Ecodesign Requiremens for Elecric Moors Towards a Sysem-Approach Demonsraing he benefis of moor sarers for fixed speed applicaions
A message from he CAPIEL Presidens Philippe Sauer CAPIEL Presiden Karlheinz Kaul CAPIEL Vice-Presiden As oulined in he Kyoo Proocol, climae change is one of mankind s key challenges for he 21 s cenury. In he conex of an ever-growing demand for elecriciy, he EU has commied iself o subsanial greenhouse gases emissions reducion including a 20% cu in Europe s annual primary energy consumpion by 2020. Improving he energy efficiency of producs has been flagged as presening a significan poenial for energy savings. Ecodesign an engineering challenge oday can play a grea role by minimizing environmenal impac, hus leaving a greener plane o he nex generaion. A CAPIEL, i is our duy o work wih decision-makers o ensure ha legislaion will achieve beer energy efficiency and reflec real-life condiions. I is also our responsibiliy o make sure ha hese regulaions are well undersood and correcly inerpreed by designers and users of elecrical producs, sysems and soluions. This brochure provides informaion and guidance as regards ecodesign for elecric moors and relaed conrol modes o achieve real-life energy efficiency. We hope ha you will find i of ineres. Yours sincerely, Philippe Sauer and Karlheinz Kaul CAPIEL is he European Coordinaing Commiee of Manufacurers of Elecrical Swichgear and Conrolgear The scope of he CAPIEL indusry covers all he equipmen, producs fiings, sysems insalled and services required for operaions of low volage swichgear and conrol gear (producs, sysems and assemblies). CAPIEL noably provides various sar & conrol soluions for inducion moors (e.g. direc-on-line, Sar Dela or sof-sarer): Sar & conrol soluions are paricularly energy-efficien for fixed-speed applicaions e.g.: PUMPS MOTOR STARTER LOW VOLTAGE POWER SUPPLY MOTOR CONVEYORS VENTILATION
EU Ecodesign Elecric moors wha is a sake? Towards beer energy efficiency The Ecodesign Direcive 2009/125/EC aims o improve he energy and environmenal performance of producs hroughou heir life cycle by sysemaically inegraing environmenal aspecs a he earlies sages of produc design. Following he Lo 11 sudy, he Ecodesign Regulaion 640/2009/EC inroduced mandaory efficiency requiremens for elecric moors: IE2 Minimum IE3 or IE2 + Variable Speed Drive (for moors 7.5 375 kw) IE3 or IE2 + Variable Speed Drive (for moors 0.75 375 kw) June 2011 January 2015 January 2017 IE: Inernaional Efficiency The Lo 30 aims o idenify he energy saving poenial of elecric moors ha are no covered (or are excluded) by Regulaion 640/2009/EC such as hose ouside he power range 0,75 kw o 375 kw. In addiion, he Lo 30 also looks ino he impac of moor conrollers on he efficiency of moor sysems. The need for a sysem-approach Real-life energy efficiency can only be achieved hrough a sysem-approach. Boh he moor and is conrol mode mus mach he inended applicaion requiremens: Selecing he righ conrol Moor Conrol mode Ecodesign requiremens for elecric moors will influence purchase decisions Applicaion specificaions LOAD/TIME PROFILE SPEED REQUIREMENTS (fixed or variable) Selecing he righ moor and impac real-life energy savings. Assessing he energy-efficiency poenial (e.g. number of sop-sar cycles per hour) LOAD REQUIREMENTS (moor will adap is power o he differen load levels) of moor conrol soluions requires a sysem-approach.
Moor sarers he bes soluion for fixed speed applicaions One size does no fi all A Variable Speed Drive (VSD) is an elecronic device used o conrol moor speed. Regulaion 640/2009/EC (Lo 11) can be misinerpreed as saying ha a less energy-efficien moor, if fied wih a Variable Speed Drive, has an equivalen level of efficiency as a more energy-efficien moor. MOTOR STARTER IE3 + + VSD IE2 Grasping he energy efficiency poenial of moor sarers for fixed-speed applicaions n Majoriy of applicaions are fixed speed where varying load levels are auomaically balanced by he moor orque: n Moor sarers are highly efficien for fixed speed and variable load applicaions n Above 30% load level, a moor equipped wih moor sarers will allow subsanial energy savings compared o a moor wih VSD: 20% 80% variable speed applicaion fixed speed applicaion 37kW Moor Sysem Efficiency 100 Moor Sysem Efficiency (%) 95 90 85 80 75 Sarer + Moor VSD + Moor 70 0 10 20 30 40 50 60 70 80 90 100 Moor Raed Torque (load level%) source: Moors wih Adjusable Speed Drives: Tesing Proocol and Efficiency Sandard - de Almeida e a.- EEMODS 2009 While VSD is he bes opion for some applicaions, moor sarers are he mos energy-efficien soluion for fixed-speed applicaions. 5 advanages of Moor Sarers Moor sarers (direc-on-line, Sar Dela or sofsarer) offer many advanages as conrol soluions: 1 Negligible energy losses 2 Opimal conrol cabine design (no need for addiional cooling meaning lower energy consumpion) 3 Simple implemenaion (no need for addiional power supply) 4 Robus moor sysem (no EMC issues, high level of safey & reliabiliy, long life-ime) 5 Low cos (affordable price, simple insallaion, operaion & mainenance)
Achieving energy-efficiency a correc moor conrol for each applicaion A Case Sudy: Bulk maerial conveyor Typical fixed speed applicaion: n Fixed speed driven by a 37kW moor n Variable load carried requiring he adapion of he load level according o he duy profile n Operaing ime (esimae): 3,600 h/year. Using a moor sarer insead of VSD would save 4.3 MWh per year (6.1%): Load Efficiency Conacor + Moor VSD + Moor Energy [MWh] per year Conacor + Moor VSD + Moor 0% Off Sandby 0.0 1.6 20% 90% 83% 3.0 3.2 40% 92% 87% 17.4 18.4 80% 94% 91% 45.3 46.8 Toal 65.7 70.0 Poenial energy losses due o an inappropriae moor conrol mode Fixed speed applicaions If all moor sarers = 80% are replaced by VSD + 34 marke share (esimae) (5% addiional losses) TWh/year = x 1.5 Nuclear plan energy producion =23 TWh/year (average) Toal energy consumpion for elecric moors: 850 TWh/year Variable speed applicaions = 20% marke share (esimae) Ecodesign requiremens mus follow a sysemapproach o ensure ha he moor conrol will mach he applicaion requiremens. Inappropriae moor conrol selecion will resul in subsanial energy losses. n Energy-efficiency mus be assessed hrough a sysem approach: he moor conrol mode mus mach he applicaion requiremens. n Moor sarers are he mos efficien conrol soluions for applicaions wih a fixed speed and variable load. n VSD if incorrecly fied can resul in an energy efficiency loss equivalen o wice he poenial gain from IE2 o IE3 (17 TWh/year*). *Source: CEMEP
CAPIEL Members CAPIEL a a glance CAPIEL represens 9 naional associaions from 8 European counries comprising more han 550 manufacurers. Members of naional associaions represened by CAPIEL include small, medium and large-sized companies employing 120,000 people direcly in Europe and have a combined urnover of 18.25 billion. CAPIEL membership includes global players like Siemens, Schneider Elecric, ABB, Eaon, Rockwell Auomaion, ec. www.capiel.eu