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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!

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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

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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 60034-2

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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

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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 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. with IEC 60034-1 Nominal value N acc. to NEMA MG1

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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)

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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)

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

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

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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

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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]

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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%

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

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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.

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

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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 R62 612 pa

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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

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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 95 000 motors manufactured annually 800 employees ISO 9001 and ISO 14001

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Automation and Drives 21 February 2006 A&D SD Standard Drives of AC Motors acc. IEC and ANEMAANEMA 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) H-compactIEC 200 - 3000 kW 2 - 11 kV 2 - 12 pole Squirrel cage Cast iron housing with cooling ribs IP55 H-modyn IEC, ANEMA 7000 - 50000 kW 9390 67000HP 6 - 13.2 kV 2 - 12 pole Squirrel cage Synchronous Base frame, Water cooling IP55, WP II Series1R.5/S.5IEC 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 Cast iron housing with cooling ribs N-compactIEC 200 - 1000 kW 400 - 690 V 2 - 8 pole Squirrel cage Cast iron housing with cooling ribs IP23, IP55 H-compactPLUS 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 Specialmotors 2000 - 65000 kW 690 V - 13.2 kV Squirrel cage synchronous Example: Motor for main cooling pump ANEMA 150 - 2500 HP 0.2 11 kV 2 - 16 pole Squirrel cage Cast iron housing with cooling ribs IP55/TEFC 200 - 10000 HP 0.2 - 13.8 kV 2 - 16 pole Squirrel cage Cast iron housing cooler assembly ODP, WP I, WP II, TEAAC/TEWAC ANEMA

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