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WEG Drives Even More Efficiency to Your System

COMPLIANT

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Technical Bulletin - WEG: Compliant to IES2

Efficiency has become one of the key challenges facing many businesses, whether it related to financial efficiency through supply chain management or human efficiency by getting the most productive workforce, making Efficiency the key to the health and growth of a business.

WEG Drives Even MoreEfficiency to Your System

Global population growth and economic development has generated significant energy demand around the world, resulting in increased use of fossil fuels, causing greater levels of pollution within our atmosphere.

The continued use of these non-renewable energy sources has produced a fearsome increase in carbon dioxide emissions (CO2) which some predict will reach unacceptable levels, worsening the environmental impacts on our natural world.

In 2030, the Europe Union has targets to reduce CO2 emission by 40% by creating renewable energy sources and increase the energy efficiency of the systems. Given this timescale the EU has placed a high priority on increasing the efficient use on the energy consumed.

Industry is by far the most significant consumer of energy with some studies suggesting that almost half of the global energy consumption come from industry, followed by the residential and commercial consumption.

Electric motors account for almost 70% for the energy consumption of industrial users where the great majority of motors installed are old and outdated.

Within the European Union all electric motors which are to be operated from a variable speed drive or inverter must adhere to a minimum of IE2 to be eligible for sale, whilst fixed speed applications must adhere to a minimum of IE3 in order to comply with the regulation 640/2009.

But the decision to invest in new equipment can be a minefield, with manufacturers all promoting the efficiency of their products with no easy means of comparing them.

With the introduction of EN 50598 the European Commission has created a standard which provides manufacturers which a clear framework by which to grade a complete machine, this in turn allows the consumer to compare the overall efficiency of a manufacturers product irrespective of their design and component selection, this is known as the Extended Product Approach.

By harnessing the Extended Product Approach the European Commission expect the increased demand for more efficient systems to help achieve its targets for carbon dioxide (CO2) reduction.

Today WEG’s super premium efficient motors are capable of meeting the highest level of efficiency, exceeding IE4 and IE5 classifications.

EU 640/2009Introduction of EU MEPS

Stage 1: Minimum IE2fron 0.75 kW to 375 kW

Stage 2: Minimum IE3or IE2 with VSD from

7.5 kW to 375 kW

Stage 3: Minimum IE3or IE2 with VSD from0.75 kW to 375 kW

2011 2012 2013 2014 2015 2016 2017

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Technical Bulletin - WEG: Compliant to IES 3

What is the Extended Product Approach?

The Extended Product (EP), according to EN 50598, is the combination of a motor system and a driven equipment, such as a fan, pump, compressor, conveyor or mixer.

The Motor System, according to IEC 60947-4-1, comprises of all the equipment necessary to control and operated the system and can include the motor or geared motor, a variable speed drive, soft starter, servo controller and all the associated controls and switchgear. Within the Motor System the individual elements are:

J Basic Drive Module (BDM): the BDM is the inverter in its most simplistic form. J Complete Drive Module (CDM): the Complete Drive Module, according to IEC 61800-2, consists of the electronic power converter connected between the electric supply and a motor as well as extension such as protection devices, transformers and auxiliaries. CDM takes the inverter and augments it with any filters, chokes, transformers or input switchgear required.

J Power Drive System (PDS): the Power Drive System, according to IEC 61800-2, consists of the Motor and the complete drive module.

Motor system

Extended product

Power drive system (PDS)

Motor control equipment = CDM or starter

Motor starter, contactor, soft-starter, etc.

Mains & mains cabling

Feeding section

Auxilia-ries

Basic drive

module (BDM)

Auxilia-ries Motor

Trans-mission

Load machine

Driven equipmentComplete drive module (CDM)

Figure 1 - Illustration of the extended product including a motor system Source: EN 50598-1 : 2014

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Technical Bulletin - WEG: Compliant to IES4

1 - The Torque or Power Versus Speed ProfileBy understanding the torque/power demand at the desired speed we can begin to build a profile of the system.

100%

100%

Constant-power loadConstant-torque load Linear-torque load Quadratic-torque load

100% 100% 100%

100%

100% 100% 100% 100%

n/nr

n/nr n/nr n/nr n/nr

n/nr

0%

0% 0% 0% 0%

T/Tr

P/Pr P/Pr P/Pr P/Pr

T = constant

P = constant P ∝ n2 P ∝ n3

T ∝ 1/n

P ∝ n

T ∝ n T ∝ n2100%

100%0%

n/nr n/nr

100% 100%

100% 100%0% 0%

T/Tr T/TrT/Tr

By combining the Driven Equipment requirements and the Motor System within our approach we can calculate the overall efficiency taking all of the elements into account. This results in an Energy Efficiency Index (EEI) which produces a value describing an energy efficiency aspect of an application, resulting from the extended product approach (EPA).This methodology enables the determination of the energy efficiency index (EEI) of the extended product (EP) based on the speed torque profiles of the driven equipment, the relative power losses of the motor system and the duty profile of the application.

