Automation and Drives Standard Drives Automation and Drives tandard Drives Saving energy with innovative electric drives S We reserve the right to make technical changes!

Automation and Drives 21 February 2006 A&D SD Standard Drives Contents 1 (CEMEP - EU) - Background 2EPACT – Main Objectives 3Comparison of EPACT / CEMEP Measures 3EPACT/ CEMEP – Motors not covered 4Measures 5Motor selection of efficiency 6Saving energy by optimising the system 7Profiting from Energy-Saving Potential 8Checklist for EFF2 and EFF1 motors 9Mechanical efficiency 10Siemens Motor Sources

Automation and Drives 21 February 2006 A&D SD Standard Drives EU CEMEP Background 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 CEMEP 1) to implement measures for improving the efficiency levels of electrical drives. Motive: Reduction of the emission of CO 2. 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

Automation and Drives 21 February 2006 A&D SD Standard Drives (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

Automation and Drives 21 February 2006 A&D SD Standard Drives Comparison of EPACT / CEMEP Law/ Voluntary commitment EPACT - USACEMEP - Europe Status Motors covered Legally prescribed minimum efficiency Voluntary undertaking to – classify efficiency – drastically reduce EFF3 motors 2-, 4- and 6-pole 60 Hz squirrel-cage motors 1 to 200HP (0.75 to150kW) 2- and 4-pole 50 Hz squirrel- cage motors 1.1 to 90 kW Efficiency determined acc. to Marking required IEEE 112 B Individual-loss procedure in acc. with IEC 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. with IEC Nominal value  N acc. to NEMA MG1

Automation and Drives 21 February 2006 A&D SD Standard Drives Comparison of EPACT / CEMEP Motors not covered EPACT - USACEMEP - Europe – Motors 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 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)

Automation and Drives 21 February 2006 A&D SD Standard Drives EPACT Rating plate – Frenstat Efficiency class (CEMEP) 60 Hz (EPACT) 50 Hz (CEMEP) Only when ordered as design UL (Option D31)

Automation and Drives 21 February 2006 A&D SD Standard Drives Measures Siemens and CEMEP, 4- pole

Automation and Drives 21 February 2006 A&D SD Standard Drives EFF2 - Rotor EFF2 - Stator EFF1 - Rotor EFF1 - Stator Measures Comparison of active components

Automation and Drives 21 February 2006 A&D SD Standard Drives Measures Reducing individual losses Better quality of laminations used Reduced magnetic stress Larger core assembly P Fe1 ~ K Fe * B 2 B 2 ~ 1/ m 2 Fe 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) P R Improved bearings and fans P CU1 ~ I 1 2 * R 1 P CU2 ~ I 2 ‘2 * R 2 ‘ Stator Rotor Efficiency increase due to better use of active materials

Automation and Drives 21 February 2006 A&D SD Standard Drives 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 instead Subdivision into three efficiency classes according to the EU/CEMEP-agreement Trend [%] [kW]

Automation and Drives 21 February 2006 A&D SD Standard Drives Saving energy by optimising the system Example: 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%

Automation and Drives 21 February 2006 A&D SD Standard Drives

Automation and Drives 21 February 2006 A&D SD Standard Drives 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.

Automation and Drives 21 February 2006 A&D SD Standard Drives Efficiency Comparison at 100% and 75% of Rated Power

Automation and Drives 21 February 2006 A&D SD Standard Drives 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 Year Energy cost: R0,2 per kWh Saving with an improved efficiency R pa

Automation and Drives 21 February 2006 A&D SD Standard Drives 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

Automation and Drives 21 February 2006 A&D SD Standard Drives 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 motors manufactured annually 800 employees ISO 9001 and ISO 14001

Automation and Drives 21 February 2006 A&D SD Standard Drives of AC Motors acc. IEC and ANEMAANEMA HP 460 – 575 V pole Squirrel cage Cast iron housing with cooling ribs IP55/TEFC ODP, WP I, WP II, TEAAC/TEWAC (MV-motors with LV-winding) H-compactIEC kW kV pole Squirrel cage Cast iron housing with cooling ribs IP55 H-modyn IEC, ANEMA kW 9390 – 67000HP kV pole Squirrel cage Synchronous Base frame, Water cooling IP55, WP II Series1R.5/S.5IEC kW kV pole Squirrel cage slip ring rotor Synchronous Cast iron-/ Steel housing, cooler assembly IP55, WP II Cast iron housing with cooling ribs N-compactIEC kW V pole Squirrel cage Cast iron housing with cooling ribs IP23, IP55 H-compactPLUS IEC, ANEMA kW 1340 – 9390 HP kV pole Squirrel cage Cast iron-/ Steel housing, cooler assembly IP23, IP55, WP II Specialmotors kW 690 V kV Squirrel cage synchronous Example: Motor for main cooling pump ANEMA HP 0.2 – 11 kV pole Squirrel cage Cast iron housing with cooling ribs IP55/TEFC HP kV pole Squirrel cage Cast iron housing cooler assembly ODP, WP I, WP II, TEAAC/TEWAC ANEMA

Automation and Drives 21 February 2006 A&D SD Standard Drives The Cost Saving Motor from Siemens Thank You