hz Special motors/constructions Pole-changing motors Brake motors, single-phase motors Variable-speed drives Force - cooled motors Integrated geared motors Intermittent operation Special environmental conditions Ex motors Hollow-shaft motors

230V, 460 V/ 60 Hz Motors with flange Special motors/ constructions Pole-changing motors Brake motors, single-phase motors Variable-speed drives Force-cooled motors Geared motors Intermittent operation Partially and completely overhauled motors NEMA - design C and D (i.e. MA > MK)

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EPACT
Rating plate Frenstat
A&D SD Standard Drives

Efficiency class (CEMEP)

50 Hz (CEMEP)

Only when ordered as design UL (Option D31)

60 Hz (EPACT)

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Measures
Siemens and CEMEP, 4- pole
A&D SD Standard Drives
Efficiency, 4 pole motors
100

EFF1_1LG6 95 EFF1_1LA9,1LA6-E,1LA6-G EU-EFF1 EU-EFF2 EFF2_1LG4

90
Efficiency %

EU_EFF2 EU_EFF1 Bisher 1LA5/6/7 Bisher 1LA6/9 EFF2_1LA5/6/7 EFF1_1LA6/9 EFF2_1LG4

Previously 1LA6/9 85

80 EFF2 1LA7, 1LA5/1LA6-A 75 Previously 1LA5/6/7

EFF1_1LG6

70 1,00

10,00 Output kW

100,00

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Measures
Comparison of active components
A&D SD Standard Drives

EFF1 - Stator

EFF1 - Rotor EFF2 - Stator

EFF2 - Rotor

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Measures
Reducing individual losses
A&D SD Standard Drives INPUT
Better quality of laminations used Reduced magnetic stress Larger core assembly Active power from mains Winding resistance reduced due to larger wire cross-section

Stator
P Fe1 ~ K Fe * B2
B2 ~ 1/ m2Fe P CU1 ~ I12 * R1

Rotor
Improved bearings and fans

CU2

~ I22 * R2

PR

OUTPUT
Mechanical output Winding resistance reduced due to larger rotor slots (section geometry)

Efficiency increase due to better use of active materials

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Voluntary Agreement (EU Project) Facilitation of motor selection

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[%]
95

Trend

EU-efficiency classes for motors: High-efficiency

90

Improvedefficiency Standard

85

80

75

Subdivision into three efficiency classes according to the EU/CEMEP-agreement

1 10

The consequence: Siemens already stopped producing EFF3-standard-motors and just produces the energy-saving motors EFF1 and EFF2 instead

70

100 [kW]

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Saving energy by optimising the system

Example: turbo machine drive
A&D SD Standard Drives Flow control by throttle Power input 285% Losses in: Transformer Flow control by rotational speed Power input 160% Losses in: Transformer ~ Motor ~ 152% Pump

281%
M 265%

158%
Inverter

M
142%

160%
X 100% Throttle valve

Motor

100%

Pump

Effective output

Effective output

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Automation and Drives

A&D SD Standard Drives

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Automation and Drives

Profiting from the energy-saving potential

Checklist for choosing drives efficiently
A&D SD Standard Drives

Always control the energy saving balance.

The purchase of a frequency converter for automatic speed control will often be amortised shortly by saving energy.
From 2000 operating hours per year on, energy-saving motors EFF1 generally are the more economic alternative.

For short operating times (e.g. actuator) energy-saving motors EFF2 are sufficient.
By exchanging existing motors into energy-saving motors, the energy-costs decrease. If the motor needs to be repaired, check, if it is more economical to buy a new energy-saving motor.

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Efficiency Comparison at 100% and 75% of Rated Power

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Efficiency Comparison 6600V 4 pole 50Hz

98 97,5

Efficiency

97 96,5 96 95,5 0 500 1000 1500 2000 2500 3000 Output Power [kW]

Siemens eff. @100% Comp.eff. @100% Siemens eff.@75% Comp.eff.@75%

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Automation and Drives

Customer Benefits
A&D SD Standard Drives

ENERGY SAVING Example: 1500kW, 2 pole, 6600V Motor (actual info) Siemens eff. 97.2% Comp. Eff. 95% Running time: 24 hours per day, 365 days per Year Energy cost: R0,2 per kWh

Saving with an improved efficiency

R62 612 pa

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Source of Supply - Imported

A&D SD Standard Drives

Czech Republic, Mohelnice Factory

From 2.2 kW to 18,5 kW ( CI and Al type ) 100 to 160 Frame size 2 to 8 pole 400V to 690 Statistics 1,91 million motors manufactured annually 1800 employees

ISO 9001 and ISO 14000

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Source of Supply - Imported

A&D SD Standard Drives

Czech Republic, Frenstadt Factory

From 22 kW to 250 kW 180 to 315 Frame size 2 to 8 pole 400V to 690V Statistics 95 000 motors manufactured annually 800 employees

ISO 9001 and ISO 14001

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Automation and Drives

of AC Motors acc. IEC and ANEMA

A&D SD Standard Drives N-compact IEC
200 - 1000 kW

H-compact IEC
200 - 3000 kW 2 - 11 kV 2 - 12 pole Squirrel cage

H-compact PLUS IEC, ANEMA

1000 - 7000 kW 1340 9390 HP 3.3 - 13.2 kV 2 - 12 pole Squirrel cage Cast iron-/ Steel housing, cooler assembly IP23, IP55, WP II

Series 1R.5/S.5 IEC

7000 - 10000 kW 3.3 - 13.2 kV 4 - 24 pole Squirrel cage slip ring rotor Synchronous Cast iron-/ Steel housing, cooler assembly IP55, WP II

H-modyn IEC, ANEMA

7000 - 50000 kW 9390 67000HP 6 - 13.2 kV 2 - 12 pole Squirrel cage Synchronous

Special motors
2000 - 65000 kW 690 V - 13.2 kV

400 - 690 V 2 - 8 pole

Squirrel cage Cast iron housing with cooling ribs IP23, IP55

Cast iron housing with cooling ribs IP55

Squirrel cage synchronous

Cast iron housing with cooling ribs

Base frame, Water cooling IP55, WP II

Example: Motor for main cooling pump

ANEMA
150 - 1340 HP 460 575 V 2 - 8 pole Squirrel cage Cast iron housing with cooling ribs IP55/TEFC ODP, WP I, WP II, TEAAC/TEWAC (MV-motors with LV-winding)

ANEMA
150 - 2500 HP 0.2 11 kV 2 - 16 pole Squirrel cage Cast iron housing with cooling ribs IP55/TEFC cooler assembly ODP, WP I, WP II, TEAAC/TEWAC

ANEMA
200 - 10000 HP 0.2 - 13.8 kV 2 - 16 pole Squirrel cage Cast iron housing

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The Cost Saving Motor from Siemens

A&D SD Standard Drives

Thank You
21 February 2006