Energieeffiziente IE2 Wechselstrommotoren der Zukunft

C. Grabner, 10. April 2013

Climate Change

IEC Standard Development

IE2 Single Phase Motors

Eco-Design Fan Application

Complete Energy Efficiency Portfolio

Content

Seite 1

Climate Change – EU 20-20-20-Goal

Global challenge

CO2-reduction within industry, traffic and home appliances

EU climate protection goals until 2020: - 20% CO2-emission

20% renewable energy + 20% energy efficiency

Seite 2

IEC Standard Development – Committee Draft WG31

Seite 3

CD IEC 60034-30-1 “Efficiency classes of line operated AC motors (IE code)” covers:

Final IE4 values Rated output power 0,12 kW up to 1000 kW Low-voltage motor limitation to 1kV Line-operated single-speed 2, 4 or 6 poles & 8 pole Three phase induction motors Single Phase Motors Line-Start-Magnet-Motors, Line-Start Reluctance-Motors

IE2 Single Phase Motors – Coupled External Circuit Topology

General design remarks Restricted 1~ power grid supply Traditional no efficiency requirements 1~ motor output power is lower than 3~ Starting torque and run-up critical Transient circuit switching and over voltage protection

Coupled external circuit Small or no-load during start, e.g fan >>> Circuit topology A High-load during start, e.g compressor >>> Circuit B

Seite 4

A B

external circuit topologies

IE2 Single Phase Motors – Principal Types of Switches

Mechanical principle Mechanical Centrifugal Switch:

Principle based on mass-spring system Switching state (normally open) is dependent on the changed centrifugal force due to speed

Mechanical Relay: Principle based on electromagnetic forces Mechanical switching in dependency on electrical current or voltage

Electronic start capacitor relay Principle based on analogy electronic circuit Start capacitor is switched off after adjustable time delay, which corresponds to nominal rotary speed after start-up

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IE2 Single Phase Motors – Motor Design for Circuit Topology A

Seite 6

A

external circuit topology A

IE2 Single Phase Motors – Motor Design for Circuit Topology B

Seite 7

B

external circuit topology B

IE2 Single Phase Motors – Motor Design B Study 550W

Seite 8

New IE-requirement Type LE71/2C-11+E2 550W, 2poles Efficiency today 60% Future IE2 level of 75% Improvement to be 15%

Main type B activities Low-friction bearing New lamination HP420 Improved cage conductivity (Aluminium instead Silumin die-casting)

B

external circuit topology B

IE2 Single Phase Motors – Motor Design B Study 550W

Seite 9

Centrifugal switching Advantages Reliable and robust (e.g. 500.000 cycles tested) Long-time in-house experience

Disadvantages Abrasion due to moving mechanical components Voluminous axial mounted switching component Extended fan cover

B

external circuit topology B

IE2 Single Phase Motors – Motor Design B Study 550W

B

external circuit topology B

0

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3

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0 150 300 450 600 750 900 1050 1200 1350 1500

Drehzahl [U/min]

Einh

eite

n

Im[A] 1E = 2,5A Md[Nm] 1E = 1Nm P1[W] 1E = 500W P2[W] 1E = 100W

eta[%] 1E = 10% cosj 1E = 0,1

Starting performance with starting capacitor

Hysterese effects

Steady operational state without

capacitor

IE2 Single Phase Motors – Mechanical Relay Protection Study 1600W

Without Protection Circuitry 230V/60Hz, 1600W CA=40uF, CB=40uF

Seite 11

Suppression of Sparking Effects 230V/60Hz, 1600W CA=40uF, CB=40uF, R1=1Ohm, R2=180kOhm

Sparking cause contact welding

IE2 Single Phase Motors – Electronic Relay Endurance Study 2500W

Seite 12

Electronic relay Advantages

Mounted in terminal box Abrasion free components - No ‘moving’ mechanical parts Logic circuit for zero-voltage detection avoids flashing arcs

Disadvantages Number of cycles restricted - 100.000 cycles qualified Inaccurateness due to potentiometer setting Temperature drift of voltage detection

IE2 Single Phase Motors – Electronic Relay Endurance Study 2500W

Seite 13

B

external circuit topology B

Eco-Design Fan Application – EU regulation 327/2011

COMMISSION REGULATION (EU) No 327/2011

Covers fans driven by electric motors from 125 W to 500 kW

Fan energy efficiency requirement Low eff. level: 1 January 2013 High eff. level: 1 January 2015

ATB is a system supplier, which is responsible for the CE conform product placing in market

Validation done by measurement

Seite 14

Eco-Design Fan Application – System Design Approach

Seite 15

Eco-Design is new & complex topic:

New theoretical calculation procedure necessary with system approach

Software MultiWing Optimizer introduced for efficiency pre-calculation

Eco-Design Fan Application – Fan Validation

Seite 16

Validation method according standard EN ISO 5801

max 100.000 m3/h max 3.000 Pa

New measurement set-up & Calibration procedure for

dp = f(dV(dt) Pel = f(dV(dt)

Eco-Design Fan Application – Type Test Certificate

Seite 17

Type test certificate

Eco-Design Fan Application – Efficiency Comparison

Seite 18

Customized IE2 and IE3 three phase squirrel cage induction motors from 90W to 1,1kW successfully established in the EU market (EU regulation IE3 starts 2017). Smaller IE2 and IE3 range below 750W is not included in the EU regulative yet.

Standard IE2 and IE3 three phase squirrel cage induction motors from 1,5kW up to 375 kW (EU regulation IE3 starts 2015/17) available

New IE2 single phase squirrel cage induction motors will complete range of line operated motor portfolio stepwise until 2014/15

Change to new IE ATB products is economic & reduces costs

Complete Energy Efficiency Portfolio – Change is Economic

Seite 19

Complete Energy Efficiency Portfolio – Further Information

Halle 15 Stand F21

Herzlich Willkommen ...

Seite 20