The ErP Directive and its impact on switchgear

1© 2015 Eaton. All Rights Reserved..

Andreas Miessen, Product Manager – EATON, Product Line Drives & Softstarters


EATON

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1979 1994 1998 2003 2004 20072005 2008 2009 2010 2011 2012

Diversified

electrical

manufacturer

Electrical

distribution


•

•


• ErP Directive

Contents and impacts

• Motor regulations

Impact on motors and their switchgear and protective devices

• Pumps and fan regulations

Achieving required efficiencies using speed control

• New device category

Variable speed starter

Agenda

Simplified, compact &

lower cost machineReliable machine

Energy efficient

machineSafer machine


Energy Efficiency

• Legislation

• ErP Directive


• In today's world, energy efficiency is on

everyone's mind

• The EU is making efforts to meet its

environmental targets

• Laws and regulations play an important role

here as well

• Goal: To use energy in a conscientious manner

and take advantage of energy saving potentials

• For the most part, this is achieved by defining

minimum efficiencies and max. losses

GHD 276 TWh16%

Haushalte 609 TWh

25%

Industrie 729 TWh

30%

Verkehr 714 TWh

29%

Energy Consumption

in Germany 2011

Reliable machineSimplified, compact &

lower cost machineSafer machine

Energy efficient

machine

ErP DirectiveEnergy Efficiency and the Applicable Laws & Regulations


• Creating a framework for defining ecodesign requirements for "energy-related

products"

• Identifying product groups with a high potential for lowering greenhouse gas

emissions cost-effectively

• Examples of product groups that are important for Eaton:

- Electric motor systems

- Pumps

- Fans

• The requirements for these product groups are defined in the corresponding

regulations. For example: EC 640/2009 for electric motors (= motor regulation)

ErP DirectiveThe Goals Behind ErP Directive



Energy efficient

machine


ErP DirectiveImplementation Guidelines / Regulations



Energy efficient

machine


ErP DirectiveImpact on the Market

In order to meet the corresponding requirements:

• the relevant products (keyword: IE2 / IE3 motors) need to be modified

• even entire processes need to be modified

(keyword: regulating flow rates with valves vs. variable pump speeds)

Eaton has responded to the changes in the market

with two main approaches:

• Switchgear and protective devices must be IE3-ready

• Developing a new device category

Ease of use of switchgear with variable speeds



Energy efficient

machine


Motor Regulations

• Content, Scope

• IE3 suitability of switching and protection devices


70

75

80

85

90

95

100

1 10 100 1000

Mo

tor

eff

icie

ncy (

%)

Motor power (kW)EFF1

EFF2

IE2

High

IE1

Standard

IE3

Premium

IE4

Super Premium

Higher

efficiency

Lower

efficiency

IE1

IE2

IE3

IE4

Class

Classification

speed

(1/min)

Continuous

duty torque

(Nm)

Classification

power

(kW)

Nominal

efficiency

(%)

Energy loss

(W)

As per

IE1

IE1 1.500 35 5.5 87.4 693

IE2 1.500 35 5.5 87.7 676.5 -2.4%

IE3 1.500 35 5.5 89.6 572 -21.2%

IE4 1.500 35 5.5 92 440 -57.5%

Motor RegulationsEfficiency Classes on Motors



Energy efficient

machine


June 2011 January 2015 January 2017

Motors must belong

to efficiency class

IE2 at the very least

[7.5–375 kW] motors:


or

IE2 + speed control

[0.75–375 kW] motors:


or

IE2 + speed control

Motor RegulationsEfficiency



Energy efficient

machine


Motor RegulationsTechnical Consequences



Energy efficient

machine


Tripping

characteristics PKZM0 …

Motor characteristics

The current when the motor

is started and the inrush peak current both

fall below the trip characteristic.

However, magnetic release tolerances

must be taken into account within the

inrush peak current range, as nuisance

tripping may occur due to these tolerances.

Instantaneous release response current

increased from 14*In to 15.5*In.

