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Automation and Drives
21 February 2006
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Contents
1 (CEMEP - EU) - Background
2 EPACT – Main Objectives
3 Comparison of EPACT / CEMEP Measures
3 EPACT/ CEMEP – Motors not covered
4 Measures
5 Motor selection of efficiency
6 Saving energy by optimising the system
7 Profiting from Energy-Saving Potential
8 Checklist for EFF2 and EFF1 motors
9 Mechanical efficiency
10 Siemens Motor Sources
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EU CEMEP Background
Background - Introduction of efficiency classesacc. 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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(Source: ZVEI brochure) : Electrical Drives: Cost savings instead of regulation
Voluntary Agreement (EU) Main motives for efficiency classification
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
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Comparison of EPACT / CEMEP Law/ Voluntary commitment
EPACT - USA CEMEP - Europe
Status
Motors covered
Legally prescribed minimum efficiency
Voluntary undertaking to– classify efficiency– drastically reduce EFF3 motors
2-, 4- and 6-pole 60 Hzsquirrel-cage motors1 to 200HP (0.75 to150kW)
2- and 4-pole 50 Hz squirrel-cage motors1.1 to 90 kW
Efficiency determined acc.to
Marking required
IEEE 112 B Individual-loss procedurein acc. with IEC 60034-2
Rating plate with Efficiency (N) and CC032A
– Efficiency class on rating plate of motor– N, 3/4 load and efficiency
class in documentation
Efficiency ( Tol.) Tolerance in acc. withIEC 60034-1
Nominal value N acc. to NEMA MG1
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Comparison of EPACT / CEMEP Motors not covered
EPACT - USA 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
– Motors <1 HP and > 200 HP– Motors > 6-pole– Voltages and frequencies different to
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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EPACTRating plate – Frenstat
Efficiency class (CEMEP)
60 Hz (EPACT)50 Hz (CEMEP)Only when ordered as
design UL (Option D31)
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Measures Siemens and CEMEP, 4- pole
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EFF2 - Rotor
EFF2 - StatorEFF1 - Rotor
EFF1 - Stator
MeasuresComparison of active components
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Measures Reducing individual losses
Better quality of laminations used
Reduced magnetic stress
Larger core assembly
P Fe1 ~ K Fe * B2
B2 ~ 1/ m2Fe
INPUT
Active power from mains
OUTPUT Mechanical
output
Winding resistance reduced due to larger wire cross-section
Winding resistance
reduced due to larger rotor slots (section geometry)
PR
Improved
bearings and fans
P CU1 ~ I12 * R1
P CU2 ~ I2‘2 * R2
‘
Stator
Rotor
Efficiency increase due to better use of active materials
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Voluntary Agreement (EU Project) Facilitation of motor selection
EU-efficiency classes for motors:
High-efficiency
Improved- efficiency
Standard
The consequence:Siemens already stopped producing
EFF3-standard-motors and just produces the energy-saving motors
EFF1 and EFF2 instead70
75
80
85
90
95
1 10 100
Subdivision into three efficiency classes according to the
EU/CEMEP-agreement
Trend
[%]
[kW]
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Saving energy by optimising the systemExample: turbo machine drive
Flow control by throttle
Power input
Flow control by rotational speed
M
Power input
~~
Transformer
Motor
Pump
Throttle valve
Effective output
X
Losses in:
Transformer
Inverter
Pump
Losses in:
Motor
M
100%
160%
281%
285%
Effective output
100%
158%
160%
152%
142%
265%
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Profiting from the energy-saving potential Checklist for choosing drives efficiently
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
Efficiency Comparison 6600V 4 pole 50Hz
95,5
96
96,5
97
97,5
98
0 500 1000 1500 2000 2500 3000
Output Power [kW]
Eff
icie
ncy
Siemens eff. @100%
Comp.eff. @100%
Siemens eff.@75%
Comp.eff.@75%
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Customer Benefits
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 YearEnergy cost: R0,2 per kWh
Saving with an improved efficiency
R62 612 pa
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Source of Supply - Imported
• 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
• 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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of AC Motors acc. IEC and ANEMA
ANEMAANEMA
150 - 1340 HP
460 – 575 V2 - 8 pole
Squirrel cage
Cast iron housingwith cooling ribs
IP55/TEFCODP, WP I, WP II, TEAAC/TEWAC
(MV-motors with LV-winding)
H-compactH-compactIECIEC
200 - 3000 kW
2 - 11 kV2 - 12 pole
Squirrel cage
Cast iron housingwith cooling ribs
IP55
H-modynH-modynIEC, ANEMAIEC, ANEMA
7000 - 50000 kW9390 – 67000HP
6 - 13.2 kV2 - 12 pole
Squirrel cageSynchronous
Base frame,Water cooling
IP55, WP II
Series Series 1R.5/S.51R.5/S.5
IECIEC7000 - 10000 kW
3.3 - 13.2 kV4 - 24 pole
Squirrel cageslip ring rotorSynchronous
Cast iron-/ Steel housing,
cooler assemblyIP55, WP IICast iron housing
with cooling ribs
N-compactN-compactIECIEC
200 - 1000 kW
400 - 690 V2 - 8 pole
Squirrel cage
Cast iron housingwith cooling ribs
IP23, IP55
H-compactH-compactPLUSPLUS
IEC, ANEMAIEC, ANEMA1000 - 7000 kW1340 – 9390 HP
3.3 - 13.2 kV2 - 12 pole
Squirrel cage
Cast iron-/ Steel housing,
cooler assemblyIP23, IP55, WP II
SpecialSpecialmotorsmotors
2000 - 65000 kW
690 V - 13.2 kV
Squirrel cagesynchronous
Example:Motor for
main cooling pump
ANEMAANEMA
150 - 2500 HP
0.2 – 11 kV2 - 16 pole
Squirrel cage
Cast iron housingwith cooling ribs
IP55/TEFC
200 - 10000 HP
0.2 - 13.8 kV2 - 16 pole
Squirrel cage
Cast iron housing
cooler assembly
ODP, WP I, WP II, TEAAC/TEWAC
ANEMAANEMA
Automation and Drives
21 February 2006
A&D SD Standard Drives
The Cost Saving Motor from Siemens
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