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Automation and Drives

Standard Drives


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21 February 2006

A&D SD Standard Drives

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


21 February 2006


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


21 February 2006


(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


21 February 2006


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


21 February 2006


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)


21 February 2006


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


21 February 2006


EFF2 - Rotor

EFF2 - StatorEFF1 - Rotor

EFF1 - Stator

MeasuresComparison of active components


21 February 2006


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


21 February 2006


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]


21 February 2006


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%


21 February 2006



21 February 2006


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.


21 February 2006


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%


21 February 2006


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


21 February 2006


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


21 February 2006


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


21 February 2006


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


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


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


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


21 February 2006


The Cost Saving Motor from Siemens

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tandard drives saving energy with innovative electric drives

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