The Extended Product Approach employs a semi-analytical model (SAM) to calculate the efficiency of each of the components at the operating points of the driven equipment. This is achieved by first understanding the operating conditions of the driven equipment.

nn

v

v

n

n

vv

This results in the most efficient component selection for the application.

Source: EN 50598-1 : 2014

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Technical Bulletin - WEG: Compliant to IES 5

2 - The Duty ProfileThis graph illustrates the various power levels required by the application, including standby, and the fraction of time during which the machine is operated at these levels. The duty profile essentially depends on the sizing of the motor and on how the extended product is operated in practice. When mapped against the amount of time spent at each duty the profile of the driven equipment is clear.

3 - The Energy Efficiency Index (EEI)By analyzing the Motor System efficiency based on the Driven Equipment’s profile this methodology enables the machine manufacture to determine their products overall Energy Efficiency Index.

TimeFractionFraction of rentime operated100%

80%

60%

40%

20%

0%OP1 OP2 OP3 OP4 OPi

Operating points (OP)

Motor system data Application operating points

SAM of the extended product

Specify interpolation procedureDetermine power demand from the losses.Specify calculation off EEI based on theapplication load-time profile

Application torque-speedoperating points

Energy Efficiency Index(EEI)

Power losses atstandardized operatingpoints according to EN 50598-2

SAM of the drivenequipment

Extended productapproach standard

SAM of the motorsystem

Source: EN 50598-1 : 2014

Source: EN 50598-1 : 2014

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Technical Bulletin - WEG: Compliant to IES6

Defining Efficiency – Complete Drive Module (CDM)

EN 50598-2: Defining Efficiency - CDM

Manufacturers of Complete Drive Modules are expected to calculate the efficiency of their products at 8 nominated points which can then be used within the semi-analytical method by the system manufacturer to determine their systems overall efficiency.

Where a CDM with 25% more losses than the reference value of IE1 is classified as IE0, whereas a CDM with 25% lower losses than the reference value of IE1 is classified as IE2.

EN 50598 is applicable to all CDM’s with power ratings from 0.12 kW up to 1,000 kW, with a voltage range from 100 V to 1,000 V.

J IE1 reference values for CDM’s J Defines testing method for CDM’s

Example J CFW500C16P0T4 losses defined as 198 W J 100% reference value = 581W

J Therefore WEG 7.5 kW CFW500 = IE2

RCDM relativetorque producingcurrent / %

PL,CDM (90;100)

PL,RCDM (90;100)

PL,RCDM (0,100) PL,RCDM (50,100)PL,RCDM (90,100) 125%

IE0

IE1

IE2

100%

75%

50 90 100

50%

0%

PL,RCDM (90,50)

RCDM relativemotor statorfrequency / %

PL,RCDM (50,50)PL,RCDM (0,50)

PL,RCDM (0,25) PL,RCDM (50,25)

100

50

25

Within the European Union, it is expected that a minimum efficiency performance of IE1 level will be introduced in 2018

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Technical Bulletin - WEG: Compliant to IES 7

Where a motor does not operate at its nominal torque and speed then the variable speed drive represents a significant opportunity for energy optimization. In addition, the greater the range of speed variation results in a greater PDS efficiency.

WEG has a complete line of variable speed drives which exceed the IE2 requirements outlined in EN 50598 and when combined together with our robust and reliable motor line create a synergic and integrated solution for all applications.

Using our IE2 motors with any WEG variable speed drive WEG can achieve an efficiency classification of IES2, however using other WEG lines of motors with the right drive we can reach much better levels of efficiency.

This makes WEG your ideal choice for all your variable speed drive and motor purchases.

EN 50598-2: Defining Efficiency - PDS

J IES1 reference values for PDS’s J Defines testing method for PDS’s

Example J CFW500C16P0T4 losses defined as 198 W + W22 IE2 4p Motor Losses of 825 W = 1,023 W J 100% reference value = 1,801 W

J Therefore WEG 7.5 kW package is classified as IES2

Defining Efficiency – Power Driven System (PDS)The classification of a Motor System consisting of a complete drive module (CDM) and motor is the similar to the method for a Complete Drive Module (CDM) but using the new nomenclature IES0 - IES2, and unlike the +/-25% tolerance permitted for a CDM, a tighter tolerance of +/-20% is consider for the IES classification.

RPDS relativetorque / %

PL,PDS (100;100)

PL,RPDS (100;100)

120%

100%

80%

50%

0%

IES0

IES1

IES2

PL,RPDS (0,100) PL,RPDS (50,100)PL,RPDS (100,100)

RPDS relativespeed / %

PL,RPDS (100,50)

50 100

PL,RPDS (50,50)PL,RPDS (0,50)

PL,RPDS (0,25) PL,RPDS (60,25)

100

50

25

WEG Achieves IE2 and IES2 Across the Range

WEG Worldwide Operations

WEG Group - Automation Business Unit Jaraguá do Sul - SC - Brazil Phone: +55 47 3276 4000 automacao@weg.net www.weg.net C

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