Motor RegulationsExample: Modifying Motor Starters



Energy efficient

machine


Eaton Motor starters are the most simple,

ready to use and reliable way to run IE3 motors

Motor RegulationsMotor Starter “IE3 Ready”



Energy efficient

machine


Pumps and Fan Regulations

• Content

• Valve system versus speed control system


Pumps and Fan RegulationsContent

• The pump and fan regulations specify minimum efficiencies for a system

• In many cases, existing flow rate regulation systems, such as those using

valves, will not meet the corresponding requirements

• Speed control systems are required in these cases in order to reduce losses



Energy efficient

machine


Source: ZVEI

Pumps and Fan RegulationsComparison Energy Consumption Valve System vs. Speed Control System



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0

2

4

6

8

10

12

14

16

18

0 10 20 30 40 50 60 70 80 90 100

Perf

orm

an

ce (

kW

)

Flow (%)

Throttle Valve

Speed Control

Pumps and Fan RegulationsComparison Energy Consumption Valve System vs. Speed Control System



Energy efficient

machine


• Options for starting motors

• The simplest type of variable motor speed

Variable Speed Starter


Star/delta

Constant

Reduced

Abrupt switching

Speed starter

Variable

Full

Soft start

DOL starter

Constant

Full

Abrupt start

Variable

frequency

drive

Variable

Full

Soft start

Cost / functionality

Speed

Torque

Behavior at start

New Device Category: Variable Speed StarterOptions for Starting Motors



Energy efficient

machine


The simplest type of variable motor speed

• Positioned between motor starters and frequency converter

• Design and appearance of a motor starter

• Ability of the variable speed control adjustment

• Out-of-the-box-commissioning without any parameterization

New Device Category: Variable Speed StarterThe Starter with Variable Speed



Energy efficient

machine


• Applications in which a DOL start is not acceptable due to mechanical

reasons or excessively high inrush currents

• Applications that already feature a motor starter but that will require

speed control in the future in order to meet the applicable legal

requirements

• Applications that already feature a low-end variable frequency drive, but

for which this drive is still too complex (or too expensive)

• Applications with fixed speeds in which a frequency other than the

mains frequency is required

• Fixed-speed applications, with a high starting frequency

New Device Category: Variable Speed StarterApplications



Energy efficient

machine


2,2 kW @ 230 V / 2,2 … 7,5 kW @ 400 V

0,25 … 1,5 kW @ 1~ 230 V & 3~ 400 V

…… on public grids and industrial

supply systems

Featuring integrated motor protection

New Device Category: Variable Speed StarterUsed Everywhere in the World



Energy efficient

machine


Ambient temperature:

• Operating : -10…60 °C (device for 7.5 kW with derating)

• Storage : -40…70 °C

• Can be mounted directly side-by-side without derating

• Can be mounted on DIN-rails and mounting plates

• Degree of protection: IP20

New Device Category: Variable Speed StarterPerfect for Panel Building



Energy efficient

machine


New Device Category: Variable Speed StarterReliable Operation

Integrated functions

designed to prevent nuisance tripping :

• The output voltage and frequency are automatically adjusted during

generator operation or excessively steep deceleration ramps in order

to prevent shutdowns due to overvoltage

• The switching frequency is automatically reduced if

the heat sink temperature is too high

• DC braking for preventing shutdowns due to overcurrent –

in fans, for example



Energy efficient

machine


… parameterized with the screwdriver

• Ramp times

• Motor protection

• Terminal configuration

• Mains voltage change

(50 Hz / 60 Hz)

Power XL DE1 Variable Speed Starter – the simplest way

to manage IE2 & IE3 motors in variable speed applications

New Device Category: Variable Speed StarterIf necessary…



Energy efficient

machine


Conclusion

Summarizing it……

• The ErP Directive must be considered for all AC motors up to 375 kW.

Eaton offers the most simple, low cost and reliable way to fulfill it

already today.

• In applications with constant speed it must be taking care of that the

motor starters are „IE3 ready“.

• The Variable Speed Starter offers an ideal solution in simple

applications with variable speed.

• From a motor starter to a variable frequency drive – Eaton provides

the optimum solution for every requirement.



Energy efficient



Further Information



Energy efficient


„Motor Protection for the

IE3 revolution “

„Successful implementation

of the ErP Directive“

For more information, you can visit : www.eaton.eu/IE3

http://www.eaton.eu/ie3

The ErP Directive and its impact on switchgear

Engineering

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